Hatch has led both the study phases and the implementation phase of the Ravensthorpe and Yabulu projects. The process
involves production of nickel/cobalt hydroxide intermediate product at Ravensthorpe in Western Australia, which is
shipped to the QNI Yabulu Refinery in Townsville, on the east coast of Australia, for further refining. The total capital
value of the projects is approximately A$3 billion.
Hatch performed detailed engineering, procurement and construction management for the
Ravensthorpe nickel project. The processing plant includes High Pressure Acid Leaching (HPAL), Atmospheric Leaching
(AL), Tailings Neutralization and Mixed Hydroxide Precipitation, while the infrastructure includes a seawater pipeline and
desalination plant, an acid plant, a camp and a power plant.
The product is a mixed nickel and cobalt hydroxide
containing 45,000 tpa of nickel to be shipped to the QNI Yabulu Nickel Refinery. Prior to commencing EPCM, Hatch
performed a review of previous studies and recommended a path forward that focused on capital value and technology
selection, and in joint venture, proceeded with a feasibility study, basic engineering and project implementation. A major
highlight of this project was the achievement of a classified injury frequency rate of 2.8, which was recognized by BHPB
to be the best safety outcome for a major metallurgical project in BHPB’s history.
This project included both pre-feasibility and feasibility studies, as well as the EPCM
implementation of a complex expansion of the Yabulu refinery to increase nickel capacity from 29,000 tpa to 75,000 tpa.
The scope of this heavily brownfield project included mixed hydroxide receival and leaching, upgrades to ammonia
stripping and ammonia recovery, a completely new solvent extraction circuit, upgraded cobalt processing facilities, a new
basic nickel carbonate nickel filtration, calcinations and reduction plant, and upgrades to all the associated utility systems
and controls. One of the major successes of this project was that the plant was able to achieve both record production,
exceeding its production target, while sustaining a 31% decrease in recordable injuries in the same year as the
construction effort was at its peak.
