Sedgman undertook detailed design to commissioning of a coal handling and preparation plant (CHPP). The objective was to replace the existing operation and enable up to 15 Mt/a raw coal processing. The project also involved design to commissioning of a raw coal overland conveyor system (OLC). Thiess Sedgman Joint Venture personnel worked together successfully with Anglo Coal in alliance-style project delivery to complete the largest coal preparation plant (CPP) in Australia.

An innovative 'pancake' construction method was used to complete the bay plant design. It entailed on-ground erection of large sections which were then lifted into place, ensuring greater safety.

The CPP maximises coking coal recovery from three distinct mining areas, produces up to five product coal types, and washes coal in both two-stage, two-product mode and single-stage mode. Other requirements were an ability to size the primary product and divert the oversize to the secondary product; and provide for raw coal bypass. The overland conveyor comprised two rope conveyors utilising cable belt technology (1,500 t/h by 17 km and 2,400 t/h by 10 km).

Client benefits included completion of the largest CPP plant in Australia with design standards setting a world benchmark for high-capacity coal processing.