Coal Intelligence · Bengalla

CHPP & Conveyors

Coal handling and preparation plant yield against washability, dense-medium separation efficiency and magnetite, and the remaining life of the belts that carry every tonne to the train.

Demonstration data. 100% of the production, quality, rail, CHPP and dragline records are DEMO records, not site data. Volumes are calibrated to public New Hope figures for Bengalla; shift-level detail is generated. Connect site systems (fleet management, LIMS, CHPP historian, rail scheduling) to replace it.

Plant yield (28d)

61.1%

540.3 kt product

Yield gap to washability (7d)

4.5 pts

baseline 2.9 pts

Organic efficiency

93.1%

actual ÷ theoretical yield

DMC Ep (7d)

0.041

baseline 0.026

Magnetite

0.94 kg/t

baseline 0.63

Feed rate

1,548 t/h

85.0% utilisation

Yield gap cost

185.7 kt

product per year vs baseline gap

CHPP and conveyor findings

Yield vs washability — 60 days

The gap is saleable coal sent to reject

Theoretical (float-sink) %
Actual yield %

DMC separation efficiency — 60 days

Rising Ep with rising magnetite points to cyclone wear or medium control

DMC Ep
Magnetite kg/t

Circuit performance (7 days)

Circuit	Feed share	Yield	Organic eff.	Ep	Cut-point RD	Product ash	Magnetite kg/t
Dense medium cyclone	78.0%	62.4%	93.1%	0.041	1.66	13.5%	0.86
Spirals	12.0%	57.6%	94.4%	0.163	1.78	15.1%	—
Flotation	7.0%	53.8%	89.7%	—	—	11.8%	—

Conveyor belt remaining life

Wear rate from top-cover thickness scans per Mt conveyed; order-by date allows for supplier lead time plus 30 days

Conveyor	Belt	Cover / min (mm)	Wear mm/Mt	Months left	Order by	Bad splices	Idlers flagged	Rip detect	Status
CV-01 ROM to CHPP feed	ST1600 1600mm 12/6	9.4 / 5.0	0.074	53.3	2030-11-06	0	11	Fitted ok	Ok
CV-02 Overland product conveyor	ST2500 1400mm 10/6	6.9 / 6.0	0.078	16.0	2027-08-29	2	37	Fitted fault	Ok
CV-03 Stacker feed	EP800/4 1400mm 8/4	7.1 / 4.0	0.051	85.6	2033-08-11	0	4	Fitted ok	Ok
CV-04 Reclaim to train loadout	ST1250 1600mm 10/5	6.2 / 5.0	0.091	18.4	2027-11-29	1	19	Fitted ok	Ok