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Mt. Arthur North Coal Project
Hunter Valley Energy Coal
near Muswellbrook, New South Wales
Australia
Roberts & Schaefer Australia Pty Ltd formed a joint venture
with Sinclair Knight Merz to provide engineering, procurement,
and construction management services for the new 15 million metric
tons per annum Mt. Arthur North Coal Project of Hunter Valley
Energy Coal (BHPBilliton).
 Located
north of Sydney near Muswellbrook, NSW, Australia the facility
is designed to provide both domestic and export quality thermal
coals.
Coal is mined from a nearby open cut mine and delivered
by rear dump trucks to one of two ROM circuits that provide a
level of redundancy for the complete operation. Each ROM circuit
begins with a 700 metric ton capacity truck dump hopper, a vibratory
feeder and a primary sizer for reducing to minus 250mm. The coal
is then conveyed on a 60-inch (1500mm) belt at a design rate of
2500 metric tons per hour to the secondary/tertiary sizing station
where the coal is further reduced to 50mm x 0 size. A roller screen
is positioned between the secondary and tertiary sizers to remove
the fines before the oversize is fed to the tertiary sizer.
Crushed coal is then sampled on and delivered via 60-inch (1500mm)
wide belts to a transfer station where it can be directed to either
a domestic coal storage pile, a CPP feed storage pile, or the
export storage pile.
The domestic storage pile system consists of a traveling stacker
fed by a 60-inch (1500mm) wide conveyor that delivers coal to
a 120,000 metric ton stockpile. Coal from the stockpile can be
reclaimed through any of eight coal valves each rated at 2,000
metric tons per hour onto a 60-inch (1500mm) wide reclaim belt.
Coal from the reclaim belt is delivered either to the overland
belt for conveyance to the export stockpile or to a 60-inch (1500mm)
wide belt feeding a check weigh bin. Coal from the check weigh
bin is fed onto an existing cable-belt for delivery to the Macquarie
Generating Station.
The CPP circuit consists of a 120,000 metric tons circular raw
coal storage pile that is serviced by a stacker/reclaimer machine
that feeds the circular stockpile and reclaims from the stockpile
at rates of up to 2200 metric tons per hour. Reclaimed coal is
delivered to a 300 metric ton CPP surge feed bin. From here coal
is conveyed into the CPP where it is pulped with water and fed
into any one of three heavy media cleaning circuits.
Each circuit has a nominal capacity of 600 metric tons per hour.
Coarse reject from the CPP is conveyed to a 500 metric ton bin
where it is loaded into pit trucks for disposal. Slimes are treated
in static thickeners and delivered to a tailings disposal area.
The washed coal is sampled and conveyed to a transfer station
where it can either be delivered to the domestic stockpile if
necessary for storage or normally to an overland belt for conveyance
to the export stockpile prior to train loading.
The export stockpile system consists of a traveling stacker that
delivers coal to a 750,000 metric ton stockpile. Coal from the
stockpile is reclaimed through any one or a combination of 14
coal valves feeding onto a 72-inch (1800mm) wide reclaim conveyor,
designed for 4500 metric ton per hour capacity, that delivers
coal to a volumetric train loadout bin.
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