From coal to gas

In a bid to trim its carbon footprint, Worsley Alumina has achieved a significant milestone by converting its first coal-fired boiler to natural gas. In alumina production, boilers are essential for the generation of steam, which is used in the refining process. 

Monadelphous supported this project by serving as a primary structural, mechanical, and piping (SMP) contractor for the transformative project.  

They navigated challenges, including an accelerated timeline due to concerns about coal supply. 

Mining Minerals Southern Region Superintendent Michael Trappitt commended the Worsley and Health, Safety, and Environment (HSE) teams' outstanding efforts within the designated timeframe. 

"FEED studies (the Critical Planning Tool) had not yet been complete when Monadelphous was engaged for the project, so the Monadelphous execution team worked closely with the customer’s engineering team to virtually design and construct from the start," Michael said. 

The journey for this project began in May 2023, with a workforce that peaked at 120 individuals, including 80 local people. The converted gas-fired boiler launched in late September, marking a tangible step towards reduced greenhouse gas emissions at Worsley. 

This shift from coal to gas not only aligns with Monadelphous' emission reduction goals but also complies with the West Australian government's coal exit timeline. 

"The maintenance required to sustain the performance of the asset has now been drastically reduced," Michael said.  

In the end, it was a remarkable effort by a relatively small and dedicated team, overcoming challenges whilst maintaining a recordable injury free safety record.  

You can read more about the project here.