Projects by region: Oceania

Dubbo Zirconia Project

Client
Alkane Resources
Location
Dubbo, NSW Australia
Products
Zirconia, Niobium, Light and Heavy Rare Earths
Project Capital Value
$893 M (ref 2011 TZMI Mineral Sands Congress Presentation)
Project Summary
The Dubbo Zirconia Project (DZP) is located 20 kilometres south of Dubbo in the Central West Region of New South Wales. The DZP is based upon one of the world’s largest in-ground resources of the metals zirconium, hafnium, niobium, tantalum, yttrium and rare
earth elements.


EPMS was initially engaged by Alkane Resources to provide design and engineering services
for their Feasibility Study considering a plant capacity of 400,000 tpa. Upon completion of the 400,000 tpa Feasibility Study. EPMS undertook a further study for a 1 Million tpa plant.
Scope
Development of Process Flow Diagrams

Development of Preliminary Process and Instrumentation Diagrams

Produced Project Design Criteria Documentation

Process Plant and Associated Infrastructure


Design, which included:


Sulphation/Roasting

Leaching

Filtration

Solvent Extraction

Zirconium Precipitation

Zirconium Washing and Recovery

Niobium Precipitation

Niobium Washing and Recovery

Waste Neutralisation

Light Rare Earths Circuit

Heavy Rare Earths Circuit

Plant Infrastructure and Services

Equipment Sizing and Selection

Preparation of Equipment Datasheets and Specifications

Detailed General Arrangement Drawings

Compilation of Capital Cost Estimate
Project Achievements
EPMS provided high quality robust deliverables for inclusion in the Feasibility Study report.
EPMS’s performance on the project was highly regarded by Alkane and as a result EPMS has an ongoing role on the owner’s team as the project progresses to the next stage.

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Southdown Project

Client
Grange Resources & Sojitz Corporation
Location
Southdown, Western Australia
Products
Magnetite
Project Capital Value
$1.6 Billion (for 7Mtpa (2009)
Project Summary
The Southdown Joint Venture is a joint venture between Grange Resources, an Australian publicly listed company (70%) and Sojitz Resources and Technology Pty Ltd (30%), a Japanese trading house. The Joint Venture proposes to mine and export 10 million tonnes of premium magnetite concentrate annually. The product will be exported from the Port of Albany and processed into pellets for international markets. The Southdown Magnetite Project mine life is estimated to be from 19 to 40 years.


EPMS was engaged by the Southdown Joint Venture as Owner’s Engineer and provided
engineering and design assistance when required. Some of EPMS’s senior management
team have had an involvement with the Southdown Project going back as far as 2006.
Scope
Development and Management of Comminution, Beneficiation and Pelletisation Testwork

Flowsheet Development

Management of Process Engineering and Process Plant Design

Balance of Plant Engineering and Design

Engineering and Design pertaining to the routing and easement requirements for the proposed slurry pipeline

Management of Tailings Management Studies being undertaken by Golders

Order of Magnitude Studies for Albany and Kemaman

Pellet Plant Layouts (Kemaman)

Port Layouts (Albany)

Investigation into Process water Options and Pricing

Early Water and Mass Balance Calculations

Document Management Support

Executive Summary Report

Project Controls Assistance

Technical Assistance
Project Achievements
EPMS maintained an involvement with the Southdown Project up until around 2010. In 2009 Grange developed their own in-house owner’s team and engaged a major EPCM consultant to finalise the PFS and undertake the DFS. EPMS are still engaged by Grange to provide technical assistance and undertake engineering studies for both Grange’s Southdown and Tasmanian operations, Savage River and Port Latta.

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Concentrate Dewatering and Storage Study

Client
Grange Resources (Tasmania)
Location
Port Latta, Tasmania
Products
Magnetite Concentrate and Pellets
Project Capital Value
Approx $93.5M (for Option B)
Project Summary
The project is located in Port Latta on the northwest coast of Tasmania where Grange Resources Tasmania Pty Ltd (Grange) owns a pellet plant and port facility. EPMS was engaged by Grange to undertake an Options Study for concentrate only production at Grange’s existing Port Latta site (Option B) and an alternative site (Option A). The sites are situated approximately two kilometres inland of exiting port facilities.




Favourable market conditions for concentrate and the need to invest heavily in the aging plant to meet operational and environmental requirements have been the impetus for this Study. The existing pellet and filter plants were installed over forty years ago and only designed for a twenty year mine life. A modern filtration plant would offer significant benefits in terms of reliability, efficiency and maintenance.

The Study concluded that the most cost-effective option would be to locate the proposed facilities filtration plant, concentrate storage shed, conveyors and all associated infrastructure on the existing port site (Option B).
Scope
Options Study including:


PFD’s (for both Options)


Development of equipment lists
(for both Options)


Development of equipment datasheets
and specifications for vendor pricing


Engineering and Design (of sufficient
detail to achieve a ±25% cost estimate)
for both Options


Compilation of Capital and Operating
Cost Estimates (for both Options)


Initial Risk Review (for both Options)
Project Achievements
EPMS was able to provide high-quality robust deliverables for inclusion into the Options Study report and the Capital Cost Estimate provided was to a level of accuracy that exceeded the industry standard for this stage of study.



EPMS’s past project experience gained on similar projects ensured that the work was completed efficiently and within the client’s extremely tight timeframe.

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South Mine Expansion

Client
Tiwest JV
Location
South Mine, Cooljarloo, WA
Products
HMC
Project Capital Value
Confidential
Project Summary
Cooljarloo, Tiwest’s mineral sands mining operation, located 170 km north of Perth, Western Australia, is made up of two mines. The Cooljarloo South Mine, the principal mine is a dredging operation.


EPMS was engaged by Tiwest to undertake a Pre-feasibility Study and Detailed Feasibility Study to consider requirements for a throughput upgrade of Cooljarloo South Mine. To facilitate the increase in capacity of 2400 t/h up to 3600 t/h, upgrades were required to Tiwest’s primary and secondary mining dredges, the feed preparation plant and concentrator.
Scope
Dredge Capability Analysis

Pump and Piping Calculations

Process Simulations using LIMN

Load Study

Cyclone Evaluations and Selections

Trommel and Boilbox Design

Slimes and Water Balance

Development of Preliminary Designs

Structural Integrity Checks

Stability and Buoyancy Analysis for Dredge and SMC

Development of Specs, Datasheets and Scopes of Work

Development of Capital Cost Estimate for Upgrade

Determination of Refurbishment Costs and Upgrade Requirements for Second-hand Dredge

PFS and DFS Reports
Project Achievements
EPMS delivered robust PFS and DFS reports within the client’s required timeframe and budget. Subsequently the upgrade works were undertaken by Tiwest and desired throughput targets were met and in some cases exceeded.

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Dongara Dredge Mining Pre-feasibility Study

Client
Tronox
Location
Dongara, WA
Products
Heavy Mineral Concentrate
Project Capital Value
Confidential
Project Summary
The Dongara Project, owned by Tronox, is located approximately 28 km south-east from the coastal town of Port Denison and some 370 km north of Perth in Western Australia. Following a successful Dredge Proof of Concept study, EPMS was again engaged by Tronox to undertake a Pre-feasibility Study for the project, considering a 1500 t/h dredge mining operation. The dredgable deposits will be mined this way after completing the dry mining of the first deposit. A feed preparation unit and pre-concentrator would be included in the dredging operation to upgrade the mined ore prior to pumping to the relocated North Mine Concentrator from Cooljarloo.
Scope
Specify and conduct vendor enquiries for a suitable mining dredge

Prepare site layout plans for dredge mining activities

Design and cost a floating pre-concentrator plant

Develop plans for the upgrading of the existing Dry Mining equipment to that required for dredging operations

Determine if an SPQ upgrade is required and develop the plans and cost to achieve this if required

Detailed process flow sheets and mass balances

Detailed P&IDs

Preliminary power reticulation designs

Update the capital cost estimate to the required accuracy (±30%)

Report written in conjunction with Tronox to cover all engineering input on this project

Preliminary plans for the change over from dry to dredge mining

Prepare a preliminary Gantt
Project Achievements
EPMS successfully worked with Tronox to execute the study and prepare the report. The project was completed within the short time frame allowed and on budget.

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Dongara Dry Mining DFS

Client
Tronox
Location
Dongara and Muchea WA
Products
Heavy Mineral Concentrate
Project Capital Value
Confidential
Project Summary
The Dongara Project, owned by Tronox, is located approximately 28 km south-east from the coastal town of Port Denison and some 370 km north of Perth in Western Australia. EPMS was engaged by Tronox to undertake a Definitive Feasibility Study for the project considering a 600 t/h dry mining operation using the relocated North Mine Concentrator from Tronox’s existing operations at Cooljarloo.


The study also included identifying methods of coatings removal from the mineral grains and design of a 50 t/h attritioning plant, to enable the Dongara HMC to be successfully processed through Tronox’s existing Dry Mill and SR kiln at Chandala, WA.
Scope
Testwork co-ordination and supervision of bulk sample spiral and coatings removal applications

Detailed flowsheets, general arrangement drawings, mass and water balances for the Dongara wet plant and new attritioning circuit

Infrastructure specifications and design for the new Dongara site including water, power, gas, communications, roads, offices and accommodation

Site layouts for both the Dongara mine site and attritioning plant at Chandala

Determine the equipment requirements for all the pumping of sand tails, concentrate and slime slurry at Dongara

Enquiries into Shire approval procedures for both construction camp and single persons’ quarters

Development of detailed cost estimates, at an accuracy of ±10%, for all designs.

Create a cashflow forecast for the execute Phase of the project.

Define a Project Execution Plan and create a project Gantt Chart for the Execute Phase of the project

Report on all outcomes and phases of work completed by EPMS
Project Achievements
EPMS worked successfully with Tronox to carry out the study and finalise the report. The project was completed within the short time frame allowed and on budget.

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Wilcherry Hill Project

Client
Ironclad Mining Limited
Location
105 km northwest of Whyalla, South Australia
Products
Magnetite
Project Capital Value
Confidential
Project Summary
IronClad Mining’s tenements in South Australia are collectively known as the Wilcherry Hill Project. The tenements are located 30km north of the township of Kimba. The Wilcherry Hill Project comprises of four tenements and covers an area of 976 km2. The tenements are EL4162 Wilcherry Hill, EL4286 Vally Dam, EL4421 Peterlumbo, EL3981 Eurilla Dam.
Scope
Preliminary Plant Designs
Order of Magnitude Cost Estimates
Conceptual Design for the Dry Magnetic
Separation (DMS) Plant
Project Achievements
EPMS provided high-quality, fit-for-purpose concept and preliminary designs that were used as the basis for detailed design.

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Cooljarloo West Pre-feasibility Study: Engineering

Client
Tronox
Location
Cooljarloo, WA
Products
Heavy Mineral Concentrate
Project Capital Value
Confidential
Project Summary
Exploration leases owned by Tronox to the west of their current mine at Cooljarloo contain three resources collectively referred to as Cooljarloo West.



As part of a Pre-feasibility Study conducted by Tronox, EPMS was contracted to supply engineering services to examine a number of options to relocate the mining equipment from Cooljarloo to the Cooljarloo West leases.
Scope
Option analysis on alternatives for the relocation of the mining activities from Cooljarloo to Cooljarloo West


Options risk analysis


Capital cost estimates and schedules prepared for client’s preferred option


Review of transportation routes


Preparation of site layouts with transportation routes


Water requirement calculations


Bulk earth works calculations


3D modelling of canal and lock routes
Project Achievements
EPMS was able to clearly identify the best option from a cost and schedule perspective. This allows Tronox to progress the project by focussing on the best method of relocation. Report was submitted as required on time and within budget.

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New Refuelling Gantry and Fire Dosing System Design

Client
Coogee Chemicals
Location
Kwinana
Products
Fuels
Project Capital Value
Unknown
Project Summary
Coogee Chemicals is a privately owned company with its head office based in Western Australian. It produces a wide range of industrial, agricultural and mineral processing chemicals for supply to both the Australian and International markets. In addition it provides bulk liquid terminal facilities for import, export and storage of chemicals and fuels and a dangerous goods transport operation in Western Australia and Queensland. EPMS assisted with the update of operations and safety infrastructure at Coogee Chemicals’ Western Australian based facility.
Scope
Development of Concept for the installation of overhead supply lines for loading arms

Development of Concept for the installation of an internal structure to support overhead pipework

Development of Fabrication/Construction Drawings sufficient to allow the installation of overhead lines

Development of Concept for the Installation of a fire sprinkler system

Development of Fabrication/Construction Drawings sufficient to allow installation of the fire distribution and sprinkler system
Project Achievements
EPMS provided high-quality, cost-effective engineering and design services to Coogee Chemicals. The project was completed on budget and within the client’s extremely tight timeframe.

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Sino Iron Project

Client
Citic Pacific Mining
Location
Cape Preston, 100km southwest of Karratha
Products
Magnetite
Project Capital Value
~ $5.9 Billion
Project Summary
The Sino Iron Project is the largest magnetite mining and processing operation under construction in Australia. The project is being developed at Cape Preston, 100 kilometres
southwest of Karratha in Western Australia’s Pilbara region.
Scope
Development of Technical and Functional Specifications for new mining fleet including, drills, shovels, trucks, mobile crushing plant, and light vehicles

Technical Evaluation of tenders

Design of temporary facilities
Project Achievements
All work was completed on time, within
budget and to the satisfaction of the client’s
project owner.

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Elite Expansion Project

Client
Coogee Chemicals Ltd
Location
Elite Chemicals Chlor - Alkali Facility, Lytton, Brisbane
Products
Sodium Hypochlorite, Hydrochloric Acid and Caustic Soda
Project Capital Value
$40M
Project Summary
Due to an increase in demand for water treatment chemicals in Queensland, Coogee Chemicals committed to expanding their Elite Chemicals plant in Lytton Brisbane during 2015. The expansion project significantly increases the capacity of the existing plant utilizing the latest technology to increase energy efficiency. The plant takes salt and water as the main inputs and processes them to produce Sodium Hypochlorite, Hydrochloric Acid and Caustic Soda.
Scope
Preparation of Scopes of Work for: structural, mechanical, piping, civil, piling


Review of Process Flow Diagrams


Review of Pump Sizing


Preparation of Mechanical Datasheets


Incorporation of site 3D Scan data into 3D model for accurate integration between new designs and existing plant


Mechanical Design and Detail Drawings


Civil Design Detail Drawings


Structural Design and Detail Drawings


Full detail design for the main process plant building including architectural drawings


Piping Design to AS4041 including 3D modelling and full Piping Isometric Drawings for all pipe >25NB


Design Support during Construction


Full 3D model produced with adaptive constraints.

Project Achievements
Design carried out to a high standard under tight schedule using a cohesive multidisciplined design team. Full 3D model created allowing additional upgrades on site to be easily designed. Seamless integration of brownfield site 3D scan data into the overall 3D model. Large quantity of piping isometric drawings created efficiently using latest 3D modelling techniques and automated isometric creation software.

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