The development of a coal perpetration plant was undertaken by Xstrata Coal in an alliance with Downer Engineering. A critical factor in the daily operation for the coal preparation plant with be the two stackers for two grades of product.
| Project Name | Development, Design, Fabrication, Installation, Commission of New Coal Preparation Plant Stackers and Associated Yard Supply Infrustructure |
| Client Company | Xstrata Coal |
| Project Type | Development, Design, Fabrication, Installation, and Commissioning of Coal Stackers |
| Project Value | $40m |
| Project Dates | Start: June 2009 Finish: July 2010 |
| Strategic Objective | To design, construct, and implement two state-of-the-art coal stackers for two grades of coal product at Xstrata Coal’s preparation plant, ensuring optimal efficiency and reliability for daily operations at a design rate of 2400 tonnes per hour (tph). |
| The Challenge / Need | The new mine required advanced stacker systems capable of efficiently handling two distinct grades of coal. While our previous project for Xstrata provided a solid foundation, this project demanded a tailored redesign to accommodate increased capacity, enhanced operational demands, and integration with the new mine’s unique infrastructure. Ensuring compliance with stringent safety and quality standards, while coordinating a multidisciplinary team across design and construction phases, added further complexity. |
| My Approach | As the principal consultant and Head Contractor, I adopted a strategic and innovative approach: Technology Leadership: Leveraged expertise from previous successful projects to design an advanced, high-capacity stacker system. Customized solutions to address specific operational requirements of the new mine. Comprehensive Design and Engineering: Managed a multidisciplinary team including engineers, drafters, and PLC/SCADA designers to deliver a robust design. Integrated advanced instrumentation, fire suppression systems, and state-of-the-art evacuation protocols. Construction Excellence: Orchestrated a skilled construction team for fabrication, erection, and installation of the stackers. Ensured seamless coordination across contractors, suppliers, and project managers. Program Oversight and Safety Leadership: Established and monitored a rigorous safety system, achieving exemplary safety performance. Provided regular updates to Xstrata’s executive board, ensuring transparency and alignment. This included in summary: Development Phase: Conducted comprehensive needs assessment and feasibility studies. Developed the project plan and secured alignment with Xstrata’s strategic goals. Design Phase: Managed a multidisciplinary team, including structural, mechanical, electrical, and instrumentation engineers. Created a customized design addressing the capacity, safety, and operational needs of the stackers and yard infrastructure. Fabrication Phase: Coordinated with fabrication contractors to ensure precise manufacturing of components. Monitored quality standards to align with project specifications. Installation Phase: Oversaw the erection and installation of the stackers and yard supply infrastructure on-site. Managed a highly skilled team of contractors, ensuring safety and efficiency. Commissioning Phase: Conducted system testing, integration, and fine-tuning to ensure operational readiness. Delivered comprehensive training and handover documentation to Xstrata Coal’s team. |
| Solution & Key Deliverables | Design Phase: Delivered a fully customized stacker design supporting 3000 tph at a belt speed of 5.6 m/s. Developed advanced safety and operational systems, including fire detection, suppression, and evacuation protocols. Construction Phase: Successfully executed the fabrication, erection, and installation of two stackers tailored to the new mine. Delivered comprehensive handover documentation integrated with BIM and operational control systems. Coal Stackers: Two stackers designed to support 3000 tph with 5.6 m/s belt speeds. Integration of advanced fire detection, suppression, and evacuation systems. Associated Yard Supply Infrastructure: Seamless integration with yard systems for material handling efficiency. Documentation and Handover: Full BIM-integrated documentation and operational handover to ensure sustained performance. |
| Result / Outcome | Delivered a fully operational coal preparation plant stacker system, meeting all capacity and performance goals. Project execution across 101,000 hours with ZERO Lost Time Injuries (LTI) and only one First Aid Injury (FAI). Reinforced Xstrata Coal’s operational efficiency and established Qfactor as the preferred partner for coal handling solutions. |
| Value-Added Differentiator | I took a phased approach that ensured seamless execution from development through commissioning. By leveraging the experience from gained previous projects and tailoring solutions to the unique requirements of Xstrata Coal’s new mine, we delivered cutting-edge stackers and yard infrastructure. This end-to-end delivery model, combined with our unwavering commitment to safety, quality, and innovation, cemented Qfactor’s reputation as an industry leader in coal preparation and handling technology. Undertaking a ‘Stock Yard’ RAMBO whole of Project Integated Design Reivew (SiD) we were able to mitigate operational constriants, maximise utility of the machines and improve functional Capacity of the whole plant. |
Check out more about the industries I have served : Here
I led the development and execution of the project as Head Contractor Program Director/delivery team.
Design for the design project the team consisted of:
- 1 x Lead designer
- 8 x Engineers,
- 10 x Drafters
- 1 x PLC/SCADA designers
- 1 x Rail Engineer
Construction for the Construction project the team will consist of:
- 1 x Project Manager
- 1 x Construction Engineer
- 1 x Contracts Manager
- 1 x Quality Manager
- 1 x Safety Manager
- 1 x Structural Fabrication contractors
- 1 x Mechanical systems Fabrication contractors
- 1 x Erection contractor
- 7 x Functional Suppliers (Motors, Gearboxes, Drives, Pullies, Idlers, P&I Monitoring/Control )
- 1 x Electrical contractor
- 1 x Construction Manager
Project was completed with 101,000 hrs with ZERO LTI and 1 x FAI.
