Fenner Dunlop conveyors enable epic stacker relocation project for one of Australia’s leading energy companies.
AGL is one of Australia’s leading integrated energy companies and has a diverse power generation portfolio including a 2200 megawatt power station serviced by the Loy Yang open cut brown coal mine in the Latrobe Valley in Victoria. The mine and power station supplies approximately 30% of the state’s power requirements.
Belle Banne Conveyor Services, part of the Fenner Dunlop Australia group of companies, was approached by AGL to engineer, supply and construct a conveyor system to enable the mine to backfill into areas of the mine where coal is no longer extracted, as opposed to shifting overburden to an external dump area. The current overburden storage area was serviced by two large stacker machines. At 2,100 tonnes and 10 stories high, one of these massive machines wouldn’t fit on a football field when fully extended.
Our TEAM supplied and installed 170, 9m long conveyor frames, 6760m of Fenner Dunlop ST2000, 2.0m wide steel cord belting, installed over 4000 new idlers and relocated two large conveyors (belt, idlers, structure) each approximately 1500m in length.
Our TEAM also helped facilitate the transfer of the first stacker on its 4 week, 19 kilometre journey down to the base of the mine to start backfilling. AGL Loy Yang’s Head of Mining Nigel Browne said the moving of a stacker of this size over this distance and involving so many obstacles is an Australian first.
During the project two separate belt installations were completed using Belle Banne’s specialist belt flaking system allowing them to pre-splice complete belt lengths off line and out of the way of mechanical and electrical works. On the new L705 conveyor, 3000m of belt was installed with two splices minimising interaction with the main project works – approximately 22 shifts down to 4 shifts, providing a significant reduction in the overall project duration.
Belle Banne has a long term relationship with Loy Yang having been a conveyor maintenance contractor at the site since 2002. There is over 80,000m of belting and approximately 60,000 idlers – all maintained by Belle Banne as part of their current belt maintenance contract.
Planning has started to relocate the second stacker into the mine by 2025. Until then, our TEAM will continue to provide conveyor engineering and maintenance solutions to both the mine and power station at Loy Yang.