Coal Supply Chain Icr
Coal Supply Chain Icr
Coal Supply Chain Icr
COAL SUPPLY
CHAIN
CONTENTS
Overview 03
Industry Strengths 04
About Austrade 28
References 28
The Commonwealth does not endorse any company or activity Before reusing any part of this document, including reproduction,
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requirements under the CC BY licence.
Unless otherwise specified, all amounts in this report are in
Australian dollars. 17-18-71. Publication date: June 2018.
Australia’s coal sector offers leading products and services that span the entire supply chain,
as well as research and innovation to help maximise productivity, efficiency and sustainability.
Australia’s coal industry has been built on over 200 mines, transport systems and loading facilities, as well
years of growth and innovation. Through continuous as training, technical support and project management.
developments in mining technology, health and safety
Australian companies can offer high-level equipment,
and environmental management, the Australian coal
technology and services across the entire coal supply
sector has established itself as a sophisticated, high-
chain, including in:
tech industry. Australia is a leading global supplier of
high-quality thermal and metallurgical coals. ›› exploration
Coal mining began in New South Wales (NSW) in the ›› mine development – design, construction and
1790s. Today, Newcastle is the world’s largest coal operation of underground and open-cut coal mines
export port and is considered the pricing benchmark
for seaborne thermal coal in the Asia-Pacific region.1 ›› engineering
jobs to the regional economy in 2015–16.3 ›› technical support and project management
Abbot Point, Hay Point and Gladstone, service the ›› automation and digital solutions.
region, helping make Queensland the world’s largest
exporter of seaborne-traded metallurgical coal.5 In addition, Australia’s strong economy, proximity to
the energy-hungry markets of Asia, the country’s rich
Australia also has significant brown coal resources,
intellectual capital and a supportive government,
although these have much lower energy content.
make Australia attractive to investors and new market
Brown coal is located mainly in Victoria.
entrants seeking sustainable, long-term returns.
Australia’s position as a major coal producer and
exporter is underpinned by a thriving equipment and Talk to your local Austrade representative for tailored
services sector. Australia is globally recognised for information about connecting and partnering with the
expertise in the design, construction and operation of Australian coal supply chain industry.
While global energy markets are undergoing rapid Australia’s high-energy, low-ash coal is valued for its
changes, coal power plants remain a significant suitability for advanced coal-generation technologies,
contributor to baseload energy for the foreseeable low levels of other elements and reduced emissions
future. Australia’s coal industry has a wide range of per unit of energy produced. Australian metallurgical
capabilities that are increasingly important in the current coal is considered to be among the best options for
global environment. These span the whole of the coal steelmaking, yielding strong cokes with low reactivity
supply chain, from surface and underground operations, and low levels of sulphur and phosphorus.11
through to coal preparation and materials handling, port
and logistics technologies and power generation.
The Bowen Basin
The industry has earned an international reputation not
The Bowen Basin is an area of coal reserves and
only for resilience, but also for its demonstrated ability
mining-related communities that extends over
to boost production, reduce costs, improve safety and
approximately 60,000 square kilometres of central
environmental performance, and eliminate bottlenecks
Queensland.
across the entire coal supply chain.6
The Bowen Basin is the largest coal reserve in Australia. It
For a detailed listing of Australian companies with contains most of Queensland’s high-quality metallurgical
capability across the coal supply chain (including coal reserves, as well as significant deposits of thermal
rail and port), read the Company Directory. coal. As of June 2016, there were 41 active coal-mining
austrade.gov.au/mets operations and two metalliferous mines. In 2016, the
Bowen Basin mines exported a record 221 million metric
tonnes of coal12, which represented 83 per cent of
Coal production and export
Queensland’s total coal production.
In 2017–18, Australian metallurgical coal exports are
In addition, the Carmichael coal mine project in the
forecast to be 192 million tonnes, with export earnings
north Galilee Basin is set to become Australia’s largest
of $35.3 billion.7 Australia’s exports of thermal coal are
thermal coal mine. The Carmichael project will be built
forecast at 203 million tonnes in 2018–19, with export
on the world’s largest single coal tenement, with the
earnings forecast to rise by 7.7 per cent in 2017–18 to
capacity to produce up to 60 million tonnes per annum
$20.4 billion. 8
at full production.13 It is scheduled to make its first coal
Australia has the fourth largest share of coal reserves shipment by early 2021. The project will be linked by a
in the world, estimated at more than 100 years of new 388-kilometre standard gauge rail line to Abbot
production for black coal and over 400 years for lignite Point Port near Bowen.
(brown coal). 9
The Port of Hay Point is one of the largest coal export
The majority of Australian coal production is exported. ports in the world14, and is situated about 40 kilometres
Australia is a leading supplier of high-quality coal to south of Mackay. The port comprises two separate
both mature and emerging markets, supplying an coal export terminals with a combined capacity of
estimated 54 per cent of world trade in metallurgical 140 million tonnes per annum. Mines are linked to the
coal and 24 per cent of world trade in thermal coal.10 port terminals through an integrated rail port network.
GEOGRAPHIC PROJECTION
Geocentric Datum of Australia
Major railway
Coal-related railway
Coal port
Note: Coal-related railways shown on
the map are preliminary and is subject to
confirmation and possible amendment.
0 – 0.5
0.5 – 1.0
1.0 – 2.5
2.5 – 3.0
3.0 – 5.0
>5.0
© Commonwealth of Australia (Geoscience) 2014. With the exception of the Commonwealth Coat of Arms
and where otherwise noted, all material in this publication is provided under a Creative Commons Attribution 3.0
Australia Licence. http://creativecommons/licenses/by/3.0/au
GEOGRAPHIC PROJECTION
Geocentric Datum of Australia
Major railway
Coal-related railway
Coal port
Note: Coal-related railways shown on
the map are preliminary and is subject to
confirmation and possible amendment.
0 – 0.5
0.5 – 1.0
>1.0 – 2.5
© Commonwealth of Australia (Geoscience) 2014. With the exception of the Commonwealth Coat of Arms
and where otherwise noted, all material in this publication is provided under a Creative Commons Attribution 3.0
Australia Licence. http://creativecommons/licenses/by/3.0/au
Australian capabilities in power generation include Australia is a world leader in sustainable mining thanks
turnkey engineering, procurement and construction to a combination of a long history of implementing
of steam cycle and boiler technologies, and the strong environmental and safety regulations, as well as
design, supply, installation and servicing of engineered adopting voluntary codes of practice and standards.
conveyor products, fuel-handling equipment and
The Minerals Council of Australia’s Enduring Value
services, and combustion technologies.
Framework for Sustainable Development provides
Australian companies can deliver all levels and stages critical guidance to mining companies on applying the
of projects from concept design and feasibility studies International Council on Mining and Metals’ Sustainable
through to asset management. Development Framework Principles at an operational
level. Australian mining companies recognise the need
Considerable experience and technical expertise to manage their mining and mineral projects in an
exists in materials handling, flow design, milling, environmentally and socially responsible manner.
combustion technology, testing and analysis. Australia They have developed a range of initiatives and protocols
has longstanding experience in electrostatic and fabric that cover all stages of the mining process, from initial
filter dust collection technologies, ash processing and exploration to mine rehabilitation and closure. In addition,
research into ash reuse. all member companies of the Council are required to sign
off on the Enduring Value framework.
Beneficial use of coal combustion by-products is
important for the sustainable use of coal. Fly-ash Read Austrade’s Sustainable Mining Industry Capability
products can potentially displace the use of other Report.
energy-intensive raw materials. The Ash Development austrade.gov.au/environment-and-energy
Association of Australia comprises producers and
marketers of power station ash; its objective is
investigating and expanding market opportunities for
the use of these materials in construction, agriculture Underground mining technologies
and manufacturing. and solutions
Over the past decade, considerable effort has been
Australian underground coal mine safety and
directed to developing low-emission fossil fuel
productivity benchmarks are among the world’s best.
technologies in Australia and internationally. The
The industry has developed innovative products and
Australian Government is engaged in domestic carbon
services, such as automation technologies and power
capture and sequestration (CCS) programs and
and safety systems that are delivering safety, efficiency
international collaborative activities to accelerate the
and cost benefits at mines around the world.
development and deployment of CCS. An independent
report commissioned by government, industry and Longwall mining, which accounts for over 90 per
research organisations has laid down a comprehensive cent of Australia’s underground coal production20, is
plan for CCS deployment in Australia. a particular area of focus. The Australian industry is
committed to optimising health, safety and productivity
Read Austrade’s Power Industry Capability Report.
around the longwall process.
austrade.gov.au/mets
Read Austrade’s Underground Mining Industry
Capability Report. austrade.gov.au/mets
CASE STUDY
CSIRO’S LONGWALL AUTOMATION TECHNOLOGY IMPROVES
PRODUCTIVITY AND PROTECTS LIVES
Underground mine operators constantly seek to improve longwall productivity and safety, and increase
the speed of roadway development, a limiting factor to longwall operation.
Developed in partnership with the coal industry, CSIRO’s Landmark Automation Steering Committee
(LASC) automation technology is designed to separate personnel from hazards while improving
productivity.
The system uses sophisticated remote guidance technology to plot the position of critical equipment
in underground longwall and roadway development mining processes in three dimensions. This allows
miners to steer the equipment and control core functions, such as longwall face alignment, horizon
control and continuous miner navigation, without having to be in hazardous areas.
Previous systems required mining operations to be stopped to correct positioning, whereas the LASC
technology allows for continuous steering. The real-time progress of the longwall can also be monitored
via the internet from anywhere in the world, leading to further gains in efficiency.
›› reduce environmental disruption and rehabilitation costs by using more accurate selective resource
recovery on longwall mining operations.
Major global longwall equipment manufacturers such as Komatsu, Eickhoff and Caterpillar have also
integrated the CSIRO technology. The technology is also being deployed in working implementations in
North America, Europe and China.
CSIRO’s longwall automation research is focusing on new in-house navigation and guidance technology
development to meet the specific requirements of international markets. Work is also being undertaken
to embed instrumentation, such as explosion-protected 360-degree scanning laser sensors, into mining
automation systems.
csiro.au
CASE STUDY
NEPEAN LONGWALL DELIVERS COMPLETE LONGWALL
MINING SYSTEMS
NEPEAN Longwall is Australia’s largest privately owned engineering, mining services and industrial
manufacturing organisation. Through its three specialist businesses – NEPEAN Conveyors, NEPEAN
Longwall and NEPEAN Power – the company supplies fully integrated mining systems, servicing and
overhaul services.
NEPEAN Longwall designs, engineers, integrates and supports longwall equipment and systems.
The company completed the first Australian installation of the Landmark Automation Steering Committee
technology, which features a positioning measurement system for the longwall shearer, automated face
alignment via a roof support control system, shearer horizon control and real-time monitoring.
The equipment has a nameplate capacity of 4,000 tonnes per hour.
The company also designed, engineered, manufactured, tested, delivered and commissioned a
complete longwall mining system for an underground colliery in central Queensland. The project set new
benchmarks for longwall capital equipment lead times and was the first longwall system supplied and
commissioned in Australia at nil price variation.
Designed to address the unique roof and floor conditions at the mine, the equipment safely and reliably
controlled the expected mining environment – which included above-seam prior workings and soft
floor – and operated with a narrow 700-millimetre cutting web. It also utilised a 1,200-tonne-rated roof
support with features to tightly control the tip-to-face distance.
nepean.com
CASE STUDY
AMPCONTROL DEVELOPS WORLD-FIRST 11KV ELECTRICAL
LONGWALL SYSTEM
Ampcontrol provides integrated electrical, monitoring and control solutions for above-ground and
underground hard rock and coal mining applications. The company has offices in Australia, the UK,
France, India, China, Hong Kong and Singapore, supporting mining OEMs, major mining companies and
contractors including BHP, John Holland, Anglo American, Komatsu Mining, Cat, Downer and Sandvik.
Ampcontrol produced the world’s first 11kV Armoured Face Conveyor (AFC) longwall system for
installation in Zone 1 hazardous areas. An 11kV electrical system for powering the longwall AFC had
never been used in underground coal mining anywhere in the world.
Due to the hazardous zone rating of the mine site, Ampcontrol developed world-first 11kV products to
suit the application and environment. The company also took extensive engineering design review,
calculation and verification testing to prove it was safe to use 11kV electrical circuitry in the hazardous
zones. It also developed a new Intrinsically Safe (IS) LED lighting system, an innovative 11kV protection
scheme and a SIL-3 rated high-integrity isolation system.
Ampcontrol, together with its project partners, was awarded a 2010 National Engineers Australia
Engineering Excellence Award for this project.
ampcontrol.com.au
CASE STUDY
MRA DELIVERS EFFICIENCY GAINS SPANNING THE SUPPLY CHAIN
Australian company MRA is a leading provider of automation and plant optimisation technology to the
materials handling industries. Established in 1998, it has become known for a range of products and
solutions that provide efficiency benefits from pit to port.
MRA’s range of coal supply chain solutions includes automated ship loading, automated stockyard
management systems, mobile machine collision avoidance systems, automated train loading systems,
automated dump station systems and advanced conveyor optimisation systems. The company’s
specialist domain knowledge in mining and ports infrastructure has seen MRA become a preferred
supplier to global OEMs and its automated systems have been installed on mobile machines throughout
the Asia-Pacific region for the past 18 years.
Ship loader automation is a major optimisation target for export terminals globally. In Newcastle,
Australia, MRA has successfully installed the Port Waratah Coal Services Carrington Ship Loaders SL4
& SL5 Boom & Spout Collision Avoidance System, and in Western Australia the Cape Preston Port
Corporation Automated Barge Loader.
MRA’s engineers are regularly engaged for specialist services in sites across China and Korea to provide
expertise in electrical and automation design and commissioning. Global exports also include ground-
breaking technology for automated barge-loading systems and a number of projects in discussion for
the supply of materials-handling products and solutions.
MRA also shares its specialist domain knowledge through collaborations with industry and globally
recognised research institutes, focusing on innovation in the materials handling industries, in particular
the mining and ports infrastructure sectors.
Its technology is providing major gains in productivity, profitability and safety and dramatically reduced
environmental impacts, by removing traditional bottlenecks.
mra.com.au
CASE STUDY
4TEL HELPS OPERATORS CONTROL COSTS AND OPTIMISE SAFETY
4Tel is a specialist software and technology company that has been servicing clients in the rail, road and
government sectors for over 17 years. 4Tel’s areas of expertise range from design and fitout of transport
control centres, to software systems designed to optimise network performance and improve efficiency.
4Tel is represented in Kenya and Chile and has plans to expand further in 2018.
As a complete solution provider, 4Tel offers consulting services as well as proprietary systems that are
built in-house and come with tailored support plans. These systems and services include:
4Tel designed, commissioned and maintains all the electronic control systems used in John Holland’s
Country Regional Network Management Centre based in New South Wales, Australia. 4Tel has been
able to digitise many of the paper-based activities including electronic tracking graphs, access and billing
systems, issuing of movement authorities, and more recently, an app that interlocks work-on-track occupancy
authorities into the network control system. Through automation of routine process and maximising the best
of the Internet-of-Things technology, 4Tel is continuously innovating new ways to create a digital railway that
improves safety and decreases costs while maximising operational efficiency.
Across the coal supply chain, 4Tel’s solutions are used for tracking assets during movements between
the pit and port, generating reports on performance and inconsistencies, and alerting receiving entities
to arriving deliveries. 4Tel’s systems enable operators to improve safety and reduce costs.
4Tel’s tracking system has customised automated reporting functions that alert coal loaders to
approaching trains. This optimises train loading and staff efficiency, and avoids penalties caused by
information delays. This real-time tracking information increases the visibility of operations across the
network, making assets dispatch and people management easier.
4tel.com.au
›› risk minimisation
Australia is a world leader in software that services
the resource industry and a significant proportion of ›› processes and data quality
the world’s mining computer software is developed
›› data accountability
in Australia. In addition to capabilities and solutions
developed within the sector, software and technologies ›› haulage optimisation.
from other sectors, such as the defence, aerospace or
automotive industries, have the potential to help solve
One of the Australian companies providing these
mining challenges.
solutions is E.J. O’Donovan & Associates, a leader
Data analytics has created a step-change in in conveyor engineering. Its dynamic analysis
technology, which together with automation can program BeltDYN enables accurate analysis of
maximise the effectiveness of coal asset utilisation. conveyor systems and its discrete element modelling
capabilities span design and quantitative evaluation of
Software applications allow coal mine operators
transfer chutes prior to manufacture and installation.
to develop economically effective plans to achieve
production targets, maximise resource utilisation and Another company is Deswick Mining Consultants,
optimise value. which provides software tools that span the coal
value chain, from receipt of a geological model
In addition to automation technologies, Australia has
through to reporting for costing. Its suite incorporates
advanced software capabilities specific to the coal
design and scheduling features across a core
supply chain, which allow operators to devise and
platform and associated modules such as design and
deliver improvements in:
solids modelling, Gantt chart scheduling, advanced
›› achieving production targets functionality for underground or open-cut coal mines,
mining data management, environment, sustainability
›› engineering design and troubleshooting and mine closure.
CASE STUDY
POLYMATHIAN OPTIMISES EFFICIENCY WITH SPECIALISED SOFTWARE
Polymathian, an industrial mathematics and software development company, specialises in maximising
value across coal supply chain operations. The company has successfully deployed optimisation
software for clients in Australia, South East Asia, South America and Africa.
Polymathian’s coal chain optimisation product, BOLT, is a decision support tool that maximises value from
pit to port and into the market. The optimisation scope spans strategic decisions to operational execution.
BOLT models in-pit operations, stockpiling, rail scheduling, port operations, vessel nominations, vessel
demurrage and marketing strategy for uncommitted coal. BOLT is in use by some of the largest coal
mining companies in Australia and around the world including BHP, Rio Tinto, Glencore and Adaro.
BOLT consists of four modules. The long-term module optimises over five or more years, and makes
strategic decisions for rail, port and marketing contracts. The mid-term module optimises mining,
stockpiling, washing/bypassing, marketing of uncommitted coal, and demurrage over a 12-month period.
The short-term rail module determines the optimal rail plan for the subsequent month. The short-term
wash module determines the optimal mine/wash plant operations for the subsequent month.
BOLT can also optimise a system of mines with shared resources; for example, determining how multiple
mines or pits can cooperate to meet contracted coal demand at shared ports and terminals.
The BOLT toolkit typically delivers an increase in margin of between 10 to 20 per cent depending on the
scale. For example, single mines versus a network of cooperating mines connecting by rail to a set of
ports.
Polymathian also offers bespoke tools for specific service providers within the supply chain, including
mine pit optimisation, rail scheduling and coordination, rail fleet management, port management (berth
utilisation and queuing) and shipping scheduling.
polymathian.com
CASE STUDY
MICROMINE SOFTWARE SPANS THE SUPPLY CHAIN
Micromine provides solutions that are relevant to every stage of the mining process, from geological
exploration and data management to resource estimation, 3D mine design, planning and production
control. Micromine solutions are used at more than 2,000 sites in over 90 countries, with more than
18 offices in major mining capitals. International clients include coal mining operators in South Africa,
Russia, Mongolia, China, Canada, Uzbekistan, Indonesia, the US and UK.
Micromine’s exploration and 3D mine design solution offers tools for modelling, estimation, design,
optimisation and scheduling. It provides users with an in-depth understanding of projects, so prospective
regions can be targeted more accurately, increasing the chance of a project’s success. Miners are
provided with interactive and easy-to-use modelling, estimation and design tools to simplify day-to-day
design and production tasks.
The fleet management and mine control solution, Pitram, provides tools for managing material and
mineral handling processing. Pitram assists with material management, which utilises mine design,
survey and production data to provide real-time stockpile balances and metals stock throughout the
mining operation. Its stockpile management solution is used to assist in managing rolling stock systems.
The solution has been widely implemented, including at the Cayeli Bakir Isletmeleri underground copper
and zinc mine in Turkey, where it has helped double the amount of mine activities achieving targets.
Cayeli reported that of the mine activities monitored, there has been a 10 per cent average increase
in productivity.
The databank management software, Geobank, is related to water flow and quality, and is used to
process the composting, standardisation and accumulation of coal washability data. Geobank’s logging
and management of drill data and Micromine’s blast drilling planning tools, along with environmental
data, can be captured and managed using Geobank’s tools.
micromine.com
CASE STUDY
SMS SIMULATIONS MINIMISE RISK FOR COMPLEX SUPPLY CHAINS
Simulation Modelling Services (SMS) provides consulting services, advanced analytics and simulation
technologies that predict and measure the performance of mining systems and supply chains, helping
clients minimise risk, reduce capital expenditure and operating expenses, and streamline production and
logistics processes.
SMS’s clients include several mining conglomerates with operations in Asia, Africa, the Middle East and
South America. The company’s solutions are used to test proposed production and logistics systems,
optimise the design and operation of existing platforms, identity opportunities to improve processes, and
pinpoint bottlenecks and constraints.
Mining and supply chain-related projects that SMS has applied its services and technologies to include:
›› Mines: Bengalla, Blackwater, Crinium North, Illawarra Coal, Kestrel, Poitrel and Wilpinjong
›› Coal terminals: Hay Point Coal Terminal, NCIG Coal Terminal, Port Kembla Coal Terminal and
Wiggins Island Coal Export Terminal.
Specific examples of value delivered to its clients include quantifying latent supply-chain capacity,
confirming equipment utilisation for proposed infrastructure in greenfield and brownfield projects,
determining capacity implication of various saleable product strategies and confirming adequacy of
stockpiles and varying throughput levels.
SMS develops models and simulates a wide range of scenarios to help clients determine the viability of
proposed supply chains, including optimising pit-to-port logistics. In addition, SMS models the impact
of proposed maintenance on everyday operations, so clients can implement alternative processes that
avoid or minimise risk and interruptions to their business.
simulationmodelling.com.au
CASE STUDY
NIER FINDS NEW SOLUTIONS TO MINING CHALLENGES
Based at the University of Newcastle, the Newcastle Institute for Energy and Resources (NIER) is one of
Australia’s premier centres for energy and resources research, supported by strong industry relationships
and national and international research collaborations.
NIER’s flagship research platforms focus on resources productivity, efficiency and sustainability. These
deliver products and services across the coal supply network, including efficiencies in energy and
water use in the sector, bulk materials handling and processing, optimisation in transport and shipping,
mineral characterisation, low emission and abatement technologies, and mining-related land and water
remediation.
One collaboration has resulted in the Reflux Classifier, an award-winning technology used in over 10
countries that has helped solve a processing problem by achieving the sharp separations essential in
the recovery of premium, high-grade metallurgical coal. It is an industrial machine that separates fine
particles on the basis of either density or size, improving the efficiency of the process with its unique
tilted design. The Reflux Classifier can be applied to a relatively broad range of particle sizes and
achieve higher recovery of valuable material than other water-based technologies.
Another research platform, the Priority Research Centre for Frontier Energy Technologies & Utilisation,
develops and commercialises new technologies to minimise greenhouse gas emissions around the
world, with a particular focus on carbon dioxide reduction, in collaboration with industry, government
agencies and international organisations.
The Centre is currently working on delivering safe, new methods of managing ventilation air methane
generated by underground coal mines. Fugitive methane emissions, a by-product of underground coal
mining, account for 64 per cent of all greenhouse gas emissions from the coal mining sector.
newcastle.edu.au/nier
Drawing on its founders’ engineering, design and manufacturing expertise, Chute Technology designs
and manufactures new installations; reworks existing transfers; conducts audits; optimises plants and
conveyor systems, develops maintenance plans, access ways and maintenance tooling; and undertakes
product development.
A three-pronged approach to mine rehabilitation and recommissioning has paid handsome time, cost-
efficiency and community dividends for Glencore as it brings its Integra Coal mine in the Hunter Valley
back into production.
Integra commissioned the Chute Technology engineering partnership to handle, in an integrated way,
a succession of tasks vital to the mine’s reintroduction, which would normally be handled in separate
stages, taking longer to coordinate and costing more.
The result has been completion on time and on budget of the complex series of tasks within the narrow
nine-week window of time required by Integra. The mine was on schedule to deliver first coal from the
longwall by mid-year and continues to build workforce numbers.
‘Thanks to the integration of tasks and our productive partnership with Integra’s on-site team, we not
only got our components of the process chain up and running in the required timeframe, we also
boosted capacity and resolved output issues with old plant not suited to higher volumes,’ says Tom
Woods, Chute Technology Partner.
Chute Technology offers a range of products for underground mines, including the Jiffy drive and T.W.
Woods’ smooth-flowing, low-height transfer chutes. These feature a Hood and Rotatable Spoon that
can be easily converted to suit any belt transfer angle. The transfer can be relocated to other planned
conveyor transfer locations with differing belt directions.
chutetechnology.com.au
When conveyor and building structures at a major coal-handling facility required assessment to confirm
that they would be economically operational for the planned life of the plant, Advitech was called in to
advise. Access to all areas of the structure to inspect and assess the structural integrity and material
quality, was a challenge, as was the discovery of significant areas of corrosion within critical structures.
These required priority design assessment and site rectification to preserve the facility’s short-term life
and allow production to continue.
Advitech developed an inspection regime and a prioritised structural assessment plan to systematically
evaluate the critical loads and potential failure regions of each structure. Structural design modelling,
load assessment and material quality evaluation determined the structural integrity and a design life.
Inventor CAD models of the structures were created to allow steelwork modifications to be designed and
construction drawings to be prepared.
Throughout this process, Advitech structural engineers provided regular site inspection and assistance
with site rectifications. The structural assets were evaluated, design life determined, damaged areas
of steelwork rectified, and a regime of ongoing inspections and monitoring of surface treatment was
established to protect the asset value and operational integrity.
advitech.com.au
CASE STUDY
ADE HELPS MINES IMPROVE SAFETY AND EFFICIENCY
Australian Diversified Engineering (ADE) works to improve haul road performance by stopping trucks
from losing control on watered roads and reducing fugitive dust emissions. The firm has a reputation for
innovative design and offering practical solutions to challenges, as well as finding efficiencies, improving
safety and removing compromises within operations.
For example, ADE recognised a significant shortcoming resulting in high fugitive dust emission and
increased reliance on water trucks that was compromising mining operations. The solution was an
innovative spray head design with superior water control that delivered consistent water application at
standard haul-road operating speeds.
ADE Spray helps make mine haul roads safer by reducing the risk of truck slides and vehicle rollovers.
The Global Haul Road Friction Protocol, developed by Road Safety Training Services, measures the
available friction in a haul road and advises a maximum recommended water application rate. This
advised rate can be directly entered into the ADE Spray control system, eliminating guesswork and
inconsistencies. Mining operators can choose to geo-fence a mine site and let the spray system
automatically control water application rates as a water truck navigates a mine site’s road network.
Within a Queensland mining operation, ADE Spray resulted in dramatically improved dust suppression
and a reduction of fugitive dust emissions leading to reduced water cart hours. A NSW operation also
saw immediate benefits, with water truck reports identifying clear paths for continual improvement.
In addition to its Australian customers, ADE has a number of major customers in America and Africa.
ade.net.au
CASE STUDY
HEDWELD HELPS MAKE HEAVY EQUIPMENT MAINTENANCE FASTER
AND SAFER
Hedweld has over 37 years of experience in designing and manufacturing innovations that improve
equipment availability, productivity and safety on mine sites globally.
The company’s Trilift® range of workshop component handling equipment and Safe-Away® range of
ladder and stair access systems are well known in the industry.
Trilift products are specifically designed to make the removal, installation and handling of components
such as tyres, suspensions, wheel motors and transmissions safer and more efficient. Most are universal
in design, allowing for usage across a range of makes and models.
Using Trilift products allows mine sites to reduce the number of hours spent performing maintenance,
decreasing labour and downtime costs and maximising equipment availability.
Hedweld has contributed to the streamlining of the Australian coal supply chain by supplying
maintenance tooling for tasks such as transmission handling and tyre handling, enabling large mining
equipment to spend less time in the workshop and more time in use. One example is the Triflift Cat 797
Transmission Hoist, which allows the Cat 797 transmission to be removed and installed without removing
the dump truck tray. This means a transmission change can be completed in eight hours, compared
with 24 hours and three shifts using the traditional procedure. This delivers an 80 per cent workshop
productivity saving and a 73 per cent labour cost saving, meaning mines can see a capital return on
investment after the first transmission change-out.
Hedweld products are exported to Africa, North and South America, Central Asia, and the Asia-Pacific
region. Hedweld commenced exporting in the 1990s and currently exports to 32 countries.
hedweld.com.au
CASE STUDY
ALFABS DELIVERS ENGINEERING SUPPORT AND EQUIPMENT TO
MINING OPERATIONS
Alfabs Mining Equipment is a heavy engineering company with a wide array of experience in
engineering fabrication. It also provides protective coatings, equipment hire, and mining, transport, rail
and onsite services.
The company’s engineering expertise includes structural steel, detailed duct and pipework, coal
conveyor and storage projects, and scheduled onsite maintenance projects.
With three locations in the mining areas of the Hunter Valley and Wollongong in NSW and Mackay
in Queensland, Alfabs has the storage and pre-assembly capacity to handle large-scale projects.
Combined with its protective coatings and transport business units, the company can offer a ‘one-stop-
shop’ solution for mining customers.
Alfabs Mining Equipment has recently overhauled and modified a Multi Bolter for the Mastermyne Group
and this unit was successfully introduced to a NSW coal mine. The project was carried out on budget
and delivered in the specified project timeline.
The LS191 LHD machine has also been repowered with a T.E. ExDES Hino engine package, which
produces 100 per cent capture of DPM’s. It has a 40-hour filter life and 90 per cent carbon monoxide
reduction. The BMA Broadmeadow mine has monitored the operational performance of two LHD’s on
site in Queensland, and following successful trials, is now re-powering their whole fleet. Specialising
in the design and manufacture of QDS, secondary support, longwall move and materials handling
equipment, all of its products are available for both sale and hire and can be designed and custom-built
to suit each client’s specific requirements.
All Alfabs equipment is supplied with a complete Plant Safety File and approvals to meet the
requirements of each specific client. Both electronic and hard copies are supplied and generally include
items such as GA drawings, engineering certificate, NDT report, design risk assessment, physical
stability test, training package, spare parts manual, maintenance/servicing schedule(s) and MDG audits.
alfabs.com.au
The following are some of the organisations involved in the Australian coal supply chain.
Contact your local Austrade representative about connecting and partnering with the Australian
resources and energy sector.
The Australian Government is committed to creating As part of the Queensland Government, the
a policy framework to expand Australia’s resource Department of Natural Resources and Mines works
base, increase the international competitiveness to ensure the responsible and sustainable use of
of our resources sector and improve the regulatory the state’s natural resources – water, land, minerals
regime, consistent with the principles of environmental and energy – for the benefit of current and future
responsibility and sustainable development. generations of Queenslanders, and to deliver policies,
programs and services that support industry while
›› industry.gov.au/resource
reflecting the needs of the broader community.
›› dnrm.qld.gov.au
METS Ignited
METS Ignited is an industry-led, government-funded,
NSW Trade & Investment
Growth Centre for the METS sector. METS Ignited
works with Australian suppliers to the mining industry, As part of the NSW Department of Industry, NSW Trade
global miners, research organisations and capital & Investment works to grow the economy and create
providers to improve the competitiveness and jobs across NSW by supporting businesses to export
productivity of the Australian METS sector. their products and services, attracting international
investment, and increasing global competitiveness.
›› metsignited.org
›› industry.nsw.gov.au/contact-us/nsw-trade-and-
investment
Resources & Energy NSW
As part of the NSW Department of Planning and
Trade & Investment Queensland
Environment, Resources and Energy plays a key
role in delivering the NSW Government’s priorities Trade & Investment Queensland is the Queensland
for economic growth by working to develop thriving Government’s global business agency, helping
resources and energy sectors in NSW. Queensland exporters take their products to world
markets and promoting Queensland as the perfect
›› resourcesandenergy.nsw.gov.au
place for investment.
›› tiq.qld.gov.au
Ai Group ›› nera.org.au
Additional resources
austrade.gov.au/mets
The Australian Trade and Investment Commission Austrade helps companies around the world to identify
– Austrade – contributes to Australia’s economic and take up investment opportunities in Australia as
prosperity by helping Australian businesses, education well as to source Australian goods and services.
institutions, tourism operators, governments and Our assistance includes:
citizens as they:
›› providing insight on Australian capabilities
›› develop international markets
›› identifying potential investment projects and
›› win productive foreign direct investment strategic alliance partners
REFERENCES
1. Minerals Council of Australia, ‘Characteristics of the Australian coal industry’,
minerals.org.au/resources/coal/characteristics_of_the_australian_coal_industry, accessed 2 May 2018.
2. Deloitte Access Economics report prepared for the Minerals Council of Australia, 2017, ‘Mining and METS: engines of economic growth and
prosperity for Australians’, minerals.org.au/file_upload/files/reports/Mining_and_METS_engines_of_economic_growth_and_prosperity_for_Australians.
pdf, accessed 2 May 2018.
3. Ibid.
4. Queensland Department of Natural Resources and Mines, ‘Queensland coal – mines and advanced projects’, July 2017,
dnrm.qld.gov.au/__data/assets/pdf_file/0011/238079/coal-mines-advanced-projects.pdf, accessed 2 May 2018.
5. Deloitte Access Economics report prepared for the Minerals Council of Australia, 2017, ‘Mining and METS: engines of economic growth and
prosperity for Australians’, minerals.org.au/file_upload/files/reports/Mining_and_METS_engines_of_economic_growth_and_prosperity_for_Australians.
pdf, accessed 2 May 2018.
6. Minerals Council of Australia, ‘Coal Hard Facts – 2nd Edition’, August 2015,
minerals.org.au/file_upload/files/publications/Coal_Hard_Facts_2nd_Edition_FINAL.pdf, accessed 2 May 2018.
7. Department of Industry, Innovation and Science, ‘Resources and Energy Quarterly’, December 2017,
industry.gov.au/Office-of-the-Chief-Economist/Publications/ResourcesandEnergyQuarterlyDecember2017/index.html, accessed 2 May 2018.
8. Ibid.
9. Minerals Council of Australia, ‘Coal Hard Facts – 2nd Edition’, August 2015,
minerals.org.au/file_upload/files/publications/Coal_Hard_Facts_2nd_Edition_FINAL.pdf, accessed 2 May 2018.
10. Minerals Council of Australia, ‘Characteristics of the Australian coal industry’,
minerals.org.au/resources/coal/characteristics_of_the_australian_coal_industry, accessed 2 May 2018.
11. Minerals Council of Australia, ‘Coal Hard Facts – 2nd Edition’, August 2015,
minerals.org.au/file_upload/files/publications/Coal_Hard_Facts_2nd_Edition_FINAL.pdf, accessed 2 May 2018.
12. Queensland Department of Natural Resources and Mines, ‘Queensland coal – mines and advanced projects’, July 2017,
dnrm.qld.gov.au/__data/assets/pdf_file/0011/238079/coal-mines-advanced-projects.pdf, accessed 2 May 2018.
13. Queensland Department of State Development, Manufacturing, Infrastructure and Planning website, ‘Carmichael Coal Mine and Rail Project’,
statedevelopment.qld.gov.au/assessments-and-approvals/carmichael-coal-mine-and-rail-project.html, accessed 2 May 2018.
14. North Queensland Bulk Ports Corporation website, Port of Hay Point, nqbp.com.au/our-ports/hay-point, accessed 2 May 2018.
15. Queensland Department of State Development, Manufacturing, Infrastructure and Planning website, ‘Abbot Point Coal Terminal Expansion – Stage 3’,
statedevelopment.qld.gov.au/assessments-and-approvals/abbot-point-coal-terminal-expansion-stage-3.html, accessed 2 May 2018.
16. Regional Development Australia Hunter, ‘2018 Hunter Investment Prospectus’,
rdahunter.org.au/initiatives/hunter-investment-prospectus, accessed 2 May 2018.
17. Hunter Valley Coal Chain Coordinator, ‘The History of the Hunter Valley Coal Chain Coordinator’,
hvccc.com.au/Documents/20130515%20HVCCC%20Brochure.pdf, accessed 2 May 2018.
18. Port Waratah Coal Services, ‘The Coal Chain’, pwcs.com.au/what-we-do/the-coal-chain/, accessed 2 May 2018.
19 Department of the Environment and Energy, ‘Australian Energy Update 2017’,
energy.gov.au/sites/g/files/net3411/f/energy-update-report-2017.pdf, accessed 2 May 2018.
20. CSIRO, ‘Longwall automation’, csiro.au/en/Research/EF/Areas/Coal-mining/Mining-safety-and-automation/Longwall-automation, accessed 2 May 2018.