Material duty
What enters, what changes and what product or waste stream leaves.
Australian mining equipment · Coal
Coal equipment. Mine to terminal.
Follow the equipment used across Australian open-cut and underground coal mining, coal handling and preparation plants, rail load-out and export terminals.
Choose a commodity
One equipment library. Four different systems.
Compare the machines used in iron ore, coal, lithium and gold—from extraction and processing to the final product handover.
Why the equipment changes
Coal does not simply copy the iron ore fleet.
Coal can start in an open cut with draglines, shovels and truck fleets, or underground with continuous miners and longwall systems. The run-of-mine stream may then pass through a coal handling and preparation plant (CHPP), where equipment separates coal from higher-density rock, manages moisture and builds a customer product. The export route adds shared rail and terminal machinery, plus coal-specific dust, gas and spontaneous-combustion controls.
Start with the material. Follow what each machine changes, then read the handover to the next system.
Functional process graphic
Follow the equipment through six operating families.
This is a representative system map. Individual mines can use alternatives, bypass stages or locate downstream processing away from the mine.
- 01Open-cut miningOpen-cut fleet
- 02Underground miningUnderground systems
- 03ROM handlingSize & transfer
- 04CHPP separationWash & separate
- 05Product preparationDewater & blend
- 06Rail and terminalRail & export
Read the whole machine
Four layers sit behind every equipment name.
The visible machine is only one part of the system. Utilities, controls, access, material condition and the next handover all influence whether it performs.
Mechanical system
Structures, drives, wear parts, bearings, hydraulics, piping and load paths.
Electrical & control
Power, instruments, PLC or DCS logic, communications, safeguards and interlocks.
Operating boundary
Ore variability, quality targets, hazards, approved limits and the downstream constraint.
01 · Open-cut mining
Back to system map ↑Draglines, drills, shovels and haul fleets
Remove overburden, expose coal seams, recover coal selectively and move coal or waste to the planned destination.
InputGeological model, overburden and coal-seam mining plan
Equipment dutyRemove overburden, expose coal seams, recover coal selectively and move coal or waste to the planned destination.
OutputRun-of-mine coal delivered to the ROM system, with waste placed in the approved dump sequence
Open the detailed guide+
Operating principle
How the system works
Production drills and blasting fragment competent overburden where required. Draglines can move large volumes of overburden directly into mined-out areas, while electric rope shovels, hydraulic excavators and front-end loaders load truck fleets. Dozers, graders and water carts maintain working areas and haul roads. Selective digging and dispatch keep coal, partings and waste in the correct material streams.
Major equipment and systems
Component-to-function map
Drilling and blasting
Rotary or down-the-hole drills, drill strings, air systems, dust controls, charging support and blast-area controls.
Dragline system
Boom, mast, hoist and drag ropes, bucket, rigging, rotating frame, walking mechanism, electrical drives and machine control.
Loading tools
Electric rope shovels, hydraulic excavators or loaders with digging attachments, crowd or hydraulic systems and undercarriages.
Mobile fleet
Haul trucks, dozers, graders, water carts, service vehicles, dispatch, positioning, roads and refuelling infrastructure.
Maintenance focus
What teams manage
- Drag, hoist and suspension ropes, bucket rigging and boom structure
- Shovel or excavator GET, undercarriage, hydraulics and slew systems
- Truck tyres, brakes, retarding, steering, powertrain and payload systems
- Drill consumables, compressors, dust control and machine electrical systems
Condition and process watch
What can reduce performance
- Coal loss or dilution at the seam contact
- Fatigue, rope deterioration and high cyclic loads
- Tyre damage, road condition and mobile-equipment interaction
- Dust, heat, water and changing geotechnical conditions
People around the system
Different disciplines, one handover.
DrillersDragline operatorsExcavator and shovel operatorsHaul-truck operatorsHD fittersAuto electriciansTyre techniciansMine controlSurvey and geology teams
Configuration boundary: Not every open-cut coal mine uses a dragline. Overburden depth, geometry, strip sequence, fleet strategy and coal selectivity determine the actual equipment mix.
02 · Underground mining
Back to system map ↑Continuous miners and longwall systems
Develop underground roadways, support the excavation and recover coal from a controlled production face.
InputApproved mine design, developed seam access, ventilation and strata-control plan
Equipment dutyDevelop underground roadways, support the excavation and recover coal from a controlled production face.
OutputCoal on the underground conveyor network, with supported roadways and managed gas, dust and water
Open the detailed guide+
Operating principle
How the system works
Continuous miners cut coal while shuttle cars or flexible haulage systems move it to a feeder breaker during roadway development. In longwall production, a shearer traverses the face, an armoured face conveyor carries coal to a stage loader and crusher, and powered roof supports advance in sequence behind the cut. Main belts then transfer coal toward the surface. Ventilation, gas monitoring, stone-dust or explosion controls and statutory electrical requirements are integral to the equipment system.
Major equipment and systems
Component-to-function map
Development package
Continuous miner cutting head, gathering arms, bolters, shuttle cars or flexible haulage, feeder breaker and services.
Longwall face
Shearer drums and ranging arms, armoured face conveyor, stage loader, crusher and powered roof supports.
Outbye transport
Panel belts, main conveyors, drives, take-ups, transfers, bunkers and surface drift or shaft interfaces.
Critical services
Ventilation, gas and dust monitoring, water, dewatering, communications, power distribution and emergency systems.
Maintenance focus
What teams manage
- Cutting picks, drums, ranging arms and shearer haulage
- AFC chains, flights, sprockets, pans and stage-loader transfers
- Powered-support hydraulics, roof-support function and hoses
- Explosion-protected electrical equipment, cables, sensors and communications
Condition and process watch
What can reduce performance
- Strata movement and changing roof or floor conditions
- Methane, coal dust, ventilation and ignition hazards
- Chain wear, overload, alignment and material blockages
- Restricted access, water ingress and service damage
People around the system
Different disciplines, one handover.
Continuous-miner operatorsLongwall operatorsDeputies and statutory officialsUnderground electriciansMechanical tradesVentilation officersControl-room operatorsGeotechnical teams
Configuration boundary: Continuous-miner, bord-and-pillar and longwall layouts are not interchangeable. Underground work is governed by mine-specific statutory, ventilation, gas, strata and explosion-protection requirements.
03 · ROM handling
Back to system map ↑Feeder breakers, crushers, screens and conveyors
Receive variable run-of-mine coal, control the feed, reduce oversize and separate streams before preparation or bypass handling.
InputRun-of-mine coal containing coal, partings, rock, fines and variable moisture
Equipment dutyReceive variable run-of-mine coal, control the feed, reduce oversize and separate streams before preparation or bypass handling.
OutputA controlled-size feed directed to the CHPP, raw-coal stockpile or approved bypass route
Open the detailed guide+
Operating principle
How the system works
ROM bins and feeders absorb truck or underground-conveyor surges. Feeder breakers, roll crushers or sizers reduce oversize with less uncontrolled impact than a free-dumping stream. Screens separate size fractions so the preparation plant can send coarse and fine coal to equipment suited to each fraction. Magnets and tramp-metal protection help protect the downstream plant.
Major equipment and systems
Component-to-function map
ROM receival
Dump hoppers, bins, feeders, rock or lump breakers, level instruments, liners and dust suppression.
Size reduction
Feeder breakers, roll crushers or mineral sizers, shafts, teeth, drives, couplings and overload protection.
Sizing
Vibrating or banana screens, decks, media, exciters, springs, support structure and discharge chutes.
Transfer
Conveyors, belt scales, magnets, metal detectors, samplers, transfer chutes and route-selection controls.
Maintenance focus
What teams manage
- Crusher or sizer teeth, shafts, bearings and drive condition
- Screen media, exciters, springs and structural connections
- Conveyor tracking, splices, cleaners, pulleys and idlers
- Chute liners, buildup, dust controls and blocked-chute protection
Condition and process watch
What can reduce performance
- Wet or sticky coal, blinding and chute blockage
- Tramp metal, oversize and impact loading
- Carryback, spillage, dust and material loss
- Feed segregation and unstable plant loading
People around the system
Different disciplines, one handover.
ROM operatorsProcess operatorsMechanical fittersElectriciansBoilermakersBelt splicersControl-room operatorsMaintenance planners
Configuration boundary: Raw-coal bypasses, crusher types, screen apertures and sampling arrangements are operation- and product-specific. They should not be inferred from another CHPP.
04 · CHPP separation
Back to system map ↑Dense-medium cyclones, spirals and flotation
Separate lower-density coal from higher-density mineral matter and build product streams that meet quality requirements.
InputSized raw coal mixed with water and divided into coarse, fine and ultrafine fractions
Equipment dutySeparate lower-density coal from higher-density mineral matter and build product streams that meet quality requirements.
OutputProduct coal, middlings or rewash streams, and reject material for controlled disposal
Open the detailed guide+
Operating principle
How the system works
A dense-medium circuit mixes water with magnetite to create a controlled-density medium. In a dense-medium cyclone, centrifugal flow helps lower-density coal report separately from higher-density rock. Drain-and-rinse screens recover medium for reuse. Fine coal can pass through classifying cyclones, spirals or fluidised-bed separators; ultrafines may use flotation, where selected particles attach to bubbles and report to froth. The flowsheet depends on washability, size distribution and product specification.
Major equipment and systems
Component-to-function map
Dense-medium circuit
Mixing and correct-medium tanks, pumps, dense-medium cyclones, density measurement and control valves.
Medium recovery
Drain-and-rinse screens, magnetic separators, dilute-medium sumps and return-water systems.
Fine-coal separation
Classification cyclones, spirals or fluidised-bed classifiers, distributors, launders and slurry pumps.
Ultrafines and control
Flotation cells, reagent dosing, air systems, froth launders, online analysers, sampling and plant DCS.
Maintenance focus
What teams manage
- Cyclone liners, vortex finders, spigots, distributors and feed pressure
- Screen media, magnetic separators and medium-recovery condition
- Slurry pumps, pipework, valves and abrasion protection
- Flotation mechanisms, air systems, level control and reagent equipment
Condition and process watch
What can reduce performance
- Medium density drift and coal misplaced to reject
- Cyclone roping, wear and unstable feed pressure
- Screen blinding, magnetite loss and water-balance changes
- Feed-quality variation, reagent response and sampling error
People around the system
Different disciplines, one handover.
CHPP operatorsControl-room operatorsMetallurgistsLaboratory techniciansMechanical fittersElectricians and E&I techniciansReliability engineersProcess engineers
Configuration boundary: Not every coal product is washed and not every CHPP uses the same combination of dense medium, spirals, classifiers or flotation. Coal washability and contract quality drive the flowsheet.
05 · Product preparation
Back to system map ↑Screens, centrifuges, filters and product stockpiles
Remove process water, control product moisture, recover water and place saleable coal into a managed stockpile or load-out stream.
InputWet coarse, fine and ultrafine product streams from the CHPP
Equipment dutyRemove process water, control product moisture, recover water and place saleable coal into a managed stockpile or load-out stream.
OutputSampled saleable coal within the required moisture and quality envelope, plus clarified or recycled process water
Open the detailed guide+
Operating principle
How the system works
Drain-and-rinse or dewatering screens remove free water from coarser coal. Basket or screen-scroll centrifuges apply centrifugal force to reduce moisture further. Fine and ultrafine streams can use thickeners, filter presses or vacuum filters. Conveyors then combine, sample and direct product to stockpiles, while stackers or dozers shape piles according to blending, reclaim and spontaneous-combustion controls.
Major equipment and systems
Component-to-function map
Coarse dewatering
Dewatering screens, spray systems, chutes and product conveyors.
Centrifuges
Rotating basket or scroll, drive, bearings, vibration monitoring, feed distributor and discharge arrangement.
Fine-coal recovery
Thickeners, flocculant systems, filter presses or vacuum filters, pumps and filtrate return.
Product handling
Sampling, belt scales, stackers or mobile plant, stockpile monitoring, water sprays and reclaim feeders.
Maintenance focus
What teams manage
- Centrifuge basket, scroll, bearings, balance and vibration condition
- Screen media, spray bars and discharge chutes
- Thickener rake, drive, feedwell and flocculant dosing
- Filter cloths, plates, vacuum or hydraulic systems and cake discharge
Condition and process watch
What can reduce performance
- Product moisture outside specification
- Centrifuge vibration, imbalance and accelerated wear
- Fine-coal losses and poor water recovery
- Stockpile heating, dust, segregation and extended residence time
People around the system
Different disciplines, one handover.
Process operatorsLaboratory and quality teamsMechanical fittersElectriciansBoilermakersWater-management teamsStockpile operatorsMaintenance planners
Configuration boundary: Product-moisture targets, residence limits, stockpile shapes and spontaneous-combustion controls are product- and site-specific. Use current CHPP and stockpile procedures.
06 · Rail and terminal
Back to system map ↑Train load-out, unloading stations and shiploaders
Load the rail consist, move product to port, receive it into the terminal and transfer the nominated coal into the vessel.
InputSaleable coal allocated to a train and customer shipment
Equipment dutyLoad the rail consist, move product to port, receive it into the terminal and transfer the nominated coal into the vessel.
OutputA documented coal cargo loaded into the nominated vessel holds
Open the detailed guide+
Operating principle
How the system works
Mine load-out bins, gates, weighing and sampling systems load each wagon. Shared rail networks move the consist to a terminal, where bottom-dump wagons or another unloading system discharge into hoppers. Conveyors route coal to dedicated stockpiles. Combined stacker-reclaimers or separate machines build and recover stockpiles, buffer bins steady the wharf feed, and travelling shiploaders place coal according to the vessel plan.
Major equipment and systems
Component-to-function map
Mine load-out
Product bin, feeders, gates, weighing, sampling, train detection and load-control logic.
Rail and receival
Locomotives, wagons, track, signalling, dump stations, hoppers and terminal train sequencing.
Terminal stockyard
Conveyors, transfers, combined stacker-reclaimers, stockpile monitoring, dust and fire controls.
Wharf system
Buffer bins, feeders, wharf conveyors, shiploader boom and chute, berth and marine interfaces.
Maintenance focus
What teams manage
- Load-out gates, samplers, weighing and train-position systems
- Dump-station hoppers, feeders, liners and dust systems
- Stacker-reclaimer bucket wheel, boom, slew, luff and travel systems
- Shiploader conveyors, motions, chute, brakes, storm restraints and wharf services
Condition and process watch
What can reduce performance
- Cross-contamination and product traceability
- Coal accumulation, dust and spontaneous combustion
- Train sequencing, shared-network constraints and terminal stockyard space
- Vessel plan, berth limits, weather and upstream feed interruptions
People around the system
Different disciplines, one handover.
Train load-out operatorsRail crews and network controllersTerminal controllersStacker-reclaimer operatorsShiploader operatorsMechanical and electrical tradesMarine coordinatorsQuality and logistics teams
Configuration boundary: Rail systems, wagon discharge, terminal layouts, dust and fire controls, stockpile rules and loading rates vary by network and terminal. Published figures are facility-specific.
Sources and further reading
Operator and equipment sources.
Source-checked 30 August 2026. Confirm details against current OEM and site-controlled documents.
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Glencore Australia — coal operations
Operator context for Australian open-cut and underground coal mines in New South Wales and Queensland.
Whitehaven Coal — Australian assets
Current operator overview of open-cut and underground coal assets, mine infrastructure and export routes.
Multotec — coal processing
Equipment-manufacturer explanation of crushing, sizing, dense-medium separation, fines recovery and dewatering stages.
Multotec — dense-medium cyclones
OEM explanation of density separation, major cyclone components, wear protection and operating variables.
NCIG — terminal services
Terminal operator description of train unloading, conveyors, stockpiles, stacker-reclaimers, buffer bins and shiploading.
Aurizon — Central Queensland Coal Network
Network operator overview of the heavy-haul rail system linking mines with Queensland export terminals.
Technical boundary: Coal equipment, CHPP circuits, underground mining methods, gas and dust controls, spontaneous-combustion management, product specifications, rail plans and terminal procedures vary materially between operations. This guide does not replace statutory appointments, competency, approved procedures, OEM manuals, engineering drawings or isolation requirements.