Camberwell Coal Pty Limited CH&PP Upgrade to 800 tph€¦ · Rom Bin & Crusher Raw Coal Stockpile & Stacker Raw Coal Stockpile & Reclaimer ... Schade Reclaimer from 600 tph to 1000

Camberwell Coal Pty LimitedCH&PP Upgrade to 800 tph

Presentation 21 May, 2003

Camberwell Coal Pty LimitedCH&PP Upgrade to 800 tph

Presentation to NSW BranchAustralian Coal Preparation Society

21 May, 2003

Camberwell CoalCamberwell Coal

Camberwell Coal Pty LimitedA.C.N. 003 825 018

Bridgman Road, Singleton, N.S.W.P.M.B. 7, Singleton, N.S.W. 2330

Phone +61-2-6570-2111 Facsimile +61-2-6570-2180

Locality

Arial Photograph of Mine Site

Camberwell Supply Process

Rom Bin & Crusher Raw Coal Stockpile & Stacker Raw Coal Stockpile & Reclaimer

Preparation Plant Clean Coal Stockpile Train Loading

Coal SeamsCoal

Seam

Sandstone

Siltstone

Mudstone

Conglomerate

<Geological Coal Seam><CBW Seam No.>

270 260 250 249 240 230 220 210 200190 180 170160

150 140 130

120110 10090 80 7060 50 40

225W

205W

175W

135W

105W

75W

55W

Arties

Middle Liddell

Lower Middle Liddell

Lower LiddellUpper BarrettLower Barrett

Upper Hebdon

Lower Hebdon

Upper Liddell

Employees / Operations

207Total

315. Staff

24 hrs/day *7days154. Preparation Operator

24 hrs/day *7days53. Maintenance (Electrical)

24 hrs/day *7days312. Maintenance (Mechanical

24 hrs/day *5days + overtime on W/ends1251. Mining

OperationsNumber

Camberwell Coal Pty LimitedCH&PP Upgrade

Background• Glennies Creek have developed an underground

operation on Camberwell’s northern high wall• Mining commenced in 1999 in a Development Phase

for future Longwall mining• Decision made early in 2001 to develop a Longwall

operation at Glennies Creek mine• Camberwell Coal has washed GC’s development

coal since commissioning• Commercial arrangements have been finalised for

Camberwell to wash GC’s Longwall coal in the future


Camberwell CHPP (2001)• Commissioned in 1991 as a 350 ROM tph Jig and

Dense Medium Cyclone Plant (Jig capacity of 500 tph)

• After internal modifications, Plant averages 545 tph with peaks of 600 tph

• Current Plant capacity 4.0m ROM tpa• 2002 Budget - 3.6m ROM tpa CCPL

- 2.0m ROM tpa GC• 2002 plant capacity required 800 ROM tph


Invitation to Tender• 8 invitations to tender were sent, 7 companies

responded• Initial invitation was for 1200 ROM tph plant with Raw

Coal Stockpile extension plus new Raw Coal Reclaimer ($18.5m - $32.0m)

• Rationalisation of GC project meant that the upgrade could be staged (Stage 1 - 800 tph, Stage 2 - 1200 tph) and use of the direct feed option meant that the extensions to the Raw Coal Stockpile or the purchase of a new Reclaimer was not required during Stage 1


Invitation to Tender• Tenders short listed to 3 possibilities• Discussions with the three possible

Tenderers continued• Sedgman Australia pty limited offered a

number of options with Camberwell accepting the upgrade tp 800 tph within the existing building

Camberwell Coal Pty limitedCH&PP Stage 1 Upgrade

Contract Details:• Increase the speed of the raw coal and clean coal conveyors to

suit a plant of 800 tph feed

• Redesign the raw coal system such that the plant can be direct fed at 800 tph whilst receiving coal at 1200 tph

• Remove the Jig and installation of a large desliming screen

• Upgrade screens, pumps, pipelines etc consistent with 2 x 400 tph modules (within the existing building)

• Option for the additional thickener not pursued

Camberwell Coal Pty LimitedProposed CH&PP Upgrade

Potential Upside for Camberwell• Increased throughput rates• State of the art equipment selected

(Multi slope screens, Climaxx type magnetic separators, variable speed pump drives)

• Ability to operate at higher feed rates without increased magnetite consumption costs

• A reliable soft ware system that will be supported for the next x years

Camberwell Coal Pty LimitedProposed CH&PP Upgrade

Potential Downside for Camberwell• Shut down associated with upgrade

5 days total plant plus21 days at 400 tph operation

or15 days total plant

• Reduced flexibility on the product stockpile• Greater intensity required in coal flow scheduling

Camberwell Coal Pty LimitedCH&PP Stage 1 Upgrade

Significant Events:• Week ending 15 .12.01 agreement signed with Glennies Creek

Coal Management Pty Limited thus enabling the CH&PP Upgrade to proceed

• Week ending 22.12.01 Development Consent received from DUAP and agreement signed with Sedgman Pty Limited for the Construction Contract

• March, 2001 – December, 2001 engineering and design work continued at Sedgman’s Brisbane office (funded by Glennies Creek)

• Week ending 22.12.01 GC issued a Letter of Intent for the purchase of equipment associated with the Mini Wall unit


Timing• Awarding of Contract 20.12.01• Orders placed for major equipment 21.12.01• Site mobilisation 22.4.02 – 29.4.02 • Pre shutdown works 30.4.02 – 13.5.02• Shutdown works (3 weeks max.) 14.5.02 – 3.6.02• Post shutdown works 4.6.02 – 17.6.02• Plant acceptance testing 11.6.02 – 17.6.02• Plant operator training 18.6.02 – 15.7.02• Practical completion 15.7.02

amberwell

Coal

Pt


Practical Completion Tests and Commissioning

• Plant to operate at a feed rate of 800 tph for a continuous 24 hour period (Completed on 26.6.02)

• Plant to operate for 68.4 hrs out of a continuous 72 hour periodie 95% availability (Completed on 8.7.02)

• Less than 10% undersize in the desliming screen overflow(Completed 8.7.03)

• Magnetite consumption equal to or less than 0.5kg/ROM input


Difficulties to Overcome Following Commissioning:

• Yokogawa software

• Ground floor spillage

• Tell tail overflows

• Glennies Creek foreign material

• Scheduling of coal flows

• Thickener and return water capacity


Plant Status 6 months After Commissioning:

• Tertiary sizer (Abon 6/250 HSS) functioning well• Yokogawa software modified to suit operations• Coarse ground floor spillage now handled by small bucket

elevator• Glennies Creek foreign material still an issue but improving• Thickener and return water still an issue on poor yielding coals.

Have contracted Sedgman to engineer a solution• Plant operates at 850 tph on reasonable yielding coals and 720

tph on poor yielding coals


Future:

• Orders have been placed for additional return water capacity thus reducing one of the restrictions preventing the CHPP from processing poor yielding coals at 800 tph

• Agreement already in place for CHPP to expand if GCCM expand their mine (1200 tph)

• A detailed 900 tph expansion study gas been completed and is currently being evaluated

• GCCM currently investigating installation of a rotary breaker orscreen at their end to minimise foreign material

• Engineering study complete to raise the reclaim rate of the Schade Reclaimer from 600 tph to 1000 tph

Documents

Camberwell Coal Pty Limited CH&PP Upgrade to 800 tph€¦ · Rom Bin & Crusher Raw Coal Stockpile & Stacker Raw Coal Stockpile & Reclaimer ... Schade Reclaimer from 600 tph to 1000