Xstrata Coal – High‑Capacity Coal Preparation Plant Stackers & Yard Infrastructure: To design, construct, and commission two state‑of‑the‑art, high‑capacity coal stackers capable of reliably handling two distinct grades of product at Xstrata Coal’s new preparation plant — delivering safe, automated, and efficient daily operations, fully integrated with yard supply infrastructure and mine systems.
Primary Sector: Robotics
Secondary Sectors: Mining & Resources | Minerals | Manufacturing
Project Snapshot
| Item | Detail |
|---|---|
| Client | Xstrata Coal |
| Project Name | Development, Design, Fabrication, Installation & Commissioning of Coal Preparation Plant Stackers |
| Project Type | Capital Project – Bulk Materials Handling |
| Project Value | $40 million |
| Project Duration | June 2009 – July 2010 |
| Location | Australia |
| Design Capacity | 3,000 tph (design), operating at 2,400 tph |
Strategic Objective
To design, construct, and commission two state‑of‑the‑art, high‑capacity coal stackers capable of reliably handling two distinct grades of product at Xstrata Coal’s new preparation plant — delivering safe, automated, and efficient daily operations, fully integrated with yard supply infrastructure and mine systems.
The Challenge
The newly developed mine required purpose‑engineered stacker systems that exceeded standard designs. While previous projects provided a performance baseline, this plant demanded:
- Higher throughput and reliability under continuous duty conditions
- Accommodation of two separate coal grades, each with unique handling requirements
- Tight integration with new yard supply infrastructure and control systems
- Compliance with stringent safety, quality, and operational standards
- Delivery across design, fabrication, construction, and commissioning while coordinating multiple disciplines and contractors
All of this needed to be achieved without production risk and within a fixed delivery window.
Our Approach
As Head Contractor and Program Director, Qfactor led the project through a fully integrated delivery model — from development through commissioning.
Technology & Engineering Leadership
- Applied learnings from previous Xstrata projects to develop advanced, high‑capacity stacker designs
- Engineered customised handling solutions aligned to the operating profile of the new mine
- Embedded automation principles, advanced instrumentation, and PLC/SCADA integration to maximise operational consistency
Integrated Design & Assurance
- Managed a multidisciplinary design team comprising:
- Structural, mechanical, electrical, and instrumentation engineers
- Lead designer, drafting team, PLC/SCADA specialists, and rail engineering expertise
- Implemented a whole‑of‑yard RAMBO / SiD Integrated Design Review, identifying and mitigating operational constraints
- Optimised stockyard functionality, improving machine utilisation and overall plant capacity
Construction & Delivery Excellence
- Coordinated fabrication, erection, and installation across multiple specialist contractors
- Maintained strict quality assurance controls aligned with project specifications
- Orchestrated seamless interfaces between civil, mechanical, electrical, and control systems
Safety & Governance Leadership
- Established a robust safety management system across all project phases
- Delivered 101,000 work hours with ZERO Lost Time Injuries (LTI) and only one First Aid Injury (FAI)
- Maintained executive‑level reporting and transparent communication with Xstrata’s leadership team
Solution & Key Deliverables
Coal Stacker Systems
- Two high‑capacity stackers, engineered to:
- Support 3,000 tph capacity
- Operate at 5.6 m/s belt speeds
- Designed for reliable handling of two distinct coal grades
Safety & Automation Systems
- Integrated advanced fire detection and suppression systems
- Purpose‑built emergency evacuation protocols
- Fully integrated PLC/SCADA control and monitoring systems
Yard Supply Infrastructure
- Seamless integration with coal yard and plant material handling systems
- Optimised stockpile management and transfer efficiency
Documentation & Handover
- Full BIM‑integrated design and construction documentation
- Comprehensive operational and maintenance handover to Xstrata Coal’s operations team
Result / Outcome
- Delivered a fully operational coal preparation plant stacker system, meeting all performance and capacity criteria
- Improved yard efficiency, machine utilisation, and plant throughput
- Achieved exemplary safety performance across a complex, high‑risk construction environment
- Strengthened Xstrata Coal’s operational capability and reliability
- Established Qfactor as a trusted delivery partner for large‑scale coal handling and automation projects
Qfactor Value‑Add
- End‑to‑end project leadership, from development through commissioning
- Proven expertise in high‑capacity, automated bulk materials handling systems
- Application of integrated design assurance methodologies (RAMBO / SiD) to unlock latent plant capacity
- Strong safety culture with measurable, industry‑leading outcomes
- Ability to tailor technically complex systems to site‑specific operational realities
By combining engineering rigour, robotics‑enabled automation, and disciplined program governance, Qfactor delivered a resilient, high‑performance stockyard solution that exceeded operational expectations and set a new benchmark for coal preparation plant design and execution.
