• Engenium

    Iron Ore Magnetic Separator Plant

    Pilbara, Western Australia, Australia

Project Summary

Project

Engenium, a project delivery and engineering consultant to Australia’s mining sector, was tasked with providing a feasibility study to design new magnetic separation technology. The technology will increase iron-ore production at an existing plant in the Pilbara region of Western Australia. The plan needed to include the type of equipment, concept arrangement, budget development, and schedule delivery. Engenium’s two key challenges included delivering the project on a fast track and compressing the feasibility study timeline to reach an investment decision for project execution. The design also needed to focus on layout tie-ins, key equipment, new building footprints and levels, piping routes, and new substation facilities. The layouts would be refined and optimized during detail design. Brownfield tie-ins, new process buildings, and multiple process and layout options were also included in the project scope.

Solution

To meet the requirements, Engenium used OpenPlant Modeler and ProSteel’s 3D plant modeling and digital workflows to develop the feasibility plant designs and pass them on to the owner-operator for review and approval. Engenium also used 3D design models to determine the amount of budget needed to complete the project. The team established a collaborative working environment to determine the process and layout options, while the 3D multidiscipline plant models included tie-ins to the existing plant that produced multiple options to enable value engineering and to support the investment. Engenium also generated critical options analysis and capital estimates using information from the design model. Moreover, identifying the preferred option enabled a fast-track project delivery.

Outcome

With the project requiring a collaborative design workflow among the multidiscipline design team, implementing an integrated solution using 3D multidiscipline plant models provided significant benefits. Engenium’s use of digital workflows enabled the team to deliver the feasibility study in less than two months, saving at least 50% when compared to other projects. Additionally, by using the software, the amount of engineering hours spent on the project were well below the benchmark for an over USD 50 million mining project.

Software

OpenPlant Modeler and ProSteel were used to refine and optimize the layouts at the detailed design stage and, along with Navigator, established new workflows using iModels to implement a collaborative workflow across the multidiscipline design team. Bentley View and Navigator enabled team members to review the design among project stakeholders, allowing them to provide feedback to the modeling team. LumenRT assisted the client with visual presentations of the project to outside stakeholders. iModels were used to make the design file sizes smaller, allowing information sharing across the multidiscipline design team.

Project Playbook: Bentley View, ContextCapture, LumenRT, MicroStation, Navigator, OpenBuildings Designer, OpenPlant, ProSteel, ProStructures

Outcome/Facts
  • Challenges included brownfield tie-ins, new process buildings, and multiple process and layout options.
  • Bentley applications enabled Engenium to deliver the feasibility study in less than two months, saving 50% in design costs, compared to other projects of a similar scope.
  • By using the software, the amount of engineering hours spent on the project was well below the benchmark for an over USD 50 million mining project.
Quote:
  • “Bentley software allowed us to deliver exceptional value and results for our client through the development of [a] multidiscipline design, in parallel, under tight schedule expectations. [We did this] through the deployment of a [single] design and review environment for the whole project team.”

    Chris Senior Engineering Director Engenium