True Water were recently engaged to complete a full Sewage Treatment Plant (STP) replacement at Glencore's Rolleston Mine Accommodation Village. It is located in the southern part of Queensland's Bowen Basin, approximately 16 kilometres west of the Rolleston Township and 140 kilometres southeast of Emerald. More than 600 staff are currently employed at the mine which extracts coal for the domestic and export markets. The Accommodation Village provides housing and facilities for the mine staff.

The Project - Mine Sewage Treatment Plant Replacement

The Rolleston mine is located in a remote area far from municipal wastewater treatment infrastructure. An on-site, reliable and high-quality sewage treatment plant is required to keep the mine and its various facilities running smoothly. True Water Australia had previously designed, manufactured, installed and commissioned a Kubota HCZ-50 sewage treatment plant to meet the needs of the Administration Complex for the Mine Infrastructure Area (MIA). With remote monitoring, onsite training of personnel and a servicing plan, the wastewater treatment system has been performing at a high standard and meeting all QLD Environmental Authority requirements for the site. True Water were engaged to design, install and commission a replacement Sewage Treatment Plant at the Rolleston Accommodation Village when the existing containerised sewage treatment system failed. A swift replacement of the existing system was required as the failed Pureplus Treatment Plant was not operating to specified treatment levels, posing health and environmental risks. The system being replaced was less than two years old. Although it had failed, there were components that were still in operational condition. It was important to retain and utilise as many existing wastewater treatment assets as possible in order to minimise the costs involved in rectification works. An assessment of site infrastructure was undertaken to evaluate the suitability of existing components to integrate into True Water’s Kubota Treatment System.

Rolleston Rehabilitation Works

From development of the mine through to today's operations, Rolleston Open Cut has demonstrated their commitment to compliance with State and National environmental standards. This includes progressive rehabilitation of mined lands.   In July 2018, Glencore received an official certification from the Queensland Government after rehabilitating 220 hectares of mined land 140km southeast of Emerald, Queensland, an area around six-and-a-half times the size of Disneyland. Rehabilitation at Rolleston Open Cut

The Solution for Glencore

“We’ve recently contracted True Water Australia to design, construct (through Kubota), supply and oversee both the installation and commissioning of a new Sewage Treatment Plant at Rolleston Coal for our 700 unit accommodation village." "During the tender process we found TWA’s technical knowledge, proven working STP systems elsewhere and compliance to government regulations to be far superior to other tenderers. This was proven through consistency in results, testing and reporting data supplied.” James Bernstein – Project Manager, Glencore, Rolleston Mine, QLD Glencore were looking for a STP replacement solution that would achieve quality and budget requirements, while also minimising operational costs throughout the infrastructure life cycle. It was vital that this included operation, maintenance and monitoring. As part of their ongoing commitment to compliance with State and National environmental standards, it was important the solution True Water provided was of the highest quality and reliability. Glencore’s process included engagement of third party consultants and industry experts to inspect STP’s True Water have in operation in similar applications. This determined the suitability of the Kubota STP for the Glencore Rolleston site. The primary project scope was to replace a relatively new system, with guaranteed STP reliability and continuity of operation being key considerations. The Rolleston mine has also received government approval to extend its mine life beyond 2040. This would create an average of 84 full-time jobs over 10 years and once completed about 1200 full-time jobs. This could potentially double the requirements of the Accommodation Village, so the Sewage Treatment Plant needed to include the potential to scale up in size to accommodate higher influent flow volumes.

Project Details

True Water designed and constructed a 100m³ Kubota K-HC-T Sewage Treatment Plant with the potential to expand the capacity of the system in stages. The Kubota Treatment Plant provides biological treatment through a Moving Bed Bioreactor. This is contained within a single treatment Train which includes no moving parts or pumps. A future upgrade would see the same system installed alongside the first stage and utilising shared infrastructure throughout (Controllers, Buffer storage tanks and Treated water storage). “The Kubota STP commissioned for the Glencore Rolleston accommodation site greatly reduces the Principal’s operational costs and maintenance whilst reliably treating wastewater with proven technology from a world leading manufacturer.” Karl Hansen – Commercial Manager, True Water Australia A key advantage of using the internationally renowned Kubota technology is they are manufactured under ISO and Internationals Standards accreditation for the treatment of wastewater. This provides uniformity and surety. Because the Treatment Plants are premanufactured, True Water can deliver large scale Kubota plants in a short period of time and include a Performance Guarantee. This ensures each treatment plant meets the specific requirements of the site and application while providing security to our client. The design and manufacture of the Kubota treatment plants focus on ease of management with a reduction of servicing frequency and operational needs. Once design was finalised, Kubota undertook manufacture of the K-HC-T Treatment Plant. The Treatment Plant was delivered to site approximately 14 weeks from the acceptance of the True Water/Kubota STP and placement of the order. Once the STP arrived onsite it was a simple process to install the tanks, make final connections and backfill around the system. A process that took only six days, from delivery to operation. The existing failed sand/media filters were removed with a portion of the existing infrastructure retained and re-purposed. By repurposing this infrastructure, True Water were able to significantly reduce the rectification costs. The assets that were proposed to be kept were inspected on site for suitability and structural integrity before being integrated into the new Kubota system. The existing pump well, controller and power supply were able to be retained. Suitable existing concrete tanks were modified and pipes realigned to allow for their integration.

The True Water/Kubota STP Solution

True Water is highly experienced in providing replacement solutions for failed or undersized commercial wastewater treatment plants with specific environmental considerations. We recently completed two system replacements on World Heritage listed Fraser Island as part of our wastewater treatment plant contract with the Queensland Government National Parks. Eurong Rangers Station Sewage Treatment Replacement Dundubara STP Rectification Works True Water chose a Kubota system for the Glencore Rolleston Accommodation Village that would provide efficient and cost-effective sewage treatment. The STP produces a high quality of treated water and a high level of nutrient reduction, ensuring exceptional environmental outcomes. During the design and planning phases, all parties took part in a high level of communication to ensure that project timelines were met and continuity of service was guaranteed. The professionalism and organisation within the Glencore and True Water teams ensured the project was delivered on time and on budget.  “It was a pleasure working with Glencore and we look forward to working with them well into the future to deliver successful and trouble-free operation of their new STP.” Karl Hansen – Commercial Manager, True Water Australia  “Their team are experts in all aspects of wastewater from pricing and design through to delivery and contract management. TWA have been extremely professional resulting in smooth sailing with all milestones met and delivered without issue or incident.” James Bernstein – Project Manager, Glencore, Rolleston Mine, QLD

Even in the simplest of installations demand significant planning and thought for the most beneficial and professional of outcomes. The Klenk Property was one such project that, on the surface, appeared incredibly straightforward but, with True Water Australia’s consummate assessment and attention to detail, numerous elements needed to be added to the install. True Water Australia’s solution to the project had to include sufficient drainage and treatment for the existing structure while taking into account the ability to also service a proposed future residence. Cost-effectiveness and a range of location options also proved to require significant forward planning. Fortunately, through True Water Australia’s unfaltering expertise and experience, an excellent result was achieved for a very happy client. The level open property at first presented minimal limitations, the treatment system needing only to service a shed on the expansive site. The future addition of a dwelling, however, meant that a higher volume of treatment would eventually be required, and the location of the proposed property and its recreational areas would also need to be taken into account, all while maintaining the most cost-effective solution. Solution The installation of an advanced secondary treatment system reduced the overall size of the disposal zone, allowing for greater utilisation of recreational areas. Several options for the location of the unit initially presented themselves but, after assessment and consideration, the final location saved the client considerably in connection costs. As with every project, True Water Australia ensured that both the client and relevant tradespeople, in this case, an electrician, were consulted at every stage of the project. This is absolutely essential so as to ensure the most cost-effective, practical and legally viable solution. Conclusion Although the Klenk Project was essentially a very standard installation, it showcases the lengths to which True Water Australia analyse every parameter of a project prior to commencement. The Klenk Project proved to be a resounding success through True Water Australia’s attention to detail, high-class workmanship and continual communication and liaison between contractors and the client. Combined with the high-quality product, its efficiency and cost-effectiveness and the financial efficiency of True Water Australia’s planning, work and solution, these factors resulted in an exceptionally happy client and a first-class outcome.

Baillies Lodges aims to set new benchmarks for premium experiential travel in a unique Australian style. Their resort, on Lord Howe Island sits on the western side of the Island with uninterrupted views of the Pacific Ocean, reef and mountains. The resort that caters for luxury holiday makers recently received a much needed upgrade to their wastewater system. Lord Howe Island is located 580km from mainland Australia posing logistical challenges for commercial infrastructure. The island is World Heritage listed and has many untouched environmentally sensitive areas. Seasonal occupancy rates see varying wastewater flows throughout the year. The sewage treatment plant upgrade required a robust solution capable of consistent treatment performance and without impact to the environment. True Water undertook the installation that saw a Kubota HC-50 Sewage Treatment Plant transported to site via the Island Trader. Irrigation was installed in conjunction with the Kubota sewage treatment plant to provide the resort with the highest quality sewage treatment system available while ensuring no impact to the World Heritage site’s views and its pristine environment.

Camp Lake Fire is a quiet and relaxing bush retreat located high on the southern shores of beautiful Lake Maroon, approximately 90 minutes from Brisbane and the Gold Coast. The retreat has recently undergone upgrades and improvements including the addition of an amenities block with True Water providing a sustainable and cost-effective sewage treatment solution to service campers and staff alike. With the retreat located close to Maroon Dam operational and performance compliance where key requirements for the sewage treatment plant. Varying flows throughout on and off-peak visitor seasons also required a solution that would effectively manage peak flows without impacting treatment quality. The 10m³ per day Kubota HC-Z sewage treatment system was chosen for its robust design, ground level finish, scalability, ease of install and its high-quality treatment process. It has been a popular choice for the tourism industry, mining industry and large-scale industrial projects throughout the world.

True Water was awarded a Design and Construct contract to provide a temporary wastewater treatment solution for the Australian Defence Force. The project forms part of the Army Aboriginal Community Assistance Programme (AACAP) which began in 1997 to assist indigenous communities by providing infrastructure including housing, essential services and health facilities. The project required a wastewater management system with capabilities for demobilisation while maintain high treatment quality objectives. This was further complicated with the addition of low to medium volumes of trade waste included within the influent wastewater. True Water was required to work closely with the Australian Defence Force, associated contractors and local trades to meet delivery and operational requirements. True Water manufactured and delivered a dual HCZ System with installation above ground to ensure future demobilisation posed no risk to people, the environment or the Infrastructure. Specification and coordination assistance was provided to ensure suitable pre-treatment technologies were included upstream of the Treatment Plant ensuring operational targets were met.

Moreton Bay Regional Council awarded True Water the contract for the design and construction of a wastewater management system after a thorough tender evaluation process. Toorbul caravan park is located within 100mof Pumistone passage, a sensitive waterway which flows directly into Moreton bay. A new wastewater management system was required when the existing system failed. Key challenges faced were sensitive wetlands and waterways within close proximity, aging infrastructure allowing stormwater ingress to the capture network, and limited available area for the treatment system True Water decommissioned the existing treatment plant and undertook remediation works for the capture network eliminating stormwater infiltration. A 20kL Kubota HCZ sewage treatment plant was delivered and installed with discharge via an engineered mound system. The application method reduced the area required for the wastewater management system and allowed for the implementation of environmental buffers and extensive revegetation within the available area and budget.

Owned and operated by the Australian Indigenous Land Corporation, Home Valley Station is one of the most remote outstations in Australia. With recent expansions to the resort sewage treatment requirements have increased. As a result, True Water were engaged to provide a scalable treatment solution to meet wastewater needs. Although the 800,000km² cattle station is isolated deep in the Kimberley and is 3hours from the nearest town of Kununurra, they can have up to 800visitors a day. Everyone using the Gibb River road is like to stop in at Home Valley and grab a meal or use the toilets, so the reliability of the Kubota plant is of key importance for the isolated site. To allow for the future, wastewater infrastructure was required to be scalable, allowing capital investment to match resort growth, and robust, ensuring a long operational life in harsh climatic conditions. Seasonal occupancy rates required the wastewater treatment system to be capable of managing highly variable flows while maintaining treatment performance. Stage 1 of the sewage treatment plant involved the design and installation of four commercial Kubota HC-Z Treatment Plant modules with a combined treatment capacity of 40m³ per day. The Treatment Plant was installed below ground to regulate temperature, improve visual amenity and eliminate any impacts the extreme climate may have on the infrastructure. Stage 2 included the addition of three Kubota HC-Z Treatment plant modules bringing the total daily treatment capacity to 70m³. “Having worked in a remote environment in the East Kimberley, it is essential to have reliable and efficient services, the Wastewater Management System installed by True Water Australia is a state of the art Kubota plant that not only allows piece of mind, it is very low maintenance and the most effective wastewater management system I have worked with over a 20year career in remote resorts around Australia. True Water Australia are a professional company offering the ultimate in customer service and customer support, they go over and above and have exceeded my expectations with each and every contact.” Lynn Stollery – General Manager, Home Valley Station, Gibb River Road, WA

True Water were recently awarded a highly contested Design and Construct contract by QLD National Parks. The contract included decommission of an existing treatment plant and delivery of a new commercial wastewater treatment plant to service the Dundubara Campgrounds and Rangers Station. The location of the project presented logistical challenges including restricted and intermittent access to site, and limited availability of trades and utilities. World Heritage listed Fraser Island requires strict environmental standards be adhered to. The treatment plant is located within 100m of the Pacific Ocean and is required to perform consistently under adverse climatic conditions. Robust and consistent treatment performance was essential to meet the strict environmental requirements for Fraser Island. Due to the seasonal occupancy fluctuations, wastewater volumes vary greatly throughout the year. True Water designed a wastewater management system utilising a Kubota HC-Z sewage treatment plant with the ability to manage variations in flow capacities and quality. Importantly, the plant selected uses simple yet reliable processes to achieve performance and reliability outcomes. The project delivery required a strong logistics strategy, easily mobilised components, thorough planning, and an experienced team to complete.

Queensland Government’s new emergency services hub for Alpha provides improved services and public health access. The Emergency Services Hub includes Hospital, Health, Ambulance, Fire and Police Facilities. The town of around 500 is the centre of an outback region in Central Queensland requiring contractors from around Australia to be involved in the project. As the site is small and all wastewater is managed wholly within the lot and surrounding the hospital, a key focus was the delivery of a safe and effective sewage treatment system that provided guaranteed amenity. To achieve beneficial outcomes for the Alpha emergency services hub, True Water redesigned the previous wastewater design and reworked the sewage treatment plant and irrigation system layout and location to address each of the challenges of the site. Challenge’s included, the remote location, temperatures variance from 4⁰ to 47⁰ and trade waste from the hospital that contains contaminants that can effect sewage treatment if not managed properly. The sewage treatment plant servicing the Emergency Services Hub is a 10m³ Kubota HC. The biological processes within the Kubota sewage treatment plant ensure reliable and cost effective treatment and provide the highest level of public health and safety. True Water secured the project as it was able to provide enhanced public health and environmental outcomes while reducing the capital and operational cost of the wastewater infrastructure.

Brisbane West Wellcamp Airport and Business Park is the aviation gateway connecting Toowoomba and south-west Queensland to the world. Developed and operated by global construction company Wagner’s, Wellcamp Airport and Business Park is the first greenfield public airport built in Australia in 50 years and the nation’s first privately funded public airport. The Airport is located approximately 15km West of Toowoomba, beyond existing sewerage service networks. Therefore it required a Sewage Treatment Plant (STP). The development posed several key challenges for effective sewage management including; highly variable flows, staging requirements and high levels of trade waste. True Water Designed and constructed a 500m³ Kubota K-HC-R Sewage Treatment Plant with Stage 1 providing up to 100m³ treatment capacity per day. The Treatment Plant will be scaled in 50m³ stages to provide efficient and cost effective sewage treatment, and exceptional environmental outcomes.   “Wagner’s is a large family company based in Toowoomba, Australia.  We needed the world’s most reliable, high quality sewage solution for the Brisbane West Wellcamp Airport and Wellcamp Business Park.  The Wellcamp Airport and Business Park offer world class infrastructure and facilities and have a focus on the highest environmental performance possible. True Water Australia was chosen after discussions with each of the leading providers in Australia.  We made this decision as True Water Australia displayed many of the traits that made Wagner’s successful, namely innovation, attention to detail, focus on quality, dedication and customer service. Wagner’s is extremely happy with the quality and performance of True Water Australia’s works and the Kubota STP.” -Denis Wagner, Managing Director, Wagner’s   Wellcamp Airport and Business Park Website