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Modern Coking Coal TechnologyPeter Long, Executive General Manager - Asia
10 February 2012
SEDGMANRecognised for leading innovative solutions for the resource industry
1. COMPANY OVERVIEW2. LOCATIONS AND PERSONNEL3. ADVANCED TECHNOLOGY FOR COKING COALS4. PROCESS DESIGN5. UGH DESIGN FOR CHPP6. DESIGNING FOR EXTREME WEATHER VARIANCES7. OVERCOMING OPERATIONAL CHALLENGES IN REMOTE
LOCATIONS8. UHG CHPP CONSTRUCTION
10 February 20122
AGENDA
• Global leader in the design, construction and operation of coal handling and processing plants (CHPPs)
• Established in 1979 in Australia• Publicly listed, ASX 300 company• Focused on technology leadership and
reputation built on delivering simple, certain quality
• Over 1,000 employees worldwide• Conceptual Design through to Operations• Contract experience from EPCM to full EPC risk• Currently undertaking coal projects in four
continents – Asia, Australia, Africa and South America
• Delivered over $1.7 billion of CHPPs in the past 6 years
• Processing capacity of more than 30 Mt/a of coal
10 February 20123
1. COMPANY OVERVIEW
10 February 20124
2. LOCATIONS AND PERSONNEL
Currently Executing 15 projects and 12 operations contracts world wide
South America 80 StaffOffice SantiagoProjects Bocamina CHP
South Africa 79 staffOffices JohannesburgProjects Atcom (Sth Africa), Benga, Zambeze (Mozambique),
Boseto (Botswana)
Mongolia / China 95 staffOffices Ulaanbaatar Beijing, ShanghaiProjects UHG Stage 1, UHG Stage 2, UHG Stage 3, Phu KamOperations UHG Management
Australia 805 StaffOffices Brisbane (head office), Townsville, Mackay & PerthProjects Bengalla Upgrade, Caval Ridge, Lake Vermont 2, Maules Creek, Middlemount Upgrade,
Narrabri, Red Mountain Upgrade, South Walker CreekOperations Agnew, Blair Athol, Cannington, Coppabella, Ernest Henry, McArthur River, Moorvale,
Middlemount, Mt Isa, Red Mountain, Sonoma
Coking coal is a high value productCurrently > US$300/t
Expected long term > US$150/t
Maximum recovery is major driver for project return
Design Elements for Maximising RecoveryAnalysis of resource
- Best practice techniques for bore core analysis and interpretation
- Simulations for accurate prediction of yield for plantdesign purposes
- Coking coals can be very different
Selection of most appropriate plant circuit and equipment for the range of coal seams to be treated
- Computer models of alternative circuits using models based on a large in-house database of actual operating plant data
Detailed Coal Handling and Plant design using 3D CAD to optimise layout for operating and maintenance
10 February 20125
3. ADVANCED DESIGN FOR COKING COALS
10 February 20126
3. ADVANCED DESIGN FOR COKING COALS
• Dense Medium Cyclones for coarse coal with circuits designed for optimum efficiency
High medium : coal ratios to maximise efficiencyLarge diameter cyclones with high spigot capacity for low yielding feed types
• High rank coking coals have a high percentage of recoverable coal in the fine circuits
Fine circuit selection critical for maximum recoveryLatest Reflux Classifier technology for fine coal to balance operation of coarse and fine circuitsLatest pneumatic / column flotation for ultrafines
• Hard coking coal is intrinsically fine, so high product moisture is inevitable if high recovery of fine coal
Free moisture can be a problem, especially in Mongolia- Poor handleability for subsequent transport- Can freeze in winter
Use of proven, large scale centrifuge technology for all plant streams to minimise final product moisture
10 February 20127
4. PROCESS TECHNOLOGY
CPP Module design feed rate 900 t/h (as);Coking coal products 8.5% to 9.0% ash, <10%TM.
Phase 1 – 5 Mt/a one CPP module60 t ROM Dump Hopper with Feeder BreakerRoller Screen & Secondary Sizer station1000 t Plant Feed Surge BinRadial Stacker for Coking ProductRadial Stacker for Thermal ProductRadial Stacker for Rejects and Tailings Dam
Phase 2 – 10 Mt/a two CPP modulesAdditional 350 t ROM Hopper with Feeder BreakerRoller Screen, Secondary & Tertiary Sizer stationReject Bin & Tailings Dam
Phase 3 – 15 Mt/a three CPP modules
10 February 20128
5. UHG DESIGN FOR CHPP
Nominal throughput 900 t/h (ar)
Two stage DMC1300mm and 1000mm diameter cyclones-50mm +1.2mm (ww)
Spirals-1.2mm (ww) +0.250mm
FlotationJameson Cells (B6000/20)-0.250mm
CentrifugesCoarse CoalFine CoalScreen bowl
10 February 20129
5. UHG DESIGN FOR CHPP
Extreme temperatures -40 to +40oC
StructuralEuro Code 3 provisions
Chinese low temp steel (D & C Grade) in impact areasReduced design stressNotch tough welds
CPP, bins & transfers contained in fully insulated shedsSignificant heating system2.6MW installed heating capacity for Phase 1
CivilCast in heatingBuilding foundations below frost line Climate controlled concrete poursWinter crash drainage
10 February 201210
6. DESIGNING FOR EXTREME WEATHER VARIANCES
Electrical and ControlsBuried and heated cable racksDouble insulated cabinetsEnclosed MCC and HV systemsInstrument selection driven by temperature varianceWinter setting which fundamentally changes the trip and shutdown sequencing
ProcessAssumes shed >0˚C Flotation dewatering selection Thickeners are covered, sheeted and heatedPipes between buildings are insulated, heat traced, have Δ50˚C rubber expansion jointAutomated plant shutdown and drain should heating system fail
TailingsPipes insulated with 10mm rigid polyurethane foam (cyano-polyester based) and protective shell Operate at above critical freezing velocityMechanically drained by diesel pump
10 February 201211
6. DESIGNING FOR EXTREME WEATHER VARIANCES
10 February 201212
7. OVERCOMING OPERATIONAL CHALLENGES IN REMOTE LOCATIONS
Issues to be considered
LogisticsSystems and proceduresTraining requirementsMaintenance
LogisticsSpare holdings on siteDelivery time of materialsVendorsQuality control
Systems and proceduresDeveloped well in advanceRemote links to monitor facility off siteTechnical support
TrainingMongolian supervisors/key managers trained in AustraliaSedgman managers and trainersOngoing development on site
MaintenanceMajority of activities performed by site personnelSpecialty maintenance tasks- OEM’s- Source from external providers- Train on site resources and procure
appropriate tools/equipment
10 February 201213
7. OVERCOMING OPERATIONAL CHALLENGES IN REMOTE LOCATIONS
10 February 201214
7. OVERCOMING OPERATIONAL CHALLENGES IN REMOTE LOCATIONS
Construction in Winter
10 February 201215
8. UHG CHPP CONSTRUCTION
Stage 1 Construction
10 February 201216
8. UHG CHPP CONSTRUCTION
Stage 1 & 2 Construction
10 February 201217
8. UHG CHPP CONSTRUCTION
Complete!
10 February 201218
QUESTIONS?