Projects

Kestrel Coal Pty Ltd engaged EPCM Projects to undertaking a debottlenecking exercise of its existing CHPP facility located approximately 50km North of Emerald, Queensland. The aim of the project was to increase feed rate and improve yield through an upgrade of the secondary DMC circuits (“DMC Upgrade”) and installation of a new Middlings circuit. The project required the delivery of 5 separate packages of work - fabrications, equipment, engineering and construction (including electrical and mechanical packages). 

The project comprised of the installation of the following:

• Flotation circuit;
• Delime annex and cyclone; 
• Reject circuit; 
• Spirals Cocking circuit; 
• Blue Product circuit; and
• Dense medium cyclone installation in both Mod 1 and Mod 2

EPCM Projects identified that efficiencies could be improved in full plant maintenance shutdowns by allowing additional major tasks to be completed in the planned timeframes with the installation of a second overhead crane on the same gantry rails as the current crane. This allowed for a revised shutdown strategy to reduce the frequency of full plant maintenance shutdown days and increase operating time.
 

EPCM Projects conducted a feasibility study which identified the requirement to install two new cranes in the CHPP replacing the current single crane. The project team also identified the need to install and additional loading bay at the southern end of the plant which required management of three separate packages of works. Fabrication, Installation, both Mechanical and Electrical and a Civil Package. These packages had to be completed while the plant was in operations.

Existing 30 year old chiller unit that serviced the CHPP operations building had been identified as defeated and required urgent upgrading. EPCM Projects conducted D&C for the installation of new unit. This required upgrade of exiting starter cell and cabling from MCC to unit. The new unit was upgraded to site specifications and installed during scheduled maintenance outages.

 Existing 20 year old compressor unit had been identified as deficient for the current CHPP requirements.

EPCM Projects conducted a completed plant air assessment which identified the current CHPP  plant air requirements and future.

RO water project is a co-commitment to Dry Disposal Project due to the risk of excess water onsite when evaporation losses in the co-disposal are stopped after changing to Dry Disposal.

Reverse Osmosis water treatment of mine affected water to raw water quality was to allow for offsetting the requirement to import raw water from offsite to reduce to total site water storage requirement and therefore reduce the risk of non-compliant water release from site to an acceptable level of risk

The added benefit was the ability to be more self-sufficient in the event of imported raw water restrictions to site.