Modular plant design

We are experienced in modular plant design and delivery for gold, copper, base metals, iron ore, coal, mineral sands and ore crushing and screening applications with a proven track record for actual design, construction and operations of this industry leading modular plant range.

Flexibility, efficiency, cost effectiveness and timeliness have been the drivers for developing our five generations of modular processing plants. 

Our fifth-generation modular plants have been designed for gold and copper and base metals ores.  The modular gold plant contains comminution, gravity separation, leaching, gold recovery, cyanide detoxification, dry stack tailings and power generation modules.  

The modular copper and base metals plants incorporate several stages of froth flotation using a combination of column and conventional flotation cells. This latest plant evolution also incorporates our SEDGMETRIX platform - plant monitoring technology, linking advanced instrumentation, Wi-Fi backbones, cloud connection between SCADA and mobile dashboard reporting system – all providing improved efficiency and advanced control, monitoring and reporting diagnostics.

Our first, second and third generation plants were developed for the coal industry in Indonesia and Australia. They were small 200-300 t/h plants and deployed to the Petangis, East and West Senakin, and Blair Athol Mines. The fourth generation took the size and engineering advancement to the next level – 550 t/h plants were installed at the Byerwen coal mine (2017 and 2019) and fully modular mineral sands plant was delivered and installed in Florida, USA. Throughout this continuous innovation journey our structural, concrete and electrical designs constantly evolved and improved based on practical experience to provide further modularisation benefits, maximising the amount of off-site preassembly and fit out of all mechanical and electrical equipment. The most recent addition to the Byerwen mine modular plant evolution incorporates a tailings filtering and disposal system (2021/22) – again building on our advanced modularisation engineering and construction expertise. The benefits of reduced cost, site time, improved safety outcomes (less working at heights and exposure to high-risk construction work and reduced site labour) continue to be demonstrated to our clients. The Byerwen mine modules were erected in 10 days – this achievement was captured by our time lapse camera.

Modules are fully preassembled including modules being fabricated and assembled prior to disconnection, wrapping and shipping. Modular designs can also be suitable for relocation and include significantly lowered concrete volumes, improving embedded carbon emissions of our designs. Cold weather requirements can also be incorporated into any of our modular plant designs.

Project examples of civil works:

Caval Ridge Coal Mine (QLD)

Caval Ridge Mine is a 5.5Mt coal mine located in the Bowen Basin. Sedgman’s work involved the detail design and quality/construction management of the bulk civil/earthworks for the 11.5km overland conveyor (OLC), run of mine (ROM) and product stockpile expansion.

Woodlawn Zinc Mine (NSW)

Sedgman was involved in the detail design and quality/construction management of the bulk civil/ earthworks for the process plant area, haul road from the box cut to the ROM and associated drainage works at the 1.5Mt minerals processing plant located near Goulburn, NSW.

Grassy Coal Mine (Canada)

Detail design of the bulk civil/earthworks for the 4.6km overland conveyor (OLC), the product stockpile pad (PSP), the mine industrial area (MIA), the coal handling plant (CHP), run of mine (ROM), associated LV and HV roads and associated drainage works while adhering to strict environmental and first nations concerns.

GEMCO Manganese (NT)

GEMCO is located on Groote Eylandt in the Northern Territory, Sedgman completed the detail design of the sands beneficiation plant and earthworks for the stockpile containment shed, loop road, associated drainage works and demolition of the existing brownfield site.

Byerwen Coal Mine (QLD)

Sedgman completed the detail design of the bulk civil/earthworks for the new CHP, light vehicle roadworks around the CHP, stockpile reclaim tunnel and stockpile pad, ROM and associated drainage works.

Boggabri Coal Mine (NSW)

Boggabri coal mine is a 7Mt coal mine located in NSW. Sedgman completed the detail design of the bulk civil/ earthworks for the stockpile expansion and concept design for the ROM pad extension and ROM bin and quality/ construction verification on site.

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