Stockpiling Success: ACE Engineers an Innovative Stacker Conveyor Solution for Tanami Mine

At Newmont Gold’s Tanami Mine, the need for increased operational output has prompted a significant underground mine expansion that has showcased the engineering capabilities of Fenner Conveyors subsidiary, ACE. The design and supply of the two cutting-edge stacker conveyor systems are a pioneering step for ACE that will set Newmont’s mine extension up for material handling success.

The total project involves a series of new conveyor systems which act as fundamental surface infrastructure to support the underground expansion. ACE was engaged to deliver the final conveyor systems that feed the stockpile on a critical production path – one being a fixed stacker system and the other a radial stacker system.

Tanami Mine, known for its hard rock gold reserves, requires innovative solutions to optimise stockpiling processes. Traditional methods of stockpile management, such as fixed stacker systems or skyline conveyor systems, service well for mining operations.

However, the radial stacker system designed by ACE for Tanami introduces a new level of flexibility and efficiency. This equipment, capable of slewing and pivoting on wheels, allows for enhanced maneuverability when loading stockpiles, enabling operators to store material in a more manageable way.

The second system delivered by ACE shares many of the mechanical and structural design features of the first, radial stacker system. However, feeding a waste stockpile, operationally the slewing motion was not required and therefore ACE recommended a fixed system.

Mock-up of the Radial Stacker System at ACE's workshop in Somersby, NSW.

The ACE team brings a wealth of experience from previous stacker conveyor system projects. Principal Mechanical Engineer, Taylor Jobson, emphasised the learning opportunities this project has provided for many of ACE's young engineers.

"It’s helped build expertise within the team across both engineering and fabrication capabilities," said Jobson. This commitment to skill development not only bolsters ACE's internal resources but also positions the company as a competitive player in the Australian market and beyond.

Collaboration has been a cornerstone of this project. ACE won the contract through Engineering, Procurement, Construction Management (EPCM) company, Worley, whose ongoing support has been instrumental. The partnership has fostered connections with various suppliers, enriching the project's execution and enhancing ACE’s capacity for future endeavours.

In July 2024, ACE showcased a mock-up of the radial stacker system at its Somersby workshop - a demonstration that garnered positive feedback from the Worley management team.

This successful presentation was a testament to the hard work and innovative thinking that ACE engineers put into the project.

"Worley has been extensively engaged throughout the project and has been a great supporter of the work our team has produced," said Jobson.

The engineering and design phase of both stacker systems involved rigorous third-party audits, ensuring that ACE met the highest standards of quality and reliability. Project Manager, Brent Lewis reflected on the validation process, expressing satisfaction with the strong results achieved.

"Our dedicated team is focused on demonstrating our capability in this space so we can win more projects in the Northern Territory and into the west of Australia," said Lewis.

Complete design model of ACE's Radial Stacker Conveyor.

The first radial stacker system was successfully delivered in September 2024, with plans for the second, slightly larger fixed waste stacker system to follow in January 2025.

Both stacker systems will feature Fenner Conveyors Group’s high-quality steel rollers and conveyor belting, engineered and manufactured with K grade covers for fire and static resistance (FRAS), to ensure safety and performance once installed on-site.

As ACE delivers the next phase of this exciting project, the integration of its innovative engineering solutions stands to not only maximize operational efficiency and output for Tanami Mine but solidify ACE’s reputation as a leader in engineered conveyor solutions.

With a commitment to innovation and growth through partnership opportunities such as this project, the future looks bright for ACE and its role in advancing both surface and underground operations for mining in Australia.