Rio Tinto Yarwun

Situated 10km north-west of Gladstone, Yarwun alumina refinery produces 3.4Mtpa of high quality product. Similarly to the QAL facility, where Walz is also engaged, Yarwun uses the world class four stage Bayer process to refine bauxite mined in Weipa on Queensland’s western Cape York. The expanded refinery incorporates a 160Mw cogeneration facility which significantly reduces the operations’ greenhouse gas impact and feeds surplus low emission electricity back into the Queensland electricity grid.

We have been working at the Yarwun refinery for many years and have a strong relationship with the facility’s operations team. With a workforce situated at the site, we provide comprehensive maintenance and shutdown services, as well as general sustainability works. We also support ongoing operations through our piping fabrication, protective coating, and light, medium and heavy fabrication facilities.

Throughout our long standing relationship, we have also completed several major capital works projects. In the last five years, Walz Group has worked with the Rio Tinto Yarwun team to deliver more than 290 projects valued at over $32M.

Some of our major capital works projects at Yarwun have included:

Thickener Corrosion Repairs

  • Completed: 2019
  • Project Value: $1.4 million

Caustic Line Replacement

  • Completed: 2019
  • Project Value: $1.5 million

Petite Sweeting Project– Structural steel and pipe installation works

  • Completed: 2018
  • Project Value: $2 million

Oxelate Project– Structural steel and pipe installation works

  • Completed: 2018
  • Project Value: $2.2 million

Mill LiqUOr Line & Spent Liquor Pipeline replacement

  • Completed: 2017
  • Project Value: $1.9 million

Queensland Alumina Limited

Queensland Alumina Limited (QAL) was Australia’s first alumina refinery and remains one of the largest in the country. Covering an 80 hectare site on the outskirts of Gladstone, the refinery produces around 3.8Mtpa of high grade product. The bauxite that is processed to make alumina is mined in far north Queensland and shipped 2,000km to Gladstone. Alumina is produced through the continuous four state ‘Bayer’ process.

Walz Group has a longstanding relationship with QAL and we are proud to be a trusted provider of scheduled maintenance and shutdown projects, as well as ongoing sustainability works. We also provide scaffolding services for shutdown works through our specialist plant and equipment. Walz also supports the refinery through our light, medium and heavy and piping fabrication facilities and protective coating services. Our constant presence on site supports the smooth operation of the refinery through a range of ongoing works. We also perform occasional major capital works.

Over the past five years we have carried out more than 390 projects at QAL, valued in excess of $46M. The works ranged from minor sustainability such as handrail replacements, to major capital works projects like replacing a conveyor.

Some of our key projects at QAL include:

  • Caustic Tank Floor Replacement (T15Q005 + T1515)
  • Major evaporation turnaround works
  • Power steam header remediation and upgrade works
  • Conveyor replacements
  • Miscellaneous structural, mechanical and piping works as required
  • Miscellaneous shutdown works as required
  • Providing scaffolding services for all shutdown works

Curtis Island LNG

The concurrent development of three liquified natural gas (LNG) plants on Curtis Island was an unprecedented achievement. It formed a significant part of what is, to date, the largest concentration of private capital investment in Australian history. This landmark program of work resulted in three plants that now yield roughly 8% of the world’s total LNG production.

The three facilities are owned by Queensland Curtis LNG (a joint venture of QGC – now a Shell-owned business, with China National Offshore Oil Corporation, and Tokyo Gas), Australia Pacific LNG (a joint venture of ConocoPhillips, Origin and Sinopec), and Santos GLNG (a joint venture of Santos, Petronas, Total, and Kogas)

There are six LNG trains on the island. Walz Group was engaged to provide structural, mechanical, and piping services for the installation of Train 2 for the QCLNG Plant.

Following completion of the QCLNG installation works, Walz was contracted by Bechtel to perform maintenance and warranty works for all three plants on the Island.

In addition to our ongoing warranty works, Walz supports operations on the island through our fabrication workshop and protective coating facility.

Gladstone Ports Corporation

Gladstone Ports Corporation (GPC) supports the trade of Central Queensland’s major resources, including coal, LNG, alumina, and agricultural products. GPC operates the port precincts in Gladstone, Rockhampton and Bundaberg. In the 2018 financial year, GPC ports were visited by 1,911 ships and processed 120 million tonnes of product.

As Gladstone locals, Walz Group has a long standing relationship with GPC. We’ve worked with them for more than 10 years, providing a range of services including piping fabrication, protective coating, and light, medium and heavy fabrication. We also have a consistent workforce based at the Gladstone Port, supporting GPC’s operations through a range of maintenance and improvement works, and selected capital works projects. Over the last five years we have carried out more than 140 projects at the port, valued at over $21M

We are currently engaged in mechanical life extension works, and corrosion and NDT repairs for Shiploaders 1, 2, and 3.

Some of our major capital works projects at the GPC Gladstone Port have included:

Stockpile 15 to 22 – Fabrication and Installation of a new Coal transferring conveyor system

  • Completed: 2014
  • Project Value: $112 million

Supply and Installation of 3 New Coal Product Transfer Trippers

  • Completed: 2013
  • Project Value: $3 million

Stockpile 22 – Fabrication and installation of a new Coal transferring conveyor system

  • Completed: 2012
  • Project Value: $16 million

WICET – MP2 Marine Works

With stage 1 of the Wiggins Island Coal Export Terminal (WICET) completed, commissioned and fully operational in 2015, the construction barge wharf at the site was rendered redundant. After considering removal of the wharf, WICET decided it would be more beneficial to decommission and preserve the facility. This would keep the option of using it again for any further expansion works in the future. Walz Group was engaged by WICET to decommission and preserve the construction barge wharf at the facility. The project scope also included removing hazards to the general public that may access the area.

This project showcases our marine infrastructure capability. It highlights the benefit of owning our own specialist marine equipment and expert operators. The scope included:

  • Decommissioning and preservation of the construction barge wharf
    • Removal, preservation and storage of pontoons, gangways and landings
    • Removal of attachments on piles / sheet piles then cleaning and restoration of surface protection
    • Design, supply and installation of a sacrificial anode system for the piles / sheet piling
    • Maintenance of existing navigational lights and installing one new light on the mooring dolphin
    • Installation of a security fence and safety signage
  • Ancillary make-safe works
    • Modification to the berthing dolphin emergency ladders x 10
    • Surface protection repairs to emergency ladder piles
    • Surface protection repairs to piles W11-C and W15-C
  • Marine equipment and personnel
    • Self-elevating platform
    • 250t crawler crane
    • Flat top barge
    • Tug boat
    • Work boat
    • Crew boat

Cement Australia – Heat Exchanger Duct Replacement

Cement Australia’s operations in Gladstone incorporate Australia’s largest cement kiln, capable of producing more than 1.6Mtpa of cement.

Early in 2017, it was identified that the heat exchanger duct between the clinker cooler and the inlet to heat exchanger no.1 (HE1) had reached the end of its life, and was significantly impacting on plant production. Cement Australia engaged Walz Group to replace the equipment to return the kiln performance to full capacity. The project required us to remove and replace the failing heat exchanger, ductwork, inlet chamber, associated supports, and specified tubes during a time critical shutdown.

We utilised our dedicated fabrication facility to manufacture all the ductwork, inlet chamber, and the associated supports and components. We also applied protective coating as required. Prior to the shutdown for the replacement works, we reinforced the plant foundation and structure to ensure it could accommodate additional loads.

Our comprehensive plant and equipment fleet was invaluable for this project, which required craneage and scaffolding to remove and replace the existing structure.

Leighton – APLNG Curtis Island Workers Camp

Forming part of the six LNG trains on Curtis Island, the Australia Pacific LNG plant is Australia’s largest producer of coal seam gas (CSG). It not only supplies Queensland’s domestic gas market, but also processes CSG into liquefied natural gas to meet the demand of customers around Australia and globally. The development of the plant took some five years, shipping its first cargo in 2016.

To support the construction of the plant, Walz Group was engaged by Leighton Contractors (now known as CPB Contractors) late in 2011 to build the works accommodation camp. Our scope incorporated:

  • Civil Works including
    • Preparation of site
    • Road construction
    • Building platforms
    • Drainage
    • Concrete works
  • Building installation
    • 2,600 residential units
    • Full commercial kitchen and dining hall to accommodate preparation of three meals a day for 2600 camp residents.
    • Miscellaneous buildings including offices, gymnasiums, laundry/toilet/washroom blocks, medical facilities, lunch cribs, security huts, etc
    • BBQ shelters, pavilions, walkways