Sedgman undertook resource evaluation to commissioning and operation of a coal handling and preparation plant (CHPP) at this greenfields mining project. Coppabella produces 8.5% ash washed product for the export Pulverised Coal Injection (PCI) market. Fast-tracking the project enabled first washed coal to be produced eight months after the start of detailed engineering design. Sedgman has since undertaken progressive upgrades from the initial 600 t/h to 850-900 t/h and continues to operate the plant, providing a benchmark for efficiency, availability and throughput capability for a single module coal preparation plant. Sedgman facilitated the upgrades without major expansion or equipment duplication.

Sedgman initially developed and operated a 500 t ROM dump hopper, two-stage crushing system and surge bin, 600 t/h single module dense medium cyclone/spirals processing plant with provision for raw coal bypass, 4,000 t product stockpile with below ground reclaim system, and 3,000 t/h train loading. Commencing production in February 1999, high export demand for the mine's PCI product quickly required progressive upgrades.

Client benefits included robust plant design and equipment selection, design enabled increases in capacity and efficient upgrades.