Background

BHP is a world-leading resources company with a presence in more than 90 locations worldwide, spanning from the mineral-rich landscapes of Australia and Chile to major operations across the United States and Canada. The company is strategically positioned to support the global megatrends of the future.

In South Australia, this global mission is brought to life through three primary mine locations: Carrapateena, Prominent Hill, and Olympic Dam. The Olympic Dam stands as one of the world’s most significant deposits of copper, gold and uranium. In an environment of this scale and importance, BHP’s primary focus is the health and safety of the employees who keep the site running.

Problem

Operating a fully integrated ore-to-metal facility, the site generates dust that is not only toxic and poisonous but also highly acidic. For BHP, the challenge was twofold: protecting personnel from direct inhalation of hazardous particles and preventing secondary contamination from being carried into clean zones.

The solution had to withstand an intense operational tempo during site outages, including:

• High-Frequency Use: Supporting 15 crews performing de-dusting cycles every 12-hour shift, with 6 de-dusting processes per person per shift on average
• Continuous Operation: Maintaining 24/7 reliability over a 45-day peak period (totaling 135 hours of active run-time).
• Corrosive Site Conditions: Surviving a harsh, acidic atmosphere that would degrade standard industrial equipment.

Solution

BHP initially trialed a Bat Booth® on-site to validate its efficacy against toxic dust. After the system passed every rigorous safety test including contributing to the elimination of specific dust-related injuries, BHP commissioned Mideco to build two custom units engineered to their specific standards.

Key features of the Olympic Dam solution include:

• Acid-Resistant Construction: To combat the corrosive environment, the units were upgraded with stainless steel casings, piping, and fittings, alongside fiberglass-reinforced plastic (FRP) floor grating, pressure relief valve (PRV) and a special plug that allowed to run the unit on plug & play principle.
• NIOSH-Compliant Speed: The system performs a 10-second cleaning cycle that adheres to NIOSH guidelines, ensuring workers are de-contaminated safely and rapidly without interrupting shift flow.
• Total Contaminant Capture: The de-dusting process prevents workers from inhaling particles during PPE removal and stops cross-contamination between work zones.

Result

Since their permanent installation in 2017, the custom Bat Booths have performed flawlessly. Despite the relentless 24/7 schedule and the acidic conditions of the Olympic Dam site, the units have required only routine filter replacements. By integrating this rapid de-dusting technology, BHP has successfully protected its workforce from respiratory hazards and set a global benchmark for safety in high-risk mineral processing.

Does your facility face extreme or corrosive conditions? Contact us.