Client name: Karara Mining Ltd

Location: Karara Iron Ore Processing Plant, Western Australia

Total project value: $100 million

Duration: 4 months

Services provided:

• Provision of concept design to a feasibility level of definition
• Review of process design criteria. Facilitation and completion of a HAZID
• Assessment of constructability of Greenfields and Brownfields design options
• Structural, mechanical and civil 3D modelling to produce material take-offs
• Preparation of capital cost estimate
• Preparation of a summary study report tailored to the client’s needs

Feasibility Study on the Expansion of Karara Iron Ore Processing Plant

A feasibility study was undertaken to design and cost the expansion of Karara’s tails filtration facility. The study focused on a solution that minimised estimated plant downtime during installation.

• Existing plant drawings and standards were leveraged to ensure a consistent and compatible design
• 3D structure was modelled around vendor provided tails filter models and model IO was optimised in consultation with vendors
• Identification of optimal positions of existing and new piping, and valve stations
• The requirement to minimise downtime of existing plant during installation was considered continuously during design development and assessed during several design reviews
• The completed design allowed for minimal operator exertion to travel from the old filter building to the new filter building and focused on safe ingress and egress

Location of the new filter building allowed existing site vehicle movements to continue unimpeded, reducing potential interruption to operation during installation.