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The Nelson Point facility comprises two rotary unloaders which deliver ore to tertiary crushing and screening complexes to produce the product which is stockpiled for reclaim and loading onto ships for export.
Sinclair Knight Merz was engaged to carry out the up-rating of 11 major shiploading conveyors, totalling 2.5km in length, along with the two shiploaders, at BHP Iron Ore’s Nelson Point facility. The previous nominal 7,000t/h to 7,500t/h capacity was increased to a design capacity of 10,000t/h, with the secondary objectives of reducing maintenance costs and improving plant availability.
The project plan included a complete rebuild of one conveyor from 1.5m to 1.8m wide, as well as substantial power and speed increases for all conveyors up to 1,050kW and 5m/s. The increased ore throughput and changed trajectories at the conveyor transfers meant that all transfer chutes and conveyor loading boots had to be replaced.
For time and cost reasons, it was decided to undertake a program of re-ratio and uprating of existing gearboxes in conjunction with a general overhaul of this equipment. This involved a tight schedule cascade remanufacturing program and achieved ‘as new’ gearbox installations for increased power rating, fully warranted with all work done in Australia.
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