BMA Goonyella – Dewatering Screens Project

Coming off the back of successfully completing the installation of the new Horizontal Belt Filter BF703, we were again engaged by BMA to assist with an upgrade of an existing dewatering screen to larger dual screens. The installation of these dual screens would assist operations with rectifying a bottleneck identified in Coal Preparation Plant 1 (CPP1), resulting in increased production rates.

These works require us to work alongside the existing CPP1 to install the new platform that will house the new dewatering screens and associated componentry. Our scope includes the supply and installation of the entire work package, including all structural steelwork, platework (chutes, underpans, feed boxes), a new gantry section and supporting trestle, pipework, handrail, grating, valves and the new conveyor componentry. We will be working alongside a number of our key subcontractors for these works who will be assisting with the civil works, electrical works, modifications to the existing conveyor belt, re-installation of an existing belt weigher and on-site installation of wear lined pipework.

Our team have become accustomed to carrying out complex on-site installations, with this project presenting its own challenges. To successfully complete this upgrade, we will be required to carry out a significant portion of the works during three plant shutdowns.

BMA Hay Point – Sustaining Shutdown Works

Continuing our working relationship with BMA at Hay Point, we were again engaged to provide marine assistance for a critical shutdown on one of their shiploaders. These works had us working alongside BMA and its nominated Head Contractor.

This project required the services of our marine equipment and specialist personnel to assist with the planned works that would be carried out during a 12 week outage. The planned works would see a range of maintenance activities completed on the shiploader to ensure it continues to operate reliably and safely.

As with all marine based works, this Project brought with it the need for our crew to continually adapt to the ever-changing weather conditions and modifications to schedule. By working closely with BMA and its Head Contractor, we were able to stay ahead of the game and address any hurdles in a safe and timely manner.

For these works, we provided the following specialist equipment together with expert operators:

  • 1 x self-elevating platform with 120t crawler crane
  • 1 x self-elevating platform with 250t crawler crane
  • 1 x flat top barge
  • 2 x tugs
  • 1 x work boat
  • 1 x crew boat

BMA Goonyella – Horizontal Belt Filter

Continuing our ongoing relationship, we were engaged by BMA to carry out the installation of Horizontal Belt Filter BF703 at its Goonyella mine in Central Queensland. It was our first time working back at the Goonyella mine in recent years and it was a great opportunity for our team to demonstrate our capabilities working alongside a new client team.

Our works for this project included the full turnkey package. We worked alongside BMA to assist with the procurement of key items such as pumps, drives, handrail, grating, valves, pipework and other miscellaneous componentry. We also looked after the fabrication of plate and structural steelwork packages, which were integral to the installation of the new Horizontal Belt Filter being supplied by BMA. This project once again gave us the opportunity to work alongside our trusted subcontractors for the civil, electrical and instrumentation works. Once commissioned, the upgrade would see an increase in the recovery of dry product through the mine.

The project was completed safely and on time, demonstrating our capabilities in this field and establishing our presence as a key contractor for further works at Goonyella moving forward.

Sedgman – Sonoma High Cut / Low Cut

Located 6km south of Collinsville in Queensland’s Bowen Basin, QCoal Group’s Sonoma Mine produces up to 4Mtpa of hard coking and thermal coal products. 

Our client, Sedgman, has operated the Sonoma plant since it was constructed in 2007, and were seeking support for the detailed design, engineering, procurement, and construction of the High Cut Low Cut Brownfield Upgrade of the coal handling and preparation plant. We worked with Sedgman to provide SMP civil works and a range of fabrication and protective coating services. Steel fabrication included steelwork, grating, floor plate, handrails, girts, cladding and a range of process platework. We also managed civil works carried out by one of Walz Group’s trusted subcontractors.

Mechanical works included installation of cyclones, coarse coal centrifuges, product screens, conveyor idler replacements, jib crane, and various pumps and drives.

Additional works comprised miscellaneous concreting, demolition of existing structures, and the construction of various ground slabs, suspended slabs and equipment plinths.

Sinosteel – Rocklands Copper Processing Plant

Sinosteel engaged Walz Group to carry out the structural, mechanical and piping works for the greenfield installation of a new 3Mtpa copper processing plant at their Rocklands mine, approximately 17km west of Cloncurry, in northwest Queensland. Our scope included the installation and commissioning of all mechanical equipment, structural steelwork and piping. Upon completion, we had installed 5,900t of structural steel, 2,500t of mechanical items and 42,000m of piping. 

Our specialist team comprised some 150 personnel at the peak of construction, and included special class welders, pipe fitters, riggers, boilermakers, equipment operators, and project support staff.

Sedgman – Whitehaven Coal Construction of CHPP and supporting conveyor.

Located approximately 30km southeast of Narrabri, Whitehaven Coal’s Narrabri mine has been successfully operating since 2012. In 2011 the mine was preparing to establish a longwall operation to transition to commercial production. As part of the ramp-up phase, Walz Group was engaged by our client, Sedgman, to work with them on the construction of a new coal handling and preparation plant (CHPP) and supporting conveyor system. The new plant would increase mine production to 6Mtpa. Our scope was to carry out onsite installation of all structural steel, mechanical equipment, platework and piping for the plant, including:

  • Raw coal reclaim tunnels — Structural steel, conveyor system, mechanical, platework
    • Reclaim conveyors and a plant feed conveyor
    • Rotary breaker station
  • Coal preparation plant building — Install associated structural steel, mechanical, platework, and pipework
  • Rejects Handling System – Structural steel, mechanical, reject conveyors
  • Product Handling System – Structural steel, mechanical, conveyors
    • Product transfer station
    • Product conveyors
  • CPP Services – Piping and mechanical installation

Sedgman – Bengalla Mine SMP and Civil Works Upgrade

We were pleased to be engaged by Sedgman to support their upgrade works for Bengalla Mining Company. The goal of the expansion was to increase mining operations from 7.8Mtpa to 10.7Mtpa, by introducing a second stage wash cycle and an additional belt press filter extension.

Our scope included the structural, mechanical, piping and civil works associated with the upgrade to the coal handling and preparation plant, and new raw coal conveyor system. We also managed the contractor for the civil works within our scope. Our work included:

  • Installation of conveyors (1,000t of structural steel)
  • Installation of mechanical equipment (chutes, cyclones, screen, sumps, pumps, conveyor mechanical)
  • Fabrication and installation of associated pipework
  • Detailed excavation and civil works required for the CHPP extension

Sedgman – Construction of Reflux Classifier and Supporting Structural Works

Our long term client, Sedgman, engaged Walz Group to support their major upgrade of the coal preparation plant at the BMA owned Saraji open cut mine near Dysart in the Bowen Basin. Our scope incorporated onsite installation of all structural, mechanical and piping works associated with the reflux classifier, an advanced fine particle gravity-based separator. Works included constructing the building to house the device and installation of all mechanical and piping components. We also modified the existing walkway, and installed the new pipe bridge walkway, connecting them both to the existing plant. We also performed all tie-ins to the existing services.

Newcrest – Tank TK201 Repair

On the strength of previous work performed for Newcrest at their Lihir Gold Mine — particularly the works carried out on Heavy Fuel Oil (HFO) tank TK202 — Walz Group was engaged to conduct a 10 year statutory inspection on HFO tank TK201.The scope included undertaking all repairs found necessary as a result of the inspection.

Similar to the TK202 works carried out in 2017, Walz identified numerous repairs and upgrades that were required to ensure the tank maintained its compliance. These works included:

  • Removal and replacement of roof components (inner rafters, annular ring, braces, roof plates, manway and miscellaneous cleats and beams)
  • Replacement of top strakes
  • Repair of external stairway
  • Replacement of all handrail and kickplate around the top of the tank
  • Replacement of goose neck vent on the roof nozzle
  • Remove and replacement of existing fire water ring main risers and circumferential pipework
  • Full blast and repaint of the inside of the tank shell and roof prior to hydro test
  • Hydro testing of the tank

QER – Demonstration Oil Extraction Facility

As part of exploring the potential for commercial development of their shale oil deposits, QER sought to build a small scale Technology Demonstration Plant (TDP) at its Stuart site, north of Gladstone. The design was based on another pilot plant located at Rifle, Colorado in the United States, which uses Paraho II above ground retorting technology.

The overall intent was to replicate and modify aspects of the Rifle, Colorado plant design. Once of the main differences was to include additional process units to form a complete end-to-end plant. This was primarily to ensure that the TDP would meet Australian standards in design and safety.

Our scope comprised onsite construction of all structural, mechanical, piping and electrical work, including:

  • Structural Steel – supply and installation (structural steel, conveyors)
  • Mechanical Equipment – installation (pumps, chutes, bins, vessels, conveyor mechanical)
  • Piping – fabrication and installation
  • Electrical – supply and installation