Project Value | $40m
Solution Provided | Pre-Feasibility Study for Conveyors and Train Load Out, Definitive Feasibility Study for Screen Building
Disciplines | Process, Civil, Structural, Mechanical, Electrical, Controls, Instrumentation, Procurement, Project Engineering
The client requested a study to expand production rates from 24Mtpa of iron ore to 28Mtpa starting in 2015. Carnac was commissioned to provide advice and recommendations regarding options to realise sustained production with lower operating costs. The study of the in-loading circuit consisted of four work packages focused on the overland conveyor upgrade and screen building efficiency. Our analysis revealed that the additional throughput could be attained with minor modifications to the existing infrastructure with all changes possible within planned shutdown windows.
A high level assessment of upgrades required to reduce the train load out (TLO) time by up to 30% was also undertaken. The study of the TLO system involved process and control, mechanical, and structural analysis of the current system. Our first principles analysis concluded that significant TLO improvements could be undertaken with minimal capital cost and significantly reduced production downtime. Conveyor belt calculations were performed in Helix Delta T and chute loading conditions were calculated using Rocky DEM Particle Simulator. TLO calculations were performed in ExtendSim.