Koolyanobbing 11Mtpa Upgrades

Engineering, procurement, construction management and commissioning for the expansion of the Koolyanobbing iron ore project from 8.5Mtpa to 11Mtpa. The project included mine equipment, long distance haulage, iron ore handling plant upgrades, rail upgrades and port upgrades.  Onyx Projects developed this project from the inception undertaking a scoping study, pre-feasibility study, feasibility study and project execution.

The Koolyanobbing 11Mtpa Upgrades incorporated the following works:

  1. Koolyanobbing Ore Handling Plant Upgrades
    Engineering, procurement, construction management and commissioning of upgrades to the ore handling plant.  The upgrades included a new primary crushing area incorporating a new ROM wall, ROM bin, apron feeder, grizzly feeder, primary jaw crusher and primary crushed ore conveyor; a new primary screening area incorporating a double deck banana screen and three discharge conveyors; a new secondary crushing area incorporating a lump bin and two cone crushers; and modifications to the product conveyors and transfer chutes for the increased throughput.
  2. Mine Infrastructure
    Design, specification, procurement, construction management and commissioning of mine infrastructure including power generation, power supply, mobile plant workshops and sewage treatment.
  3. Road Overpass
    Project management and construction management of a subcontractor designed road overpass over a rail line.
  4. Road Haulage
    Road haulage planning and procurement of triple trailer side tipping road trains.
  5. Mining Equipment
    Mining equipment planning, procurement and project management of the purchase and supply of mining equipment including:Track dozers, graders, water carts, haul trucks, drill rigs and wheel loaders.
  6. Above Rail
    Above rail infrastructure planning, procurement and project management of the supply and construction of a locomotive and wagon maintenance facility, locomotives, port shut tractor and iron ore wagons by the above rail service provider.
  7. Below Rail
    Below rail infrastructure planning, procurement and project management of the supply and construction of the port yard extension and additional and extended rail passing loops by the below rail service provider.
  8. Esperance Port Upgrades
    Upgrade and debottlenecking works on the iron ore circuit to increase throughput from 8.5Mtpa to 11Mtpa.  The works included the engineering, procurement, construction management and commissioning of replacement rotary car dumper hoppers, removal of rotary car dumper hopper unloading conveyors and replacement with belt feeders, transfer chute modifications, tramp metal magnet installation and the upgrade of conveyor drives to VVVF control.  The work was carried out during a series of shutdowns which were planned and managed by Onyx Projects.
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