Moatize Coal Mine FEL2 Upgrade Study

The Moatize studies required development of technically robust and commercially defensible options for ROM beneficiation and plant upgrades within an operating coal mine. The scope spanned FEL1 trade-off assessments through to FEL2 level definition, requiring alignment between engineering design, cost estimation and project delivery considerations.

Key challenges included evaluating multiple design options for plant upgrades, developing CAPEX estimates exceeding $215M, and ensuring accuracy of material take-offs for steel and concrete across conveyors, transfer stations and sizing infrastructure. Integration with existing site infrastructure required analysis of current conveyor systems and interfaces.

The work also required development of design criteria, basis of estimate and identification of risks and opportunities, alongside procurement of vendor pricing for mechanical equipment to support cost certainty.

Phronis delivered engineering and estimating support across FEL1 and FEL2 stages. We prepared trade-off CAPEX estimates to compare design options and developed a FEL2 level capital estimate for the upgrade works.

Our team undertook conveyor design calculations to determine belt widths and power requirements, and completed analysis of transfer and sizing stations to generate steel and concrete material take-offs. Existing conveyor infrastructure was reviewed to support integration and quantify upgrade requirements.

We supported procurement activities by obtaining vendor pricing for key mechanical equipment and undertook preliminary sizing of mechanical piping and sumps. Quality assurance reviews and markups of engineering drawings were completed to ensure consistency and accuracy.

In addition, we contributed to preparation of design criteria, basis of estimate, and documentation of project risks and opportunities for inclusion in the study report.

Phronis supported delivery of feasibility and FEL2 study outcomes for plant upgrades at the Moatize Coal Mine, providing engineering inputs and cost estimates to inform project decision-making.

The development of trade-off estimates enabled comparison of design options, while the FEL2 CAPEX estimate and supporting vendor pricing improved cost certainty. Material take-offs and design calculations provided a quantified basis for infrastructure requirements across conveyors and processing systems.

Preparation of design criteria, basis of estimate and risk identification strengthened the overall study documentation. Collectively, these inputs supported evaluation of upgrade options for ROM beneficiation and CPP improvements within the Moatize operation.