Image: Mangoola Coal Preparation and Handling Plant: Exceeding expectations from studies to commissioning

Minerals & Metals2 min read

Mangoola Coal Preparation and Handling Plant: Exceeding expectations from studies to commissioning

Wybong, Hunter Valley, NSW, Australia
Xstrata Coal (now Glencore)

Mangoola Open Cut is a thermal coal mine, located on a previously undeveloped 150 million tonnes coal reserve in the Wybong area, Hunter Valley, New South Wales.

Ausenco QCC delivered the greenfield 1,800 t/h Coal Handling & Preparation Plant (CHPP) under an alliance style Engineering, Procurement and Construction (EPC) contract in 2011.

The Challenge

Coal quality was somewhat different to normal Hunter Valley coal; the coal had higher moisture levels and relatively poor washability - some seams contained high levels of clays which presented some handling and processing challenges. Ausenco QCC developed a processing and product strategy that included two stage processing and suitable product handling capability. Plant design also needed to consider appreciable variation in feed quality.

The scope of the Mangoola CHPP Project was to establish a greenfield facility, capable of processing 1800 t/h coal in a two stage washery. The scope extended from raw coal dump station to rail loadout.

The Better Way

We delivered a class-leading design for efficiency, maintainability and operability. Our scope included early studies, definitive feasibility, full detailed design and engineering, procurement, construction and commissioning.

The raw coal receival, crushing and treatment, and plant feed system was capable of 2000 t/h, while the two-stage washing, using a dense, medium cyclone and spirals processes operated at 1800 t/h. The scope also included rejects and tailings handling, product coal storage and handling, overland conveying, train loading and diversion of major high voltage power supply lines.

The Mangoola CHPP Project created a showcase facility and was one of five projects Ausenco QCC delivered for Xstrata Coal under an alliance delivery model. Ausenco QCC and Xstrata worked as a team with shared risks, rewards, and objectives. The one-team collaboration contributed to the project’s outstanding results.

The Outcome

Mangoola CHPP is widely regarded as a benchmark plant and continues to demonstrate its robustness.

We delivered via EPC a greenfield 1800 t/h CHPP, including the design and engineering of a two-stage dense medium cyclone and spirals process plant.

The project was completed below budget and well ahead of schedule in 2011, with zero Lost Time Injury.