5.95 Mtpa ROM;
4.7 Mtpa Hunter Valley thermal coal product
haul road and a light vehicle road
span bridge suitable for multiple loaded mine-haul trucks
New 66kV HV
power supply and site reticulation
- 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.
- 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.
- 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.”