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Port Waratah project

Port Waratah Coal Services Bucketwheel Reclaimer

Port Waratah Coal Services | Australia | 2004–2005

Service life

extended for another 25 years of operation

Design

throughput of 2,500 tph

Saved

A$12 million and 1 year compared to procuring new reclaimer

Challenges

  • Refurbish and return to service a decommissioned bucketwheel reclaimer after 25 years of operation
  • The bucketwheel reclaimer had been decommissioned for several years due to a number of major structural defects
  • The reclaimer needed to be recommissioned as fast as possible to capitalize on the increased market demand for coal

Solutions

  • Conducted a feasibility study and developed a refurbishment methodology that incorporated many safety features to return the reclaimer to operation as fast as practically possible
  • Used an innovative solution to lift the superstructure in-situ without dismantling the bucket wheel-boom and counterweight frame structures in order to change the slew bearing and rocker assembly
  • Designed and fabricated a purpose-built support frame and two high-capacity hydraulic jacks

Highlights

  • Safely returned the reclaimer to service
  • Much faster than procuring a new machine
  • Less CAPEX than procuring a new machine
  • 2008 Bulk Handling Facility of the Year Award from the Australian Bulk Handling Review (ABHR)

Project numbers

$12 million and 1 year's operation saved by not procuring new machine
25 year service life extension after refurbishment
2,500 tph design throughput

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