Stanwell Power Station Fly Ash Collection and Tanker Load Out Facility

The existing fly ash offtake system was constrained by TLO infrastructure originally designed for emergency collection, limiting throughput and broader utilisation opportunities. The project required development of a new multi-user FA transfer and TLO facility capable of achieving a minimum throughput of 300,000tpa and 150tph, while integrating with existing systems.

Key challenges included ensuring no adverse impact on power station operations, maintaining compatibility with Siemens T3000 control, electrical and security systems, and preserving functionality of existing ash handling and disposal processes. The design also needed to address health, safety and environmental risks associated with the current TLO configuration, including fugitive dust and plant proximity.

Additional complexity arose from accommodating a range of tanker configurations, minimising installation downtime, and providing storage capacity to manage fluctuations in ash production and demand.

Phronis delivered a comprehensive design and construction approach involving integration of civil, mechanical, electrical and control systems.

The solution included design of a new 600t high-set TLO silo, load-out systems, weighbridge, access roads and a pneumatic transfer system incorporating air transfer vessels and blowers. Electrical and instrumentation systems were designed to integrate with existing plant systems, including control, access and security infrastructure.

The facility layout and configuration were developed to support multi-user operation, automated load-out and future expansion, including provision for additional TLO infrastructure. The design also considered separation of FA offtake from existing ash systems and incorporation of appropriate materials and construction practices.

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The project enables increased utilisation of fly ash, reducing reliance on ash repositories and extending their operational life, while supporting supply of supplementary cementitious materials to market.

The new TLO facility provides a high-capacity, integrated load-out solution capable of accommodating a range of tanker configurations and supporting continuous operation aligned with plant output. Improved separation of systems and enhanced containment measures reduce risks associated with fugitive dust, spillage and operational safety.

The design supports operational flexibility, future expansion and alignment with existing plant systems and control philosophy. Specific outcomes relating to project delivery, performance metrics or operational improvements beyond the stated objectives are not provided in the available information.

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