Drayton South Open-Cut Coal Mine
Better productivity for less
Anglo American Metallurgical Coal
|
Australia
|
2009–2014
5.95 Mtpa ROM;
4.7 Mtpa Hunter Valley thermal coal product
17 km
haul road and a light vehicle road
25 m
span bridge suitable for multiple loaded mine-haul trucks
New 66kV HV
power supply and site reticulation
Challenges
- Anglo American’s Metallurgical Coal business unit wanted to triple its metallurgical production by 2020, while pursuing thermal markets for exporting its New South Wales Hunter Valley assets.
- The replacement mine was to be integrated with the existing brownfield operations and infrastructure, with limited access through existing mine operations.
- There were tight environmental and community requirements due to the site's proximity to other industries and agricultural enterprises.
Solutions
- Concept, prefeasibility, and feasibility studies and a detailed engineering and execution plan were developed. Engineering of the surface infrastructure and coal-handling plant were included.
- The design was revised to delete the raw coal stockpile. Two reclaimers were able to be upgraded, saving the A$20 million cost of constructing a new, third reclaimer.
- Re-engineering, consolidation of size, and better local and overseas sourcing of HDPE pipes for the water reticulation system resulted in CAPEX savings of approximately $A14 million.
- Water balance modeling determined that instead of a new dam, a series of low-cost retention ponds could be constructed as the mine developed, saving A$4 million.
Highlights
- The Drayton South feasibility study received one of Anglo’s best Independent Project Analysis (IPA) review scores; FEL Index and rating of 4.75 “Best Practical."
- A previous recommendation to increase capacity by increasing the belt width on load-out conveyors was challenged. Instead, load-out was improved by increasing speed, enabling existing belts and structures to be retained and saving A$10 million.
- Access to the site was restricted to a single entry point through the existing operating mine. We adapted additional remote access gates for use during construction, a productivity improvement that saved between A$5 million and A$8 million.
- A rolled steel arch was chosen as a bridge solution that was suitable for the limited life expectation required, saving A$5 million.
“The Hatch team provided the needed expertise and experience for a project of this nature and demonstrated the flexibility required to adjust in an environment of significant regulatory approval uncertainty in New South Wales.”
Project numbers
5km public road relocationNew 66kV HV power supply and site reticulation
A$500 million estimated capital cost
500 jobs maintained with transition to replacement mine