Another Major Turnkey Conveyor Project Secured by Fenner Conveyors
Fenner Conveyors is proud to have been awarded a major turnkey conveyor project with Malabar Resources.
The project, which will see the installation of a 9-kilometre long overland conveyor system, provides the opportunity for Fenner Conveyors’ to again showcase their ability to deliver sophisticated, engineered conveyor solutions tailored to the unique challenges of the mining industry.
Part of the Maxwell Underground Project, the overland system will be managed completely in-house; a truly collaborative project for the Fenner Conveyors Group. The overland conveyor system design, engineering, manufacture and on-site construction will be led by ACE, composite ‘Yelloroll’ Rollers will be supplied by CPS, and Australian-made Steel Cord Fenner Dunlop Conveyor Belting – another example of Fenner Conveyors' end-to-end conveyor capability.
ACE General Manager, Mark Wilcock says, “We are excited and extremely proud to have been chosen by Malabar Resources to take on responsibility for this key aspect of the Maxwell Underground Mine development.”
Maxwell Mine will be the largest underground metallurgical coal mine in NSW and the overland conveyor system provides the key link between the underground operations and the coal processing plant.
“Our unique position in the market, with our complete portfolio of in-house capabilities, provides us with unmatched technical understanding of the interactions between all key components in the conveyor system.”
“This enables us to confidently design and manufacture a best-in-class system, utilising advanced technologies to ensure energy efficient and reliable conveyor operation for the complete life of the mine.”
Tailored Solutions for Complex Challenges
The design and construction of overland conveyor systems such as the one being delivered for Malabar’s operation are no simple feat. The layout of these systems is dictated by several unique factors, including the constraints of the local topography, environmental impact considerations and the desire to minimise infrastructure across the conveyor's length.
In the case of the Malabar overland conveyor system, ACE’s design team was faced with many of these challenges, including topographical challenges, along with limited access for power, roads, and other utilities.
Principal Engineer, Taylor Jobson, said that this "constrained geometry", which features vertical and horizontal curves over its length requires careful planning and several design iterations to ensure optimal functionality, while keeping costs in check.
“The system is designed to have the full 2.8MW of drive power located at the head end of the conveyor. While this creates some challenges in managing tension distributions, by distributing power this way, the site can avoid placing excessive infrastructure along the conveyor route, reducing both capital expenditure and complexity,” explained Jobson.
"Within the Fenner Conveyors portfolio, we pride ourselves on our ability to optimise complex systems and design solutions that balance performance with safety, cost-efficiency and operational sustainability.”
Engineering Excellence: Optimising Belt Performance and Cost-Efficiency
When it comes to overland conveyor systems, the belt is typically the most expensive and power-hungry component. Therefore, optimising carcass design and mass —while still ensuring the system operates efficiently—is key to achieving long-term cost savings for mining customers. This project is no exception.
The system has been designed with an overarching philosophy aimed at achieving best in class frictional coefficient losses. This philosophy starts at the design phase and carries through to the manufacturing of high tolerance and low rolling resistance CPS rollers, innovative belt cover compounds, manufacturing of high tolerance roller frames, right through to an engineered installation methodology which ensures the design intent is fully maintained to the finished product.
All of this combines to a system which, despite the challenging topographical conditions is expected to run extremely efficiently with minimised total power consumption & less tension load through the overall system.
Redundancy is also a key consideration for critical infrastructure like overland conveyors. This system splits the power load between two separate drives. If one of the two drives is taken offline for maintenance, it can still operate at reduced throughput.
“This proactive approach to power management ensures smoother operation and contributes to total cost-of-ownership benefits across the lifespan of the conveyor,” explained Jobson.
Customised Engineering for Long-Term Benefit
Another important aspect of the belt design is the decision to use steel cord belt, providing a stronger carcass with less stretch than traditional fabric-ply or solid woven belting.
Business Development Manager, Dean Callaway, said the belt is a showcase of Fenner Conveyors’ in-house custom engineering capabilities, as it has been optimised specifically for the proposed system and application.
“The beauty of engineering is that there’s so many factors at play – curves, slopes, loads, speeds, capacities, safety requirements, etc – and accounting for these in our custom conveyor solutions is where the passion of our engineers lies,” said Jobson.
“While many sites are happy with an off-the-shelf belt specification, we are able to truly demonstrate the benefit of this approach when customers like Malabar allow us to engineer a tailored solution.”
It’s rare for belting manufacturers to be able to supply this level of customisation and is one of the factors which set Fenner apart in the market.
“What enhances this approach is we are delivering the entire system; we are managing the schedule, when equipment is delivered, how each component is being designed which means we can engineer aspects for ease of installation and future maintenance works. This is where we thrive because we are able to deliver the most value to a customer’s operation,” explained Jobson.
By working closely with Malabar Resources to identify and overcome the challenges posed by site constraints and system design, the Fenner Conveyors Group have designed a solution that offers both operational excellence and significant cost efficiencies, without compromising on performance.
Executive General Manager – Engineering, Matt Einhorn, said Fenner Conveyors is not just a supplier - “We are a trusted partner capable of providing strategic engineering insights that optimise the entire conveyor system lifecycle.”
Ultimately, Fenner Conveyors’ ability to deliver a comprehensive and sustainable solution was key to securing this major project.
Looking Ahead: Fenner Conveyors as the Supplier of Choice
The successful award of this 9km overland conveyor is a clear indication of Fenner Conveyors’ capacity to manage complex, large-scale systems from concept through to completion. It is a testament to the value that the Fenner Conveyors Group brings as a supplier of choice for the mining and resource industries.
As the industry moves toward increasingly complex, larger-scale projects, Fenner Conveyors’ commitment to excellence, engineering expertise, and an ability to deliver tailored solutions will continue to position the company as the supplier of choice for future projects.
“We look forward to working closely with Malabar Resources to ensure the long-term success of this project through our reliable, high-quality products and engineering innovations,” said Wilcock.
