Douglas-Middelburg Coal Plant


BHP Billiton Energy Coal South Africa (BECSA)


Mpumalanga Province, South Africa


USD$150 million


Engineering, Procurement and Construction Management

The construction of the coal washing plant at the Douglas-Middelburg Optimisation (DMO) Project was secured by DRA Global early in 2008. The new coal processing plant for BHP Billiton Energy Coal South Africa (BECSA) will assist BECSA to maintain current export and Eskom supply till 2034.

The DMO project consisted of the engineering and design of a raw coal handling and coal preparation plant, slimes handling and product handling facilities with DRA operating on an EPCM basis. The plant provides a throughput of 14 Mtpa and features one of the world’s largest 2-module DMS plants, using cyclones measuring 1150mm in diameter and 4.2m wide vibrating screens.

The main focus for the client and DRA Global on this project was to design the largest feasible DMS modules for optimum throughput. A versatile plant design was proposed, capable of coping with coal from many different sources and producing prime grade export coal and middling’s suitable for local power generation.

DRA's scope of work included:

  • Engineering
  • Draughting for earthworks and civils
  • Structural, mechanical and process engineering
  • Power reticulation and control systems
  • Overseeing construction, risk and safety management
  • Commissioning and final handover