Tailings Leach Feed Tank Bypass

Introduction

Incon was engaged to deliver civil and structural engineering design services for the Tailings Leach Feed Tank bypass system at BHP Olympic Dam. The project formed part of a critical reliability and risk mitigation initiative to maintain continuous plant operations during required maintenance of key process infrastructure. The scope focused on the detailed design of structural supports and foundations to enable integration of a new bypass manifold within an operational processing facility.

Project
description

The existing Tailings Leach Feed Tank (4241TK1075) had experienced significant underfloor corrosion and was at risk of failure, with potential to disrupt production for up to six months if not addressed .

To mitigate this risk, a bypass system was developed to reroute slurry flow directly from the thickener underflow pumps to the tailings leach feed pumps, eliminating reliance on the deteriorating tank during maintenance activities.

Incon’s scope included:

Structural design of multiple pipe supports (PS1–PS6)
Design of associated concrete foundations, including bored piers and pad footings
Integration of supports within an existing bunded and congested plant environment
Development of detailed calculation packages and design documentation in accordance with BHP standards

The design needed to align with strict operational, safety, and constructability requirements for a live mining and processing facility.

Challenge

Live Operational Environment -The bypass system had to be designed for installation within an active processing plant, requiring minimal disruption to ongoing operations and strict adherence to safety protocols.
Space Constraints & Congestion -The supports were located within an existing bund area surrounded by pumps, pipework, and infrastructure, limiting foundation footprint and constructibility options.
Complex Load Conditions -Structural design needed to account for pipe loads derived from slurry flow, thermal effects, and operational scenarios, interfacing with mechanical and piping systems.
No Existing Structural Dependency -Supports were required to be independent of existing pipe racks, necessitating standalone foundation solutions within constrained ground conditions.
High Compliance Requirements - All deliverables had to meet stringent BHP design criteria, QA processes, and documentation standards, including formal calculation packages and Safety in Design (SiD) integration.

Solution

Incon delivered an optimised and constructible structural solution tailored to the constraints of the Olympic Dam site:

Efficient Structural System Design -Developed cantilevered and T-shaped pipe support configurations to minimise footprint while maintaining structural integrity and accessibility.
Foundation Optimisation -Designed a combination of bored piers and pad footings to suit varying support conditions, ensuring stability while reducing excavation and interference with existing infrastructure.
Integrated Design Coordination - Worked closely with process and piping teams to align structural supports with pipe stress outputs and operational requirements, ensuring accurate load transfer and system performance.
Constructibility Approach - Configured support layouts to allow staged installation and minimise plant downtime during tie-ins and commissioning.

Outcome

The completed design enabled the successful implementation of a bypass system that:

Eliminated reliance on a high-risk asset
Allowed continued plant operation during tank maintenance
Reduced potential production downtime significantly
Provided a flexible and maintainable long-term solution
Incon ’s design approach ensured a balance between structural efficiency, operational continuity, and constructability within a complex mining environment.

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