Overview

Rio Tinto commissioned Liberty Industrial for the deconstruction of this High-Intensity Smelting Facility – a complex dismantling and salvaging of significant components of industrial plant and equipment which included a 65m high, 1.2t coal drying and grinding structure; Flue gas desulphurisation plant; Hot metal handling equipment with an 80-tonne induction furnace; Hot metal desulphurisation plant; Off gas scrubbing and cooling infrastructure; and a 25 megawatt power station.

Challenges

This project was the first of its kind and had never before been attempted in Australia.
Realising maximum value possible for the client from a number of reusable plant, equipment and materials.
Minimising waste disposed in landfill.
Carrying out lifts of up to 108t, relying heavily on complex engineering lifts using large crawler and mobile cranes.
Managing a crew of up to 60 members (at peak) across multiple work fronts within a very small footprint.

Hismelt Kwinana being demolished through induced collapse demolition

Robust Solutions/Exceptional Outcomes

Robust solutions

Careful planning and extensive consultation to develop an innovative asset and recovery methodology.
Use of 3D modelling simulation software.
Sourcing of asset and resources recovery buyers.
Deployment of two Project Managers, three Safety Managers, five Supervisors, three Leading Hands and five Project Engineers to support demolition crew.
Provision of state-of-the-art demolition equipment, including Liberty Industrial’s heavy duty customised 230t Liebherr 994 complete with the world’s largest shear attachment − the Genesis GXT 2555R.

Exceptional outcomes

This ground breaking project was masterfully executed in alignment with Rio Tinto’s budget (Liberty realised a cash positive outcome), schedule and zero incident policy.
Over 2000 bulk units were methodically dismantled, cleaned to export standard, match-marked, labelled, recorded and packed, with each item given clear instructions on how to be reassembled.
Four bulk shipments of over 18,000m2 and 280 shipping containers were shipped 7600km away to Shandong Province in China.
108,000t (97%) of the site’s 111,000t of waste was recycled with only 300t (3%) of all waste going to landfill.
12,000t of scrap metal was recycled.

Value Add

Demolition Simulation and Modelling

With exclusive license to demonstrate using Extreme Loading® for Structures (ELS) software developed by Applied Sciences International (ASI).

Deconstruction

Use of best approach demolition and dismantling such as explosive using world class fleet, safety and engineering methodologies in explosives and rigging.

Decontamination and Industrial Cleaning

Designing engineered solutions for decontamination such as removal of asbestos, heavy metals, PCBs, dioxins, PFAS and NORMs.

Ground and Waste Water Treatment

Treatment of a wide range of contaminants and complex water treatment and soil vapour extraction.

Asset and Resource Recovery

Comprehensive waste and recycling management to contribute to the circular economy to extend the lifecycle of materials.

Site Remediation

Site rehabilitation via methods such as bioremediation, containment, decontamination, dewatering, stabilisation, treatment and tracking to disposal of contaminants.