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Dartbrook Mine 1997 - 2010
Anglo American Metallurgical Coal
Hunter Valley, New South Wales, Australia

Sedgman was engaged to expand Dartbrook's existing coal handling facilities to include a new raw coal stockpile, an expanded product coal stockpile and 1,000 t/h coal preparation plant (CPP). The new CPP was required to process the ROM coal to primarily remove higher than expected levels of calcium and iron. Sedgman designed the coal handling and preparation plant (CHPP) to the highest Australian coal industry standards at the time in terms of safety, environment and control of product quality. The design incorporated best proven technology and maximum automation to minimise operating costs. Materials handling and electrics were designed to maximise use of the existing installation.

The CPP consists of a 500 t/h dense medium bath module and a 500 t/h dense medium cyclone/spirals module. The preparation facility featured multiple bypass options to provide the significant operational flexibility required to optimise trace element ash removal and control overall product ash values. As well as the CPP, the coal handling facilities were expanded to include a new 80,000 t circular raw coal stockpile and a 200,000 t product coal stockpile.

Client benefits included use of best proven technology with a strong focus on safety, environment and product quality control. Dartbrook is an underground coal mine in New South Wales' Upper Hunter Valley. The operation was placed on Care and Maintenance in 2007. The long term future of the mine is under review by the joint venture partners with a range of options being considered.

Wilpinjong Mine 2005 - 2007
Peabody Energy
New South Wales, Australia

Sedgman initially undertook resource evaluation, definitive feasibility study and cost estimation of a 1,600 t/h coal handling and preparation plant (CHPP). Sedgman was subsequently engaged to undertake the detailed engineering design, procurement and commissioning. The combination of a modular bay plant design and ‘pancake’ construction method minimised working from heights and resulted in a much safer workplace. Construction costs were reduced by 10% with the plant was erected two weeks faster than could have been achieved through conventional methods.

Plant features include:

Client benefit:

Bengalla Mine 1999 - 2002
Coal & Allied
Hunter Valley, New South Wales, Australia

Sedgman undertook resource evaluation to commissioning of a preparation plant, 200,000 t capacity raw coal stockpile, two 600 t/h dense medium cyclone/spirals processing modules and two 250,000 t capacity product coal stockpiles. Up to 17 individual coal seams are mined concurrently in the open cut mine and fed to the coal handling and preparation plant (CHPP) on overland conveyors. Each seam has unique coal quality characteristics, and variations within the short and long-term mining sequence presented unique challenges.

Sedgman produced materials handling and processing systems to meet quality requirements of a high-grade export energy coal. Unique environmental challenges of the location were met, with measures often exceeding community and regulatory expectations. Productivity and safety were well above industry averages. Sedgman used extensive computer modelling and production simulations during design to optimise stockpile capacity and plant configuration. All operating systems and equipment are fully automated and monitored from a control room. A fully-automated unit train load-out system provides individual wagon loads to 0.5% accuracy at a 4,500 t/h nominal loading rate.

Client benefits included high productivity and safety standards and effective dust and noise mitigation measures.

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