Dawson Coal Project

The Thiess Sedgman Joint Venture (TSJV) worked in an alliance with Anglo American Metallurgical Coal to design, construct and commission the largest coal handling and preparation plant (CHPP) in Australia.

The TSJV undertook detailed design to commissioning of the CHPP to replace an existing operation and enable 15 Mt/a of raw coal processing. The project also involved design to commissioning of a raw coal overland conveyor system (OLC).

An innovative ‘pancake’ construction method was used to complete the plant design. It entailed on-ground erection of large sections which were then lifted into place, ensuring greater safety.

The CHPP maximises coking coal recovery from three distinct mining areas, produces up to five product coal types, and washes coal in both two-stage, two-product mode and single-stage, single-product mode. Other requirements were an ability to size the primary product and divert the oversize to the secondary product; and provide for raw coal bypass. The overland conveyor comprised two rope conveyors utilising cable belt technology (1,500 t/h by 17 km and 2,400 t/h by 10 km).

Anglo subsequently engaged the TSJV in an alliance to design, built and commission 700 t/h Lake Lindsay CHPP. Also in the Bowen Basin, the Lake Lindsay project included a 21 km single flight belt conveyor, one of the longest coal overland conveyors in the world.