Dofasco Inc. Iron Ore Pellet Terminal

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Dofasco Inc., the largest Canadian steelmaker, retained Ausenco to conduct a feasibility study to upgrade and expand their iron ore pellet terminal at its Hamilton works. Ausenco was subsequently asked to provide complete EPCM services for the project. The new unloading, storage, and distribution system features a 50-60% greater handling and stacking capacity, mainly due to increased flow of pelletised and auxiliary materials over the dock area. 

The facility is capable of off-loading 30,000 ton bulk carriers, storing and retrieving the pellets, as well as charging the plant furnaces at a continuous rate of 3,600 t/h. 

Terminal throughput can reach 9 Mt/y, while the stockpiling capacity was increased to 3 million tons. An integrated material handling system, including over 7,000 ft of high capacity overland style belt conveyors, was installed in combination with an intermediate storage facility and a furnace feed batching system. 

The new wharf incorporates a 1,400 ft bulkhead extension consisting of 80 ft long steel sheet piling driven to the underlying tile/shale complex and tied back to a 20 ft deep retaining wall. Poor soil conditions and potentially high settlements necessitated piled foundations for conveyor structures, transfer towers, pellet silos and control building. 

The entire materials handling system on the dock is fully integrated and automatically operated from a centrally located control complex.

Project details

Hamilton, Ontario
Business line
Process Infrastructure
Dofasco Inc.
Solution phase
Innovate, Create
Engineering, Global procurement, Construction management, Commissioning, EPC/EPCM