The Development of Hunter Valley Coal Preparation Plant

The Hunter Valley Coal Preparation Plant and associated materials handling facilities commenced operation in mid 1982. The new plant and coal handling system were designed to integrate with existing mining and preparation plant operations, but also to be flexible to future mining and marketing developments. The system includes: raw coal stockpiles, a 900 tph dense medium/water washing cyclone preparation plant, clean coal stockpiles, a 7.8 km overland conveyor, large finished product stockpiles and a high capacity train loading plant.The plant's development is described with reference to the original planning objectives. Features aimed at providing operational flexibility and performance are emphasised, including the use of; automated stackers and reclaimers, modular plant, distributed PLC control, a single flight overland conveyor, a network of automatic samplers and blending options to assist quality control.Details are also provided of an innovative technique for control of reclaimer rail track forces, stacker and reclaimer anti-collision systems and the use of DC injection braking.