acps new south wales february meeting · 2018. 3. 20. · acps new south wales february meeting...
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ACPS New South Wales February MeetingFebruary 15, 2012 – New South Wales, Australia
Peabody Energy Australia Wilpinjong CHPP Expansion Project
Challenges and Successes
Safety Contact
Meeting Agenda
Project Introduction
Project Introduction – Production Objectives
Project Introduction – FEED and Contract Strategy
Project Introduction – Process Objectives
Process Design – Coal Handling Plant
Coal Handling Plant – Objectives
Coal Handling Plant – Process Flow Diagram
Coal Handling Plant – Process Flow Diagram – Raw Coal Handling
New ROM
Bin
CV-104
Raw Coal
Conveyor
New Sizing
Station
New Raw
Coal
Stacking
Conveyor
Existing
Radial
Stacker
Coal Handling Plant – Process Flow Diagram – Product Handling
Clean Coal Stacker CV-606Clean Coal Stacker CV-606
CV-605 Drive TowerCV-605 Drive Tower
New Reclaim Conveyor CV-802 connects to existing TLO
New Reclaim Conveyor CV-802 connects to existing TLO
Coal Handling Plant – Interface Point Challenges
New Stationary Tripper installed on existing Product Conveyor diverts washed coal to new Product Stockpile
New Stationary Tripper installed on existing Product Conveyor diverts washed coal to new Product Stockpile
New Conveyor CV-605New Conveyor CV-605
Existing Product Stacker CV-602Existing Product Stacker CV-602
Existing Product Conveyor CV-601Existing Product Conveyor CV-601
New Tripper HeadNew Tripper Head
Process Design – Coal Preparation Plant
CPP Expansion under construction (September 2011)
Coal Preparation Plant – Process Objectives
New
Spirals
Circuit
Expansion
Coal Preparation Plant – Major Process Decisions
Coal Preparation Plant – Process Flow Diagram
Coal Preparation Plant – Other Process Considerations
Field modify existing thickener with external launder to increase capacity
Field modify existing thickener with external launder to increase capacity
New higher capacity and re-designed centerwellNew higher capacity and re-designed centerwell
Coal Preparation Plant – Other Process Considerations
New D&R screens with large fixed sieve panelsNew D&R screens with large fixed sieve panels
Commissioning Performance
First train loading operations from new product stockpile (November 2011)
Commissioning Performance – Key Results
Commissioning Performance – Key Results
99
95
90
80
70
60
50
40
30
20
15
108
6
4
2
1
0.01 0.1 1 10 100
% P
ass
ing
Size (mm)
Rosin Rammler
Nominal Plant Feed
Coarsest Plant Feed
Finest Plant Feed
Initial Sizing
After Wet Tumble
Plant performance test sample aligned with nominal design size distribution
Plant performance test sample aligned with nominal design size distribution
Wet tumble of plant feed was within finest design envelope limits
Wet tumble of plant feed was within finest design envelope limits
Commissioning Performance – Coarse DMC Performance
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30
Par
titi
on
Nu
mb
er
(To
Pro
du
ct)
Specific Gravity
Coarse Dense Medium Cyclone (Plus 14 mm)
Actual
Guaranteed (Whitten)
Actual (Whitten)
Commissioning Performance – Fine DMC Performance
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30
Pa
rtit
ion
Nu
mb
er
(To
Pro
du
ct)
Specific Gravity
Fine Dense Medium Cyclone (14 mm x 4 mm)
Actual
Guaranteed (Whitten)
Actual (Whitten)
Commissioning Performance – Fine DMC Performance
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30
Pa
rtit
ion
Nu
mb
er
(To
Pro
du
ct)
Specific Gravity
Fine Dense Medium Cyclone (4 mm x 1 mm)
Actual
Guaranteed (Whitten)
Actual (Whitten)
Commissioning Performance – Spirals Performance
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30
Pa
rtit
ion
Nu
mb
er
(To
Pro
du
ct)
Specific Gravity
Spirals (1.0 mm x 0.10 mm)
Actual
Guaranteed (Whitten)
Actual (Whitten)
Project Implementation – Other Capital Cost Considerations
Reclaim CV-202 from new Raw Coal stockpile onto existing Plant Feed Conveyor CV-201
Project Implementation – Other Capital Cost Considerations
Capital Cost Considerations – Imported Fabrication
Pre-assembly of new ROM bin in Tianjin before blasting and painting
Pre-assembly of new ROM bin in Tianjin before blasting and painting
Capital Cost Considerations – Lower Cost Engineering
Relocated sample system as part of new fixed tripper assembly on CV-601
Relocated sample system as part of new fixed tripper assembly on CV-601
Lessons Learned
CPP addition after enclosure November 2011
New CPP addition in September 2011
Lessons Learned – Procurement and Fabrication
New CPP addition in September 2011
Lessons Learned – Process Design and Engineering
New CPP addition in September 2011
Lessons Learned – Change Management
Conclusion
The Wilpinjong expansion project proved to be a successful cooperation between Peabody and Ausenco Taggart having met the Owner’s objectives for Safety performance, Process guarantees, Completion Schedule, and Capital costs.
Completed CPP Expansion with new CV-605 in the foreground (December 2011)
ACPS New South Wales February MeetingFebruary 15, 2012 – New South Wales, Australia