Roy Hill Iron Ore Project

Engineering Design Verification

This project required METS to review the existing design for the Roy Hill project. This review would identify issues with equipment arrangement and sizing that would prevent the required production rate of 55 Mtpa of iron ore concentrate. The review and recommendations covered the design of the beneficiation plant, rail transport and the port/ship loading facilities.

The project was broken down into several stages. The initial stage was to review the deliverables provided from the final study to ensure that the findings and delivered documents were correct. The testwork results were also analysed to ensure all required information for the design had been tested appropriately and that the study included the required level of variability.

Once verified, and any queries clarified, the next stage involved using the information from these deliverables in order to analyse the selected equipment and process for suitability for the application. Some equipment was identified as requiring upgrading to ensure plant throughput would be met, and modifications to the process flow were recommended to enable a higher plant uptime, with sufficient surge capacity and interlinking to allow for downtime throughout the plant.

The reports written and advice provided ensured that the final POSCO design was excellent and well-considered, giving the company the comfort of knowing that the plant design would be well-regarded.


Project Brief

Roy Hill Iron Ore Project

Outcome

  • Put forward design recommendations that facilitate improved plant operation
  • Put forward design recommendations that optimise plant CAPEX and OPEX
  • Completed several mini studies for client

Background

POSCO E&C STX (POSCO) is a Korean based company with a heavy interest in steel mills and iron ore projects. POSCO was a contender to win the design and construction stages of the Roy Hill Project in the Pilbara region of Western Australia.

Project Objectives

METS was required to meet performance guarantees relating to the rate of final product produced through the process plant. METS reviewed the project deliverables from a value engineering study that had been conducted, and the resulting design. This review verified the design against both the requirements for each section of the plant, product transport areas, and the sizing of the equipment against the process parameters.

Challenges

The challenges encountered during the project review included developing an understanding of the detailed level of study in a short period of time, yet grasping sufficient understanding of the various ore bodies and characteristics required to pass through the process plant.

Our Approach

The project was broken down into several stages. The initial stage was to review the deliverables provided from the final study to ensure that the findings and delivered documents were correct. The testwork results were also analysed to ensure all required information for the design had been tested appropriately and that the study included the required level of variability.

Once verified, and any queries clarified, the next stage involved using the information from these deliverables in order to analyse the selected equipment and process for suitability for the application. Some equipment was identified as requiring upgrading to ensure plant throughput would be met, and modifications to the process flow were recommended to enable a higher plant uptime, with sufficient surge capacity and interlinking to allow for downtime throughout the plant.

The reports written and advice provided ensured that the final POSCO design was excellent and well-considered, giving the company the comfort of knowing that the plant design would be well-regarded.