Bulga Open Cut Coal Mine Flocculant Plant

About the project

As part of Glencore’s Bulga Open Cut Mine Tailings Dam relocation project, Pensar was awarded a design and construction contract for the construction of a flocculant plant capable of dosing multiple dredged tailings feed lines at demanded dosing rates.


Mt Thorley, New South Wales

Client & Duration

February 2021 - December 2022

Project Scope

  • Mechanical and electrical components
  • Geotechnical investigation works for input to the structural concrete slab design
  • Installation of underground mechanical and electrical services
  • Construction of a 20m x 20m concrete slab
  • Supply of off-site fabricated items and installation of 50m3 hoppers and 100m3 mixing tank, water and solution poly tanks, mechanical pipework, switchboard, all platforms, walkways
  • Installation of water pump, transfer pump and dosing pumps
  • Installation and termination of electrical local control stations, actuated valves, level instruments, flow meters and pressure sensors
  • Full plant commissioning against set design and performance guarantees


  • Construction of the plant beside an operational mine road
  • The delivery of damaged or defective equipment to site meant that processes were implemented to ensure that all future equipment was inspected before the removal from delivery trucks. Any identified
    defected equipment was returned to the manufacturers promptly
  • Completing construction through COVID-19 conditions where stringent travel restrictions were in place between Queensland and New South Wales meant our internal electrical works crew had
    to be replaced with local workers to comply with both Government and Glencore requirements
  • Plant wet commissioning and technical adjustments for dosing requirements


  • Zero LTIs, safety breaches, environmental or quality incidents
  • Zero non-conformance items issues 
  • Our project team was able to ramp up site works to achieve project practical completion on time despite the delays that COVID-19 had on the program

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