Sedgman undertook resource evaluation to commissioning of a preparation plant, 200,000 t capacity raw coal stockpile, two 600 t/h dense medium cyclone/spirals processing modules and two 250,000 t capacity product coal stockpiles. Up to 17 individual coal seams are mined concurrently in the open cut mine and fed to the coal handling and preparation plant (CHPP) on overland conveyors. Each seam has unique coal quality characteristics, and variations within the short and long-term mining sequence presented unique challenges.

Sedgman produced materials handling and processing systems to meet quality requirements of a high-grade export energy coal. Unique environmental challenges of the location were met, with measures often exceeding community and regulatory expectations. Productivity and safety were well above industry averages. Sedgman used extensive computer modelling and production simulations during design to optimise stockpile capacity and plant configuration. All operating systems and equipment are fully automated and monitored from a control room. A fully-automated unit train load-out system provides individual wagon loads to 0.5% accuracy at a 4,500 t/h nominal loading rate.

Client benefits included high productivity and safety standards and effective dust and noise mitigation measures.