Mining & Resources

Engineered Efficiency delivers specialised process engineering, water treatment, pipeline design, and commissioning services for remote mining and resource projects. From hydrogeological modelling and complex overland fluid transport to the wet commissioning of novel process plants, we provide robust, compliant, and fit-for-purpose solutions. We support mine operators, EPCM contractors, and site personnel in achieving operational readiness, environmental compliance, and long-term water security in some of Australia's most challenging environments.

Our capabilities & skills:

Engineered Efficiency offers a comprehensive suite of engineering, design, and project delivery services tailored to the heavy resources and mining sectors:

  • Fluid Transport & Pipeline Engineering: Complex overland pipeline design (using WaterCAD), slack flow management, air/vacuum relief design, and environmental water diversion.

  • Hydrogeology & Groundwater Modelling: Submersible bore pump sizing, borefield design, and advanced analytical groundwater modelling (utilising Python scripting and Thies Wells) for accurate transient drawdown calculations.

  • Water Treatment & Process Engineering: Potable camp water systems, Multi-Media Filtration (MMF), UF membrane separation, UV disinfection, and hypochlorite dosing to ADWG requirements.

  • Commissioning & Plant Start-up: Dry and wet commissioning schedule development, EPCM contractor integration, detailed flowsheet preparation, check/handover sheet generation, and compliance auditing for Australian Standards.

  • Mechanical & Control Systems: Wireless telemetry design, process plant control system integration, and minimal-footprint pump station design utilising screwpiled structural supports.

Mining & Resources Case Studies

Case Study 1: Northern Minerals – Browns Range Rare Earth Project

Engineered Efficiency has provided ongoing process, water systems, and commissioning engineering support to the Browns Range (Wolverine) Rare Earth project in the Tanami since its inception in 2016. Our involvement spans multiple critical site infrastructure and operational readiness phases:

Investigations & Solutions Completed:

  • Water System Optimisation: Diagnosed and rectified critical flaws in the original 9km bore water supply system (including reversed pump operation and underrated pipework), successfully redesigning the overland pipeline and camp take-off system.

  • Telemetry & Automation: Designed and supplied a 1km-range wireless telemetry system integrating the camp water supply into the main process plant control system.

  • Advanced Borefield Design: Completed preliminary borefield and pipeline design for a new beneficiation plant, utilising advanced Python-based hydrogeological modelling (analytical transient wells) to accurately calculate maximum drawdowns and recoveries.

  • Process Plant Commissioning: Supported the owner's team through the start-up of a novel beneficiation and hydrometallurgical plant designed by a Chinese EPCM. We facilitated commissioning workshops, interpreted vendor data, checked classified pressure vessels, and developed detailed execution schedules and ADWG-compliant disinfection procedures.

Case Study 2: BHP – Mining Area C (MAC) Water Treatment Plant

Working on behalf of Hydramet, Engineered Efficiency provided comprehensive commissioning planning services for the BHP Mining Area C (MAC) Water Treatment Plant, a facility designed to produce 1.5ML/day (and later expanded to 2.2ML/day).

Investigations & Solutions Completed:

  • Systemisation & Planning: Developed the integrated commissioning schedule and planning flowsheet alongside the client’s project planners.

  • Compliance & Handover: Prepared exhaustive checksheets and handover forms adhering strictly to BHP specifications.

  • Procedural Development: Drafted detailed procedures for dry commissioning, wet commissioning, flushing, and ADWG-compliant disinfection.

  • Waste Minimisation: Strategically planned the distribution network commissioning to align with site water demand timing, significantly minimising water usage and on-site waste disposal.

  • (Note: Engineered Efficiency has successfully duplicated this methodology for the MAC Phase 2 expansion, as well as the BHP Yarri WTP and BHP Newman upgrades.)

Case Study 3: Regis Gold – McPhillamy’s Gold Project Water Diversion

Engineered Efficiency was engaged by Regis Gold to design a highly complex internal water management and external water diversion pipeline network for the McPhillamy’s Gold project in NSW. Strict environmental regulations required total internal water recovery and external water routing around a topographically challenging, hilly mine site.

Investigations & Solutions Completed:

  • Network Design: Utilised WaterCAD to rapidly design a network of 13 overland pipelines ranging from 1km to 6km in length and DN180 to DN560 in diameter.

  • Hydraulic Engineering: Engineered solutions to accommodate over 100m of elevation variance, specifically accounting for slack flow and strategic air/vacuum relief.

  • Low-Impact Pump Stations: Devised a rapidly deployable, easily removable pump station system using high-efficiency semi-submersible centrifugal pumps.

  • Structural Innovation: Supported the on-shore headworks with a minimal-disturbance, screw-piled concrete sleeper system designed to safely resist the reaction load of the pumps.