Client name: Karara Mining Ltd

Location: Perenjori, Western Australia

Total project value: undisclosed

Duration: 4 months (2020)

Services provided:

• Provision of concept design to a feasibility level of definition
• Review of process design criteria
• Facilitation and completion of a HAZID
• Assessment of constructability of greenfields and brownfields design options
• Structural, mechanical and civil 3D modelling and material take-offs
• Preparation of capital cost estimate

Karara Tails Filter Upgrade Feasibility Study

Karara mine is located 200 km south-east of Geraldton in the Shire of Perenjori, Western Australia. It is the largest and the first major magnetite mining operation in the mid-west region. Tetra Tech Proteus conducted a feasibility study to design and cost the expansion of Karara’s tails filtration facility. The study focused on a solution that minimised estimated plant downtime during installation.

Designs were undertaken in conjunction with existing plant drawings and standards to ensure consistency and compatibility. Works were also arranged in phases to minimise downtime of current plant operations during installation. The 3D structure was modelled around vendor-provided tails filter models and model IO was optimised in consultation with vendors.

The location of the new filter building allowed existing site vehicle movements to continue unimpeded, reducing potential interruption to operation during installation. The completed design allowed for minimal operator exertion to travel from the old filter building to the new filter building and focused on safe ingress and egress.