In 2018, BHP approved one of the largest iron ore operations in the world. The $4.7 billion South Flank project is expected to produce 80 million tonnes of iron ore per year and create more than 3000 jobs.
It also aims to enhance the average quality of the company’s Western Australian iron ore production from 61 per cent to 62 per cent, and the overall proportion of lump from 25 per cent to around 35 per cent.
The project will involve building a new crushing and screening plant, stockyard and train loading facility, procuring a new mining fleet, a substantial mine development and an overland conveyor belt.
BHP estimated around 85 per cent of the project’s spend will be awarded to companies based in Australia, with around 90 per cent of the contracts going to companies in Western Australia.
Fenner Conveyors (formerly trading as Fenner Dunlop) was one such business, as it was recently awarded a $16 million contract to manufacture and deliver around 50 kilometres of low rolling-resistance (LRR) conveyor belt for the project’s overland conveyor belt package.
PowerSaver is Fenner Conveyors’ low-rolling resistant compound designed to reduce indentation loss, resulting in an overall reduction in power consumption and therefore less energy required to drive the conveyor system.
Simultaneously, Conveyor Products & Solutions (CPS) was contracted to design and manufacture the overland conveyor idler systems.
Through early engagement with the client, CPS was able to develop a composite roller specification capable of long life and heavy duty OLC operation.
CPS worked through iterative design changes and modifications to optimise entire conveyor design (drives, belts, idlers, pulleys and structure). This included material development to suit 219mm diameter composite rollers which significantly reduced belt indentation power losses. The roll diameter, spacing and bearing combinations were optimised to reduce power draw.
The idler sets were designed with installation in mind and incorporated precision jigging points and alignment positions to reduce manhours during construction and maintain ±0.5mm tolerances.
All idler sets were manufactured in Australia and delivered ahead of schedule in a total of 8 months. All idler sets were installed without survey errors, reduced man hours and completely injury free.
Through this unique combination of high-tolerance idler frames and composite roller technology, coupled with low-rolling resistant conveyor belting, both businesses successfully delivered one of the most advanced, reliable, and cost-efficient overland conveyors in the world.
