RobeR ts & s chaefeR c ompany
Company p rofile
H o W THe WorlD proC e SSe S i TS reS o U r C e S ROBERTS & SCHAEFER COMPANY
PRESENTATION OF
GENERAL QUALIFICATIONS
TO PERFORM PROFESSIONAL
ENGINEERING AND www.r-s.com
CONSTRUCTION SERVICES
Chicago Pittsburgh Indonesia Poland 222 South Riverside Plaza 4412 Route 66 Sequis Center; 7th Floor ul. Bojkowska 37 Chicago, IL 60606-3986 Apollo, Pennsylvania 15613 JL Jenderal Duirman KAV 71 Gliwice, Poland 44-100 TEL: 312-236-7292 TEL: 801-984-0900 Jakarta, Indonesia 12190 TEL: +48-32-461-2722 FAX: 312-726-2872 FAX: 801-984-0909 TEL: +62 (0) 21-252-4177 FAX: +48-32-461-2720 Email: [email protected] Email: [email protected] FAX: +62 (0) 21-252-4138 Email: [email protected] Email: [email protected]
Salt Lake City Australia 10150 South Centennial Parkway Level 11, 199 Grey Street, India Sandy, Utah 84070 South Bank 20, White House, C.G.Road TEL: 801-984-0900 Qld 4101 Australia Ahmedabad, India 380006 FAX: 801-984-0909 TEL: +617 3234 9555 TEL: 079-40328000 Email: [email protected] FAX: +617 3234 9595 FAX: 079-40328001 Email: [email protected] Email: [email protected]
HOW THE WORLD PROCESSES ITS RESOURCES ROBERTS & SCHAEFER COMPANY
www.r-s.com
CONTENTS
Who We Are A Team of Expertise Coal Fuel Handling Pet Coke and Alternative Fuel Handling Limestone and Gypsum (FGD) Handling Coal Preparation and Handling Metals and Minerals Processing and Handling Aggregate, Cement and Sand Handling Port and Marine Projects Specialty Projects Another Look Project Management & Execution Summary
HOW THE WORLD PROCESSES ITS RESOURCES PREFACE
Roberts & Schaefer Company (R&S) provides a wide range of services from complete turnkey design/build responsibility on domestic and international multi-million dollar facilities to engineering-only and feasibility studies. Our expertise in engineering, design, procurement, installation, construction management, commissioning and performance testing enables us to handle projects of all sizes. Roberts & Schaefer’s full service includes the engineering disciplines of: • Layout & Plant Design Engineering • Mechanical & Piping Design Engineering • Civil, Foundation and Structural Design Engineering • Process Design Engineering Project Lifecycle • P & ID Development With specialties in: Study/Planning • Process Flowsheet Development • Feasibility Studies and Project Evaluation Engineering & Design • Cost Analysis and Estimation
Procurement In execution of these services, the major market sectors served include: • All forms of bulk material handling projects for mining and minerals industries with specialized expertise in coal mining and coal processing. Construction • Coal fi red electric utilities including fuel handling, limestone and gypsum handling for fl ue gas desulfurization. Testing/Commissioning • Petroleum Coke handling at refi neries and power stations • The aggregate, cement and sand industry, with its broad spectrum of individual operations ranging from portable plants to sophisticated Operations & Maintenance high technology facilities • Turnkey services for a wide range of marine and coastal structures and materials handling systems located onshore, offshore in deep water, an on rivers and inland waterways through our Soros brand. The measures of a company providing • Proprietary equipment supply including specialized stackers, reclaimers, specialized engineering, procurement and ship loaders and unloaders, belt feeders, curved conveyors, gates and specialized products unique to coal and mineral benefi ciation construction services are the professional quality of its staff personnel and the history of its project experience.
INTRODUCTIONA FULL SERVICE ORGANIZATION
Section 01 1 WHO WE ARE
Over the century since its founding in Chicago in 1903, Roberts & Schaefer Company has grown to become one of the leading global Engineering and Construction service providers focused on engineered bulk material handling solutions for the power and mining industries. During its history R&S acquired Soros, a leading global provider of material handling solutions for port and marine applications and Separator, providing services to Eastern European coal, minerals, and power markets. R&S provides its full range of capabilities and services globally through these brands. R&S is renowned for its technological leadership and innovation, we are widely known as an innovator in bulk material handling for coal and minerals processing systems, fuel handling systems for power generation, precious, base metals and industrial minerals benefi ciation plants, coal preparation facilities, aggregate facilities, cement production plants, and truck/rail/ship/barge terminal systems. Many of these facilities are augmented by ancillary infrastructure such as rail or water loading and unloading systems, open and totally enclosed storage, truck maintenance facilities, access and mine roads, reclaim installations, programming and PLC automated control systems, water supply, treatment and delivery systems, air quality control and dust collection systems. R&S has the capability to undertake such projects in their entirety and actively solicits the award of complete responsibility in the design and delivery of such facilities. Experience brings innovation, the application of new ideas and concepts and For over 100 years, Roberts & Schaefer different approaches to present industry practices. We understand the processes; has engineered solutions to process and we understand the steps to organize all aspects of a project; and we understand handle the world’s resources—with a the best technology for the applications. spirit of innovation, a dedication to quality Our engineering capabilities, technical expertise, and ability to execute and a skill for management. projects on a turnkey basis provide a signifi cant value proposition to both A&E fi rms and end customers, such as electric utilities, coal producers, and other mining companies.
INTRODUCTION
2 Section 01 OUR PROJECT EXPERTISE
In the projects experience section of this qualifi cation manual you will fi nd summaries of our current and historical projects, most from the last 15 years, that demonstrate our breadth and depth of capabilities. The project section is organized into the following topics:
COAL FUEL HANDLING Coal handling is a critical step in the power generation process as there are multiple points in the chain from production. R&S has developed innovative solutions to meet requirements at each of these stages, including the design and construction of rapid discharge unloading facilities, stacking tubes, conveyor systems, reclaiming hoppers, crushers, silos, and various other systems. In addition, R&S designs and installs industry-leading dust suppression and collection systems that maintain air quality throughout the coal handling process. The Company is capable of taking full turnkey design and construction responsibilities for coal fuel facilities and has completed both new and retrofi t projects
FLUE GAS DESULFURIZATION (“FGD”) FGD is the technology used for removing sulfur dioxide from the exhaust fl ue gases in coal-fi red power plants. Environmental protection legislation mandates that utilities install FGD systems to curb their emissions profi le and lessen their impact on the environment. The most common FGD technology is wet scrubbing, which uses a crushed limestone reagent to absorb SO2 from the power plant’s fl ue gasses. A byproduct of this process is gypsum, a compound that is marketable for use in the building products industry. R&S is the industry leader in the design, procurement, and construction of solutions for handling limestone and gypsum within the FGD process. The Company’s engineers understand the challenges associated with moving limestone and gypsum and have years of experience designing grinders, dryers, impactors, conveyors, screen feeders, sizing screens, surge bins, silos, and boiler houses. The Company is also experienced in the handling of lime and activated carbon from dry scrubber and mercury removal applications.
INTRODUCTION
Section 01 3 OUR PROJECT EXPERTISE
ALTERNATIVE FUEL HANDLING As utilities and other power generators strive to reduce operating costs and explore environmentally friendly technologies, they are employing alternative fuel sources, such as petroleum coke, bituminous waste (gob), biomass, and bio-fuels. Wood chips, used tires, sugar cane waste, municipal waste, and virtually any other combustible material are being considered as alternative fuel sources. In particular, R&S engineers have extensive experience and knowledge of how petroleum coke is handled at the refi nery, utilized as a fuel source, and its applications to the cement industry. This assures careful analysis, correct criteria and equipment selection, and effi cient facility confi guration for every project.
COAL MINING AND PROCESSING Leveraging a history of engineering excellence and material handling expertise, R&S began designing solutions for coal mining and processing customers in the early 1900s and quickly established itself as a leading provider of coal handling solutions for mining applications. Today, R&S continues to offer the coal mining and processing industries innovative and cost effective solutions for cleaning, transporting, conveying, storing, reclaiming, and loading coal.
PRECIOUS & BASE METALS R&S provides material handling and processing solutions to customers mining various precious and base metals, including copper, gold, silver, and others. The Company has experience designing and implementing systems that enable gold and silver extraction, carbon absorption technologies, and grinding, fl otation, and leaching circuits for high-grade ore processing. R&S also maintains strong relationships with outside processing experts so that it has access to additional resources and capabilities that can be employed as necessary in conjunction with its materials handling capabilities.
INTRODUCTION
4 Section 01 OUR PROJECT EXPERTISE
INDUSTRIAL MINERALS R&S offers material handling solutions to customers involved in the mining and processing of limestone, phosphate, potash, borax, soda ash, and other industrial minerals. The Company designs and constructs systems that enable conveying, crushing, piping, screening, stacking, separating, tacking, and other related functions.
AGGREGATES, SAND & CEMENT R&S has provided the aggregates and sand industries with innovative solutions for wet and dry-production circuits, contamination prevention, environmental compliance, loading systems, and others applications. R&S leverages its core expertise to provide the cement industry with specialty material handling solutions for production and processing plants, including in-plant raw materials-handling and conveying systems, dust collection systems, air-handling transport systems, and air-handling systems for plant operations.
PORTS AND MARINE R&S and Soros have provided engineering, design, procurement and construction services for marine related bulk handling projects ranging from fertilizer and concentrate handling to the world’s highest capacity systems for ship unloading and for the ship loading of coal, iron ore, bauxite and alumina.
SPECIALTY MATERIALS R&S offers full turnkey material handling solutions to a number of specialty material markets. The Company has recently completed several specialty materials projects, including synthetic fuel projects for the benefi ciation of oil shale, and facilities for bitumen extraction from tar sands and the enhancement of low-grade coals for use as alternate fuels.
INTRODUCTION
Section 01 5 OUR TEAM
Roberts & Schaefer Company is a subsidiary of Elgin National Industries, Inc., a privately held corporation, and is organized in two divisions with industry focus. These are: • Power, headquartered in Chicago, IL and • Mining, headquarter in Salt Lake City, UT. R&S has fi ve operating offi ces located in Chicago, Salt Lake City, Australia, Poland and Indonesia. Each division has all the major disciplines of engineering, project management and administrative support required to accept total project responsibility or exercise specifi c disciplines of engineering as the need dictates. The total technical expertise and administrative resources of the R&S divisions are available within the company to provide assistance, consultation and staff support. The operating philosophy of R&S provides an inter-division fl exibility that allows its total resources of engineering design, procurement and construction management services to be accessible for a specifi c project. R&S has established an outstanding staff of engineers, designers, project managers and administrative support personnel with the technical and managerial expertise to execute its work. The computerization of our drafting and design capabilities, scheduling, cost control, and project management, provides the methods for effi cient and effective performance. This qualifi cation manual contains the resumes of our entire technical team. Project Managers are the single point of contact, internal and external, responsible for all aspects of the projects. R&S applies industry standard project management Our reputation and fi nancial stability techniques based on Project Management Institute guidelines (PMBOK). is exemplifi ed in our ability to provide bonding for projects in excess of From material handling systems to advanced process engineering, all disciplines are coordinated with a single point of responsibility. The Project Execution section $100,000,000. Roberts & Schaefer is of this qualifi cation manual fully describes our approach to projects. insured for errors and omissions insurance in the amount of $20,000,000. We continually reinvest in our people and technology to maintain the highest professional standards of capability, effi ciency and effectiveness. We know our responsibility to technical quality and professional service has resulted in our continuing presence in the industries we serve. Roberts & Schaefer Company is the best choice for your bulk material handling and processing needs.
INTRODUCTION
6 Section 01 A TEAM OF EXPERTISE
Roberts & Schaefer Company is comprised of nearly 250 highly qualifi ed engineers, designers, draftsmen, project managers, construction managers and administrative personnel in our fi ve offi ces. This section highlights the company leadership and provides the resumes for our technical staff.
Presidents David Carter—President, Global Resources Jeff Rodabaugh—President, Power Division Brian Petersen—President, Mining Division
Senior Management Personnel (Power Division) Ravji Patel—Senior Vice President Robert Williams—Vice President of Sales and Marketing Alan Bontjes—Vice President of Project Management David Fong—Vice President of Construction Management Ramesh Amin—Vice President of Estimating David Waltersdorf—Vice President of Engineering
Senior Management Personnel (Mining Division) Bruce Hale—Senior Vice President of Business Development Daniel Schilaty—Vice President of Project Management Michael Harris—Vice President of Estimating Rainer Stephenson—Vice President of Engineering W. Albert Niedzinski—Vice President & General Manager, Poland Steve McCoy—General Manager, Australia
INTRODUCTION
Section 01 7 LUMINANT POWER
OAK GROVE POWER STATION, FRANKLIN, TEXAS
Engineering, procurement and construction management the coal, limestone and gypsum handling systems; the contract was awarded by Fluor. The coal handling system is designed to receive coal from trains at the rapid discharge rail unloading facility. The received coal is transferred to a 7,000-ton capacity storage silo. The silo loading chute work has a diverter gate to divert coal to a 10,000-ton additional storage pile adjacent to the silo. The unloading and stockout rate is 4,800 TPH. The coal is reclaimed from the storage silo by four variable speed belt feeders. The coal is reclaimed from the storage pile by two variable speed belt feeders. The dual conveyor total reclaim rate from either system is 3,000 TPH. At the crusher building the coal is crushed by two 1,500 TPH crushers before being transferred on dual conveyors to the plant transfer tower. The plant surge hopper has four variable speed belt feeders discharging to the four plant distribution conveyors. Units 1 & 2 both have two rows of silos. The fi ve silos per row are each feed by a reversing shuttle conveyor. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression and the distribution conveyor has wash down. The limestone handling system is designed to receive limestone at the limestone storage building. Limestone is delivered to the building by truck and reclaimed from the storage pile with a chain reclaimer fed by mobile equipment. The limestone is conveyed at 350 TPH to two storage silos at the limestone preparation building. The gypsum handling system is designed to receive gypsum from the process fi lters and convey it at 150 TPH to the 400-ton load-out silo. Gypsum is reclaimed by a rotary plow feeder and loaded into either railcars or trucks with a telescopic chute. Ancillary systems for the coal, limestone, and gypsum include service water.
COAL FUEL HANDLING EXPERIENCE
Section 02 1 XCEL ENERGY SERVICES
COMANCHE STATION (UNIT 3), PUEBLO, COLORADO
Engineering, procurement and construction of a coal unloading and handling system at Public Service Company of Colorado’s Comanche Station. The coal handling system is designed to receive coal from trains at the rapid discharge rail unloading facility. The received coal is transferred to either a new stacking tube with a storage pile capacity of 40,000-tons or to the existing stacking tube. The unloading and stockout rate is 4,000 TPH. The coal is reclaimed from the new storage pile by four variable rate belt feeders located under the pile. The coal can also be reclaimed from the storage pile by an emergency hopper/belt feeder located at the edge of the pile. The two reclaim-conveyors each have a reclaim rate of 1,500 TPH. At the crusher building the coal is crushed by two 1,500 TPH crushers before being transferred on dual conveyors to the plant transfer tower. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression. Ancillary systems include sump pumps and service air. The six plant silos are arranged in a single row and feed by a conveyor with a traveling tripper.
COAL FUEL HANDLING EXPERIENCE
2 Section 02 WISCONSIN ENERGY
ELM ROAD STATION, OAK CREEK, WISCONSIN
Engineering and procurement for the coal handling conveying system; the contract was awarded by Bechtel Power Corporation The coal handling system is designed to receive coal at the rotary car dumper. The receiving hopper includes a traveling lump breaker. The received coal is transferred by a series of conveyors to either the enclosed storage building, the emergency stock-out pile conveyor with telescopic chute, or to the crusher tower. The unloading and stock-out rate is 3,000 TPH and the coal diverted to the crusher tower is variable up to 3,000 TPH. The coal is stockpiled in the storage building by a traveling stacker. The storage barn has a single pile capacity of 66,000 tons or separate piles for the bituminous and PRB coals. The coal is reclaimed from the storage building by a traveling portal scraper reclaimer. The barn is designed for an initial reclaim conveyor with provisions for a future traveling portal scraper reclaimer and a second reclaim conveyor. The reclaim rate is variable up to 3,000 TPH. Reclaim from the emergency or the inactive coal piles are by two hoppers with Stamler reclaim feeders through a series of conveyors to the crusher tower at 2,000 TPH. The crusher tower is divided into two areas, one for the bituminous coal for the Elm Road units and the other for the PRB coal for the Oak Creek units. Each area has a surge bin with dual belt feeders and twin roll mill crushers rated at 1,575 TPH each. Dual conveyors transfer the coal to the existing silo fi ll system for the Oak Creek units. A second set of dual conveyors transfer the coal to the silo fi ll conveyors with traveling trippers for the Elm Road units. Each unit has 5 silos in a single row, both in the same line. All areas of the coal handling system are provided with bag house dust The coal handling system provides collection with pneumatic return to the plant coal silos or fog type suppression. bituminous coal to the new Elm Road An as-received and as-fi red, for both Elm Road and Oak Creek (future) sampling Units 1 & 2 and PRB coal to the existing systems are provided. Ancillary systems include washdown, conveyor creep Oak Creek Units 5 & 6. drives, and closed circuit TV. An ash reclaim apron feeder and conveyor system at 150 TPH is also provided for adding some ash to the coal stream prior to the crusher tower.
COAL FUEL HANDLING EXPERIENCE
Section 02 3 SALT RIVER PROJECT
SPRINGERVILLE GENERATING STATION (UNIT 4), APACHE COUNTY, ARIZONA
Engineering, procurement, expediting, and fi eld technical assistance of the coal handling system expansion. The conveying system is designed to receive rail delivered PRB coal. New chute work was designed to tie into the existing transfer tower to feed the new transfer tower for Unit 4 coal handling. The coal is transferred on dual 3,000 TPH stockout conveyors to dual radial stacker-reclaimers and discharged to form two 90,000-ton capacity storage piles. The coal is reclaimed from the two storage piles by the two radial stacker-reclaimers each with a reclaim capacity of 1,500 TPH. The dual reclaim conveyor path is through the new transfer tower to the Unit 4 crusher tower. At the crusher tower, the reclaim conveyors discharge to the surge hopper. The coal is crushed with two 750 TPH double roll crushers from 4-inch to ¾-inch before being transferred to the expansion of the existing Unit 3 crusher tower which feeds coal to Unit 3 and new Unit 4 coal silos. Seven of the conveyors are enclosed in 3,300 feet of tubular gallery. The coal handling system expansion includes dust collection for all new transfer points, dust suppression for the coal pile, and conveyor gallery ventilation. An as-fi red coal sampling system is located in the Unit 4 crusher tower.
COAL FUEL HANDLING EXPERIENCE
4 Section 02 PLUM POINT POWER PARTNERS
PLUM POINT STATION, OSCEOLA, ARKANSAS
Engineering, procurement, construction, start-up and commissioning of the coal conveying and dust collection systems. The conveying system is designed to receive coal at the rotary car dumper. The received coal is transferred to the fi rst stacking tube to form a 40,000-ton capacity storage pile or transferred to the second stacking tube to form an additional 40,000-ton capacity storage pile. The unloading and stockout capacity is 4,000 TPH. The coal is reclaimed from the two storage piles by two variable rate rotary plow feeders for a total reclaim capacity of 1,200 TPH. Normally one plow will reclaim from each pile, but the travel distance will allow each plow to reclaim from both piles. An emergency reclaim hopper with a variable speed belt feeder and a separate reclaim conveyor to the crusher building is also provided. At the crusher building both reclaim conveyors discharge to the surge hopper. The coal is crushed with two 1,200 TPH crushers before being transferred on dual conveyors to the silos at the power plant. Dual conveyors with traveling trippers feed the fi ve silos in a single row. Both as-received and as-fi red sampling systems are provided. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression.
COAL FUEL HANDLING EXPERIENCE
Section 02 5 DUKE ENERGY
EDWARDSPORT POWER STATION, EDWARDSPORT, INDIANA
Engineering and procurement of a coal and slag handling system for Edwardsport Power Station in Edwadsport, Indiana.
Coal Handling System Coal handling system requires to transfer train unloaded coal to be stored and feed to the Rod Mills. Train reclaimed coal is transported via belt conveyors (By Others) to the coal Bunkers. Coal Bunkers provide storage capacity of 2600ST. Stored coal is reclaimed from the coal bins via Diamondback Hoppers to volumetric belt feeders (0-200TPH). The Feed of coal to the volumetric feeder is start and stopped by power shut off gate. Each volumetric belt feeder feed coal to Granulator to crush coal to 0-3/4 particle size. Granulator discharges coal to Weigh Feeder to feed grinding mill at a controlled rate, determined by the process requirements.
Slag Handling System Slag from the gasifi cation process is collected, partially dewatered and delivered to the slag transport conveyors via two equipment streams, each comprising of a slag drag conveyor and a coarse slag screen (By others). A slag transport conveyor is dedicated to its respective equipment stream of slag drag conveyor and coarse slag screen. Cleaned and partially dewatered slag is transported by each slag transport conveyor (80 TPH) to the slag storage. Slag is dumped in 8 slag storage bins via reversing shuttle conveyors (80 TPH). Each reversing shuttle conveyor is designed to service a row of four slag storage bins. A cross-over chute arrangement is provided to transfer slag from either slag transport conveyor to any one of the reversing shuttle conveyor. Each slag transport conveyor and reversing shuttle conveyor is capable of transporting the entire slag production from the two streams by means of diverter gates at the feed to transport conveyors.
COAL FUEL HANDLING EXPERIENCE
6 Section 02 CONSTELLATION ENERGY
C.P. CRANE STATION, BALTIMORE, MARYLAND
Engineering, procurement and construction for a fuel switch to PRB coal. The coal handling system upgrade is designed to receive coal at the existing storage pile reclaim feeders. New chutes were provided from the feeders to the existing reclaim conveyor. The reclaim conveyor modifi cations include new drive, pulleys, idlers, to increase capacity to 425 TPH. The modifi ed reclaim conveyor feeds a new conveyor within a new transfer structure that replaces the existing breaker structure. From there, a new conveyor feeds the new crusher tower with surge bin, with two posimetric feeders and hammermill crushers. The new hammermill crushers enable the removal of the existing crushers under the powerblock day silos. From the output of the crushers, a new transfer conveyor was added to feed a new powerblock feed conveyor. A new powerblock feed conveyor is installed adjacent to the existing powerblock feed conveyor utilizing the existing structure with modifi cations. The new reclaim, crushing and conveying system increases the present 200TPH capacity to 425TPH capacity. Powerblock Units 1 and 2 each have a set of four in line coal day silos fed by a series of cascading conveyors, diverter gates and chutes. This existing cascading conveyor system was replaced with a new, increased capacity 425TPH system. The new cascading conveyor systems were installed during outages for each R&S has extensive experience in fuel Unit to minimize overall downtime. switching to Powder River Basin coal A dozer trap and temporary reclaim conveyor are provided to bypass the existing and its distinct handling requirements. breaker house during construction. Ancillary systems include wet dust collection, wash down and vacuum cleaning piping for the new transfer tower, crusher tower, and connecting conveyors.
COAL FUEL HANDLING EXPERIENCE
Section 02 7 AES – PUERTO RICO
TOTAL ENERGY PLANT, GUAYAMA, PUERTO RICO
Engineering, procurement, construction, start-up and commissioning of the coal, limestone and aggregate material handling systems; the contract was awarded by Duke/Fluor Daniel. The coal and limestone are received in self-unloading ships. The ash is shipped out in geared ships or ocean barges. The dock area consists of the coal/limestone receiving hopper with belt feeder and the aggregate ship loader. The single path series of conveyors with a length of 3,600 feet from the dock to the material handling areas are reversing conveyors and handle all three materials. The coal or limestone is conveyed from the 50,000-ton capacity ships at 3,000 TPH to the storage areas and the aggregate is conveyed at 1,800 TPH from the storage area to the 9,000-ton capacity ocean barges. The coal handling stockout and reclaim system consists of two stacking tubes with a total pile capacity of 98,000 tons and a series of ten variable rate vibratory feeders located below the piles for reclaim at 720 TPH. The crusher house includes a surge bin, two variable rate vibratory feeders, and dual path 100 percent redundant cage-paktor crushers. The plant feed conveyor with a capacity of 720 TPH transfers the coal to the plant conveyor with a traveling tripper for delivery to the four silos of each unit. The coal handling system includes wet suppression, bag house dust collection, ventilation, and wash down for dust control. The limestone stockout and reclaim system consists of a conveyor from the second coal stacking tube to the limestone stacking tube enclosed in a dome for dust and moisture control. The stacking tube forms a 60,000 ton capacity pile. A mobile equipment fed hopper with variable rate vibratory feeder loads the reclaim conveyor to covey the limestone at 60 TPH to the Limestone Preparation Building. The limestone system includes wet suppression, bag house dust collection, and ventilation for dust control. The bottom and fl y ash are combined from the ash silos and conveyed to the initial storage area. This manufactured aggregate (ash product) is reclaimed by mobile equipment to a hopper with a 1,800 TPH feeder breaker and sent to the ship loader via the reversing conveyor system. The shiploader is equipped with a telescopic spout and a retractable boom conveyor. The aggregate systems include wet suppression for dust control.
All unloading, stockpiling, reclaiming, crushing, and ship loading operations are controlled by a series of programmable logic controllers (PLCs).
COAL FUEL HANDLING EXPERIENCE
8 Section 02 TENNESSEE VALLEY AUTHORITY
KINGSTON FOSSIL PLANT, KINGSTON, TENNESSEE
Engineering, procurement, construction, start-up, and commissioning of the rail unloading and coal blending system. The Kingston coal handling facility received coal by train that was unloaded at a rotary car dumper on ladder tracks. To modernize and increase the unloading system capacity a rapid discharge bottom dump unloading system was furnished with a capacity of 4,400 TPH. To stockout and store regional coals for blending the fi xed stockout conveyor was replaced by a sacking conveyor and transfer conveyor to two stacking tubes. Each stacking tube provided for a 62,000-ton capacity segregated pile. Reclaim for blending from the piles is by two variable capacity rotary plow feeders. The reclaim capacity was increased from 2,000 to 2,400 tph. At the new crusher building two 1,200 tph crushers processed the coal, and then transfer the coal to the existing dual plant supply conveyors. These conveyors were modifi ed with new drives and increased belt speed for the increased capacity. The ancillary systems included fi re protection, wet-dust suppression, as-received and as-blended sampling systems, and ventilation systems. All process equipment is controlled by a distributed control system. There are provisions for a third stacking tube and the transfer conveyor would be extended and reversing.
COAL FUEL HANDLING EXPERIENCE
Section 02 9 BASIN ELECTRIC POWER COOPERATIVE
DRY FORK STATION & MINE, GILLETTE, WYOMING
Engineering, procurement, and construction management of the coal handling system. The coal handling system is designed to receive coal from the top of existing mine Silo 3. The existing mine system includes truck dump, crushing, and three 6,400-ton mine storage silos. The received coal is transferred at 2,500 TPH to two new mine storage silos with 5,400-ton capacity each. Truck coal can also be delivered to the The coal is discharged from these two silos by multi-directional mass fl ow gates power station and unloaded at a truck to a variable speed reversible conveyor. The conveyor capacity is 4,000 TPH to hopper with provisions for a second the existing system and 1,200 TPH to the fi rst transfer house in the new system. future truck hopper. Two in series overland conveyors transfer the coal from the mine area to the power station. The coal is stored in two 13,000-ton yard storage silos with provisions for a future third silo. The coal is reclaimed from each storage silos by four variable rate belt feeders onto dual reclaim conveyors. The conveyors have a capacity of 800 TPH each. Two conveyors in series transfer the coal from the transfer tower at the silos and truck hopper to the power station transfer house. The second conveyor has a manual belt plow to form an emergency coal pile and an ash analyzer. These two conveyors have provisions for future second conveyors. At the power station transfer house the coal is conveyed to the Unit 1 plant silos. A conveyor feed the fi ve silos in a single row with traveling tripper. The transfer house has provisions for feeding coal to future Unit 2. All areas of the coal handling system are provided with bag house dust collection with processed dust return or fog type dust suppression.
COAL FUEL HANDLING EXPERIENCE
10 Section 02 TRACTEBEL POWER – CHOCTAW GENERATION
RED HILLS GENERATION FACILITY, CHOCTAW COUNTY, MISSISSIPPI
The project consists of rear dump trucks unloading 36" x 0" lignite into a hopper which feeds an 1,800 TPH feeder breaker which crushes the lignite to 8" x 0". The lignite is then conveyed at a rate of 1,800 TPH to two 20,000 T Eurosilo storage silos for a total storage capacity of 40,000 tons. The lignite is reclaimed from the Eurosilos with uncoalers (2 per Eurosilo) onto 1,500 TPH conveyor belts which feed a crushing station with two 750 TPH crushers which reduce the size to 1/2" x 0". From the crushers, the lignite is conveyed on 750 TPH conveyors to the power block and tripper conveyors and traveling trippers. The power block consists of two circulating fl uidized bed boilers and one generator with a 440 MW net rating. Each boiler is served by four lignite silos. Ancillary systems include sampling system, dust collection systems, dust suppression systems and fi re detection systems.
COAL FUEL HANDLING EXPERIENCE
Section 02 11 WESTERN KENTUCKY ENERGY
COLEMAN STATION, HAWESVILLE, KENTUCKY
Engineering, procurement and construction of a fuel blending system, limestone handling system, and gypsum handling system. The coal facility accepts coal from the existing crusher building and conveys it to two concrete stacking tubes, which form two 10,000 ton storage piles. The coal is then reclaimed by belt feeders and is delivered to two reclaim transfer conveyors, which deliver the coal to the existing coal reclaim conveyors. The new coal stockpiles are adjacent to the existing coal stockpile. The limestone facility accepts limestone from a truck receiving hopper and is conveyed to a 14,000 ton stockpile. The stored limestone is then conveyed to two one-hour day bins. The gypsum facility accepts gypsum from the existing gypsum building and conveys it to a new radial stacking conveyor, which makes a 10,000 ton gypsum stockpile. The material then gets loaded into trucks.
COAL FUEL HANDLING EXPERIENCE
12 Section 02 FIRST ENERGY
W.H. SAMMIS PLANT, STRATTON, OHIO
Engineering, procurement, construction, start-up and commissioning of the coal handling system upgrade for rail deliveries. The plant coal handling facility received coal by barge that was unloaded by a continuous bucket ladder unloader. To greatly increase the unloading capacity, a rapid discharge bottom dump train unloading system rated at 4,000 tph was installed. The coal source initially remains Pennsylvania coal, but the delivery cost was greatly reduced due to the decreased unloading time compared with the barge system. The railcar unloading hopper discharges using a single 96-inch wide belt feeder. A third-rail system for automatic in-motion unloading and a roller railside car shaker were also furnished. The train unloading system is located approximately 2,350 feet from the coal yard reclaim area due to the site conditions. The unloading conveyor discharges to a stacking tube to form a 30,000-ton storage pile near the train unloading system. Four variable rate vibratory feeders reclaim this pile and feed onto the 1,000 TPH transfer conveyor. The 1,900 feet long transfer conveyor transfers the coal to a stacking tube to form a 15,000-ton pile in the coal yard reclaim area. This dual staking tube system allows for rapid unloading of the railcars and then a reasonable conveying rate to the coal yard area, on an as needed basis. The R&S ancillary systems included wet suppression for dust control, tunnel ventilation, and wash down.
PRB coal is now also received at the plant.
COAL FUEL HANDLING EXPERIENCE
Section 02 13 SANDOW DEVELOPMENT COMPANY (LUMINANT)
TXU-SANDOW (UNIT 5), ROCKDALE, TEXAS
Engineering, Procurement and Construction of a new coal and limestone handling facility. The new coal handling system included the reconditioning of four 320TPH crushers that feed two new coal conveyors that transfer the coal to the powerblock feed conveyors. The coal conveyors are also used to transport limestone from the limestone transfer conveyor to the limestone silo in the powerblock. The new limestone system included the addition of a new 640TPH limestone chain reclaimer and transfer conveyor. Additional systems added were a new as-fi red sampling system, emergency reclaim hopper, belt scales and upgraded control system.
COAL FUEL HANDLING EXPERIENCE
14 Section 02 TENNESSEE VALLEY AUTHORITY
PARADISE PLANT, DRAKESBORO, KENTUCKY Engineering, Procurement and Construction of a new coal crushing facility. The new system included the addition of a new 2000TPH conveying system fed from the existing conveying system. The new conveying system fed a 210T crusher surge bin. From the outlet of the crusher surge bin, two new posimetric feeders were installed to feed the new 600TPH/ea hammermill coal crushers. The coal crushers discharged onto two new 1200TPH coal conveyors which conveyed the crushed coal to the existing coal handling conveying system. The project included many modifi cations to the existing conveying system to integrate with the new conveying system. New dust suppression systems were also added. ALLEN FOSSIL PLANT, MEMPHIS, TENNESSEE Engineering, procurement and construction of a new coal crushing facility. The new crushing facility was fed from an existing coal handling system via Paradise Plant, Drakesboro, Kentucky two 1200TPH conveyors into a 150T crusher surge bin. On the surge bin outlet are two posimetric feeders which feed two 600TPH hammermill crushers. A new 1200TPH crushed coal collecting conveyor transfers the coal to the existing conveyor system within the existing crusher building. The existing crusher building was modifi ed to accommodate the new conveyor, new proportioning gate and feed skirts onto the existing transfer conveyors. Additional systems include, coal sampler, dust suppression systems and modifi ed control system.
COAL FUEL HANDLING EXPERIENCE
Section 02 15 OMAHA PUBLIC POWER DISTRICT
NORTH OMAHA STATION, OMAHA, NEBRASKA
The project included a new third rail control system for dumping rail cars at a rate of 1,500 TPH. Several existing conveyor drives/motors were replaced with larger drives beginning with the conveyors at the rail unloader to the crusher building and into the coal storage bunker area. The drive/motor change outs were coordinated with the Station to avoid plant downtime. New trippers were furnished for each set of coal bunkers. An existing rail car thaw shed heater system was replaced with a new heater system and associated controls. In addition, the dust collection system was upgraded throughout.
COAL FUEL HANDLING EXPERIENCE
16 Section 02 WISCONSIN PUBLIC SERVICE CORP
WESTON STATION, ROTHSCHILD, WISCONSIN
Engineering, Procurement, Construction Start-Up and Commissioning of the Coal Handling System at the WPS Weston 4 generating station near Rothschild, Wisconsin. Coal is received by rail and discharged by an existing rotary rail car dumper. The coal is then fed onto an existing stockout system, through a new diverter gate and onto the fi rst of the new conveyors provided by R&S, Conveyor CVY-11. Conveyor CVY-11 is a fi xed cantilevered stockout conveyor with a new telescopic chute located at the head end for dust control purposes. The coal forms a 20,000 ton capacity conical storage pile located over a new reclaim hopper. The coal reclaim system starts with the new reclaim hopper and slide gate located above a frozen coal cracker. The frozen coal cracker feeds the coal onto a variable frequency belt feeder with the capacity ranging from 400 to 1,600 tons per hour. The belt feeder feeds the coal onto Conveyor CVY-13 with a capacity of 1,000 TPH and onto the existing crusher building. The existing crusher building has been modifi ed to feed the coal to both Weston Units 3 and 4. A magnetic separator has been installed at the head end of Conveyor CVY-13 to pick up any tramp iron that may have found its way into the as-received coal. A two way diverter gate then directs the coal to an existing conveyor or through another diverter gate and into one of two surge bins. One surge bin is the existing Unit 3 bin and the other bin is a newly provided bin for Unit 4. The new Unit 4 surge bin includes a slide gate at the bottom that will allow the coal to be fed through a new coal crusher and onto new reclaim conveyor that has a capacity of 1,000 TPH. The reclaim conveyor also feeds the coal into Junction House No. 2 and onto conveyor CVY-16. A new magnetic separator has been installed at the head end of CVY-16 to pick up any tramp iron that may have come from the crushing operation. Conveyor CVY-16 feeds the coal into Junction House No. 3 and onto new power feed conveyor CVY-17, also with a capacity of 1,000 TPH. Conveyor CVY-17 feeds the coal onto fi xed tripper conveyor CVY-18 located in the tripper bay of the new unit 4 generating building. Conveyor CVY-18 feeds the coal into the fi ve (5) coal silos with the same capacity of 1,000 TPH. A dust collection system picks fugitive dust from all transfer points and pneumatically conveys the dust to one of two designated coal silos.
COAL FUEL HANDLING EXPERIENCE
Section 02 17 AMEREN ENERGY
COFFEEN GENERATION STATION, COFFEEN, ILLINOIS
Engineering, procurement, fabrication, construction and commissioning of a coal handling system. Two new magnetic separators were installed at the head end of two existing coal feed conveyors. A new diverter gate was installed in the existing conveyor discharge chutes to direct the coal into one of three new 65 Ton capacity surge bins. A rod gate and a posimetric weigh belt feeder was installed under each of the three surge bins to feed the coal into a reversible hammermill. The hammermills have a capacity of 450 TPH. A splitter gate was installed under each hammermill to direct the coal onto one of two new surge bin feed conveyors, C-1 and C-2. The two conveyors are 36" wide belts with a capacity of 850 TPH. New conveyor belt scales were also installed on the C-1 and C-2 conveyor belts. A new Surge Bin was installed with four (4) rod gates and four new posimetric feeders installed under the four surge bin draw-off hoppers. The posimetric feeders each feed a new coal silo feed conveyor. The new silo feed conveyors, labeled T1, T2, D1 and D2, are 36" wide belt conveyors with a capacity of 600 TPH. All four of the silo feed conveyors feature a travelling tripper that is used to discharge the coal into Unit 1 and Unit 2’s existing Coal Silos. A new surge bin level monitoring system was also installed for the new Surge Bin.
COAL FUEL HANDLING EXPERIENCE
18 Section 02 AMEREN ENERGY
EDWARDS POWER STATION, BARTONVILLE, ILLINOIS Engineering, procurement and construction for the coal handling system upgrade at the Edwards Power Station in Bartonville, Illinois. The existing coal handling system was upgraded to increase the rail-unloading rate to 3,000 TPH, for switching to PRB coal. To handle this increased rate the existing conveyors from the rotary dumper were upgraded from 48 inch or 54 inch to 60-inch conveyors including new drives, pulleys, idlers and belting. The existing 42-inch pedestal mounted radial stacker was replaced with a new 60-inch belt radial stacker with a stockout capacity of 3,000 TPH. The reclaim conveyors were upgraded with new chute work and loading skirts for improved coal fl ow and reduced spillage.
DUCK CREEK POWER STATION, CANTON, ILLINOIS Engineering, procurement, construction, start-up and commissioning of the coal handling system upgrade. The coal handling facility receives coal by train, and it is unloaded by a rotary car dumper. The rotary car dumper was modifi ed by others for switching to western PRB coal with the unloading capacity increased from 2,000 to 3,000 TPH. The conveyor system from unloading through stockout was upgraded with 45-degree idlers, new pulleys, new belt, new drives, and new conveyor components, as required, for the increased capacity of 3,000 TPH. The modifi cations included conveyor chutework and skirtboards, and conveyor/ building structural steel and foundations. The stacker-reclaimer boom conveyor was modifi ed with a new drive, chutework, and structural steel for the increased capacity
COAL FUEL HANDLING EXPERIENCE
Section 02 19 SANDY CREEK POWER PARTNERS
SANDY CREEK ENERGY STATION, RIESEL, TEXAS
Engineering, procurement, and construction management of the coal conveying and dust collection systems. The conveying system is designed to receive coal at the rotary car dumper. The received coal is transferred to the fi rst stacking tube to form a 15,000-ton capacity storage pile or transferred to the second stacking tube to form an additional 15,000-ton capacity storage pile. The unloading and stockout capacity is 4,000 TPH. The coal is reclaimed from the two storage piles by two variable rate rotary plow feeders to the reclaim conveyor for a total reclaim capacity of 1,200 TPH. Normally one plow will reclaim from each pile, but the travel distance will allow each plow to reclaim from both piles. An emergency reclaim hopper with belt feeder and a separate reclaim conveyor to the crusher building is also provided. At the crusher building both reclaim conveyors discharge to the surge hopper. The coal is crushed with two 1,200 TPH crushers before being transferred on dual conveyors to the silos at the power plant. Dual conveyors with traveling trippers feed the six silos in a single row. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression. Both as-received and as-fi red sampling systems are provided.
COAL FUEL HANDLING EXPERIENCE
20 Section 02 AMERICAN ELECTRIC POWER
JOHN W. TURK POWER PLANT, FULTON, ARKANSAS
Engineering, procurement and construction assistance of the coal handling system from the coal receiving rail dump hoppers to the coal bunkers in the boiler building; the contract was awarded by Shaw, Stone & Webster. The conveying system is designed to receive coal at the rotary car dumper. The received coal is transferred from the unloading hopper to the unloading conveyor by two variable speed belt feeders rated at 1,500 TPH each. There are provisions for a future At the central transfer tower, the coal is transferred to the fi rst lowering well or emergency reclaim system with to the crusher tower. At the fi rst lowering well, the coal is discharged to form a a drag feeder and a separate reclaim 20,000-ton capacity storage pile or transferred to the second lowering well to form conveyor to the crusher tower. an additional 20,000-ton capacity storage pile. The unloading and stockout capacity is 3,000 TPH. The coal is reclaimed from the two storage piles by two variable rate rotary plow feeders for a total reclaim capacity of 950 TPH. Normally, one plow will reclaim from each pile, but the travel distance will allow each plow to reclaim from both piles. The reclaim conveyor path is through the central transfer tower to the crusher tower. At the crusher tower, the reclaim conveyors discharge to the surge bin. The coal is crushed with two 950 TPH crushers before being transferred on the plant feed conveyor to the silos at the power plant. The six silos in a single row are fed by a single conveyor with traveling tripper. There are provisions for a future second conveyor from the crusher tower to the plant, a conveyor with traveling tripper for silo fi ll, and Unit 2 silo fi ll. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression.
COAL FUEL HANDLING EXPERIENCE
Section 02 21 DYNEGY MIDWEST GENERATION
BALDWIN POWER STATION, BALDWIN, ILLINOIS
Engineering, procurement and construction management of a complete fuel switch to Powder River Basin coal; the contract was awarded by Sargent & Lundy. The project consisted of upgrading the existing stockpiling/reclaiming coal handling system beginning with the rotary car dumper area. New unloading hoppers, two 1,500 TPH each belt feeders, and a new 3,000 TPH conveyor were furnished. The new conveyor feeds two upgraded stackout conveyors through a new splitter gate. The stackout conveyors are equipped with new telescopic spouts to form 5,000-ton active coal storage piles. The coal is reclaimed from the piles with four 60" wide, 6,000 TPH belt feeders and existing vibratory feeders. It is then conveyed to the crusher building where new diverter gates and surge bins were furnished. The conveyors throughout the system were retrofi tted with new idlers, belt plows, skirtboards, control devices, drives and motors, etc. Since the power station was in constant operation, the modifi cations were coordinated with the station to maintain a constant coal supply to the bunkers.
New items also included magnetic separators and belt scales.
COAL FUEL HANDLING EXPERIENCE
22 Section 02 TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK FOSSIL PLANT, STEVENSON, ALABAMA
Engineering, procurement, construction, start-up and commissioning of the coal handling system upgrade for blending. The coal handling system receives coal by train, and it is unloaded at a bottom dump system. The conveyor system through stockout was upgraded to increase the unloading capacity from 1,400 to 2,200 TPH since western PRB coal is being received for coal blending. The conveyor system was upgraded with 35-degree idlers, new drives, and conveyor components. Transfer conveyors to/from the existing crusher building to a new crusher house were included. The new crusher house included a diverter gate for crusher by-pass, a 2,200 TPH crusher, and a proportioning gate. The proportioning gate sent 1,400 TPH of coal back to the existing crusher building or 2,200 TPH to stockout For stockout and blending a short fi xed stockout conveyor was replaced with a 2,200 tph capacity pedestal radial stacker. The radial stacker forms two segregated piles, a low sulfur pile with a capacity of 21,500 tons and a high sulfur pile with a capacity of 19,200 tons. The coal is reclaimed with the existing reclaim system.
COAL FUEL HANDLING EXPERIENCE
Section 02 23 DUKE ENERGY
CLIFFSIDE STATION, CLIFFSIDE, NORTH CAROLINA
Engineering, procurement, and erection assistance of the coal handling system upgrade. The coal handling system upgrade is designed to be completed in two phases. Phase I includes removing the existing rotary car dumper and converting to a bottom dump system with upgrades with conveying to the existing crusher house. Phase II includes adding a new crusher structure, transfer house, and pedestal mounted circular stacker. The coal handling system is designed to receive coal from trains at the new rapid discharge rail unloading facility. The received coal is transferred initially to the existing crusher house at a capacity of 1,500 TPH and fi nally to the new crusher structure at a capacity of 2,400 TPH. To handle this increased unloading rate the existing unloading hopper gates and feeders are replaced with new slide gates and variable speed belt feeders. A new control room is also provided. The rail-receiving conveyor is upgraded from 54 inch to 60 inch with new stringers and hoods (phase I) and new drive, belt, idlers, pulleys, and chute work (phase II). The new crusher structure includes a diverter gate, two by-pass grizzly screens rated at 2,400 TPH, and two granulator crushers rated at 1,800 TPH. The coal is conveyed through a new stockout transfer structure to the new pedestal mounted circular stacker. The fi rst conveyor includes a modular sampling system. The new pedestal mounted circular stacker boom is cable supported with luffi ng for dust control. The 2,400 TPH stacker forms two 89,500-ton capacity piles, one for each of Units 5 and 6. All structures in the upgraded coal handling system are provided with bag house dust collection or wet dust suppression. Ancillary systems include wash down water systems for all structures and sump pumps in the rail dump structure.
COAL FUEL HANDLING EXPERIENCE
24 Section 02 SOUTHERN COMPANY SERVICES
GEORGIA POWER COMPANY PLANT, MILLEDGEVILLE, GEORGIA
Engineering, procurement, fabrication, construction and commissioning of a synfuel processing. A new coal receiving hopper was installed in a reclaim pit and new tunnel provided by the owner. A 600 ton capacity vibrating feeder was installed under the new hopper. The vibrating feeder feeds the coal onto new reclaim conveyor SF1, with a capacity of 600 TPH and travelling at a speed of 300 FPM. A magnetic separator provided by the owner, was installed on the new reclaim conveyor. Reclaim conveyor SF1 feeds the coal to a new crusher building and then into a new crusher, provided by the owner. The coal is then discharged onto a new 48" transfer conveyor SF2, with a capacity of 600 TPH. The owner also installed a new belt scale on this conveyor to verify the tonnage being supplied to the synfuel plant. The synfuel plant discharges its product onto a new 48" stacker feed conveyor, SF3. SF3 also has a capacity of 600 TPH. The owner installed a new tramp iron magnet on conveyor SFS to pick up any ferrous iron that may have been introduced during the synfuel process. An owner supplied sampling system was also installed on conveyor SF3. The radial stacker was provided by the owner and is used to create an outdoor stockpile. The outdoor stockpile is reclaimed by mobile equipment that pushes the synfuel into a new reclaim hopper. The new reclaim hopper is provided with a new mass fl ow gate that is used to discharge the synfuel onto an existing conveyor system that feeds the Georgia Power Company fuel silos.
COAL FUEL HANDLING EXPERIENCE
Section 02 25 HUANENG POWER INTERNATIONAL
DANDONG GENERATING STATION, DANGDONG, CHINA
Engineering, procurement and commissioning of two stacker/reclaimers and a traveling hopper; the contract was awarded by Sargent & Lundy LLC. To stockout and reclaim the coal two stacker/reclaimers were provided. The stacker/reclaimers have a stacking capacity of 1800 TPH and a reclaiming capacity of 720 TPH. The stacker/reclaimer boom is 100 feet long with a 21-foot diameter bucket wheel reclaimer. The machine is capable of slewing a total of 270 degrees and can travel more than 1000 feet over rails. Each machine has an on board control cab and is completely controlled by a programmable logic controller (PLC). For coal deliveries by self-unloading ships, a traveling hopper located on the dock was provided. The hopper capacity is 155 tons of coal and incorporates four vibratory feeders each of which is rated at 1000 TPH. The vibratory feeders in turn feed dual unloading conveyors, which send the coal through a series of conveyors and transfers to the stacker/reclaimers. The traveling hopper can move over 375 feet on rails. R&S has signifi cant international project The traveling hopper is equipped with on board PLC and dust experience and is an expert in specialty suppression systems. material handling equipment.
COAL FUEL HANDLING EXPERIENCE
26 Section 02 BALTIMORE GAS & ELECTRIC COMPANY
BRANDON SHORES, UNITS 1 AND 2, ANNE ARUNDEL COUNTY, MARYLAND
Complete project management, From here coal is directed to either the detailed engineering, procurement inactive storage pile (by a cantilevered and construction services were provided conveyor fi tted with a telescopic chute), under a turnkey contract. This contract or the active storage pile (by the yard covered the major coal handling facilities belt for delivery to a stacker reclaimer). serving two new 620 MW units of the The stacker reclaimer has a 20' diameter This project had unique construction Brandon Shores Power Plant on the bucket and is fi tted with a trailing challenges due to the seasonal Patapso River. A major feature of the tripper and stacking slewing boom. availability of the river access and coal handling facility is a system to 4,400 TPH of coal handling capability. interface restrictions with the power receive coal by 7,000-ton capacity The storage yard itself has a concrete block general contractor. The entire barges. This installation involved reclaim tunnel traversing the length of project took approximately 26 months extensive marine works, including the coal yard. This tunnel provides live from award to operation of Units a 3-barge dock, jetty way and a barge storage for a major portion of the coal No. 1 and No. 2. haul system to move the barges yard. The reclaim tunnel is fi tted with during unloading. fi ve 12' diameter dischargers feeding A high capacity 4,000 TPH continuous vibrating feeders. These feeders in bucket elevator barge unloader was turn, feed the main reclaim belt. The installed on the new jetty way. An reclaimed coal is then loaded on a innovative construction method was transfer belt. This transfer belt joins developed for the assembly of the barge with the yard belt in a combination unloader. The entire machine was transfer sampling building ahead of pre-assembled on shore and shipped the main power block. In this building, in one piece on a fl oating barge crane. coal is crushed to a 2" x 0 product and is conveyed to reversible shuttle conveyors The barge unloader discharges to a high that feed the coal bunkers. The coal capacity 72" collecting conveyor. The reclaim rate feeding the bunkers is conveyor is in a fully enclosed ventilated 850 TPH. gallery. Coal is conveyed over the water and inland to a transfer station some The reversible shuttle belt conveyor 2,100' away (of which 1,700' are over system feeding the power block provide water). Once the coal is delivered on fl exibility in plant loading requirements. shore it is sampled at a transfer station. This system is fully automated with It is then either directed to a radial individual remote stations, each of stacker (discharging to a ground storage which is capable of operating the system serving the existing Wagner equipment from barge to bunker. Station), or onto another conveyor An additional coal handling system serving the main coal storage stockpile serves Unit No. 2 of the Brandon Shores system for Units 1 and 2. This conveyor Power Plant. This system begins atop discharges to another transfer station. the bunkers for Unit No. 1, where coal is transferred from conveyors and conveyed to atop the coal bunker serving Unit No. 2. Coal conveyed to the bunker is dis- tributed by traveling shuttle conveyors. The coal conveying rate is 850 TPH.
COAL FUEL HANDLING EXPERIENCE
Section 02 27 U.S. GENERATING COMPANY
SCRUBGRASS FACILITY, KENNERDELL, PENNSYLVANIA
Engineering and procurement of a fuel handling facility for an independant power project (IPP). The fuel (bituminous gob) is delivered by truck to a coarse reclaim hopper and a fi ne reclaim hopper. The coarse gob is reclaimed on a 48" variable speed belt feeder. The fi ne gob is reclaimed by a special designed variable speed rotary plow feeder, integral with the fi nes hopper. Both the coarse and the fi ne material are collected on a 36" reclaim tripper belt. This belt terminates in a 6,000 ton capacity storage barn. The belt is fi tted with a traveling tripper which traverses the operating length of the building. Material is reclaimed from the storage pile by a traveling scraper-reclaimer rated at 250 TPH. This reclaimer traverses the pile length and reclaims material to the 30" reclaim conveyor. Additionally, provisions are included for emergency reclaim by an aboveground dump hopper. The reclaim conveyor is fi tted with a belt scale and a magnetic separator for tramp iron removal. The reclaimed gob is discharged to a vibrating scalping screen with a nominal 4" deck. The +4" material (considered refuse) is discharged along with the tramp iron to separate tote bins. The through product from the scalping screen is collected in a 20-ton, surge bin from which it is fed by twin vibratory feeders to two crushers. Each crusher unit is rated at 120 TPH and makes a nominal 1/4" x 0 product. The processed fuel is then collected on the fuel bunker feed conveyor/tripper conveyor, which terminates on the boiler bunker system. A traveling tripper is provided for bunker fi lling. A control system is provided, which interfaces with the owner-supplied distributed control system. The project was completed in approximately 12 months.
COAL FUEL HANDLING EXPERIENCE
28 Section 02 BECHTEL POWER CORP.
MORGANTOWN ENERGY PROJECT, MORGANTOWN, WEST VIRGINIA
Engineering and procurement of a fuel handling/processing facility. This facility handles both bituminous coal and bituminous coal gob. The material is handled in twin unloading hoppers, rated at a nominal 30 tons each. Vibrating feeders are provided for reclaiming. The reclaimed material is collected on a 36" fuel transfer belt rated at 500 TPH. The material is then transferred to a 60" high angle elevating conveyor using a fl exible belt wall. This unique conveyor is a special design and is fi tted with a service-way the entire elevated length. The material from the elevating conveyor discharges to a 36" reversible silo feed belt rated at 500 TPH. This belt discharges material to either the coal silo or the gob silo. The silos themselves were not in our scope of supply; however, we did provide the engineering. Fuel silos are fi tted with variable speed, specially designed, rotary plow feeders. The rotary plow feeders discharge to twin-way feeders which convey the material to either the BMR or Hammermill crushers for processing. The crushed material is collected and conveyed to the second high angle elevating conveyor (rated at 120 TPH) for delivery to the bunker fuel bins. An emergency hopper is provided, suitable for front end loading, and fi tted with an en-masse elevating conveyor for emergency reclaiming. Ancillaries for this project include exclusive dust collection (particularly in the area of the truck dump) and heating and dust collection for the BMR and Hammermill units. The scope of supply included the supply of low voltage electrical apparatus, control and instrumentation and control panels. An interface was provided with the owner-supplied distributed control systems. Site restrictions for this project were extremely limited, since this facility is located within the city of Morgantown, and adjacent to the campus of the University of West Virginia. Facilitation of construction, shop and pre-assembly of components were provided by Roberts & Schaefer at near-by staging areas. The project schedule was approximately 15 months.
COAL FUEL HANDLING EXPERIENCE
Section 02 29 AES – BARBERS POINT
BARBERS POINT, OAHU, HAWAII
Engineering, procurement and construction of a coal handling facility. The scope of supply started at the owner’s harbor loadout conveyor. This conveyor discharges atop one of two concrete lowering walls provided by Roberts & Schaefer. The material delivered from the owner’s loadout system is conveyed at the rate of 1,250 TPH. Provisions are included for the discharge of the material either to lowering tube No. 1 or to coal transfer conveyor No. 1 for delivery to lowering tube No. 2. Open ground storage is provided. The material is reclaimed by front-end loader to a similar above ground reclaim hopper. The hopper is fi tted with a variable speed trip feeder for reclaiming at a rate of 1 to 270 TPH. The reclaim feeder is fi tted with belt scale and a magnetic separator for tramp iron removal. The reclaimed material is crushed or by-passed ahead of the coal transfer conveyor. The coal transfer conveyor delivers the crushed coal to a generation building. The material is discharged to an en masse chain conveyor which distributes and/or selectively fi lls the owner’s four coal silos. A complete control and instrumentation package is included complete with interface to Owner’s control system. A complete "as fi red" sampling system in the generation building is provided before storage. Both the crusher building and the bunker area are provided with a complete dust collection system.
The project schedule was approximately 18 months.
COAL FUEL HANDLING EXPERIENCE
30 Section 02 CITY UTILITIES
JAMES RIVER POWER STATION, SPRINGFIELD, MISSOURI
Design, supply, installation, and commissioning of a turnkey expansion to the existing coal yard to facilitate fuel blending. This project consisted of the installation of a new 48" conveyor that is fed from an existing stockpile feed conveyor. The new conveyor transports material to a new stockpile through a stacking tube. The material is reclaimed from the new stockpile by weigh belt feeders and a 36" reclaim conveyor. The existing crushing station was modifi ed to accept the new conveyor and the existing conveyor to feed the existing crushers. The existing programmable logic control (PLC) system was expanded to accommodate the new equipment. Ancillary systems included fi re protection, wash-down and pumping systems.
COAL FUEL HANDLING EXPERIENCE
Section 02 31 J. A. JONES CONSTRUCTION COMPANY
COGENERATION FACILITY, FORT DRUM, NEW YORK
Engineering, procurement and construction of a complete coal yard facility servicing a cogeneration installation in Fort Drum, New York. The coal yard was fed through unit train deliveries. A gas fi red enclosed thawing shed with soaking area (4-car total) was provided ahead of the unloading hopper. The rail cars were unloaded by use of a side mount car checker into the twin compartment 60-ton reclaim hoppers. The unloading hoppers are fi tted with The scope of supply included the complete 12" x 12" grizzly and the full area coal valves. At a rate of 150 TPH, twin vibrating electrical supply and installation, including feeders reclaim the coal to a 36" crusher feed conveyor. This conveyor is fi tted with instrumentation and control systems. a belt scale and magnetic separator for tramp iron removal. Interfaces with the boiler block control The reclaimed coal passes over an "as received" 2-stage sampling system and is system were also included. discharged to a vibrating scalping screen. By-pass provisions are included ahead of the scalping screen. The oversize from the scalping screen is discharged to 300 TPH coal crusher. The crushed product is combined with the screen through product and is conveyed by a 30" stock out conveyor to a storage belt. The discharge of the stock out conveyor is equipped with a telescopic chute to minimize fugitive dust. Under the active storage pile, a reclaim tunnel houses a 30" reclaim conveyor. This conveyor is fed by twin vibrating feeders, each of which is fed by high capacity pile dischargers. The 30" reclaim conveyor returns the material to the boiler block. In the boiler block, the material is discharged to the fi rst of three bins, or transferred to the tripper conveyor which feeds bunkers No. 2 and No. 3. Ancillaries for this project included dust collection, bin vent fi lters, ventilation and dust suppression. Because of the extreme climactic conditions and plant location, all conveyors were housed in enclosed galleries. The project schedule was approximately 16 months.
COAL FUEL HANDLING EXPERIENCE
32 Section 02 AMERICAN ELECTRIC POWER
CARDINAL PLANT, BRILLIANT, OHIO
R&S designed and installed a new silo transfer conveyor (capacity of 2100 TPH) with a new silo discharge belt feeder, feeding the new plant feed conveyor which feeds a reversing bunker feed conveyor. The single speed belt feeder has a 48" wide belt and operates at 108 FPM, which gives it a capacity of 300 TPH of coal. The coal handling system includes a complete dust collection system. Engineering and procurement for the coal blending system. To allow for blending, R&S furnished a radial stacker and second reclaim system. To access the existing system the 2,500 TPH conveyor from the barge unloader to stockout had a transfer house added. At the transfer house the belt was split with a diverter gate added to either feed coal to the new radial stacker or back onto the existing belt. The radial stacker stockpiled the coal to form a 90-degree pile with a capacity of 20,000 tons. The new reclaim system consisted of a hopper with a variable speed belt feeder and one reclaim conveyor below one end of the new stockout pile. The reclaim conveyor transferred the coal back to the existing system where it is blended with coal from the existing reclaim system.
COAL FUEL HANDLING EXPERIENCE
Section 02 33 MORE EXPERIENCE
KANSAS CITY POWER AND LIGHT, SPECIALIZED BELT FEEDERS, LA CYGNE, MISSOURI R&S added a blending system at their existing La Cygne facility. This addition/retrofi t required development of specialized belt feeders for reclaiming and blending due to the high capacity and physical restraints of the existing system. The following nine belt feeders were developed: • 54" 102 FPM, single-speed, truck-unloading belt feeder rated at 1,200 TPH of 2" x 0" coal • Twin 72" wide belt feeders rated at 1,200 TPH of 2" x 0 coal with a variable speed drive, allowing belt speeds of 10 to 102 FPM and providing a downturn to 120 TPH minimum • Four 54" wide belt feeders, each rated at 1,200 TPH of 2 x 0 coal with a variable speed drive, allowing belt speeds of 10 - 102 FPM and providing a downturn to 120 TPH • Twin 120" wide belt feeders (believed to be among the largest ever manufactured in the U.S.) rated at 600 TPH of 2 x 0 coal with a variable Above: Kansas City Power and Light, Specialized Belt Feeders, speed drive, allowing belt speeds of 5 - 50 FPM and a downturn to 60 TPH La Cygne, Missouri Each of these units is complete with abrasion resistant steel lined loading skirts with adjustable seal rubber. BLACK HILLS POWER AND LIGHT, NEIL SIMPSON STATION, GILLETTE, WYOMING Roberts & Schaefer Company supplied a storage silo unloader belt feeder at the above referenced plant. This single speed belt feeder has a 48" wide belt and operates at 108 FPM, giving it a capacity of 300 TPH of coal. It is equipped with a rack & pinion type regulating gate and head pulley alignment device. A dual belt wiper cleans the outside of the belt while a belt plow cleans the inside of the belt.
Above & Left: Black Hills Power and Light, Neil Simpson Station, Rapid City, South Dakota
COAL FUEL HANDLING EXPERIENCE
34 Section 02 MORE EXPERIENCE
SOUTHERN ILLINOIS POWER COOPERATIVE, MARION GENERATION STATION, MARION, ILLINOIS Engineering and procurement of the coal and limestone handling system upgrade. Coal and limestone are received by trucks for a new CFB unit that was added to the station. New coal and limestone receiving/reclaim hoppers were added to improve receiving and to increase the reclaim capacity from 200 to 300 TPH. The coal hopper has a variable speed feeder/breaker, and the limestone hopper has a variable speed belt feeder. At the transfer tower addition, the existing 24-inch reclaim and silo fi ll conveyor system was upgraded to 300 TPH with increased belt speeds, new drives, and conveyor components as required. A new silo fi ll conveyor system with a shuttle conveyor was added to convey coal to four silos and a diverter gate directed the limestone to one silo at the new CFB unit. Insertable bag fi lter dust collectors were furnished for the silo fi ll area. The work was coordinated so as not to cause any interruption in the existing station operations. PROGRESS ENERGY CAROLINAS, ROXBORO POWER STATION, ROXBORO, NORTH CAROLINA Engineering and procurement of the coal unloading system upgrade. The coal handling system received coal by unit train that was unloaded by a rotary car dumper. To modernize and increase the unloading system capacity, a new rapid discharge bottom dump unloading system with a capacity of 4,800 TPH was furnished. A new hopper and grillage, and a third-rail system were added. A fl oor mounted roller railside car shaker was also furnished. The unloading hopper discharge used a single 108-inch wide collecting belt feeder. The feeder discharges to a new conveyor to transfer the coal to the modifi ed transfer tower. The conveyor from the transfer tower to the radial stacker and the radial stacker boom conveyor were modifi ed with new drives and increased belt speed to handle the new 4,800 TPH unloading capacity. The coal yard has two stockout areas for future coal blending. The as-received sampling system was modifi ed too for the new conveyor to the transfer tower. Progress Energy Carolinas, Roxboro Power Station, Roxboro, North Carolina
COAL FUEL HANDLING EXPERIENCE
Section 02 35 MORE EXPERIENCE
CS ENERGY, KOGAN CREEK POWER STATION, SURAT BASIN, AUSTRALIA Engineering, procurement and construction of the coal handling system ROM Truck Dump to Bunker Tripper. The plant consisted of 180m3 Truck Dump Hopper, a feeder breaker delivering ROM coal at a rate of 1100 TPH. The coal is then screened with oversize and tramp being discarded before loading onto a 3km overland conveyor. The coal is sized through a two stage crushing process and delivered to bunker feed conveyor or the ROM (uncrushed) coal can be directed onto the emergency stockpile. Coal is reclaimed from emergency stockpile via stockpile reclaimers via bulldozer push to the primary crusher. The coal is delivered to the bunkers via a tripper conveyor at a rate of 1100 TPH. HOPEWELL PAGBILAO, CONVEYOR SYSTEM, Top: CS Energy, Kogan Creek Power Station, QUEZON PROVINCE, PHILIPPINES Surat Basin, Australia Engineering, procurement and operation and maintenance technical assistance Below: Hopewell Pagbilao, Conveyor System, of a conveyor system. The system transfers coal from the stockpile to the bunkers Quezon Province, Philippines of a 700 MW power plant. The conveyor system runs from the ship unloader to the stockout/reclaim, then to the coal crushers and fi nally to the coal bunkers. The total length of the conveyor system is 9,000' and has a width of 54". The system capacity is 1,600 TPH. The project scope also included four 1,000 TPH vibrating screens, two 800 TPH crushers, dust collection system, water spray system for the coal pile, vacuum cleaner system, magnetic separator, belt scale and metal detector.
COAL FUEL HANDLING EXPERIENCE
36 Section 02 MORE EXPERIENCE
CENTRAL GENERADORA ELECTRICA, SAN JOSE POWER STATION, GUATEMALA CITY, GUATEMALA Engineering and procurement for a new coal handling system; the contract was awarded by JBV Guatemala LLC. The project consisted of a new coal unloading and storage system and a coal silo fi lling system. The unloading and storage system consists of a self unloading ship fed hopper with a variable speed belt feeder that feeds an 850' long, 2,200 TPH, 60" wide overland conveyor. The overland conveyor transports the coal to a radial stacker that creates a 50,000-ton storage pile for station use and a 40,000-ton storage pile for resale. The new coal silo fi lling system consists of a front end loader fed reclaim hopper with variable speed belt feeder, which feeds an 800' long, 220 TPH, 24" wide belt conveyor. The belt conveyor then feeds a drag chain conveyor above the three coal silos that is equipped with discharge gates used to fi ll the silos.
Above: Central Generadora Electrica, San Jose Power Station, PT FREEPORT, IRIAN JAYA, INDONESIA Guatemala City, Guatemala The unloading system consists of a 60" wide conveyor with a 2,000 MTPH capacity that receives coal from the barge unloading conveyor through the receiving hopper and discharges to the 50' high conical pile. The coal from the stockpile is reclaimed by dual 30" wide conveyors, 250 STPH capacity each, and fed to the crushers. The crushed coal is conveyed to the boiler house and discharged into the silo from trippers. The scope of supply also includes belt scale, sampling, magnetic separator, dust collection, dust suppression, electrical control devices, PLC and electrical engineering.
Left: PT Freeport, Irian Jaya, Indonesia
COAL FUEL HANDLING EXPERIENCE
Section 02 37 MORE EXPERIENCE
SOUTHERN ELECTRIC INTERNATIONAL, BIRCHWOOD PROJECT, KING GEORGE COUNTY, VIRGINIA Design, engineering and procurement of a coal handling system for Southern Electric International’s Birchwood project in King George County, Virginia. The scope of the project includes a rotary dumper, radial stacker, reclaim tunnel with vibrating hoppers, crusher house and associated conveyors. The facility unloads coal from railroad cars, transfer the coal to storage and from storage to the power plant’s coal bunkers. WISCONSIN POWER & LIGHT COMPANY, SHEBOYGAN, WISCONSIN Engineering consulting services were provided to develop a coal unloading, storage and blending system addition at their Edgewater Generating Station. The facility criteria was based on incorporating the existing rail dump, sampling and conveying system components into the new blending addition. Conceptual recommendations were presented to accomplish the project criteria, followed by a fi nal report containing a written facility description, preliminary general arrangement drawings and a budget cost estimate. POTOMAC ELECTRIC POWER COMPANY, WASHINGTON, D.C. The evaluation and subsequent total engineering and design to completely rebuild and modernize a coal unloading, sampling and storage-reclaim facility at the Chalk Point Power generation station. The work required extensive fi eld measurement of reusable foundations, structures and equipment; the designs for new structures and equipment; and the engineering and design for a complete new electrical distribution system, the controls, system interlocks, instrumentation with alarms, annunciator-communications and lighting. NORTHERN STATES POWER COMPANY, MINNEAPOLIS, MINNESOTA Engineering consulting services were provided to inspect, evaluate, recommend, and develop conceptual plans and modifi cations for the coal receiving, storage and handling systems at their Black Dog, Riverside and Highbridge Generating Stations. Northern States decision to fuel their stations with western sub-bituminous coal necessitated an evaluation to improve their coal handling facilities, storage and reclaim systems, dust collection and control, as well as operating practices. The ultimate goal of the project was to improve operating costs. The study prepared a summary report of recommendations and considerations. A fi nal report followed, addressing those preliminary recommendations selected by Northern States, providing conceptual drawings and capital cost estimates.
COAL FUEL HANDLING EXPERIENCE
38 Section 02 MORE EXPERIENCE
ASSOCIATED SOUTHERN ENGINEERING CO., CALIFORNIA BIOGEN POWER FACILITY, SAN BERNARDINO COUNTY Engineering design and procurement services were provided for construction of a truck-receiving, coal and sorbent storage and reclaim system, and ash recovery and truck loadout system. Work included the design of a truck dump to receive 25-ton We can customize our service to include capacity highway truck-trailers delivering coal or sorbent to a receiving pocket just the assistance you need, from fi tted with a screw reclaim feeder. Received material is transported to a 980-ton complete design and construction to capacity coal storage bin, 40-ton capacity coal day bin or 55-ton capacity sorbent performing conceptual and feasibility storage bin via a 24" diameter screw conveyor, bucket elevator and diversion gates at a rate of 160 TPH. All storage and day bins are fi tted with reclaim screw feeders studies, or furnishing only equipment. which deliver on demand coal and sorbent to a fl uid bed combustor. High tempera- ture bed ash (600°F) and fl y ash (380°F) produced by the combustor are collected and transported to a loadout station via screw conveyors and bucket elevators. In route to the loadout station storage bins, the ash passes through hollow fl ight type water cooled screw conveyors for ash temperature control prior to storage and loadout. Telescoping loadout chutes deliver bedash and fl yash from 225-ton capacity storage bins to highway trucks for material removal from the facility. A programmable logic controller provides the control means for automatically receiving, storing and reclaiming both coal and sorbent. UTAH POWER & LIGHT COMPANY, NAUGHTON STATION KEMMERER, WYOMING Detailed engineering design, procurement and construction inspection services were provided for UP&L’s Coal Yard Upgrade Project, at their Naughton Station in Kemmerer, Wyoming. The upgrade provided a completely new coal yard reclaim system, replacing the existing equipment, but basically utilizing the existing reclaim tunnel and conveyor structures. To maintain coaling the station during the upgrade construction schedule, a temporary reclaim station was constructed. The facility was converted to a dual reclaim system, refi tted with variable rate feeders, new high capacity belt conveyors, belt scales for control and a circuit to accommodate handling frozen coal during winter months. A programmable logic controller provides the control means to automatically coal the station, adjusting to the station demand and distribution requirements to the various units.
COAL FUEL HANDLING EXPERIENCE
Section 02 39 MORE EXPERIENCE
POTOMAC ELECTRIC POWER COMPANY Complete project management, detailed engineering, procurement assistance and construction inspection services were provided to upgrade the coal handling facility serving the Chalk Point Generating Station. The fi rst phase of the project initiated with a detailed inspection and evaluation of the facility. This phase provided a written report recommending resolution of the identifi ed problems. The second phase executed the engineering services to completely rebuild portions of the facility, including: modernization of the coal unloading rotary dump and dump station, replacing the sampling system, upgrading the stacker/reclaimer unit, and the addition of a circuit to handle frozen coal reclaimed from the storage yard. The work required extensive fi eld measurement of reusable foundations, structures and existing equipment; the design for new structures and application of coal handling equipment; as well as the design for a complete new electrical distribution system, the controls, system interlocks, instrumentation with alarms, annunciator, communications and lighting. The coal yard facility upgrade provided a system with an unloading and storage capacity of 2,400 TPH. All the upgrade work and the addition of each new systems was accomplished without a coal yard outage. POTOMAC ELECTRIC POWER COMPANY The engineering, procurement and construction for a 25' extension of the coal yard stacker conveyor at the Potomac River Station. The existing cable supported truss was extended with a new truss and support cables including concrete anchors. The conveyor idlers, pulleys and bearings, belting and skirtboards were replaced. A daily CPM schedule was required to assure that the work would be performed during a three week scheduled outage. PACIFICORP, DAVE JOHNSTON POWER STATION, GLENROCK, WYOMING Engineering, procurement and construction of an upgrade to the existing coal handling system. The scope of the project included a new railroad car spotter, coal crushers and belt feeders with telescopic chutes. The project also included modifi cations to existing conveyors to increase their capacity from 900 TPH to 1,200 TPH.
Top & Above: Pacifi Corp, Dave Johnston Power Station, Glenrock, Wyoming
COAL FUEL HANDLING EXPERIENCE
40 Section 02 MORE EXPERIENCE
COMED, FISK STATION, WAUKEGAN STATION AND JOLIET NO. 9 STATION The Waukegan Station project consists of constructing a new 200" long, rail mounted stacker with a rear pivot mount and articulating boom. Design capacity is 1800 TPH—a fully-automated stacker that gives ComEd the ability to form a 44" high 16,000 ton coal storage pile. The Joliet No. 9 Station project consists of a new counter-weighted pedestal mounted stacker. Design capacity is 1,600 TPH, and allows ComEd to form a 45" high 23,000 ton coal storage pile—shortening the train unloading time by about 50%. WESTVACO-COGEN SOUTH PROJECT, CHARLESTON, SOUTH CAROLINA The work includes furnishing engineering and design, material procurement, and steel fabrication for coal and wood waste handling system. Major items will include the following: coal unloading building with car shaker, hoppers, gates, belt feeders, conveyors, dust collection and suppression; coal crusher with buildings; wood waste hogs with building, reclaim drag conveyors, belt conveyors, metering and control systems and equipment. PSI ENERGY, WABASH RIVER GENERATING STATION, WEST TERRE HAUTE, INDIANA Engineering, procurement and construction of the coal handling system for the Wabash River Generating Station’s Coal Gasifi cation Repowering Project. The system takes the coal from the existing conveyors at the crushing house and transports it to the new coal gasifi cation plant. The coal gasifi cation plant transforms the solid coal into gas allowing PSI to use it in a boiler that was originally designed for gas. The coal gasifi cation plant also removes the sulfur and particulate matter from the coal before burning, helping PSI meet Top: ComEd, Fisk Station, Waukegan Station environmental regulations. and Joliet No. 9 Station The scope of the project included all conveyors, drives, structural steel, Bottom: Westvaco-Cogen South Project, foundations, fi re protection, electrical and controls. The system is rated Charleston, South Carolina at a capacity of 1,600 TPH.
COAL FUEL HANDLING EXPERIENCE
Section 02 41 MORE EXPERIENCE
BALTIMORE GAS AND ELECTRIC, C.P. CRANE STATION, BALTIMORE, MARYLAND Engineering, procurement and construction of a coal handling system and dust suppression and collection upgrade at their C.P. Crane Station originally built in 1958. Most of our construction occurred during a six week planned shut down during the Spring of 1994. The challenge of this project was to plan so that all the material, site preparations, equipment and workers were deployed, ready to start and fi nished during the shutdown. The scope of the project included replacing conveyor idlers, pulleys, chutework, covers, skirts, reducers and motors. It also included modifying the existing silo hopper bottom to accept new conveyor feeders. As part of the project the existing car dump hoppers were demolished and replaced. A limestone handling system with a capacity 6 TPH was also installed. A dust collection and suppression system was also part of the project. AES, WARRIOR RUN POWER STATION, CUMBERLAND, MARYLAND Engineering, procurement and construction of a new coal handling facility . The new coal handling system included the addition of a new 300TPH coal truck unloading hopper system and conveying system that feeds a new coal crushing station. The new coal crushing station included a coal bypass system, crusher surge bin, vibrating feeders and coal crushers. The coal bypass system is used above the crusher surge bin to divert coal to a storage pile which may be later reclaimed via hopper/feeder to feed the coal crushing system. The new crushers fed a new conveying system to the coal silo area. A drag chain was used to fi ll the four coal silos. The new system also included dust suppression, dust collections and new as-fi red coal sampling systems.
COAL FUEL HANDLING EXPERIENCE
42 Section 02 MORE EXPERIENCE
ASSOCIATED ELECTRIC CO., HIGH CAPACITY STACKER, NEW MADRID, MISSOURI Engineering, procurement, construction and startup services for a new unloading and storage facility including a new high capacity stacker. The system included a new rotary car dumper and train positioner system which dumps into a hopper and onto two new 72” belt feeders rated at 2000TPH each. From the belt feeders, the coal is transported to a new transfer conveyor rated at 4000TPH which feeds a new pedestal type radial stacker. The radial stacker is equipped with slewing and luffi ng capabilities to create two 24,000 ton ready piles. The coal is reclaimed from the ready piles via eight new vibratory reclaim feeders rated at 400TPH each which were installed in the existing tunnel to feed two existing, modifi ed 850TPH reclaim conveyors. The reclaim conveyors then feed the crusher surge bins in the new addition to the existing crusher house. The coal is drawn out of the bins by four new vibratory feeders rated at 550TPH each to feed four new reversible hammermill crushers also rated at 550TPH each. Once crushed, the material is conveyed via two new 850TPH conveyors to the existing coal bunker feed conveyors and tripper system. Associated Electric Co., High Capacity Stacker, New Madrid, Missouri Ancillary systems include dust collection, vacuum cleaning, fi re protection and washdown collection pumping. Fuel switch to Powder River Basin coal.
COAL FUEL HANDLING EXPERIENCE
Section 02 43 MORE EXPERIENCE
ALABAMA POWER COMPANY, J. H. MILLER STEAM PLANT, WEST JEFFERSON, ALABAMA At Alabama Power as part of their coal handling system upgrade, we added a 72" wide belt feeder. This single speed barge unloading feeder operates at 90 FPM and handles 1,800 TPH of coal. It is equipped with the following features: • Skirtboard • Rack & pinion type regulating gate • Head pulley alignment device • Dual belt wiper • Belt plow SEI, BIRCHWOOD STATION, KING GEORGE COUNTY, VIRGINIA A total of six belt feeders were installed at this location with the following characteristics: • Two 60" wide, 100 FPM single speed belt feeders rated at 1100 TPH of coal. • Four 42" wide variable speed belt feeders. The belt speed can be varied from 50-100 FPM. This gives them a capacity ranging from 250-450 TPH of coal. All these belt feeders are equipped with the following features: • Rack & pinion type regulating gate • Head pulley alignment device • Dual belt wiper • Belt plow
COAL FUEL HANDLING EXPERIENCE
44 Section 02 MORE EXPERIENCE
BECHTEL CONSTRUCTION COMPANY, MT. POSO COGENERATION COMPANY, MT. POSO COGENERATION PROJECT FLUIDIZED BED BOILER (49 MW)
Engineering design, procurement and construction management services were provided for construction of a fuel handling system for a 49 MW, coal fi red cogeneration power plant. Work included the design of a truck dump to receive 27-ton capacity, highway trucks with tandem trailers. The dump is fi tted with two vibrating reclaim feeders which reclaim coal at a rate of 200 TPH and discharge to an en-masse type conveyor which transports the coal to a silo fi ll bucket elevator. A rotary drum type magnetic separator located at the discharge of the en-masse conveyor removes tramp iron from the as-received coal. The silo feed elevator discharges directly to a 3,000-ton capacity concrete coal storage silo providing approximately 4.5 days fuel supply. The silo is fi tted with a single, totally enclosed, variable rate vibrating feeder to reclaim stored coal. Reclaimed coal reports directly to a ring-type granulator crusher which reduces the 2" x 0 as-received coal to a nominal 1/2" x 0 product required at the boiler feed. The silo reclaim feeder and crusher are rated at 200 TPH. Sized coal discharges directly to a reclaim en-masse conveyor which transports the coal to the day bin fi ll bucket elevator. Coal is elevated to a point above two 300 ton capacity day bins and is directed to the appropriate bin via an automatic fl op gate located in the day bin elevator discharge chute. The day bins provide approximately 24 hours of live storage and are positioned directly above two gravimetric feeders which feed coal at a metered rate to the boiler. The coal handling and storage system is entirely enclosed and is provided with a dust collection system designed to maintain a negative pressure within the system. The truck dump is totally enclosed and fi tted with a dry fog type dust suppression system to minimize fugitive dust emissions. A programmable logic controller provides the control means for automatically receiving, storing and reclaiming coal.
COAL FUEL HANDLING EXPERIENCE
Section 02 45 MORE EXPERIENCE
NORTHERN INDIANA PUBLIC SERVICE CO., R. M. SCHAHFER GENERATING STATION, WHEATFIELD, INDIANA A total of four belt feeders were installed at this location with the following characteristics: • Two 72" wide variable speed belt feeders for the rotary car dump, each with a capacity of 300-1,500 TPH of coal. • Two 60" wide variable speed belt conveyors for the reclaim hopper, each with a capacity of 150-1,000 TPH of coal. All these belt feeders are equipped with the following features: • Rack & pinion type regulating gate • Head pulley alignment device • Dual belt wiper • Belt plow • Skirtboard KANSAS CITY POWER & LIGHT COMPANY, LACYGNE, KANSAS Engineering, procurement and construction for fuel yard modifi cations. FRU-CON CONSTRUCTION CORPORATION, NORTH BRANCH POWER PROJECT, BAYARD, WEST VIRGINIA Engineering and procurement for fuel and limestone handling system for 80 MW cogeneration project.
COAL FUEL HANDLING EXPERIENCE
46 Section 02 MORE EXPERIENCE
CONTINENTAL ENERGY ASSOCIATES, HAZLETON GASIFICATION PROJECT, HAZLETON, PENNSYLVANIA Engineering, procurement and construction of a 600 TPH anthracite culm handling and processing complex. As part of an overall electric generating facility, anthracite culm is used as a fuel source for atmospheric gasifi cation. Roberts & Schaefer was commissioned to build a facility to reclaim anthracite culm from the existing indigenous banks to benefi ciate the material to specifi c thermal quality and size characteristics. Scope of supply started with a hillside truck dump fi tted with protective grizzly and reclaim vibratory feeder. The raw anthracite culm was delivered to a process plant where it was pre-screened to eliminate oversize ahead of the cleaning process. A Baum jig was used for benefi ciation. A water clarifi cation circuit consisted of clarifying cyclone thickener and settling pond were included. The processes anthracite culm was rescreened, crushed, and sorted into product sizes usable in the gasifi cation process. This project offered many design challenges, since it was the fi rst plant built for reprocessing anthracite culm. The quality characteristic of the culm being extremely abrasive required unusual wear resistant materials. The entire project was completed in 14 months. ATLANTIC CITY ELECTRIC, BEASLEY’S POINT, NEW JERSEY Engineering, procurement and construction for coal yard addition and up-grade.
COAL FUEL HANDLING EXPERIENCE
Section 02 47 MORE EXPERIENCE
TVA GALLATIN, FOSSIL PLANT, GALLATIN, TENNESSEE A complete design-build contract for a 1400 TPH Barge Unloading Facility including the associated material handling system. Complete marine facilities to dock and unload barges, as well as tugboat moorings are included. The project also includes a clamshell barge unloader, double-roll crusher, and a sampling and service building. The turnkey project is based on a feasibility study completed earlier by R&S. CENTRAL HUDSON GAS & ELECTRIC, DANSKAMMER GENERATING STATION, NEWBURGH, NEW YORK The project is comprised of self-unloading vessels (30,000 ton DWT class) which deliver coal to the existing Roseton Dock. This tonnage is three times the amount now delivered by rail. The dock will be modifi ed to receive additional coal. A coal receiving hopper and a belt conveyor will be installed on a marine cell in which the vessel will unload at rates up to 2000 metric TPH. The hopper will be enclosed to the maximum extent possible to insure a fugitive dust nuisance does not occur. The self-unloading vessel with coal is breasted against the existing dock. The unloading conveyor boom is positioned over the receiving hopper and inside the enclosure. Conveyor BC-1, located under the receiving hopper, will convey coal to Transfer Tower #1, then the coal transfers to Conveyor BC-2 at the rate of 2000 MTPH. Conveyor BC-2 will travel to Transfer Tower 2, where the coal will be proportioned between the existing stockout (500/1000 MTPH rating) via Conveyors BC-3 and BC-4. BATU HIJAU MINING PROJECT PT NEWMONT NUSA TANGARRA, SUMBAWA, INDONESIA Scope: Engineering, supply and commissioning of a concentrate feed conveyor and shiploader at the port, and a coal barge unloading and stockpile system at the power plant. The project consisted of a 1450 TPH, 36-inch-wide, 1417-foot-long, copper concentrate conveyor and shiploader. The copper concentrate conveyor is fed by two variable speed reclaim feeders located in the copper concentrate building. The reclaim feeders are fed by front end loaders. The copper concentrate conveyor feeds the shiploader. The shiploader slews through a 285-degree arc and incorporates a shuttling type boom and conveyor. The shuttling boom can provide reach from 41 feet out to 135 feet from the shiploader pivot. The shuttling boom conveyor transports the copper concentrate to the ship through a telescopic loading spout. An operator’s cab is provided on-board the shiploader with a radio control unit that permits remote operation. Top: TVA Gallatin Middle: Danskammer Generating Station Bottom: Batu Hijau Mining Project
COAL FUEL HANDLING EXPERIENCE
48 Section 02 MORE EXPERIENCE
ALLEGHENY POWER SERVICE CORPORATION, WILLOW AND PLEASANTS ISLAND, PARKERSBURG, WEST VIRGINIA Engineering, procurement and construction of coal handling, coal storage, coal weighing and coal sampling systems. TENNESSEE VALLEY AUTHORITY, SHAWNEE STEAM PLANT, PADUCAH, KENTUCKY Engineering and procurement of a coal handling system. VIRGINIA ELECTRIC POWER COMPANY, BREMO STATION, RICHMOND, VIRGINIA Engineering, procurement and construction of coal handling, crushing and sampling facilities to increase the capacities of the existing system. WISCONSIN POWER AND LIGHT COMPANY, PORTAGE, WISCONSIN Engineering, procurement and construction for a coal yard storage and reclaim addition. ELECTRIC POWER RESEARCH INST. (EPRI), PENNSYLVANIA ELECTRIC COMPANY, HOMER CITY STATION Turnkey engineering, procurement, construction and start-up services for coal handling system and coal cleaning test facility to demonstrate state-of-the-art coal cleaning processes, instrumentation and automated controls for the electric power industry. SOUTHWESTERN ELECTRIC POWER COMPANY, WELSH POWER PLANT, CASON, TEXAS Engineering, procurement and construction of the bunker room tripper conveyor and coal handling system addition for Unit No. 3. CENTRAL HUDSON GAS & ELECTRIC, DANSKAMMER POINT STEAM ELECTRIC GENERATING STATION, NEW JERSEY Engineering, procurement and construction of a coal handling system for Units 3 and 4 of the Danskammer Station
COAL FUEL HANDLING EXPERIENCE
Section 02 49 MORE EXPERIENCE
ASSOCIATED ELECTRIC COOPERATIVE, INC. (REA PROJECT) NEW MADRID PLANT, NEW MADRID, MISSOURI Engineering, design and material procurement for a coal handling modifi cation to provide a new reinforced concrete reclaim hopper, conveyor tunnel, reclaim belt conveyor and stockout belt conveyor. ORLANDO UTILITIES, ORLANDO, FLORIDA Engineering and procurement of the No. 2 unit fuel supply system. TAIWAN POWER, KAONSIUNG, TAIWAN Engineering and procurement for coal yard addition and upgrade at Talin Station. BLACK HILLS CORPORATION, GILLETTE, WYOMING Engineering, procurement and construction of coal yard upgrade and coal handling addition. TENNESSEE VALLEY AUTHORITY, TUSCUMBIA, ALABAMA Engineering, procurement and construction for the emergency replacement of bunker feed conveyors at the Colbert Steam Plant. SOUTH MISSISSIPPI ELECTRIC POWER ASSOCIATION, GARDNER, KENTUCKY Engineering, procurement and construction of a coal handling and processing facility. UTAH POWER AND LIGHT, CHACO, UTAH Engineering, procurement and construction of a coal handling and processing facility.
COAL FUEL HANDLING EXPERIENCE
50 Section 02 MOTIVA ENTERPRISES
MOTIVA REFINERY, PORT ARTHUR, TEXAS
R&S was awarded a contract from Bechtel for engineering and procurement of the pet coke handling system at Motiva Enterprises LLC’s refi nery in Port Arthur, Texas. The delivery of equipment for the system will be completed in 2009 and R&S has subsequently submitted a proposal for installation of the system. The Motiva pet coke handling system is designed to receive coke from two 750 TPH pet coke crushers at discharge hoppers #1 and 2 with belt feeders at the transfer towers. The pet coke is conveyed from the transfer towers to the train loadout area at 1,500 TPH. The pet coke is transferred to the two train loadout silos by two silo feed conveyors. The 1,600-ton capacity silos discharge to the railcars through diamond back hoppers with isolating chutes and rolling blade control gates. All areas of the pet coke handling system are provided with wet dust suppression. Ancillary systems at the train loadout area include washdown and service air.
About Petroleum Coke: Our experience in designing and The use of coker drum technology in an oil refi nery improves the yield of the higher building these systems, assures that we value gasoline and diesel products; as a result most new refi ners include a coker in their design and many existing refi neries are converting to add cokers. The residue will fi nd the optimum solution to suit from the coker, petroleum coke, is a solid carbon similar in many ways to coal and your needs. It will be a solution that is is typical used as a fuel to generate power or steam, often being blended with coal. economical, reliable, safety conscious Pet coke handling includes crushing, storage, reclaim, blending, loading/unloading, and environmentally sound. and transportation, both at the refi nery and at the end use location.
PETROLEUM COKE HANDLING EXPERIENCE
Section 03 1 CHEVRON
EL SEGUNDO REFINERY, EL SEGUNDO, CALIFORNIA
Feasibility Study, Engineering, Procurement and construction of improvements to the coke handling system. R&S prepared a feasibility study that included investigating the coke conveyors, the coke crushing, truck loading and washing, pumping the pit sumps, and removing the coke solids from the recycle cutting water. At the conclusion of the study R&S was awarded the engineering, procurement and ultimately the construction. A big concern was designing a layout that could be built during normal coker and refi nery operations. R&S was able to construct 90% of the project pre turn-around as planned and completed the last 10% during the turn. Start-up was completed prior to the scheduled completion. The major equipment and construction involved with this project included: • Replace the 30' long turbine sump pumps with submersible sump and modify the coke sump pits to better settle • Fabricate and install a second mobile crushing unit as a back-up to the existing mobile crusher • Upgrade the existing mobile crusher to match the safety and automation levels of the new crusher • Construct two new conveyors and a fully enclosed transfer station including new directionally adjustable chute work, a cyclone dust removal system, and a transfer building. • Fabricate and install a new 500 ton capacity pant leg load-out hopper. The hopper includes two automatically actuated knife gates for loading the trucks, a 104' long truck scale, a pulse jet bag house dust collection system, and future support and access for additional conveyors should a new storage facility be required. • Install a new PLC system that fully automates the hopper level and truck loading and provides feedback to the coke control room and the crane operators from which they can make real time production decisions. The truck driver remains in his cab and is only required to select his fi nal destination to activate the automated loading. The knife gate is activated in such a way as to assure loading to within 200 pounds of maximum load. • Fabricate and install a new automated truck wash system.
PETROLEUM COKE HANDLING EXPERIENCE
2 Section 03 TESORO REFINING
GOLDEN EAGLE REFINERY, MARTINEZ, CALIFORNIA
Engineering and procurement for the coke handling system. Tesoro Refi ning and Marketing Company (Tesoro) has implemented major modifi cations to their coking facility at the Golden Eagle Refi nery located at Martinez, California, an essential part of which is the Coke Handling System for loading coke product into trucks for transport to market. The system incorporates two switchback conveyors, with a transfer station at the switchback. The conveyors receive coke from a feeder/breaker and deliver the product to either of two twin bolted steel loadout silos situated above dual drive-through loading lanes. The entire facility is enclosed for dust control. In order to circumvent the ventilation problems associated with steam, dust and visibility inside a conventional enclosed conveyor gallery, the conveyors are enclosed locally with light gauge material around the carry and return belts; leaving the walkways open for maintenance and ventilation. An automated wash-down system enables cleaning of the enclosed conveyors with spray nozzles located inside the enclosure and pipe drainage to sump pumps. The two loadout lanes (one below each silo) are fully automated. RF readers and weigh scales communicate with a PLC to control the silo discharge slide gates for loading trucks within plus/minus 200 lbs. The trucks exit the enclosed loading lanes through an automatic wash station to remove latent dust prior to entering the State road system.
PETROLEUM COKE HANDLING EXPERIENCE
Section 03 3 OXBOW CARBON
PORT OF LOS ANGELES (LAXT), LOS ANGELES, CALIFORNIA
Engineering, procurement and construction for the LAXT Petroleum Coke Storage and Reclaim Facility. The Project consists of a storage facility, including a large storage shelter, an enclosed truck dump and associated material processing and material handling equipment. The project was integrated into the Existing Facilities, increasing enclosed petcoke storage and enhancing the performance and versatility of the Existing Export Facilities. The Facilities receives petcoke and coal and provides storage to optimize shipping via ocean vessels. This Project improved the availability of LAXT Facilities for receiving an expanded range of petcoke grades including uncrushed petcoke for onsite crushing to specifi cation via a new 550 TPH truck dump system. The Project increased the onsite petcoke storage capacity by 170,000 tons through a storage conveying system which includes a high angle conveyor and traveling tripper stacking conveyor in a new metal building with a footprint of 240' by 475' with an eave height of 95' above Grade. The Project improved the Facilities ability to export of optimized blends of petcoke products via a 2200-TPH reclaim system.
PETROLEUM COKE HANDLING EXPERIENCE
4 Section 03 PETRÓLEOS DE VENEZUELA S.A. (PDVSA) - MARAVEN
CARDON REFINERY PROJECT, CARDON, VENEZUELA
Roberts & Schaefer, in conjunction with EMS-TECH Inc., provided a combination stacker/reclaimer and transfer car to Foster Wheeler for export to the Cardon Refi nery project in Venezuela. This system handles petroleum coke at 350 TPH stacking and 2,000 TPH reclaiming. The stacker unit has a nominal 40 meter boom with convoluted counterweight. The stacker is fed by an elevated traveling tripper which inclines at 16 degrees to the discharge pivot of the stacker. The tripper and stacker units are rail mounted with individual drives and have an overall travel of 235 meters. The stacker has luffi ng capacity of +16 degrees to -10 degrees. The stacker unit is capable of forming two longitudinal piles. The slewing range is approximately 270 degrees. The stacking belt is a nominal 36" operating at two meters per second with a variable rate slewing speed of .06 to .18 RPM. Luffi ng speed is limited to 6 meters per minute. Stacker unit is capable of fully automatic operation. Reclaimer is a bucket wheel type rail mounted unit, designed to traverse the longitudinal piles created by the stacker. The wheel centers of the reclaimer are approximately 44 meters with an active bucket reclaim range of approximately 37 meters. Twin harrows with hoist winches are included for pile scrape down. An on-board operator’s cab gives total vision to the reclaiming operation. The bridge conveyor on the reclaimer is a 60" nominal belt rated at 2,000 TPH operating at 3.6 meters per second with a bridge traverse speed of 12 meters per minute. A transfer car is provided to convey the reclaimer from the fi rst longitudinal pile to the second longitudinal pile. The transfer car is a structural frame “low hog,” wheel mounted, traversing device complete with on-board electrical room and operator’s cab. Anchors and tie-downs are provided in the transfer car, which is capable of speeds from 5 to 15 meters per minute.
PETROLEUM COKE HANDLING EXPERIENCE
Section 03 5 PETROLA AMERIVEN
COKE AND SULFUR HANDLING SYSTEMS, JOSE, VENEZUELA
Engineering, procurement,and commissioning Services for the design, supply and start-up of a coke and a sulfur processing facility at the Hamaca Refi nery in Jose, Venezuela. The petroleum coke handling system consists of a feeder breaker, a 36" coke loadout conveyor and four coke storage bins. Petroleum coke is received by end loader and fed onto the coke loadout conveyor. 36" coke loadout conveyor has a capacity of 350 TPH of petroleum coke weighing 56 pounds per cubic foot. The coke is fed to the top of the coke storage bins and sent through a 4-way diverter chute which allows the coke to be fed into one silo at a time. Each coke storage bin can hold a total of 175 tons of petroleum coke. A coke truck loading spout is installed at the bottom of each bin for loading the coke into trucks. The sulfur handling system consists of one high angle conveyor and two sulfur storage silos. The high angle conveyor receives sulfur pastilles from one (1) to fi ve (5) sulfur pastille conveyors provided by others and transfers the product to the top of two sulfur pastilles storage bins. A diverter gate on top of the silos distributes the pastilles into either bin No. 1 or bin No. 2. Sulfur pastilles high angle conveyor has a capacity of 30 TPH and runs at a speed of 200 FPM. The incline of the high angle conveyor is 60 degrees. Two truck loading spouts are installed on the bottom of each bin for loading out trucks. Ancillary systems include insertable dust collectors, one on top of each coke bin. The insertable dust collectors are used to vent the bins during the loading operations as well as collect fugitive dust and return the dust back to the bins.
PETROLEUM COKE HANDLING EXPERIENCE
6 Section 03 MORE EXPERIENCE
SHELL DEER PARK, DEER PARK, TEXAS Roberts & Schaefer Company was awarded a design and supply contract from Foster Wheeler USA Corporation for a pet coke handling system for Shell Deer Park Refi ning Company, DPRLP Maya II Expansion Project near Deer Park, Texas. The project consisted of a new pet coke hopper which feeds a 660TPH feeder breaker. Once reduced, the material is fed onto a 42", 362' long conveyor that transports the pet coke to an existing conveyor system. MIDDLE EAST OIL REFINERY (MIDOR), ALEXANDRIA, EGYPT Roberts & Schaefer Company was awarded a turnkey design, supply, install and commission contract from the Middle East Oil Refi nery (MIDOR) for a pet coke stockpiling and truck loading facility at the MIDOR refi nery located near Alexandria, Egypt. The project consisted of a traveling overhead bridge crane which picks the pet coke up from a pad and loads it into a hopper. Under the hopper a 300MTPH feeder breaker reduces the pet coke and transfers it to a conveyor which stockpiles the material to an open pile. The material is reclaimed from the stockpile by four variable rate vibratory feeders. The vibratory feeders feed a 300MTPH reclaim conveyor that transports the pet coke to a 100T surge bin. The surge bin is equipped with a loading spout and cutoff gate to fi ll open trucks. A truck scale is provided under the bin to monitor the amount of pet coke loaded in each truck. The entire operation is controlled by a programmable logic controller (PLC).
Top & Above: Middle East Oil Refi nery (MIDOR), Alexandria, Egypt
PETROLEUM COKE HANDLING EXPERIENCE
Section 03 7 MORE EXPERIENCE
PROTEXA CONSTRUCTION COMPANY, PEMEX REFINERY PETROLEUM COKE HANDLING PROJECT
Contract to handle petroleum coke was received from Protexa Construction Company for Pemex Refi nery. The scope includes engineering, material procurement, shipment and fi eld services. The project consists of two feeder breakers, two feeder breaker transfer stations with 500 TPH hoppers, 42" high temperature belt conveyor, transfer tower, hoist and miscellaneous hardware for conveying system.
PETROLEUM COKE HANDLING EXPERIENCE
8 Section 03 RELIANT ENERGY
SEWARD STATION, NEW FLORENCE, PENNSYLVANIA
Fuel: Bituminous Gob Engineering, procurement and construction management for the fuel handling and limestone storage systems; the contract was awarded by Duke/Fluor Daniel. Bituminous Gob fuel for the new CFB (Circulating Fluidized Bed) boiler is brought in by trucks to six truck dumps, conveyed to a screening station and then conveyed to a 44,000T capacity storage barn. The fuel is reclaimed by a portal reclaimer and conveyed to a crushing station where the fuel is reduced in size from 2"x 0" to 3/8"x 0". The fuel is then conveyed to the boiler where it is stored in eight coal silos. Other systems include truck scales, dust collection, emergency fuel reclaimers, sampling systems and a rock handling system.
PETROLEUMALTERNATIVE COKE FUEL HANDLING HANDLING EXPERIENCE EXPERIENCE
Section 03 9 U.S. GENERATING COMPANY
SCRUBGRASS FACILITY, KENNERDELL, PENNSYLVANIA
Fuel: Bituminous Gob Engineering and procurement of a fuel processing and material handling facility. The Bituminous Gob fuel is delivered by truck to a coarse reclaim hopper and a fi ne reclaim hopper. The coarse gob is reclaimed on a 48" variable speed belt feeder. The fi ne gob is reclaimed by a special designed variable speed rotary plow feeder, integral with the fi nes hopper. Both the coarse and the fi ne material are collected We can provide you with complete on a 36" reclaim tripper belt. This belt terminates in a 6,000 ton capacity stockpiling, reclaiming, blending, storage barn. The belt is fi tted with a traveling tripper which traverses the unloading and loading facilities. operating length of the building. Whether it’s 50 TPH or 10,000 TPH Material is reclaimed from the storage pile by a traveling scraper-reclaimer rated of gob, wood chips, or biomass, we at 250 TPH. This reclaimer traverses the pile length and reclaims material to the can design the system to handle it. 30" reclaim conveyor. Additionally, provisions are included for emergency reclaim by an above ground dump hopper. The reclaim conveyor is fi tted with a belt scale and a magnetic separator for tramp iron removal. The reclaimed gob is discharged to a vibrating scalping screen with a nominal 4" deck. The +4" material (considered refuse) is discharged along with the tramp iron to separate tote bins. The through product from the scalping screen is collected in a 20-ton, surge bin from which it is fed by twin vibratory feeders to two crushers. Each crusher unit is rated at 120 TPH and makes a nominal 1/4" x 0 product. The processed fuel is then collected on the fuel bunker feed conveyor/tripper conveyor, which terminates on the boiler bunker system. A traveling tripper is provided for bunker fi lling. A control system is provided, which interfaces with the owner-supplied distributed control system. The project was completed in approximately 12 months.
ALTERNATIVE FUEL HANDLING EXPERIENCE
10 Section 03 CONTINENTAL ENERGY ASSOCIATES
HAZLETON GASIFICATION PROJECT, HAZLETON, PENNSYLVANIA
Fuel: Anthracite Culm Engineering, procurement and construction of a 600 TPH anthracite culm handling and processing complex. As part of an overall electric generating facility, anthracite culm is used as a fuel source for atmospheric gasifi cation. This project offered many design R&S was commissioned to build a facility to reclaim anthracite culm from challenges, since it was the fi rst the existing indigenous banks to benefi ciate the material to specifi c thermal plant built for reprocessing anthracite quality and size characteristics. culm. The entire project was completed Scope of supply started with a hillside truck dump fi tted with protective in 14 months. grizzly and reclaim vibratory feeder. The raw anthracite culm was delivered to a process plant where it was prescreened to eliminate oversize ahead of the cleaning process. A Baum jig was used for benefi ciation. A water clarifi cation circuit consisted of clarifying cyclone thickener and settling pond were included. The processes anthracite culm was rescreened, crushed and sorted into product sizes usable in the gasifi cation process. The quality characteristic of the culm being extremely abrasive required unusual wear resistant materials.
PETROLEUMALTERNATIVE COKE FUEL HANDLING HANDLING EXPERIENCE EXPERIENCE
Section 03 11 ATLANTIC ENERGY
B.L. ENGLAND GENERATING STATION, NEW JERSEY
Fuel: Tire Derived Fuel (TDF) Engineering, procurement and construction services of a Tire Derived Fuel (TDF) system. The TDF system will be an auxiliary fuel handling system for one coal fueled utility steam generator. Ultimately, the TDF system was to be used to supply two utility coal fi red steam generators. The initial TDF System will be designed to supply TDF to both steam generators, separately. The TDF will be processed and size reduced at an off-site receiving and processing facility owned and operated by others. The 1" x 0 TDF will be delivered to the utility power plant site by 20-ton self-dumping trucks, where it will be stored in a 7 to 10-day storage pile. The TDF will be reclaimed to supply the steam generating until via the existing coal handling system (which was upgraded by R&S in 1988). Delivery trucks will dump the tire chips directly into the reclaimer. Project scope of work consists of furnishing the complete TDF system with all accessories including motors, starters, MCCs, and controls integrated into the existing PLC based coal handling control system.
ALTERNATIVE FUEL HANDLING EXPERIENCE
12 Section 03 WESTVACO
COGEN SOUTH PLANT, CHARLESTON, SOUTH CAROLINA
Fuel: Wood Waste Engineering and procurement of the wood waste and coal handling system. The wood waste conveying system is designed to receive wood waste at the existing bark screen building. The received wood waste is transferred to the wood hog building at a capacity of 200 TPH. At the wood hog building the wood waste is reduced in size by one of two 100 TPH wood hogs before being conveyed to the hogged wood storage pile. The wood is reclaimed from the storage pile by three variable rate drag reclaimers at 100 TPH each through a series of conveyors and transfer towers to the power plant wood waste metering bin. The live-bottom metering bin is discharged through six sets of discharge screw conveyors, three conveyors in each set. The coal handling system is designed to receive coal in conventional bottom-dump railcars. The coal is reclaimed from the two silos by two belt feeders to either of the dual reclaim conveyors for a reclaim capacity of 100 TPH each.
PETROLEUMALTERNATIVE COKE FUEL HANDLING HANDLING EXPERIENCE EXPERIENCE
Section 03 13 MORE EXPERIENCE
HANNA NICKEL MINING COMPANY, RIDDLE, OREGON
Fuel: Wood Waste Engineered procurement and construction of a waste wood incineration system to provide process heat. The facility consists of the design of the receiving hopper for the fuel, the handling of the fuel to the incinerator and all related pollution control devices. Complete responsibility for all civil, structural, mechanical, electrical and instrumentation engineering. LIBERTY POWER COMPANY, TALLAHASSEE, FLORIDA
Fuel: Wood Chips Preliminary engineering, design and cost estimating for a 45 MW wood chip burning plant material handling system. LIHUE PLANTATION COMPANY, LTD., LIHUE KAUAI, HAWAII
Fuel: Biomass Lihue Plantation Company, Ltd. of Lihue, Kauai Hawaii awarded Roberts & Schaefer Company a contract to provide engineering, equipment and materials, and construction management for a new cut sugar cane conveyor system. A fl ume system originally sluiced the cut sugar cane from the raw cane cleaning and cutting station to the sugar mill for processing. The project included a unique 1,600' long, 60" wide belt having two horizontal curves. All conveyor components incorporated into the horizontal curves are standard manufactured items. With this concept, we were able to use the existing fl ume superstructure resulting in considerable cost and time savings. Lihue Plantation Company, Ltd., Lihue Kauai, Hawaii While not used for fuel in this case, the project demonstrates our ability to handle general Biomass.
ALTERNATIVE FUEL HANDLING EXPERIENCE
14 Section 03 CONSTELLATION ENERGY
BRANDON SHORES POWER STATION, BALTIMORE, MARYLAND
Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; the contracts was awarded by URS Washington Group. The limestone handling system is designed to receive limestone from 2,000 or 4,000-ton capacity barges with a rotary clamshell bucket crane. The material is unloaded and conveyed at 1,500 TPH through a series of transfer towers to either a storage dome or a stacking tube (inactive storage pile). The capacity of the storage dome is 8,000-ton and the pile is formed with a stacking tube. Additionally, 400 TPH can be diverted directly to the limestone preparation building. Limestone is reclaimed from the storage dome with mobile equipment and a reclaim chain conveyor. Limestone is also reclaimed from the inactive storage pile with mobile equipment and an emergency reclaim chain conveyor. The reclaimed limestone is conveyed at 400 TPH through a series of transfer towers to the two storage silos at the limestone preparation building. The building also is equipped with an emergency hopper/feeder and 200 TPH bucket elevator to supply limestone. The limestone handling systems are provided with insertable dust collectors or fog type dust suppression. R&S performed installation of the coal The gypsum handling system is designed to receive gypsum from the process handling systems at the Brandon fi lters and convey it at 400 TPH to the gypsum storage dome with a radial stacker. The dome capacity is 10,000 tons. Shores Power Plant during its original construction in 1981. Gypsum is reclaimed from the storage dome with a radial scraper reclaimer and conveyed at 1,200 TPH to a series of transfer towers and onto a barge loadout shuttle conveyor equipped with a telescoping discharge chute. A 750 TPH emergency reclaim chain conveyor is also located in the storage dome. The limestone and gypsum handling systems share several transfer towers.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 1 AMERICAN ELECTRIC POWER
MITCHELL PLANT, CRESAP, WEST VIRGINIA
Engineering, procurement, construction, startup and commissioning of the limestone and gypsum handling systems; the contract was awarded by E & C Group, Inc. The limestone handling system is designed to receive limestone from 1,000 to 2,000-ton barges with a rotary clamshell bucket crane. The receiving hopper is provided with fog type dust suppression. The limestone is unloaded and conveyed at 750 TPH to a transfer house. From there the limestone is conveyed and discharged through a stacking tube to a 40,000-ton limestone storage pile. Limestone is reclaimed from the storage pile by gravity or with mobile equipment to two hoppers with variable rate vibratory feeders and conveyed at 750 TPH to a transfer house. From there the limestone is conveyed to two storage silos at the limestone preparation building. Limestone can also be reclaimed from the storage pile with an emergency feeder breaker. The gypsum handling system is designed to receive gypsum from the process fi lters at 200 TPH and convey it to either an emergency storage pile or through a series of transfer houses. At the last transfer house the gypsum is either conveyed to the gypsum storage building or to the barge loading dock. R&S has unmatched experience in the At the storage building the gypsum is discharged through a traveling tripper. loading and unloading of river barges The tripper stockpiles 14,200 tons in the building. Gypsum can also be conveyed at 1,000 TPH to the storage building from the receiving hopper with a rotary and designing the marine infrastructure plow feeder located at the dock. The receiving hopper is provided with fog type to support it. dust suppression. Gypsum is reclaimed from the storage building with a traveling portal scraper reclaimer and conveyed at 1,000 TPH to either barge loadout or the wallboard storage building. An emergency gypsum reclaim hopper fed by mobile equipment is located at the end of the storage building. Barge loadout is through a transfer house and onto a barge loadout shuttle conveyor equipped with a telescopic chute. The gypsum is conveyed to the wallboard storage building is through a series of transfer houses.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
2 Section 04 PROGRESS ENERGY
CRYSTAL RIVER STATION (UNITS 4 & 5), CRYSTAL RIVER, FLORIDA
Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; R&S was awarded the turnkey contract from Environmental Partners Crystal River. The limestone handling system is designed to receive limestone from back-dump trucks at two receiving hoppers with drag chain reclaim conveyors. There is space allowed for a future third receiving hopper. The limestone is conveyed at 1,700 TPH to the limestone storage shed by the stockout conveyor with a traveling tripper. The traveling tripper forms a 47,000-ton limestone storage pile. Limestone is reclaimed from the storage pile with a traveling portal reclaimer and conveyed at 500 TPH to a transfer tower. The storage shed also has an emergency chain reclaimer fed by mobile equipment. The limestone is conveyed to the crusher building across a certifi able belt scale. At the crusher building with surge bin, the limestone is crushed by one of two roll crushers before being transferred to the three silos at the limestone preparation building. The center silo is fed by chute work and a reversing conveyor feeds the end silos. All areas of the limestone handling system are provided with bag house dust collection or wet dust suppression. The gypsum handling system is designed to receive gypsum from the process fi lters and convey it at 210 TPH on a series of conveyors to the last gypsum transfer tower. The gypsum is conveyed to this gypsum transfer tower across a certifi able belt scale. At the gypsum transfer tower the gypsum is transferred to either truck feed conveyors to load at one of two truck areas or to the stockout radial stacker to form an 11,000-ton storage pile.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 3 LUMINANT POWER
OAK GROVE POWER STATION, FRANKLIN, TEXAS
Engineering, procurement and construction management the coal, limestone and gypsum handling systems; the contract was awarded by Fluor. The limestone handling system is designed to receive limestone at the limestone storage building. Limestone is delivered to the building by truck and reclaimed from the storage pile with a chain reclaimer fed by mobile equipment. The limestone is conveyed at 350 TPH to two storage silos at the limestone preparation building. The gypsum handling system is designed to receive gypsum from the process fi lters and convey it at 150 TPH to the 400-ton load-out silo. Gypsum is reclaimed by a rotary plow feeder and loaded into either railcars or trucks with a telescopic chute. The coal handling system is designed to receive coal from trains at the rapid discharge rail unloading facility. The received coal is transferred to a 7,000-ton capacity storage silo. The silo loading chute work has a diverter gate to divert coal to a 10,000-ton additional storage pile adjacent to the silo. The unloading and stockout rate is 4,800 TPH. The coal is reclaimed from the storage silo by four variable speed belt feeders. The coal is reclaimed from the storage pile by two variable speed belt feeders. The dual conveyor total reclaim rate from either system is 3,000 TPH. At the crusher building the coal is crushed by two 1,500 TPH crushers before being transferred on dual conveyors to the plant transfer tower. The plant surge hopper has four variable speed belt feeders discharging to the four plant distribution conveyors. Units 1 & 2 both have two rows of silos. The fi ve silos per row are each feed by a reversing shuttle conveyor. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression and the distribution conveyor has wash down. Ancillary systems for the coal, limestone, and gypsum include service water.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
4 Section 04 DOMINION VIRGINIA POWER
CHESTERFIELD POWER STATION, CHESTER, VIRGINIA
Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems. The limestone handling system is designed to receive limestone from 4,000-ton capacity barges with a rotary clamshell bucket crane. The material is unloaded and conveyed at 750 TPH to a transfer house and onto an 8,000-ton limestone storage building and discharged through a telescoping discharge chute. Limestone is reclaimed from the storage pile with three variable rate vibrating feeders and conveyed at 300 TPH to a transfer house and onto three storage silos (two current and one future) at the limestone preparation building. The gypsum handling system is designed to receive gypsum from the process fi lters and convey it on a reversing conveyor at 300 TPH to either the gypsum storage building with a traveling discharge tripper or to the emergency discharge bunker. The tripper stockpiles 9,000 tons in the building. Gypsum is reclaimed from the storage building with a portal scraper reclaimer and conveyed at 600 TPH to a transfer house and onto a barge loadout conveyor equipped with a pivoting discharge chute. An emergency gypsum reclaim hopper fed by mobile equipment is located at the end of the storage building.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 5 DAYTON POWER & LIGHT
STUART GENERATING STATION, ABERDEEN, OHIO
Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems. The limestone handling system is designed to receive limestone from barges and convey the limestone at 1,000 TPH through a series of transfer towers to either an elevated stockout conveyor with a traveling tripper or to divert some limestone to the storage bins at the limestone preparation building. The traveling tripper forms a 50,000-ton limestone storage pile. Limestone is reclaimed from the storage pile with four hoppers and variable speed belt feeders and conveyed at 450 TPH to a transfer tower. From there dual conveyors transfer the limestone to three storage bins at the limestone preparation building. The bins are fed by chute work or dual reversing conveyors. All areas of the limestone handling system are provided with bag house dust collection or wet dust suppression. The gypsum handling system is designed to receive gypsum from the process fi lters and convey it at 250 TPH each on dual conveyors to a transfer tower and onto two radial stackers. The radial stackers each stockpile three conical piles of 5,700 tons each. Gypsum is reclaimed from the storage piles with hoppers and variable rate screw feeders fed by mobile equipment. The gypsum is conveyed at 500 TPH to the barge loadout area and onto a barge loadout shuttle conveyor equipped with a telescopic chute. Alternately, gypsum can be directly transferred from the radial stacker through a transfer hopper and conveyors to the barge loadout shuttle conveyor.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
6 Section 04 DAYTON POWER & LIGHT
KILLEN GENERATING STATION, MANCHESTER, OHIO
Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems. The limestone handling system is designed to receive limestone from barges and convey the limestone at 1,000 TPH and discharge through a telescopic chute to a 9,000-ton limestone storage pile. Limestone is reclaimed from the storage pile by a hopper with variable speed belt feeder and conveyed at 250 TPH to a transfer tower at the limestone preparation building. The limestone is distributed to the two surge bins by chute work or a conveyor. All areas of the limestone handling system are provided with bag house dust collection or wet dust suppression. The gypsum handling system is designed to receive gypsum from the process fi lters and convey it at 140 TPH to a transfer tower and onto a radial stacker. The radial stacker stockpiles three conical piles of 3,000 tons each. Gypsum is reclaimed from the storage piles with a hopper and variable rate screw feeder fed by mobile equipment. The gypsum is conveyed at 500 TPH to the barge loadout area and onto a barge loadout shuttle conveyor equipped with a telescopic chute.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 7 AES – PUERTO RICO
TOTAL ENERGY PLANT, GUAYAMA, PUERTO RICO
Engineering, procurement, construction, start-up and commissioning of the coal, limestone and aggregate material handling systems; the contract was awarded by Duke/Fluor Daniel. The coal and limestone are received in self-unloading ships. The ash is shipped out in geared ships or ocean barges. The dock area consists of the coal/limestone receiving hopper with belt feeder and the aggregate ship loader. The single path series of conveyors with a length of 3,600 feet from the dock to the material handling areas are reversing conveyors and handle all three materials. The coal or limestone is conveyed from the 50,000-ton capacity ships at 3,000 TPH to the storage areas and the aggregate is conveyed at 1,800 TPH from the storage area to the 9,000-ton capacity ocean barges. The limestone stockout and reclaim system consists of a conveyor from the second coal stacking tube to the limestone stacking tube enclosed in a dome for dust and moisture control. The stacking tube forms a 60,000 ton capacity pile. A mobile equipment fed hopper with variable rate vibratory feeder loads the reclaim conveyor to covey the limestone at 60 TPH to the Limestone Preparation Building. The limestone system includes wet suppression, bag house dust collection, and ventilation for dust control. The coal handling stockout and reclaim system consists of two stacking tubes with a total pile capacity of 98,000 tons and a series of ten variable rate vibratory feeders located below the piles for reclaim at 720 TPH. The crusher house includes a surge bin, two variable rate vibratory feeders, and dual path 100 percent redundant cage-paktor crushers. The plant feed conveyor with a capacity of 720 TPH transfers the coal to the plant conveyor with a traveling tripper for delivery to the four silos of each unit. The coal handling system includes wet suppression, bag house dust collection, ventilation, and wash down for dust control. The bottom and fl y ash are combined from the ash silos and conveyed to the initial storage area. This manufactured aggregate (ash product) is reclaimed by mobile equipment to a hopper with a 1,800 TPH feeder breaker and sent to the ship loader via the reversing conveyor system. The shiploader is equipped with a telescopic spout and a retractable boom conveyor. The aggregate systems include wet suppression for dust control.
All unloading, stockpiling, reclaiming, crushing, and ship loading operations are controlled by a series of programmable logic controllers (PLCs).
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
8 Section 04 INDIANAPOLIS POWER & LIGHT
HARDING STREET STATION, INDIANAPOLIS, INDIANA
Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; the contract was awarded by Advatech. The limestone handling system is designed to receive limestone from trucks. The receiving hopper discharges through a lump breaker and belt feeder to a conveyor that conveys the material at 400 TPH through a transfer tower to two storage silos at the limestone preparation building. The gypsum handling system is designed to receive gypsum from the process fi lters and convey it at 140 TPH to either an emergency stockout pile or the storage barn. At the storage barn, a reversing shuttle conveyor forms a 6,000-ton storage pile. The gypsum is reclaimed and loaded into trucks with a front-end loader.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 9 DUKE ENERGY
CAYUGA GENERATING STATION, CAYUGA, INDIANA
Engineering, procurement, construction, start-up and commissioning of a limestone and gypsum material handling system for the Cayuga generating station Units 1 and 2 scrubber project. Limestone is received by rail or truck and is dumped into the Limestone Track & Truck Hopper. Two variable frequency belt feeders with capacities from 300 to 600 tons per hour feed the limestone onto Conveyor LH-1. LH-1 has a capacity of 1,000 TPH and sends the limestone to a conical storage pile through a telescopic chute used to control dust. This active limestone stockout pile has a capacity of 7,700 tons. Below the storage pile is the Limestone Reclaim Hopper with two variable frequency belt feeders, (100 to 400 TPH Ea.) that feed the limestone onto Conveyor LH-2. LH-2 feeds the limestone to the top of the Limestone Preparation Building where it transfers onto reversible Limestone Conveyor LH-3. LH-3 feeds the limestone into either the Unit 1 or Unit 2 limestone day bin. Synthetic Gypsum is produced and then dewatered by three vacuum belt feeders in the Gypsum Dewatering Building. Two gypsum stockout systems have been provided, the emergency gypsum system and the in-spec gypsum system. The emergency gypsum system (B train) involves two conveyors. Gypsum Transfer Conveyor GH-1B collects gypsum from the dewatering vacuum fi lters and transfers the product onto Gypsum fi xed stockout conveyor GH-2B in Transfer Tower 1B. Conveyor GH-2B is a fi xed stacker conveyor with a telescoping chute at the head end to help control dust. Conveyor GH-2B is capable of forming a stockpile of 2,600 Tons. The in-spec gypsum is collected by Gypsum Collecting Conveyor GH-1A (A train) in the dewatering building and transfers the product onto Gypsum Radial Stacker GH-2A in transfer Tower 1A. The GH-2A radial stacker is capable of forming a kidney shaped stockpile with a capacity of 10,400 Tons. Ancillary equipment includes a dust fogging system for controlling dust in the limestone handling system.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
10 Section 04 CINERGY SERVICES
MIAMI FORT STATION, NORTH BEND, OHIO R&S was awarded a turnkey contract from Cinergy Services for a limestone and gypsum material handling system at the Miami Fort Station. The limestone is received from a barge unloading station and conveyed to a limestone stockout pile at 700 TPH. Limestone is reclaimed with two hoppers and belt feeders to two day bins in the limestone preparation building. The gypsum is received from the dewatering building vacuum belt feeders. From there it is conveyed at 160 TPH to a stockout pile or an emergency stockpile. Gypsum is reclaimed with a reclaim hopper and belt feeder and conveyed to a barge loadout station. GIBSON GENERATING STATION, OWENSVILLE, INDIANA Cinergy Services awarded a turnkey contract for limestone and gypsum handling systems at their Gibson Generating Station in Owensville, Indiana to R&S. The limestone facility is designed to receive limestone from a rail unloading station and convey to a stockpile at a rate of 2,500 TPH. Above: Miami Fort Station, North Bend, Ohio Limestone is reclaimed with hoppers and belt feeders to three day bins in the limestone preparation building. Below: Gibson Generating Station, Owensville, Indiana The gypsum facility accepts gypsum from the dewatering building’s vacuum belt feeders to a transfer house. From there it is conveyed at 300 TPH to an emergency stockpile TPH or to another transfer house on its way to a 25,000 ton stockout pile.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 11 CINERGY SERVICES
ZIMMER PLANT, MOSCOW, OHIO
Engineering, procurement, construction, start-up, and commissioning of the gypsum handling and barge loading system. The gypsum handling and barge loading system is designed to receive the gypsum at the barge loader conveyor from either the existing radial stacker or by front-end loaders into a dozer trap. The 36-inch barge loader conveyor has a capacity of 600 TPH and is 1,014-foot long. The conveyor has a 320-foot span over the existing 200-foot diameter thickener and pump house. The conveyor transports discharges the gypsum into a moveable-loading chute with a telescoping spout. The chute/spout is designed to fi ll covered barges through open hatches, which requires that the chute/spout be able to move laterally and extend and retract. A certifi ed belt scale weighs the amount loaded into each barge. A new barge haul system positions the barges. A new river cell was constructed as part of the project to support the conveyor structure and the barge haul equipment. A programmable logic controller (PLC) controls the entire operation.
R&S engineering excellence and demonstrated abilities on the job have resulted in long term customer relationships.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
12 Section 04 WESTERN KENTUCKY ENERGY
COLEMAN STATION, HAWESVILLE, KENTUCKY
Engineering, procurement and construction of a fuel blending system, limestone handling system, and gypsum handling system The limestone facility accepts limestone from a truck receiving hopper and is conveyed to a 14,000 ton stockpile. The stored limestone is then conveyed to two one-hour day bins. The gypsum facility accepts gypsum from the existing gypsum building and conveys it to a new radial stacking conveyor, which makes a 10,000 ton gypsum stockpile. The material then gets loaded into trucks. The coal facility accepts coal from the existing crusher building and conveys it to two concrete stacking tubes, which form two 10,000 ton storage piles. The coal is then reclaimed by belt feeders and is delivered to two reclaim transfer conveyors, which deliver the coal to the existing coal reclaim conveyors. The new coal stockpiles are adjacent to the existing coal stockpile.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 13 AMERICAN ELECTRIC POWER
CARDINAL PLANT, BRILLIANT, OHIO Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; the contract was awarded by Black & Veatch The limestone handling system is designed to receive limestone from river barges at a receiving hopper with a vibratory feeder. The limestone is conveyed at 1,000 TPH to a 27,000-ton limestone storage pile and discharged through a telescopic chute. Limestone is reclaimed from the active storage pile with two vibratory feeders and conveyed at 375 TPH to two storage silos with provisions for a third silo at the limestone preparation building. An emergency reclaim hopper with vibratory feeder is also provided near the pile. The gypsum handling system is designed to receive gypsum from the process fi lters onto dual conveyors at 225 TPH each. One conveyor with telescopic chute conveys the gypsum to a 6,800-ton waste gypsum stockpile. The other conveyor transfers the gypsum to an enclosure to form a 16,000-ton commercial gypsum stockpile. Gypsum is reclaimed from the commercial pile by two hoppers with belt feeders and conveyed at 1,000 TPH to a traversing hopper with telescopic chute for barge loadout.
AMOS PLANT, WINFIELD, WEST VIRGINIA Engineering and procurement of the limestone and gypsum handling systems. The limestone handling system is designed to receive limestone from barges at the receiving hopper with a belt feeder. The limestone is conveyed at 1,500 TPH and discharged through a telescopic chute to a 22,000-ton limestone storage pile. Limestone is reclaimed from the storage pile with two hoppers, one with a variable speed belt feeder and the other with a variable speed feeder/breaker. An emergency hopper with belt feeder is also provided. The limestone is conveyed on dual conveyors at 500 TPH each to three storage silos at the limestone preparation building and fed to the silos by chute work or transfer conveyors. The limestone handling system is provided with water type or fog type dust suppression. The gypsum handling system is designed to receive gypsum from the vacuum fi lters onto two conveyors at 300 TPH each. One conveyor transfers the gypsum to a 5,000-ton gypsum standby pile for truck loading with mobile equipment. The other conveyor conveys it to a transfer tower and onto a radial stacker to form a 15,000-ton gypsum stockout pile.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
14 Section 04 GEORGIA POWER COMPANY
SCHERER PLANT, JULIETTE, GEORGIA
Engineering and procurement of the limestone handling system. The limestone handling system is designed to receive limestone from bottom dump railcars at the receiving hopper with two belt feeders. The limestone is conveyed at 4,000 TPH and discharged through a telescopic chute to a limestone storage pile with a combined active and reserve capacity of 60,000-ton. Limestone is reclaimed from the storage pile with two hoppers, each with a variable capacity rotary plow feeder. The limestone is conveyed on dual conveyors at 250 TPH each to two storage silos at the limestone preparation building and fed to the silos by chute work or a reversing transfer conveyor. Space is provided for a future diverter gate and conveyor to future silos. The unloading structure is provided with a climate controlled operators cab and air compressors. The limestone handling system is provided with dust collection at the unloading structure and ventilation systems in the unloading and reclaim vaults and tunnels.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 15 MIRANT MID ATLANTIC
CHALK POINT, DICKERSON, MORGANTOWN STATIONS, MARYLAND
Engineering, procurement, and construction assistance of limestone handling for fl ue gas desulfurization (FGD) systems. The limestone handling systems are all designed to receive limestone by either truck or railcar at the combined receiving hoppers. Each receiving hopper has dual drag chain feeders at 200 TPH capacity to feed the unloading conveyors. The limestone is conveyed at 400 TPH through the unloading transfer stations to enclosed storage structures and stockpiles with telescopic chutes. The storage structures and capacities are as follows: • Chalk Point – dome with 9,000-ton capacity. • Dickenson – structure with 4,000-ton capacity. • Morgantown – dome with 18,000-ton capacity as well as 1,750 TPH stockout for potential tie-in to an existing barge unloading system. The reclaim systems are each a reclaim hopper with drag feeder below the storage pile and an emergency reclaim hopper with belt feeder fed by mobile equipment. The limestone is conveyed to the limestone preparation buildings and discharges to the silos by chute work or a transfer conveyor. The number of silos and capacities are as follows: • Chalk Point – two silos at 200 TPH capacity. • Dickenson – two silos at 200 TPH capacity through two bucket elevators. • Morgantown – three silos at 400 TPH capacity, the transfer conveyor is reversing. Ancillary equipment includes dust collection system, structure and tunnel ventilation fans, and power distribution equipment.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
16 Section 04 SANTEE COOPER
CROSS STATION, CROSS, SOUTH CAROLINA
Engineering, procurement, fabrication and delivery to site of a limestone handling system; the contract was awarded by Worley Parsons. Limestone is received from trucks with a capacity of 20 to 40 tons at the outdoor limestone storage pile. The limestone can be reclaimed by one of two pieces of equipment. The fi rst option is to push the limestone by end loader to the feed end of the limestone reclaim feeder, a chain conveyor provided by Joy Mining Machinery Corporation with a capacity of 125 tons per hour. The limestone reclaim feeder feeds the limestone onto a crusher feed conveyor with a capacity of 125 TPH designed and supplied by R&S. This conveyor feeds the crusher building. At the head end of the crusher feed conveyor, a magnetic separator collects any tramp iron that may have found its way into the as-delivered limestone. The second option is to use an end loader to dump the limestone into the emergency limestone reclaim chain conveyor, a chain feeder that was designed and manufactured by R&S. This feeder also has a capacity of 125 TPH. The emergency limestone feeder feeds the limestone onto the emergency crusher feed conveyor. This conveyor also feeds the crusher building but bypasses the crusher and feeds the limestone directly onto one of the two overland conveyors. At the crusher building the limestone is reduced to a size of 1/8" x 0 by a Penn Crusher hammer mill and is then discharged into a two-way diverter gate and then onto one of two limestone overland conveyors as provided R&S. A dust collector is provided for the feed onto the overland conveyors to pick up any fugitive dust from the discharge of the limestone onto the overland conveyors. The limestone overland conveyors have a capacity of 125 TPH and run to the top of three limestone storage silos and discharge onto one of two limestone cross conveyors. The cross conveyors also have a capacity of 125 TPH and are used to distribute the limestone into the three silos. The limestone can be reclaimed from the silos by the use of a rotary silo discharger that was provided by Decker Industries. The silo dischargers feed the limestone onto a weigh belt feeder which then feeds the limestone into one of three ball mills for further processing.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 17 SANTEE COOPER
WINYAH STATION, GEORGETOWN, SOUTH CAROLINA
Engineering, Procurement, Fabrication and delivery to site of a limestone handling system; the contract was awarded by Worley Parsons. Uncrushed and Crushed Limestone is received from trucks with a capacity of 20 to 40 tons at one of two outdoor limestone storage piles. The Uncrushed Limestone is reclaimed by Front End Loader and conveyed to the top of the Crusher House. At the head end of the crusher feed conveyor, a magnetic separator collects any tramp iron that may have found its way into the uncrushed limestone. The crushed limestone is reclaimed by end loader and is deposited into the Reclaim Platform Conveyor, a chain feeder that was designed and manufactured by Joy Mining & Machinery Co. This feeder has a capacity of 125 TPH. The Reclaim Platform Conveyor feeds the limestone through a diverter gate and onto one of the two silo feed conveyors. An emergency portable reclaim hopper and 36" wide 125 TPH belt feeder is also provided in the event that the owner’s crusher feed conveyor system is inoperable. At the crusher building the limestone is reduced to a size of 3/4" x 0 by a Penn Crusher hammer mill and is then discharged into a two-way diverter gate and then onto one of two limestone silo feed conveyors as provided by R&S. A dust collector is provided for the feed onto the silo feed conveyors to pick up any fugitive dust from the discharge of the limestone onto the conveyors. The limestone silo feed conveyors have a capacity of 125 TPH and run to the top of three limestone storage silos and discharge onto one of two limestone cross conveyors. The cross conveyors also have a capacity of 125 TPH and are used to distribute the limestone into the three silos. The limestone can be reclaimed from the silos by the use of a rotary silo discharger that was provided by others. The silo dischargers feed the limestone onto a weigh belt feeder which then feeds the limestone into one of three ball mills provided by others for further processing.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
18 Section 04 FIRST ENERGY
BAY SHORE STATION REPOWERING PROJECT, OREGON, OHIO
Engineering, procurement, construction, start-up and commissioning. Roberts & Schaefer Company was awarded a turnkey contract from Foster Wheeler USA to design, furnish, install and commission a limestone grinding and preparation system at the Bay Shore Unit 1 power station near Oregon, Ohio. The project consisted of a limestone truck hopper which feeds a 200 TPH receiving conveyor. The receiving conveyor feeds a bucket elevator that fi lls a storage silo. The limestone is reclaimed from the silo by a 50 TPH weigh belt feeder which, in turn, feeds a pocket conveyor. The pocket conveyor sends the limestone to the dryer rod mill. The rod mill reduces the limestone size and heats the limestone with an air heater combustion chamber. Once through the rod mill, the product is sent to a pocket conveyor and then to the sizing screens. The oversize material is sent back through the rod mill, and the undersize material is sent to a surge hopper. The product is then transported to the limestone day bins via a conveyor. Dust collection systems are provided throughout the system.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 19 TENNESSEE VALLEY AUTHORITY
PARADISE FOSSIL PLANT, PARADISE, KENTUCKY
Engineering, procurement, construction, start-up and commissioning of the Limestone Receiving, Handling, and Storage System; the contract was awarded by Advatech. Limestone is received by trucks and dumped into a single receiving hopper to a 48" receiving conveyor operating at 900 TPH. It is then transferred to a 36" unloading conveyor and transported at 900 TPH to a 4000 ton concrete storage silo. The limestone is reclaimed from the silo via (2)-36" variable speed belt feeders operating at 30 to 300 TPH each. Each belt feeder transfers to a 30" limestone transfer conveyor operating at 300 TPH up to (2)-400 ton steel surge bins in TVA’s limestone preparation plant. Each surge bin feeds a TVA supplied weigh belt feeder. Limestone can also be fed to the transfer conveyors with a front end loader via an emergency hopper and conveyor. Bin vent fi lters were provided for the silo and also for each surge bin.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
20 Section 04 AES – BARBERS POINT
COGENERATION PLANT, BARBERS POINT, HAWAII
Engineering, procurement and construction of the limestone storage, reclaim and preparation facilities at an independent power producer at Barbers Point, Hawaii; the contract was awarded by Black and Veatch. The limestone is delivered to open yard storage by rear dump trucks and is stored in the storage yard serviced by front end loaders. Reclaim of the limestone is through the use of twin dozer trap/feeders and twin elevating conveyors. The reclaimed limestone is delivered to the limestone pulverizer belt, which houses twin 20 TPH limestone grinding mills. The limestone is dried by use of independent air heating system with the fi nal product collected as dust collector discharge product. Individual rotary vane feeders are provided to maintain system pressure and to regulate the product discharge rate. The pulverized limestone product is conveyed pneumatically overland at the rate of 40 TPH to the limestone plant storage hopper system. Dust collection is provided for the storage hoppers. The remote location of this project and the lack of local structural building materials necessitated shipment from the mainland and major pre-assembly of the components.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 21 SCRUBGRASS POWER GENERATING CO.
SCRUBGRASS POWER PLANT, VENTIGO COUNTY, PENNSYLVANIA
Engineering, procurement and construction of a limestone storage and reclaim and processing facility. The scope of our supply started with an enclosed limestone dump barn designed to handle both rear dump and bottom dump units. The received material is stored in 30-ton hoppers fi tted with a protective grizzly and manual shutoff gate. The material is reclaimed from the limestone hopper, at the rate of 80 TPH, by a vibrating feeder. The feeder discharges to a bucket elevator for delivery to the 100-ton storage bin. The surge bin is fi tted with twin discharge outlets, each with a manual cut-off gate. Each outlet has a 30 TPH vibrating mill feeder for reclaiming of the 1-3/4" x 0 limestone to the Bradley air swept mills. The Bradleys, rated at 30 TPH each, are fi tted with air locks and rotary vane feeders. The secondary bag houses are also independent, and a bag house is provided for each cyclone. The product from the two cyclones and the two bag houses is collected in a common pneumatic line. Twin (one operating and one spare) blowers are provided. The pneumatic line is run along the existing conveyor route to the boiler block where it is delivered to the limestone storage silo. A fugitive dust collection system is provided at the dump bin crushing station and storage silo. The scope of supply also included complete electrical installation and tie-in to the owner’s supplied DCS system.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
22 Section 04 SOUTHERN INDIANA GAS & ELECTRIC
CULLEY STATION, NEWBURG, INDIANA
Engineering, procurement and The limestone transfer conveyor construction of a limestone unloading, discharges into an enclosed limestone storage and reclaiming system. storage shed, which consists of a concrete lowering tube as the center The limestone is delivered on river of a circular (segmented) structure. barges and unloaded by a clam-shell type barge unloader. The unloaded The storage structure houses A fi fth transfer conveyor delivers the material is delivered to a receiving approximately 750 tons of limestone. product to a new limestone silo. Each hopper located on a fl oating barge. An open section in the wall is provided transfer station is equipped with an The barge is fi tted with drainage pump to allow the owner’s front end loaders independent dust collecting system. and is anchored to two 20' diameter to build additional storage or work on Additionally, our scope of supply concrete capped river cells. the enclosed storage pile. An above included gypsum handling, storage grade reclaim hopper with a ramp Material is reclaimed from the receiving and reclaim. suitable for an unloader is provided hopper via an apron feeder. A riverside for limestone reclaiming. This hopper is dust collection system is included on the fi tted with an especially designed feeder fl oating dock. break unit which regulates the feed Material reclaimed from the receiving while minimizing oversize material. hopper is conveyed by a belt conveyor The reclaimed and crushed material to a combination loadout and storage is conveyed by a belt conveyor to a new facility. Since this facility is also capable transfer station where tramp iron is of unloading coal at the same time, a fi re removed with a magnetic separator. At protection system is provided on a belt on the transfer point the material is deliv- the fl oating dock at the loading/transfer ered to another transfer conveyor which station. A bifurcated chute and fl op gate delivers the material to an existing belt are provided at the discharge of the line feeding the existing power block. unloading conveyor to transport the coal The limestone is then conveyed on or limestone to a loadout bin or to the an additional length of the conveying limestone transfer conveyor. Sampling system to an elevated transfer tower is also included. adjacent to the new FGD installation.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 23 MORE EXPERIENCE
RELIANT ENERGY, SEWARD STATION, NEW FLORENCE, PENNSYLVANIA Engineering, procurement and construction management for the fuel handling and limestone storage systems; the contract was awarded by Duke/Fluor Daniel. Fuel for the new CFB (Circulating Fluidized Bed) boiler is brought in by trucks to six truck dumps, conveyed to a screening station and then conveyed to a 44,000T capacity storage barn. The fuel is reclaimed by a portal reclaimer and conveyed to a crushing station where the fuel is reduced in size from 2"x 0" to 3/8"x 0". The fuel is then conveyed to the boiler where it is stored in eight coal silos. Other systems include truck scales, dust collection, emergency fuel reclaimers, sampling systems and a rock handling system. The limestone is brought in by truck to dump hoppers and reclaimed by vibratory feeders. The limestone is conveyed to a covered 14,000T storage pile. Vibratory feeders reclaim the limestone from the covered storage and then conveyed to the limestone preparation building surge bin. JEA, NORTHSIDE GENERATING STATION, JACKSONVILLE, FLORIDA Engineering, procurement, construction, and commissioning of the limestone handling system; the contract was awarded by Foster Wheeler USA. The limestone handling system is designed to receive the limestone at the limestone preparation building. The building houses three identical grinding and drying systems. Each grinding and drying system is fed by a 50 TPH conveyor that feeds the limestone to an impactor. The impactor feeds the limestone dryer/ mill. The product from the dryer/mill is transported via a pocket conveyor to a limestone screen feeder that moves the product to sizing screens. Oversized products from the sizing screens are directed back through the dryer/ mill for reprocessing. The proper sized product is sent to a surge bin. A pneumatic transport moves the product from the surge bin to the limestone silos at the boiler house. Ancillary systems for the limestone preparation building include bag house dust collection and ventilation
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
24 Section 04 MORE EXPERIENCE
AMERICAN ELECTRIC POWER, ZIMMER COAL PLANT, MOSCOW, OHIO Engineering, procurement of the FGD handling for the Zimmer Power Plant scrubber installation. This project involved the design and supply of a totally enclosed conveying system for the FGD sludge from the Zimmer scrubber installation. The FGD handling consisted of several conveyor fl ights including overland conveying and stacking. Extreme site limitations required pre-fabrication of tubular enclosed sections off-site. Roberts & Schaefer established a staging area down river. Construction crews were located at this staging area to pre-assembly conveyor components, conduit light fi xtures, and perform structural welding of tubular sections. The pre-assembled parts were then loaded on river barges and shipped to the Moscow site intact, and in accordance with the required construction sequence. Total engineering and procurement was spread out over approximately a two-year time frame to accommodate various phases of construction as required by American Electric Power. A.B.B. TAIWAN FGD sludge handling and unloading system; engineering, procurement and construction management. NORTHERN INDIANA PUBLIC SERVICE COMPANY/PURE AIR, BAILEY GENERATING STATION Gypsum handling system; engineering and procurement. CITY OF OWENSBORO, KENTUCKY Gypsum handling conveyors.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04 25 LUMINANT MINING COMPANY
KOSSE MINE, KOSSE, TEXAS
Engineering, procurement, construction of a 4,000 TPH lignite handling and rail loading system. The lignite handling and loading system is designed to receive raw coal from 175-ton bottom dump or 250-ton back dump trucks. The receiving hopper has a capacity of 500-tons and discharges through two feeder/ breakers to a conveyor that conveys the material at 4,000 TPH to the transfer tower at the coal storage building. At the storage building a traveling tripper discharges the coal to a 100,000-ton raw coal storage pile. The transfer tower is designed for a future screening plant feed conveyor and a clean coal-collecting conveyor. Coal is reclaimed from the storage building with two rotary plow feeders, each with a capacity of 3,730 TPH. The loadout conveyor at 4,000 TPH transfers the coal from the storage building The storage building is designed for a to the batch weigh dual hopper loadout system where the railcars are loaded. future clean coal conveyor with traveling Ancillary systems include wet dust suppression, wash down, service air, and tripper and segregated piles. closed circuit TV.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 1 XSTRATA COAL COMPANY
OAKEY CREEK MINE, BOWEN BASIN, AUSTRALIA
Engineering, procurement and construction for upgrades to increase the capacity of the fi nes circuit of the Main Plant to achieve a whole plant average of 1,350 TPH. The fi nes circuit capacity of the current 4th module coal preparation plant was increased to an equivalent whole plant feed rate of 650 tph without compromising the current effi ciency. The upgrade included the installation of a product thrower on the end of the existing 17M product conveyor. The upgrade of Main Plant was to achieve an average equivalent whole plant target throughput of 1350 TPH through the fi nes plant: • All major fi nes circuit pump capacities including clarifi ed water; • Jameson Cell capacity Clean coal and desliming cyclone capacities; • Spiral product dewatering capacity; • All major fi nes circuit pipeline sizes. • Modifi cation of the spirals tailings dewatering system The upgrade of the 4th Module was to achieve an average equivalent whole plant target throughput of 650 TPH through the fi nes plant. This was achieved through the following key changes: The main plant consists of 3 separate • Upgrade of 4AM Conveyor coarse coal processing circuits, separate • Additional 2 desliming cyclones and 3 spiral product cyclones; and common fi ne coal and reject processing circuits and common water • Installation of a new bank of 8 triple start spirals; treatment and reticulation circuits. • Installation of 2 fi ne coal centrifuges; • Installation of larger spiral rejects screen; • Pipework, collection and distribution boxes associated with the above circuits, • Pumps, pipework and other equipment outside the above circuits necessary to achieve the Performance Tests. • Electrical installation and controls upgrade
COAL PREPARATION AND HANDLING EXPERIENCE
2 Section 05 ARCH COAL COMPANY
BLACK THUNDER MINE, WRIGHT, WYOMING
Feasibility study, engineering and procurement of a 7,000 TPH coal handling system expansion with a 4 km overland conveyor. The coal handling expansion includes a single near-pit crushing unit, with a 1,000-ton capacity dump hopper and a passive dust control system to accommodate 340-ton haul trucks. The dump hopper includes a drag chain feeder to feed a crusher unit. The crusher unit has a capacity of 7,000 TPH to crush -60-inch x 0-inch ROM coal and produces a 2-inch x 0-inch product. The coal is then conveyed from the crushing unit by an overland conveyor with a capacity of 7,000 TPH of crushed coal, a distance of approximately 2 ½ miles and over 300 feet of lift to the new train loadout silos. The overland conveyor is powered by four 1,750 HP drives. Control systems allow equal drive sharing of the load during all starting, running and stopping conditions. An intricate static and dynamic design analysis of the overland conveyor provides for all design considerations over the operating range and conditions of the conveyor. The elevated portion of the overland conveyor is enclosed in long-span tubular galleries. It is signifi cant to note that a number The train loadout consists of two 18,500-ton capacity silos each including of the concepts developed by Roberts an under-silo batch loading system. & Schaefer in the 1988 project were A three-stage sample station is included to sample the crushed coal to included in the 2006 project including: ASTM standards. the passive dust control system, overland conveyor support system, non-enclosed and at-grade drive systems. It is also signifi cant to note that the new project has long-span conveyor tubes (300 ft) with intermediate struts making it some of the longest spans in the industry.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 3 CONSOL ENERGY
ROBINSON RUN MINE, MANNINGTON, WEST VIRGINIA
Engineering, procurement and construction of a 2,500 TPH of a 3 section, 6.7 km overland conveyor for coal. Each conveyor in the series has a belt width of 60 inches, belt speed of 750 feet per minute, and a capacity of 2,500 TPH of minus 10-inch coal. The fi rst belt is 7,077 feet long with the drive at the center with a tripper back onto the belt. The second belt is 3,396 feet long with the drive at the head end. The third belt is 11,427 feet long with the drive at the head end. The three belts have a total length of approximately 22,000 feet and convey the coal downhill. The conveyors are each equipped with a disc brake at the drive and tail pulley, belt turnovers on the return belt and the third belt has a take-up on both ends.
COAL PREPARATION AND HANDLING EXPERIENCE
4 Section 05 WESTERN CANADIAN COAL COMPANY
WOLVERINE MINE, TUMBLER RIDGE, CANADA
Engineering, procurement and construction of a 320-460 MTPH R&S Coal Flo® Thermal Dryer System. The system is capable of handling 460 MTPH of J-Seam coal at 10.84% moisture and 320 MTPH of Upper Seam at 12.08% moisture. The process results in coal at 6% total moisture. While evaporating approximately 26 MTPH of water, the system meets MWLAP requirements of 7.08 TSP per second and SO2 emissions of 5.6 GPS (based on the alkalinity of the water and sulfur content of the coal). The coal to be dried is fed by conveyor into the feed control bin and discharged to the dryer bed with an automatically controlled gate. On the dryer bed the coal is fl uidized by the upward stream of hot gases and dried almost immediately then settles into the discharge hoppers. As the drying gases are pulled through the coal bed, heat and velocity are quickly dissipated. Gases leaving the drying chamber pass through cyclone dust collectors and a venture scrubber and mist eliminator for removal of coal particles and water droplets. A fail-safe PLC control system with automatic and manual emergency sprays A fail-safe PLC control system with provides a maximum degree of safety. automatic and manual emergency sprays provides a maximum degree of safety.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 5 TRITON COAL COMPANY
NORTH ROCHELLE MINE, GILLETTE, WYOMING
Engineering, procurement and construction of a 6,000 TPH coal handling, storage, and train loadout system with overland conveyor. The coal handling system is designed to receive raw coal from 240-ton dump trucks with material size of 8" x 0". The receiving hoppers have a capacity of 535 tons. The hoppers feed two feeder breakers rated at 2,000 TPH each that feed the transfer conveyor to the crusher station. A 4000 TPH roll crusher reduces the coal to 2" x 0". The coal is then fed to a 7,000-foot long overland conveyor rated at 4,000 TPH. The overland conveyor conveys the coal to a traveling tripper conveyor at the coal storage barn. The traveling tripper discharges the coal to the slot storage coal barn with a capacity of 50,000 tons. Coal is reclaimed from the storage barn with 26 vibratory feeders with a rated capacity of 800 TPH each, of which 10 are variable rate. The vibratory feeders feed the loadout conveyor rated at 6,000 TPH, which in turn feeds, the loadout system. The batch weigh dual hopper loadout system incorporates a 300-ton surge bin and a 140-ton weigh bin to load unit trains at a capacity of 6,000 TPH. A train-loadout sampling system is provided. A programmable logic controller (PLC) and operator interface terminal (OIT), located in the loadout structure, control the entire system from tuck dump to loadout system. Ancillary systems include wash down, ash/moisture analyzers, air compressors, All areas of the coal handling system are and sump pumps. provided with bag house dust collectors.
COAL PREPARATION AND HANDLING EXPERIENCE
6 Section 05 PT KALTIM PRIMA COAL (KPC)
KALTIM PRIMA COAL FACILITY, SANGATTA, EAST KALIMANTAN, INDONESIA
Engineering, procurement, construction, start-up and commissioning of the Coal Crushing and Handling Facility Coal is received from off-road trucks with a capacity of 100 to 220-tonnes at the truck dump hopper. The hopper is located at the western end of the stockpile and consists of a single 300-tonnes hopper, with main dump face. The truck dump area will have a secondary side dump face at a future date. The hopper discharges through a feeder breaker to the sizer station feed conveyor. The feeder breaker reduces the received coal from 500 mm to 200 mm x 0 mm at an average capacity of 2,000 MTPH (2,500 MTPH peak). At the sizer station the coal is further reduced to 50 mm x 0 mm, and then it is conveyed and discharged to the stockage pile with a traveling tripper. The storage pile has a total capacity of 200,000 tons. A reclaim tunnel under the full length of the stockpile houses the reclaim conveyor and includes fi ve equally-spaced draw-down hoppers with coal valves and stockpile activators. The coal is discharged directly onto the reclaim conveyor at an average capacity of 4,000 MTPH (4,500 MTPH peak). Downstream of each reclaim discharge valve, a belt scale respectively controls the valve coal feed rate, while indicating total metric tons. Each coal valve also has an average capacity of 4,000 MTPH (4,500 MTPH peak). Diverse coal stockpiles can be blended via the use of these coal valves. The reclaim conveyor includes a sampling system A tramp iron magnet and a metal meeting KPC & Australian standards. detector are included on the sizer The reclaim conveyor discharges into a surge bin. Additionally, coal from the station feed conveyor. existing system can be discharged to the surge bin. The 400-ton surge bin discharges through a single variable speed belt feeder with an average capacity of 4,000 MTPH (4,500 MTPH peak) to the existing overland conveyor. The surge bin is designed for a future second outlet and belt feeder. Dust suppression is provided at the truck dump hopper, at the discharge of the sizer, and at the load area of the existing overland conveyor. Additional ancillary systems include fi re detection and protection, wash down hose stations, and tunnel ventilation.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 7 BHP BILLITON
BLACKWATER MINE, BOWEN BASIN, AUSTRALIA
Feasibility Study, engineering, procurement and construction of a 1,800 TPH coal preparation, storage and reclaim facility. R&S completed a feasibility study for BMA for a new coal preparation plant at their Blackwater Mine. The results of this coal preparation plant study were combined with requirements for the coal handling and tendered on an EPC basis. R&S Company in Joint Venture with Barclay Mowlem (now Laing O’Rourke) was awarded the Engineering, Procurement, and Construction (EPC) contract by BMA for the coal handing and coal preparation for the Blackwater Mine in Australia’s Bowen Basin. R&S scope in particular included the design, procurement, and construction and commissioning of the coal handling system and the coal preparation plant. • 2,200 tph material handling system • 1,800 tph (2 x 900tph) CPP • Heavy media cyclones (50mm x 1.4ww) • Spiral circuit (1.4ww x 0.3mm) • Column Flotation Circuit (0.3 x 0) Microcells • Disc Filter – fi nes dewatering This is now one ne of the largest Coal is delivered by a variety of haul trucks (belly dumps, rear dumps or 8 triple coal handling/prep plants in the area side dumps) to either of 3 X 600-tonne ROM hoppers. Coal is fed from the ROM with a fully automated train load hoppers, via apron feeder through three stages of crushing where it is reduced out system (TLO). from a maximum of 1200mm to 50mm x 0. A series of conveyors and transfer stations can direct the coal to circular storage and reclaim for the preparation plant feed = 60,000 tons, or direct bypass to product stockpile. ROM coal is reclaimed via a circular stacker reclaimer to the CPP. The product stockpile consist of 2 stockpiles of 225,000 tons each, and the coal is stacked via 2 X travelling stackers that are capable of stacking on either stockpile. Coal is reclaimed from the product stockpile via 2 off portal reclaimer to a batch weigh rail loadout station that is capable of loading 10,000 ton trains under 2 hours.
COAL PREPARATION AND HANDLING EXPERIENCE
8 Section 05 WHITE MINING (FELIX RESOURCES)
ASHTON MINE, HUNTER VALLEY, AUSTRALIA
Engineering, procurement, construction, operation and maintenance for the relocation of 350 TPH coal preparation, storage and reclaim facility. The design and construction included the incorporation of used equipment and building and conveyor structure relocated from 3 three previously operating plant sites located throughout Australia that had been dismantled and shipped to site. • 400 TPH material handling system • 350 TPH Coal Preparation Plant • Heavy media cyclones (50mm x 1.4mm) • Spiral circuit (1.4mm x 0.090mm) • Coking and Thermal Products Coal is delivered by haul trucks to ROM hoppers utilizing the R&S passive dust hood design. Coal is fed from the ROM hoppers through a rotary breaker where it is reduced from a maximum of 1200mm size to 50mm x 0. Coal is then delivered via a storage bin to the coal preparation plant where it is processed to produce a nominal 9.0% ash product. A skyline conveyor a tripper stockpiles the product for recovery through coal valves to the train loadout bin. The project was developed and fi nanced under a Build, Own, and Operate, Transfer (BOOT) partnership with White Mining, R&S, and Itochu.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 9 NADWISLANSKIA SPOLKA WEGLOWA (NSW) S.A.
PIAST MINE, BIERUN, POLAND
Engineering and procurement of a 900 MTPH coal preparation, storage and reclaim facility with rail load out. In 1997 and 1998 R&S was awarded contracts to supply conceptual engineering as well as state of the art coal processing and control equipment to the KWK Piast Mine, for their new 900 MTPH fi ne coal preparation facility. With assistance from Roberts & Schaefer the project received grants for US sourced equipment from ECOFUND, an environmental fund set up to proactively impact environmentally friendly projects in Poland. The balance of funding came from a combination of NSW S.A operating funds, regional government loans and central government funding. Detailed engineering was awarded to Separator, at that time still government owned engineering offi ce. The project stalled in 2001 due to ownership changes and the collapse of central Government funding. The project resumed in 2007 with the R&S re-engaged to complete the job. The 900 MTPH CCP consists of 2 x 450 MTPH circuits incorporating: • Fine coal Jig section, • R&S and AKW classifying cyclones, MD Technology spirals • Tabor screens • CMI and Decanter Clean Coal Centrifuges This is a green-fi eld fi ne coal preparation facility processing • Jeffrey vibrating feeders 19mm-0mm raw coal from existing Facility features: coarse coal preparation plant. • 6000 MT raw coal surge/compensating silo, with raw/clean coal blending station • 1500 MTPH railcar loading system supplied from a 50,000 MT Clean Coal stockpile with stacking tube and a 1500 MTPH reclaim system in a tunnel • 300 MTPH refuse transfer and railcar loading system
COAL PREPARATION AND HANDLING EXPERIENCE
10 Section 05 ELECTRICITE DE FRANCE (EDF)
COAL TAILINGS REPROCESSING FACILITY, RYBNIK, POLAND
R&S was contracted by EDF to engineer the relocation and re-design of a tailings reprocessing facility for a regional electric power plant, located in Rybnik, Poland. The plant was intended to economically re-process 450MTPH of coal tailings from local coal mine to recover usable coal that could be burned in their CFB’s. The plant was designed around a modular platform to allow it to be moved to another location after the 15M metric tons of tailings were re-processed. The plant was re-designed to utilize state of the art equipment, including cyclones, vibratory screens, Teeter Bed Separators, centrifugal dryers and a cone thickener. Another engineering task was the creation of a long-range mining plan to effi ciently re-deposit the fi nal tailings back at the site including the re-planting of vegetation to meet local ordinances.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 11 AUSTRAL COAL (XSTRATA)
TAHMOOR MINE, NEW SOUTH WALES, AUSTRALIA
Engineering, procurement and construction of an upgrade to the existing Jig CPP of 550 TPH capacity to 750 TPH. The existing Jig was removed and replaced by upgrading the Primary and Secondary Heavy Medium Circuits to include Primary and Secondary Heavy media cyclones, 50mm x0.5mm, and installing a Flotation Tank Cell, 0.5mm x 0mm, into the fi nes circuit. The Tank Cell acts as a rougher to reduce the load on the existing conventional fl otation circuit. Filtration capacity was increased by the addition of a 3rd Drum Filter. The crushing and sizing circuit was modifi ed by the installation of a Primary and Secondary sizer and new Coal Screen. The project also included extensive modifi cation to the feed conveyor to both align with the new ROM sizing module and increase capacity.
The installation for this brownfi eld upgrade was constructed during a limited period during which the plant production was shutdown.
COAL PREPARATION AND HANDLING EXPERIENCE
12 Section 05 BHP BILLITON
MT ARTHUR NORTH MINE, HUNTER VALLEY, AUSTRALIA
Engineering, procurement and construction management of a 1,800 TPH coal handling, preparation plant, storage and reclaim facility. R&S in 50% / 50% Joint Venture with Sinclair Knight Mertz (SKM) was awarded the Engineering, Procurement, and Construction Management (EPCM) contract by BHP Billiton for the civil, site development, coal handing, and coal preparation for the Mt Arthur North Mine in Australia’s Hunter Valley. The R&S scope in particular included the design, procurement, and construction oversight of the coal handling system and the coal preparation plant. • 2,200 tph material handling system • 1,800 tph (3 x 600tph) CPP • Heavy media cyclones (50mm x 2mm) • Teeter-bed separator (2mm x 0.5mm) • Spiral circuit (0.5mm x 0.125mm) • Spiral circuit (0.5mm x 0.125mm) Coal is delivered by 240-ton haul trucks to 700-ton ROM hoppers. Coal is fed from the ROM hoppers through three stages of crushing where it is reduced from a maximum of 1200mm to 50mm x 0. The facility also includes a Bypass System A series of conveyors and transfer stations can direct the coal to storage and to deliver product to Macquire Generation reclaim in one of three different storage stockpiles (domestic thermal for domestic power consumption. coal = 150,000 tons, preparation plant feed = 120,000 tons, and export product coal = 500,000 tons). Coal from the product coal storage stockpile is delivered to a rail loadout station.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 13 CHEVRON MINING
ELKOL TIPPLE UPGRADE, KEMMERER, WYOMING
Engineering services and equipment procurement were provided for a new truck dump, crushing, conveying, rail loadout and truck loadout system to upgrade aging facilities at Chevron Mining’s Elkol Tipple near Kemmerer, Wyoming. Design throughput is 750 TPH. Major components of the work included the following, listed in fl ow path sequence: • New truck dump with dust stilling shed (end dump mine haul trucks) • McLanahan feeder/breaker • Transfer conveyor to crushing station • Crushing station with McLanahan double-roll crusher • McLanahan sample system with sweep sampler, feed and reject conveyors, crusher and rotary sample collector • Transfer conveyor to rail loadout station • Rail loadout station with control cab and fl op gate • Transfer conveyor to truck loadout silos • Modifi cation at roof of existing loadout silos to receive new transfer conveyor • New shuttle conveyor at roof of existing loadout silos
COAL PREPARATION AND HANDLING EXPERIENCE
14 Section 05 BHP BILLITON
MARUWAI MINE, CENTRAL KALIMANTAN, INDONESIA
Feasibility study for the proposed new coal mine in Central Kalimantan, Indonesia for BHP Billiton Indonesia The project is located some 540 km from the port and required the development of transport infrastructure for 4.0 MTPA of product. The mine and ROM facilities are to be located within the mining area with the crushed product overland conveyed to a dual circuit (500 TPH module) coal preparation plant and stock out of single product coal ready for loading into road train type haul trucks for the 130 km road haulage to the barge port. Stockpiled coal will be located at the barge port near Melak on the Mahaham River before being delivered into barges and transported 400 km to the offshore fl oating coal storage and transshipment facility. The Maruwai site also required the establishment of all the ancillary infrastructure required to support the project. The study included: • 1000 TPH Coal Preparation Plant • Materials Handling system • Overland Conveyor • Truck Loading and Dump Systems • Barge Loading and River Port Facility • Haul Road • Maintenance, Offi ce, and Admin Complex • Man Camp Facilities • On-site power generation, utilities, infrastructure
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 15 INTEGRA COAL
CAMBERWELL MINE, HUNTER VALLEY, AUSTRALIA
Engineering, procurement and construction of upgrades to increase the output of an existing coal preparation plant. Two projects were executed to increase the capacity of the existing CPP from 750 TPH to 1000 TPH. The fi rst stage involved upgrading one of the two DMC circuits to include a new wing tank, 1100mm DMC, and large gravel pumps and modifi ed dense medium The projects were completed in 2004 recovery circuit. and 2005, respectively. The spirals circuit capacity was increased through the installation of additional spiral banks and dewatering cyclones. The raw and product coal conveyors were increased in capacity by a combination of higher speeds and wider belts. The second stage expansion added new dewatering capacity for the coarse coal circuits. • Throughput from 750 TPH to 1000 TPH • Materials Handling system capacity increase to 1200 TPH • 1100mm DMC (50mm X 1.4mm) • Spiral Circuit Upgrade (1.4mm x 0.090mm) • Tailing System upgrade • Tailing System upgrade The projects were brown fi eld upgrades allowing minimal production downtime for construction installation.
COAL PREPARATION AND HANDLING EXPERIENCE
16 Section 05 POLUDNIOWY KONCERN ENERGETYCZNY (PKE)
SOBIESKI MINE, JAWORZNO, POLAND
Engineering, procurement for upgrades to the coarse coal and fi ne coal circuits in the coal preparation facility. The project included the addition of a new raw coal feed system, new product sizing screens to meet the new boiler parameters, new fi ne slurry circuit pumping system and dewatering equipment. The power plant storage yard was also redesigned with a new stockpile In 2007 and 2008 additional confi guration to enable the creation of a clean coal blending station. modifi cations engineered by R&S were carried out at the Sobieski This was necessary to provide consistent BTU and ash levels with varying coal quality feed from different seams at the mine in order to provide maximum burn facility, dealing with refuse handling effi ciency and fl exibility. and plant automation. Elgin’s Equipment Group supplied CMI fi ne coal dewatering centrifuges for the plant and provides maintenance services for that equipment.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 17 KOMPANIA WEGLOWA (KWK)
KNUROW MINE, POLAND Engineering for the rebuilding of the KWK Knurow Mine Coal Preparation Plant at the Main Skip Tower. Project involved increasing the capacity of the fl otation circuit, introduction of high speed fi ne coal dryers and associated equipment – vibratory screens, belt scales, PLC controls, fl occulation system, pumps and process piping. New equipment required partial demolition of the reinforced concrete building fl oors, columns and load bearing members, with immediate replacement with new steel/concrete elements. The projects was accomplished with no down time at the plant.
Knurow Mine, Poland
HALEMBA MINE, POLAND Engineering of modifi cations to the Halemba Mine existing coal washery in the coarse coal and fi ne coal circuits. The project required engineering the construction workfl ow to provide extremely limited disruptions to operations, with a target of zero down time. The washery structures were over 50 years old and severely corroded, which required wholesale replacement of load bearing members. Areas modernized included ROM coal feed system, crushing screening/sizing section, new Coarse Coal Jig washery (GI), new Fine Coal Jig washery (GII), new blending system in each washery, new mechanical coal drying circuit, new water slurry circuit, and whole plant dust collection system, as well as PLC controls for the washery. The Elgin Equipment Group supplied CMI coal dewatering centrifuges for the plant and provides maintenance services for that equipment.
COAL PREPARATION AND HANDLING EXPERIENCE
18 Section 05 KOMPANIA WEGLOWA (KWK)
MURCKI MINE, POLAND Design for a modifi cation to the KWK Murcki coal mine existing coal washery in the coarse coal and fi ne coal circuits, as well as closing the water slurry circuit due to environmental concerns. The project required engineering the construction work fl ow to provide extremely limited disruptions to operations, with target being zero down time. Work proceeded in stages. Areas modernized included, crushing screening/sizing section, Coarse Coal Jig washery and Fine Coal Jig washery, new blending system in each washery, new mechanical coal drying circuit, new water slurry circuit, and whole plant dust collection system, as well as PLC controls for the washery. Subsequently R&S received other engineering orders from KWK Murcki for improvements in the stockpile area and train loadout.
Murcki Mine, Poland
ZIEMOWIT MINE, POLAND R&S prepared a feasibility study pertaining to the phased modernization of the facility and was subsequently contracted to provide engineering services to phase in some of the study objectives, dealing with the clean coal and refuse slurry circuits and ultimately provided full plant as-built engineering documentation.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 19 THUNDER BASIN COAL COMPANY
BLACK THUNDER MINE, WRIGHT, WYOMING
Complete project management, detailed engineering, procurement and construction management services were provided to add two run-of-mine, semi-mobile, near-pit crushing stations and an overland conveying system to the existing Black Thunder Mine. The Black Thunder Mine is the largest surface coal mining operation in North America, producing nearly 30 million tons per year. The facility includes two The near pit crushing and conveying semi-mobile, near-pit crushing units, each arranged with 500-ton capacity dump project received the outstanding project hoppers and fi tted with passive dust control systems. Drag chain type feeders of the year award, presented by the are fi tted to the dump hoppers and reclaim the coal. Each feeds a crusher unit Wyoming Engineering Society. designed to crush 2,600 TPH of -60"x 0 run-of-mine coal, producing a 2"x 0 product. Coal is conveyed from each crushing unit to a permanent 72" wide overland conveyor. The conveyor moves 5,200 TPH of crushed coal at 1,000 FPM, a distance of 11,700' to an existing slot and silo storage area. The overland conveyor is powered by four 1,100 HP drives, arranged with three drives at a forward location and one drive at a tail location. Control systems allow equal drive sharing of the load during all starting, running and stopping conditions. An intricate static and dynamic design analysis of the overland conveyor was completed to provide for all the design considerations over the operating range and conditions of the conveyor. A three stage sample station is included to sample crushed coal to ASTM standards. Ancillary equipment includes: a) dust collection and/or suppression at the crushers, conveyor transfer points and sample station with provision to add dust collection at the primary dump station,b) modifi cations to existing facilities and conveyors to accommodate the new system and c) all electrical work, including programmable logic control with interfaces into an existing control network and power distribution starting from a remote 69 kilo-volt grid.
COAL PREPARATION AND HANDLING EXPERIENCE
20 Section 05 AMAX COAL COMPANY
WABASH MINE, KEENSBURG, ILLINOIS
Engineering, procurement and construction of a 1,500 TPH coal preparation, storage and reclaim facility. The plant was built at an existing mine site, which previously operated separate fi ne and coarse coal cleaning plants. The new facility replaced all existing cleaning facilities while increasing total plant capacity. The existing operations were kept on stream during the construction phase. The project consisted of the installation of a new rotary breaker circuit, raw coal storage facilities (twin open storage piles with transfer conveyor and concrete dust tube). Reclaim to the new preparation plant was accomplished by in-line vibratory feeders, feeding the plant feed belt housed in a concrete reclaim tunnel. The clean coal from the new plant tied into the existing clean coal storage system. Refuse was transported to the existing refuse bin. Plant circuitry consisted of wet screening using “banana” screens for separation to the coarse circuit (which uses twin heavy medium vessels). The intermediate fraction is cleaned in heavy medium cyclones while the 16 mesh x 100 mesh material is cleaned in conventional spiral circuit. The -100 mesh material is thickened in a static thickener and dewatered on seven 3-meter belt presses. The overall project was completed This plant design is unique in that screen bowl centrifuges are used to dewater in approximately 14 months. the 1/8" x 100 mesh material due to the severe restrictions on product total moisture. With potential for low gravity separation requirements, this plant also incorporates a magnetite recovery circuit. This circuit includes a magnetite thickener, and was designed to minimize loss of ultra fi ne magnetite.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 21 MINGO LOGAN COAL COMPANY
BLACK BEAR PREPARATION PLANT, MOUNTAINEER MINE, GILBERT, WEST VIRGINIA
Engineering, procurement and construction of a 1,600 TPH coal preparation plant and material handling facility. This project is one of the largest coal preparation facilities in North America and encompasses extensive material handling, storage, blending and reclaim facilities in addition to the preparation plant. The location, together with the distance between the mine face and the loadout, presented unusual engineering challenges. The raw coal was received at the mine site and stored in a 6,000-ton silo prior to being conveyed overland on a 2-fl ight transfer conveyor system to the plant site. At the plant site, additional unloading facilities were provided, consisting of truck dumps and open storage. The combined R.O.M. product was screened and passed through a rotary breaker, prior to storage in three 6,600-ton raw coal storage silos. Overfl ow provisions are included in the silo along with emergency reclaim provisions. The preparation plant consists of two independent 800-ton circuits. Separate surge bins are provided ahead of both circuits to guarantee uniform splitting of the plant feed. Each circuit consists of wet screening of the raw coal into three fractions: a 6 x 3/8 fraction for processing in the coarse vessel circuit, a 3/8 x 16 mesh fraction for the heavy medium cyclone circuit and a 16 mesh x 0 fraction which is the coarse deslimed product. The 16 mesh x 0 material is classifi ed at approximately 65 mesh with the overfl ow reporting to a spiral circuit and the underfl ow reporting to single stage froth fl otation. Clean coal dewatering is accomplished by the use of conventional vertical centrifuges for the vessel. Horizontal screen bowl centrifuges are provided for the combined spiral circuit and froth circuit products. The water clarifi cation and magnetite control circuits are common to both the A and B circuits of the plant. The clean coal is collected on a single conveyor with a tail drive located in the coal preparation plant and transported to the three clean coal silos, approximately 1-1/2 miles down stream. The three clean coal silos are equipped with high rate vibrating feeders that feed the 4,000 TPH loadout system. Plant refuse system consists of a loadout bin with surplus ground storage for the +100 mesh refuse. The -100 mesh refuse is thickened and ponded in a settling basin/aquifer system, located approximately half way between the plant and the loadout facility. Fresh water rate to the preparation plant, as well as all fi re protection and ancillaries, is included in the scope of our supply. This particular project had unusual time restraints. The plant itself was operational in approximately 11 months with the total facilities operable in approximately 13 months.
COAL PREPARATION AND HANDLING EXPERIENCE
22 Section 05 KENTUCKY CRITERION COAL COMPANY
DEANE, KENTUCKY
Engineering, procurement and construction of a 750 TPH cleaning plant and raw coal facility. A few years prior to the installation of this plant, Roberts & Schaefer had constructed a high rate train loadout system fed by open storage pile and stacking conveyors. An extensive truck dump and crushing station were provided. The 750 TPH plant and raw coal handling facility were added and tied into the previously supplied system. The new raw coal storage consisted of a unique high wall dumping facility with lateral feed of the dump area. It was provided with guide rails and concrete curbing. A pocket containing a feeder breaker system was installed at the dump area of the high wall to crush oversize material obtained from some of the local strip pits. At the bottom of the high wall, an above grade reclaim tunnel was installed housing two reclaim belts, fed by vibrating feeders. This system provided a myriad of blending options. Reclaim material is crushed and then by-passed to the existing loadout facility or fed to the new preparation facility. The preparation plant consisted of wet screening on double deck raw coal screens ahead of a single 20' heavy medium vessel. No pre-wet screens were included in this plant. The intermediate size was split at 3/8". The feed to the vessel circuit is 6" top size x 3/8". The 3/8" x 0 slurry is deslimed at 1 mm ahead of the heavy medium cyclone circuit. The 1 mm x 0 material is classifi ed at 100 mesh with the This project was done in phases with underfl ow reporting to conventional spiral circuit. The -100 mesh reports to the the raw coal addition operable in water clarifi cation circuit. Conventional vertical centrifuges are used for product approximately seven months, and the dewatering. Medium density control is accomplished by the use of a conventional plant completion approximately six overdense control circuit. The raw 100 mesh x 0 is combined with the 48 mesh x 0 months later. The plant is presently refuse product and thickened in a unique “soft bottom” static thickener, prior to being pumped overland to a slurry impoundment system. Plant refuse is collected operating at capacities in excess and conveyed to a remote refuse loading bin by an overland conveyor belt system. of 950 TPH.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 23 MAPCO COAL COMPANY
PONTIKI MINE, LOVELY, KENTUCKY
Engineering, procurement and construction of a 500 TPH plant addition. This project required a major scheduling and coordinating effort. The addition was designed to increase existing plant capacity, while keeping the facility operable during the erection and installation of the additional equipment. Roberts & Schaefer Company elected to add a heavy medium cyclone circuit in a size fraction which maintained the feed rate to the existing vessel circuit, and simultaneously reduced the feed to the existing heavy medium circuit. This was effected by selective screening raw coal ahead of the existing circuit. Additional rework was required on existing equipment such as replacement of the existing heavy medium vessel, and modifi cations to the existing screening facilities. Also included was a complete control system incorporating both the existing and new facilities. The existing water clarifi cation circuit and static thickener were refurbished so they would be adequate for the increased capacity. The changes were made by the use of magnetic separation tailings as rinse water for the heavy medium rinse screens. Existing material handling facilities for raw coal and clean coal were upgraded to accommodate the additional capacity. This project also had an unusual time restraint, requiring completion in accordance with predetermined plant shut down periods. The total project was completed in approximately nine months.
COAL PREPARATION AND HANDLING EXPERIENCE
24 Section 05 BLUE RESOURCES, INC.
J. W. CORNETT PREPARATION PLANT, LEATHERWOOD, KENTUCKY
Engineering, procurement and construction of a 1,250 TPH preparation plant and coal handling facility. This project was unique because of the extreme site constraints, resulting from mountainous terrain. Raw coal was received from two truck dump areas which obtain coal from two separate seams. A storage and reclaim facility for raw coal was designed to permit coal blending from the two seams. The screening and breaker station was provided to make a 6" x 0 product, which is fed to the preparation plant. Raw coal is wet screened with a combination incline and pre-wet screens to make a 6 x 4" feed to a heavy medium low fl ow bath circuit. The 1/4" x 0 raw coal is partly deslimed over sieve bends and passed through super-scalping units for refuse scalping ahead of the raw coal cleaning circuit. The raw 1/4" x 0 overfl ow from the super- scalping circuit is screened in high refuse capacity double deck Deister tables. The 28 mesh x raw coal is classifi ed at approximately 100 mesh; the classifying cyclone underfl ow reports to a spiral circuit. The cyclone overfl ow is delivered to the water clarifi cation circuit, which used a 120' diameter high capacity thickener. The clean coal products and refuse products are mechanically dewatered. A stoker product is made from the bottom deck of the low-fl ow circuit clean coal screens. The primary rejects from the low-fl ow circuit are rewashed in a secondary vessel. A middlings product is made from the secondary vessel circuit. The clean coal stoker and the middlings product are collected and transported to a series of open storage piles with transfer belts, gates and lowering tubes which effect complete fl exibility for product storage. The entire storage system is located over a common reclaim tunnel, approximately half a mile in length. Vibrating feeders and intermediate belt scales allow for blending. The reclaimed/ blended coal is transported on a high capacity reclaim belt to a loadout system. This loadout system is unique in that it adds a separate system for stoker batch weighing, to the conventional batch weighing concept.
An additional feature of this project is the overland refuse belt which conveys refuse from the valley fl oor to a neighboring bench at a substantially higher elevation.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 25 CONSOL, INC.
BAILEY MINE COAL PREPARATION PLANT, ENON, PENNSYLVANIA
As an addition to the original Bailey Mine complex, initially installed by Roberts & Schaefer in 1983, we designed, engineered, procured and installed a large capacity facility. This plant addition combined with the original plant to make the Bailey Preparation Plant the highest annual production facility in North America. Plant input often exceeds 3,200 TPH with one of the highest availability ratios in the industry. Roberts & Schaefer completed the facility The installation consists of a second stream raw coal handling system with so that it was operating at full capacity in scalping screens and rotary breaker. Breaker rejects are gravity fed to the 11 months from date of award. existing loadout bin. The 4" x 0 breaker through product is the plant feed at a nominal 1,600 TPH. The plant circuitry consists of heavy medium vessel circuit for the 4" x 3/8" raw coal with the 3/8" x 0 wet screened product deslimed at .5 mm. A heavy medium cyclone circuit is used for the 3/8" x .5 mm fraction. The .5 mm x 0 raw coal is cleaned in two stage hydrocyclones with the hydrocyclone overfl ow classifi ed at 100 mesh. Froth fl otation is provided for the 100 mesh x 0 material. Clean coal products are centrifugally dried for the plus .5 mm fraction. The froth concentrate is dewatered in vacuum fi lters. The mechanically dried clean coal product in the size range of 3/8" x 0 is then collected and transported to the thermal dryer. The thermal dryer (the largest in the United States) was designed and furnished by Roberts & Schaefer. The dried clean coal and dewatered refuse are conveyed to the existing facilities. The project had unusual physical and time constraints since the existing complex had to be kept in operation essentially around the clock during construction of the new facilities. The commitments for coal sales by the client required an accelerated schedule.
COAL PREPARATION AND HANDLING EXPERIENCE
26 Section 05 MORE EXPERIENCE
LUBELSKI WEGIEL S.A., BOGDANKA MINE, POLAND Design and engineering of a ROM breaking/sizing station and overland conveyor system to send ROM coal from the newly opened Stefanow deep mine to the existing Bogdanka Coal Preparation Plant. The overland belt system consists of three separate conveyors with 1800 metric TPH capacity, with the longest belt being 8900 feet long. The conveying system runs in an elevated enclosed gallery on trestles, with specialized sound abatement features, to meet strict environmental regulations, as well as allowing local farmers unimpeded road and fi eld access. Engineering design was accomplished using state of the art design software, optimizing idler spacing, pulley design, take- up design and belt tensions to provide a most effi cient and reliable system. KATOWICE COAL HOLDING S.A., STASZIC MINE, POLAND Engineering, procurement and construction of an addition to the existing coal washery. Above: Lubelski Wegiel S.A., Bogdanka Mine, Poland The project included a 4000 MT storage silo and load-out, including coal blending utilizing state of the art equipment and automation. Below: Katowice Coal Holding S.A., Staszic Mine, Poland Project involved the installation of high effi ciency Elgin Equipment Group Tabor “banana” screens, CMI Centrifuges, and other crushers, cyclones, belt presses and high speed centrifuges, as well as a very challenging construction of the 4000 MT capacity silo on a “fl oating” concrete mat, due to poor soil conditions and subsidence. Modernized plant started production on budget and ahead of schedule.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 27 MORE EXPERIENCE
INTEGRA COAL/VALE, GLENNIES CREEK COLLIERY, HUNTERS CREEK, AUSTRALIA Roberts & Schaefer were awarded the contract to design, procure, construct, install and commission the integration of new and existing conveyor equipment at the Glennies Creek Colliery. Scope included modifi cation to the existing drift conveyor to discharge to new 1400 mm wide Raw Coal conveyor at 3000 TPH, scalping screen, refurbish and install a used rotary breaker, a new 1400 mm wide Raw Coal conveyor at 3000 TPH loading coal onto the stockpile and a 1000 mm wide Reject conveyor loading from the rotary breaker onto a rejects stockpile. The system was installed on existing mine spoil area, requiring special fl oating foundation systems and structural designs which would accommodate a large degree of foundation settlement. WESTFARMERS, CURRAGH MINE, BOWEN BASIN, AUSTRALIA Roberts & Schaefer undertook a series of benchmarking, peer review and feasibility studies to identify the optimal method of increasing the capacity of the existing Above: Integra Coal/Vale, Glennies Creek Colliery, Hunters Creek, Australia mine operation at Curragh. The studies initially considered a brown fi eld expansion of the existing facility Below: Westfarmers, Curragh Mine, Bowen Basin, Australia before settling on the installation of a new 1200 TPH stand alone coal preparation plant. The plant is to be sited adjacent to the existing facility allowing it to utilize infrastructure and coal storage facilities already in place. The study investigated the tie in of the new plant to existing raw coal and product handling facilities. Detailed technical design, costing and scheduling was completed in developing the feasibility study. The study included a: • 1200 TPH Coal Preparation Plant, two stage to produce both coking and thermal coal products • Primary and Secondary Heavy media cyclones (50mm x0.5mm) • Column fl otation circuit (0.5 mm x 0mm) • Spiral circuit – retreat for fl otation tails • Belt fi lter dewatering • Coking and Thermal Products
COAL PREPARATION AND HANDLING EXPERIENCE
28 Section 05 MORE EXPERIENCE
BOWIE RESOURCES, NO. 2 MINE EXPANSION, PAONIA, COLORADO Engineering, procurement, and construction for the mine expansion. The Bowie No. 2 Mine, located high on a mountain side, was operating in a very confi ned space and trucking coal down the mountain. An expansion project was initiated to convey the coal down the mountain at 1,500 TPH to a storage/loadout location at the base near the highway. The project includes two downhill conveyor segments with declining angles ranging from minus 10° to minus 15°. They are regenerative conveyors, producing electrical power from the gravitational forces. The conveyors pass through 3 CSP tunnels. Facilities at the base of the mountain include two coal stacking tubes and underground reclaim conveyor to a truck loading station. Coal from the surface stockpile feeds through fi ve (5) structurally reinforced openings in a 16-ft. diameter CSP reclaim tunnel to vibrating feeders; thence to a reclaim conveyor to a truck loading area. Trucks are loaded by front end loader. RIO TINTO ENERGY, SPRING CREEK MINE, DECKER, MONTANA Engineering, procurement, construction and Start-up of a new Truck Dump, transfer conveyor and extension of an existing overland conveyor for transporting 3,500 TPH of coal to an existing crusher station. This project consisted of a new truck dump handling 240 ton trucks. Trucks discharged to a small bin which fed a 72" wide feeder breaker. The feeder breaker discharged to a 72" wide transfer conveyor, and then to a rearward extension of an existing overland 54" conveyor. The extension of the existing overland conveyor was constructed utilizing existing conveyor sections, components, and covers that were stored and owned by the mine. In addition to the conveyor system, R&S also provided a fogging system for the transfer stations to minimize dust. An new power distribution center with new Top: Bowie Resources, No. 2 Mine Expansion, Paonia, Colorado MCC was also part of this scope, along with a new compressor installation. Bottom: Rio Tinto Energy, Spring Creek Mine, Decker Montana
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 29 MORE EXPERIENCE
NORFOLK SOUTHERN RAILWAY COMPANY, KOPPERSTON, WEST VIRGINIA
Engineering, design, procurement and construction management of an overland coal transportation system at the Norfolk Southern Harris Mine facility. The project included a reclaim tunnel under the existing storage pile and three conveyors totaling 3,200 feet which feed a 3.9 mile overland conveyor. The overland conveyor runs from the Harris mine to the Kopperston area. The overland conveyor has two miles of elevated trusses. Nearly a half million cubic yards of earth were excavated to prepare the site for the conveyor route. Two 12,000 ton capacity silos were also included in the scope of work at the Kopperston side. These silos are 70' in diameter and 182' high and are of slipform construction. A single reclaim conveyor from both silos feeds a new train loadout structure built over the existing Norfolk Southern tracks. In addition to the engineering, design, procurement and construction management facility, Roberts & Schaefer operates the facility under its TranService, Inc. subsidiary.
COAL PREPARATION AND HANDLING EXPERIENCE
30 Section 05 MORE EXPERIENCE
DRUMMOND COMPANY, INC., SHOAL CREEK MINE, SHOAL CREEK, ALABAMA As part of a new mine project, Roberts & Schaefer Company, on a turnkey basis, supplied the slope conveyor running from the mine mouth. This conveyor sends ROM coal from the mine to a grizzly, which removes the oversize material, and then onto the raw coal storage belt (supplied by others). The conveyor is 72" wide, 4,600' long and has an 1,100' vertical rise. It moves 5,500 TPH of coal and operates at a speed of 800 fpm. The steel cord belt is considered to be the strongest in North America, and weighs 80#/ft. Two 2,000 HP motors mounted on each of two tandem drive pulleys (a total of 8,000 HP), drive the belt. NORFOLK & WESTERN RAILWAY COMPANY, LAMBERTS POINT COAL LOADOUT FACILITY, NORFOLK, VIRGINIA Complete project management, detailed engineering, procurement and construction management services are being provided for the addition of coal surge silos and modifi cations to the existing conveyor system. This will increase the through-put capacity at the lamberts point yard transshipping port near Norfolk, Virginia. The lamberts point facility receives coal by rail and transfers it via twin rotary Norfolk & Western Railway Company, Lamberts Point Coal car dumpers and a duel conveyor system to two shiploaders. The new surge bins Loadout Facility, Norfolk, Virginia will allow the car dumping operation to continue during normal operating delays in the shiploading operation. The existing facility has a present through-put rate of 39 million tons per year, with the surge system planned to increase through-put to some 44 million tons per year. The dual rail car dumpers with variable speed reclaim feeders deliver the coal to two 96" wide dump station reclaim conveyors, discharging at a transfer station to two 96" wide dock conveyors which transport the coal to the shiploaders. The modifi cation will revise the transfer station and existing conveyor transfer. A new directional gate will allow coal to be directed to either the existing dock conveyors or onto new conveyors and to the silo surge system. The silos will be fi tted with variable speed reclaim belt feeders to transfer the coal back onto modifi ed dock conveyors. The feed rate to the silos is 6,000 TPH per conveyor and the running rate from the silos is 8,000 TPH per conveyor.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 31 MORE EXPERIENCE
NORFOLK & WESTERN RAILWAY COMPANY COAL GROUND STORAGE FACILITY ISLE OF WIGHT COUNTY, VIRGINIA
Roberts & Schaefer Company was selected to furnish the complete project management, permitting, detailed engineering, procurement and construction management services for a coal storage terminal facility. This facility will assemble and store coal for ship loading and transhipment for the Norfolk & Western Railway Company. The ground storage terminal system will initially provide a facility capable of storing 1.63 million tons of coal on the ground with an annual throughput capacity of 8 million tons. The fi nal phase of the project will increase the ground storage capacity to approximately 8 million tons with an annual throughput capacity of 40 million tons. The proposed facility will receive coal by rail, transfer the coal to ground storage at the design rate of 6,000 TPH. This will be done through an automated high capacity tandem rotary car dumper, conveyors, surge bins and automated stacker/reclaimer. The coal will be stored on a surface constructed to prevent contamination of the ground water table, as well as allow various trans-shippers to have their coal stored and reclaimed without contamination from other grades of coal. The coal handled will be primarily of metallurgical quality. During operations, the environmental conditions of wind, precipitation and humidity will be monitored through a computerized system to determine the effects the weather will have on the stored coal. An automatic dust suppression system is provided, and controlled by the computerized monitoring system. It is used to protect the environment from air borne dust from the ground storage and conveying systems. Upon request by the trans-shipper, coal will be reclaimed from storage at a design rate of 6,000 TPH by the stacker/reclaimer. The stacker/reclaimer is fi tted with a 210' boom arranged to deliver reclaimed coal via yard conveyors to two over the track loadout silos. Each silo is capable of storing 11,500 tons of coal. The coal will be discharged from the silos through a unit batch weigh system at the nominal rate of 8,000 TPH. From there it will go directly into 220 car unit trains for transporting to Norfolk Southern Corporation’s Lamberts Point Terminal for loading into ships.
COAL PREPARATION AND HANDLING EXPERIENCE
32 Section 05 MORE EXPERIENCE
INDUSTRIAL MINERA MEXICO S.A., PASTA DE CONCHOS MINE, MEXICO Engineering, design, selection and procurement of machinery components for the 150 MTPH, which will be integrated into the existing facilities. The plant design includes material handling and preparation equipment such as sieve bends, screens, spirals, centrifuges, magnetic separators, crushers, etc. THE CARTER MINING COMPANY, GILLETTE, WYOMING Complete project management, detailed engineering, procurement and construction services were provided under a turnkey lump sum contract for The Carter Mining Company’s Rawhide Mine expansion plan adding an in-pit crushing and conveying facility to modernize the mining operation. The Rawhide Mine has a production rate of 10 million tons per year. The facility includes an in-pit truck dump station designed to accommodate 180 ton capacity bottom or end dump trucks. Two dump hoppers with a combined 350-ton capacity are each fi tted with a feeder- breaker to reduce run-of-mine coal to a nominal 10"x 0 product at a combined rate of 6,000 TPH. Each feeder-breaker discharges directly onto a 72" wide over-land The Carter Mining Company, Gillette, Wyoming conveyor approximately 9,000' centers. The overland conveyor is designed to operate near 1,000 FPM and deliver the crushed coal to a single 12,000 ton concrete storage silo. Coal is reclaimed from the storage silo and conveyed into the existing Rawhide coal handling facility. The overland conveyor is powered by three 1,700 horsepower motors arranged at a single drive station on the return run of the conveyor, designed for the static and dynamic requirements for the full range of operating climactic conditions.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 33 MORE EXPERIENCE
AMAX COAL COMPANY, GILLETTE, WYOMING Complete project management, detailed engineering, procurement and construction were provided under a turnkey contract to build the coal handling, crushing, storage and loadout facilities for the Belle Ayr Mine of Amax Coal Company, designed for an annual production rate of 12 million tons per year. Run-of-mine coal is delivered at a rate of 2,000 TPH to a truck dump-primary crushing station, primary crushed, and conveyed to secondary crushing. The coal is then crushed to a fi nal 2"x 0 product, sampled and conveyed to two 12,000-ton storage silos, each confi gured to fl ood load unit trains at a nominal rate of 9,000 TPH. The silos are arranged in-line over the track loading loop. The Belle Ayr Mine was the fi rst major, high capacity coal facility constructed in the Power River Basin of Wyoming. LAUREL RUN MINING COMPANY, MT. STORM, WEST VIRGINIA Complete project management, detailed engineering, procurement and construction were provided under a turnkey contract to construct an overland Laurel Run Mining Company, Mt. Storm, West Virginia conveyor serving the Laurel Run Mine. The overland conveyor traverses a relatively level terrain, transporting 2"x 0 coal from a breaker station some 7,200' to storage silos. The belt has a capacity of 600 TPH and a speed of 630 FPM. It is 36" wide, has a 450 HP drive motor, and a 100 HP creep-drive motor. A belt turn-over is provided on the return run. The entire conveyor including the walkway is enclosed in a Corten tube and is supported on steel stringers.
COAL PREPARATION AND HANDLING EXPERIENCE
34 Section 05 MORE EXPERIENCE
ROCHELLE COAL COMPANY, ROCHELLE MINE, GILLETTE, WYOMING Project management, engineering services and detailed design were provided for the 2,000 TPH coal crushing, handling and load-out facility, initially designed to produce 4 million tons per year. 48"x 0 run-of-mine coal is delivered via 170 ton bottom or end dump trucks and dumped into a receiving hopper, fi tted with an apron feeder, feeding a single-pass two stage crusher. The station is designed to allow expansion to a duplicate circuit and a capacity of 4,000 TPH. 2"x 0 coal reports to an overland conveyor system which delivers the coal to a sampling- transfer station. This transfer station is arranged to direct the coal to the silo feed conveyor for unit-train loading, or in the future, to additional storage facilities. A single 15,000 ton silo, located over the track, is arranged with a batch weigh system to load unit train rail cars at a design rate of 7,000 TPH. AMAX COAL COMPANY, EAGLE BUTTE MINE, GILLETTE, WYOMING All project management, detailed engineering, procurement and construction Rochelle Coal Company, Rochelle Mine, Gillette, Wyoming management services were provided for an addition to the Eagle Butte Mine to increase its coal receiving and crushing facilities from 4,000 to 8,000 TPH. The new facility addition includes installation of a new truck dump hopper, fi tted with two 84" apron feeders, feeding two two-stage quad-roll crushers each discharging onto a single 72" wide collecting conveyor. Ancillary facilities were also furnished to include an electrical boiler plant to heat the structure, and a dust collection system to meet federal and state air quality standards. The heating and dust collection systems utilized the concept which directs heated air (discharged from the dust collector system) through a heat exchange (heat wheel) to recover the otherwise lost BTU’s in the dust collector exhaust. This effi ciently preheats incoming outside air required for the heating system.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 35 MORE EXPERIENCE
KERR MCGEE COAL CORPORATION, GALATIA, ILLINOIS Complete project management, detailed engineering, procurement and construction were provided under a turnkey contract for a slope conveyor. The single conveyor serving the Galatia Mine is 5,100' long and has a 48" wide belt with steel chord fabric. The conveyor receives coal from the underground mine, and conveys it to open storage. The conveyor is designed to operate at 615 FPM, and has a capacity of 1,500 TPH. Coal is elevated approximately 450' from the mine to storage, and the conveyor is driven by twin 750 HP motors and drives with a soft-start. The conveyor is supported on steel stringers within the mine and steel stringers and structural trusses on surface.
Kerr McGee Coal Corporation, Galatia, Illinois
NORTH AMERICAN COAL COMPANY, POWHATAN POINT, OHIO Complete project management, detailed engineering, procurement and construction were provided under a turnkey contract to construct a single overland conveyor system. The overland conveyor transports 2"x 0 clean coal from a preparation plant to a railroad loading pocket, a distance of 5,150' centers. The conveyor is essentially horizontal. It is designed to convey at a rate of 1,200 TPH. The conveyor has a width of 42" and operates at 600 FPM.
COAL PREPARATION AND HANDLING EXPERIENCE
36 Section 05 MORE EXPERIENCE
ARCO COAL COMPANY, BEAVER CREEK MINE, PRICE, UTAH Complete project management, detailed engineering, procurement and construction were provided under a turnkey lump-sum contract for the addition of a truck-receiving, coal storage and recovery system at the Beaver Creek Mine of Arco Coal Company. The work included the design of a truck dump to receive 25-ton capacity highway truck-trailers, a receiving pocket and feeder, a stack-out conveyor (with a 85' high dust tube for the storage of 45,000 tons of coal) and a recovery conveyor rated 2,100 TPH. The recovery conveyor was installed in a 14' steel culvert, which c onnected to an existing system. The existing recovery conveyor was extended to accommodate the new storage pile. The recovery conveyor delivers reclaimed coat to a 10,000 ton capacity train loading silo. The contract included the construction of all roadways, ramps, railroad crossings, surface drainage, power distribution and yard lighting.
UNITED STATES STEEL CORPORATION, ARCO Coal Company, Beaver Creek Mine, Price, Utah HUEYTOWN, ALABAMA Complete construction management, detailed engineering, procurement and construction were provided under a turnkey contract for overland conveyor system. The conveyor system originates at a storage silo where 4"x 0 coal is delivered by reciprocating feeders onto the fi rst of three conveyors that have a total length of 5.1 miles. All conveyors have a capacity of 850 TPH, a width of 36" and a speed of 600 FPM. Each of the three drives are identical, and idlers are rope-supported. The system transverses hilly terrain and required extensive cut and fi ll areas.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 37 MORE EXPERIENCE
KERR-MCGEE COAL CORPORATION, GILLETTE, WYOMING Complete project management, detailed engineering, procurement and construction services were provided under a turnkey contract to build the coal handling, crushing, storage and loadout facilities, designed for an annual production rate of 16 million tons per year. ROM coal is delivered to a truck dump-primary crushing station via end or bottom dump trucks, at a rate of 3,900 TPH. It is then conveyed to a secondary crushing plant after primary crushing, sampled after secondary crushing and conveyed to four 15,000-ton storage silos. These silos are arranged to manually fl ood-load unit trains at a nominal rate of 9,000 TPH. The coal handling, crushing, sampling and dust collection system is arranged using a dual circuit concept, with each circuit rated at 1,900 TPH. The silos are arranged in-line, with a rotating chute device used to direct coal to the various silos without interruption of the coal fl ow. WYOMING FUEL COMPANY, NEW ELK MINE, WESTON, COLORADO Detailed engineering services were provided for the New Elk Mine Coal Handling and Preparation Facility of Wyoming Fuel Company located near Weston, Colorado. Roberts & Schaefer Company’s initial participation involved preparation of the general arrangement layouts of the total facility. This established the most economical plant confi guration to fi t the existing terrain Kerr-McGee Coal Corporation, Gillette, Wyoming and also tie into the existing facilities. The 400 TPH preparation plant layout was based on a fl owsheet prepared by Wyoming Fuel Company, utilizing a heavy media vessel to clean the coarse coal fraction and deister tables to clean the 1/4" x 100 mesh fraction. The plant is also arranged to suite expansion to double the plant feed rate. Phase two of the project furnished the engineering disciplines necessary to detail design the preparation plant. These services included the foundation support system, structural steel design, platework detailing for chute work, sumps and similar material and slurry handling items, the process piping fl owsheets and detailed process piping, and utility piping. Response to the project schedule required the utmost in coordination and control.
COAL PREPARATION AND HANDLING EXPERIENCE
38 Section 05 MORE EXPERIENCE
BETHLEHEM MINES CORPORATION, EBENSBURG, PENNSYLVANIA Complete project management, detailed engineering, procurement and construction were provided under a turnkey contract to construct a mine slope conveyor system. The slope conveyor is inclined 16-1/2°, and conveys 5"x 0 crushed coal collected from a series of underground transfer conveyors to grade. The conveyor discharges into two 5,000-ton capacity storage silos. The conveyor is powered by two 1,250 HP motors, and conveys 1,800 TPH a distance of 3,300', with a vertical lift of 1,000'. The belt is 54" wide, steel cable construction and operates at 635 fpm. The project included a traveling tripper loading over a 6 track storage yard. WESTERN COAL COMPANY, SAN JUAN STATION, NEW MEXICO Complete project management, detailed engineering, procurement and construction were provided under a turnkey contract for a coal crushing and storage facility at the Public Service Company of New Mexico’s San Juan Station. This includes a 2,000 ton pocket for the receipt of coal by rail or truck, primary and secondary crushing, and sampling. Coal is crushed to a 2"x 0 product and conveyed with 72" wide conveyors throughout the facility at 4,000 tons per hour, reporting to two 135' high stacking tubes. These provide the normal storage of 250,000 tons of coal of which 50,000 tons are in live storage. Coal is recovered by six feeders beneath each tube at a rate of 1,200 TPH and conveyed to bunkers in an adjacent power plant. The design included water supply and distribution, fi re water lines, dust suppression, substation, haulage and access roads and a railroad alignment including yard tracks and bridges. Conveyors are contained in fully enclosed galleries, and the crushing and sampling stations are completely enclosed.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 39 MORE EXPERIENCE
PITTSBURG & MIDWAY COAL MINING COMPANY, ELKOL PREPARATION PLANT, KEMMERER, WYOMING All engineering, procurement and construction services were furnished under a turnkey contract to modify P&M’s existing Elkol tipple near Kemmerer, Wyoming. Under severe physical and operating conditions the load-out tipple was modifi ed to add ASTM sampling system to the station, and a certifi ed belt scale. The addition was accomplished through major modifi cations to the existing chute work, adding two belt conveyors and extensive changes to the structure. The fi nal system allows P&M to meet their customer’s requirements of weight and quality verifi cation. CARBON COAL COMPANY, GALLUP, NEW MEXICO Complete project management, detailed engineering, procurement and construction services were provided under a turnkey contract to construct the coal preparation facility at the Mentmore Mine of Carbon Coal Company. Run-of-mine coal is delivered to the plant site via haul trucks, dumped, primary crushed and delivered to a surge pile ahead of the plant, or directed to a secondary crushing station, Carbon Coal Company, Gallup, New Mexico reduced to 2" x 0 and conveyed to a clean coal storage pile. The preparation plant circuit is a Baum jig and water only cyclones, designed to clean 420 TPH of 4" x 0 raw coal, with a closed water circuit. After washing, the clean coal is directed to the clean coal storage pile. A reclaim system delivers clean coal to a loading station for unit train loading and shipment. The clean coal is sampled prior to reporting to the 350-ton capacity, loadout bin. The loadout bin is fi tted with a manual operated loading system rated at 3,000 TPH. Ancillary facilities included a water supply and distribution system, a fi re protection system and truck service facilities with change and warehouse area.
COAL PREPARATION AND HANDLING EXPERIENCE
40 Section 05 MORE EXPERIENCE
OLD BEN COAL COMPANY, PIKE COUNTY, INDIANA Complete project management, detailed engineering, procurement and construc- tion were provided under a turnkey contract to construct two overland conveyors systems. One conveyor system is designed to convey coal from a truck unloading station with a maximum size of 24" to a pocket feeding a rotary breaker. Coal is discharged from the pocket by a reciprocating feeder at 1,200 TPH to a 48", 265 foot belt conveyor and is delivered to a rotary breaker for reduction to -4" size. This product reports to a system of fi ve overland conveyors arranged in a series to transport coal 4.6 miles. All conveyors are 42" wide. They have a capacity of 1,200 TPH and operate at 650 FPM. Conveyors range in length from 1,010 to 7,140'. Alignments and lengths were selected to provide for variations in ground contours, for highway, railroad and stream crossings, and surface ownerships. The conveyors have rope supported idlers and are hooded. ARCH OF ILLINOIS, CAPTAIN MINE PREPARATION PLANT, PERCY, ILLINOIS Engineering, procurement and construction of a 5.5 mile conveyor system and truck dump. The conveyor system transports raw coal from Arch’s Conant Mine to their Captain Mine preparation plant located near Percy, Illinois. It eliminates the need for trucks to continually transport coal between the mine site and the plant, resulting in a considerable saving in operating costs. Its capacity is 2,850 TPH and operates at a speed of 944 FPM. The conveyor system utilized existing modules and mobile transfer stations. A programmable logic controller was incorporated into the system to control the entire system’s activities.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 41 MORE EXPERIENCE
ZEIGLER COAL HOLDINGS COMPANY, PIER IX AND SHIPYARD RIVER COAL TERMINAL Roberts & Schaefer Company was the prime consultant for an “Engineer’s Assessment” of Pier IX located in Newport News, Virginia and Shipyard River Coal Terminal located in Charleston, South Carolina. The evaluation covered physical assessment of the facilities and equipment, general state of repair and operating conditions with investigation into each facilities maintenance program and downtime history. A descriptive analysis was prepared on the capabilities and capacities of the facilities with regard to receiving of coal shipments from both the CSX Railroad and Norfolk Southern Railroad, loading, storage, blending and sampling of coal and other products. Financial data was examined to establish the asset value for both facilities, as well as the operating costs for existing volumes at maximum capacity, and fi ve year projections were comprised on base case projections and sensitivities. Market conditions, contracts and competitors were evaluated from historical records, present tonnages and future projections. A thorough environmental assessment was composed for each facility that included a summary of any risks and liabilities and the status of all permits. ARCH MINERALS, CAVE BRANCH PREP PLANT, LYNCH, KENTUCKY Engineering, procurement and construction of a plant expansion. This project expanded the plant capacity from 700 TPH to 1300 TPH. The project required designing a new equipment to fi t around the existing one. The project scope included upgrading conveyors, modifying screens, installing new sieve bends, cyclones, centrifuges, sumps, pumps, spirals and fl otation cells. Also included process, air, fl oor drain and washdown piping, chutes, hoppers and sluices.
COAL PREPARATION AND HANDLING EXPERIENCE
42 Section 05 MORE EXPERIENCE
EIGHTY-FOUR MINING, EIGHTY-FOUR, PENNSYLVANIA Engineering, procurement and construction of a ROM coal handling and stockpile storage system. The facility includes a 6,000 TPH ROM belt, 200,000 ton storage pile with a 2,000 TPH reclaim feeder system and a scalping screening station that feeds an existing preparation plant. UTAH POWER & LIGHT COMPANY, COTTONWOOD MINE, ORANGEVILLE, UTAH Complete project management, detailed engineering, procurement and construction services were provided under a turnkey contract to build a 1,500 TPH coal facility at the Cottonwood Mine of Utah Power & Light. The facility includes an 8,500-ton capacity run-of-mine coal surge silo, a screen/rotary breaker station with secondary crushing, a sampling system and conveying to a 1,000-ton capacity truck loading station. The coal is trucked to the Hunter Generating Station. Truck weights are certifi ed in a platform scale with remote print-out. The work included major earthwork within the mine site which was necessary to develop access and haul roads, parking areas, storage and warehouse space, Above: Eighty-Four Mining, Eighty-Four, Pennsylvania and suffi cient area for the coal handling system. Water collection and diversion to meet all O.S.M. regulations was also included with the project. Below: Utah Power & Light Company, Cottonwood Mine, Orangeville, Utah
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 43 MORE EXPERIENCE
JIM WALTER RESOURCES, BROOKWOOD, ALABAMA Engineering, procurement and construction of a fi ne coal jig circuit. RIDGEWAY COAL COMPANY, META, KENTUCKY Engineering, procurement and construction of a 650 TPH coal preparation plant, complete with raw coal, clean coal and refuse handling. SOUTHERN OHIO COAL COMPANY, LANGSVILLE, OHIO Engineering, procurement and construction of a 1,200 TPH coarse coal cleaning plant to supplement an existing fi ne coal facility. BETHLEHEM STEEL CORPORATION, DRENNAN, WEST VIRGINIA Engineering, procurement and construction of an 800 TPH heavy medium cyclone cleaning plant with raw coal, R.O.M. coal, clean coal and refuse handling. CYPRUS COAL COMPANY, STONEY FORK, KENTUCKY Engineering, procurement and construction of a 400 TPH preparation plant and material handling facility. KERR MCGEE CORPORATION, GALATIA, ILLINOIS Engineering, procurement and construction of a 1,000 TPH clean coal plant complete with coal handling and unit train loading facilities. ASSOCIATED ELECTRIC COOPERATION, INC., MOBERLY, MISSOURI Engineering, procurement and construction of a 1,500 TPH preparation facility with extensive storage and blending.
COAL PREPARATION AND HANDLING EXPERIENCE
44 Section 05 MORE EXPERIENCE
CONSOLIDATION COAL COMPANY, BLACKSVILLE, WEST VIRGINIA Engineering, procurement and construction of a 400 TPH fi ne coal cleaning addition. FREEMAN UNITED COAL COMPANY, WALTONVILLE, ILLINOIS Engineering, procurement and construction of a 1,200 TPH coal cleaning facility, complete with coal handling and thermal drying. FREEMAN UNITED COAL COMPANY, VIRDON, ILLINOIS Engineering, procurement and construction of the Crown No. 3 complex, including a 1,300 TPH jig plant. TENNESSEE VALLEY AUTHORITY, DRAKESBORO, KENTUCKY Engineering, procurement and construction of a 2,000 TPH four circuit cleaning plant with independent magnetite recovery and water clarifi cation circuits.
Tennessee Valley Authority, Drakesboro, Kentucky
ZEIGLER COAL COMPANY, MURDOCK, ILLINOIS Engineering, procurement and construction of a 1,000 TPH central cleaning complex, complete with storage, reclaim and refuse handling. KAISER RESOURCES, INC., SPARWOOD, BRITISH COLUMBIA Engineering, procurement and construction of a 1,400 TPH heavy medium cleaning facility with thermal dryers and unit train loading.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 45 MORE EXPERIENCE
ARMCO STEEL CORPORATION, SUNDIAL, WEST VIRGINIA Engineering, procurement and construction of a 550 TPH heavy medium and froth fl otation cleaning facility with extensive rough terrain conveying systems. PEABODY COAL COMPANY, MORGANFIELD, KENTUCKY Engineering, procurement and construction of a 2,000 TPH heavy medium cleaning plant and coal handling facility. PITTSTON COAL COMPANY, MCCLURE, WEST VIRGINIA Engineering, procurement and construction of a 500 TPH heavy medium cleaning plant, coal storage and reclaim and thermal drying facility. SHELL OIL COMPANY, LIMERA, OHIO Engineering, procurement and construction of a 1,000 TPH heavy medium vessel, heavy medium cyclone and water only cyclone preparation plant with extensive raw coal and clean coal handling facility. MONTEREY COAL COMPANY, WAYNE COUNTY, WEST VIRGINIA Engineering, procurement and construction of a 1,000 TPH heavy medium vessel, heavy medium cyclone and froth fl otation preparation plant and coal handling facility. INLAND STEEL COMPANY, MCLEANSBORO, ILLINOIS Engineering, procurement and construction of a 1,320 TPH heavy medium/froth fl otation, preparation plant complete with middlings circuit, thermal drying and coal handling facilities. CONSOLIDATION COAL COMPANY, ENON, PENNSYLVANIA Engineering, procurement and construction of a 900 TPH preparation complex, complete with thermal drying and unit train loading.
COAL PREPARATION AND HANDLING EXPERIENCE
46 Section 05 MORE EXPERIENCE—INTERNATIONAL
HINDUSTAN STEEL LIMITED, BIHAR, INDIA Turnkey engineering, procurement and construction of a 770 TPH heavy medium cyclone and water-only cyclone coal preparation plant including coal handling and train loading facilities. HINDUSTAN STEEL LIMITED (PATHERDIHI CENTRAL COAL WASHERY), BIHAR, INDIA Turnkey engineering, procurement and construction of a 500 TPH coal preparation plant including raw coal unloading, crushing and storage blending bunker and clean coal storage and train loading. The plant consists of a baum jig primary circuit with heavy medium vessel and heavy medium cyclone secondary circuits including water clarifi cation and slurry fi ltering. TURKISH COAL ENTERPRISE, AMASRA, TURKEY Turnkey engineering, procurement and construction supervision of a 230 TPH heavy medium vessel, heavy medium cyclone and froth coal preparation plant. TURKISH COAL ENTERPRISE, CATALAGZI, TURKEY Turnkey engineering, procurement and construction supervision of a 230 TPH heavy medium vessel, heavy medium cyclone and froth coal preparation plant. TURKISH COAL ENTERPRISE, ZONGULDAK, TURKEY Turnkey engineering, procurement and construction supervision of a 230 TPH heavy medium vessel, heavy medium cyclone and froth coal preparation plant.
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 47 MORE EXPERIENCE—INTERNATIONAL
KATOWICE COAL HOLDING COMPANY, KATOWICE, POLAND The project consisted of modernizing the Staszic Mine Coal Preparation Plant and Screening Station. The project also included several new conveyors, a new 6,000 metric ton concrete coal storage silo, and reclaim facilities with coal blending capabilities. The 20-meter diameter silo was of U.S. design, but supported on a foundation of Polish design that consisted of a 3-meter thick by 23-meter wide by 32-meter long reinforced concrete slab with 350 compacted “stone piles” that extended an average of 7 meters deep. This project was a blend of U.S. and Polish technology. R&S was responsible for the basic engineering, and the Polish supplied the conveyors. TURKISH COAL ENTERPRISE, TUNCBILEK, TURKEY Turnkey engineering, procurement and construction supervision of a 150 TPH heavy medium vessel, heavy medium cyclone and froth coal preparation plant. BP CANADA, LTD., SUKUNKA COAL PROJECT PLANT, CHETWYND, BRITISH COLUMBIA, CANADA Turnkey, engineering, procurement and construction of a 265 TPH coal thermal dryer size #7.5 (27 TPH water evaporation). BRITISH COLUMBIA COALS, LTD., GREEN HILLS PLANT ELKFORD, BRITISH COLUMBIA, CANADA Turnkey, engineering, procurement and construction of a 372 TPH coal thermal dryer size #20 (55 TPH water evaporation).
COAL PREPARATION AND HANDLING EXPERIENCE
48 Section 05 MORE EXPERIENCE—INTERNATIONAL
BRAZILIAN NATIONAL STEEL COMPANY, CAPIVARI MINE, BRAZIL Engineering, procurement and supply of a 65 TPH heavy medium cyclone circuit addition. CARDINAL RIVER COALS, LTD. DIVISION OF LUSCAR CONSOLIDATION COAL CO., CARDINAL RIVER PLANT, LUSCAR, ALBERTA CANADA Turnkey, engineering, procurement and construction of a 250 TPH coal thermal dryer size #7.5 (16 TPH water evaporation). CHINA NATIONAL TECHNICAL IMPORT EXPORT CORPORATION, XINGLONGZUANG, SHANDONG PROVINCE, P.R.C. Engineering, procurement and construction supervision of a 1,030 TPH batac jig, heavy medium cyclone and froth fl otation plant with complete coal handling including thermal drying. DENISON MINES, LTD., QUINTETTE PLANT, TUMBLER RIDGE, BRITISH COLUMBIA, CANADA Turnkey, engineering, procurement and construction of a 468 TPH coal thermal dryer size #12.5 (38 TPH water evaporation). DENISON MINES, LTD., QUINTETTE PLANT, TUMBLER RIDGE, BRITISH COLUMBIA, CANADA Turnkey, engineering, procurement and construction of a 468 TPH coal thermal dryer size #10 (28 TPH water evaporation). INDUSTRIAL MINERAL DE MEXICO, NUEVA ROSITA, MEXICO Two PACTI non recovery coke ovens complete with ancillary equipment for a demonstration type plant to make coke from coal using the non-recovery process (each oven is capable of producing 12 tons of coke per cycle).
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 49 MORE EXPERIENCE—INTERNATIONAL
TAIWAN POWER, TALIN COAL TERMINAL Engineering and procurement for conveyors for power plant. TAIWAN POWER, LINCOU STATION Engineering and procurement for material handling.
COAL PREPARATION AND HANDLING EXPERIENCE
50 Section 05 COAL THERMAL DRYER EXPERIENCE
CONSOL PENNSYLVANIA COAL COMPANY, BAILEY MINE, GREEN COUNTY, PENNSYLVANIA • 682 TPH Coal Thermal Dryer Size #17.5 • 50 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction PBS COALS INC., CAMBRIA PREP PLANT, SOMERSET COUNTY, PENNSYLVANIA • 210 TPH Coal Thermal Dryer Size #5 • 16 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction PEABODY COAL COMPANY, HAWTHORN MINE, SANDBORN, INDIANA • 246 TPH Coal Thermal Dryer Size #7.5 • 18 TPH water Evaporation Rate • Turnkey engineering, procurement and construction BETH ENERGY MINES, CAMBRIA MINE 133, EBENSBURG,PENNSYLVANIA • Two 800 TPH Coal Thermal Dryers Size #12.5 • 53 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction JIM WALTER RESOURCES, #4 MINE, BROOKWOOD, ALABAMA • 600 TPH Coal Thermal Dryer Size # 12.5 • 40 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 51 COAL THERMAL DRYER EXPERIENCE
CONSOLIDATION COAL COMPANY, LOVERIDGE PLANT, FAIRVIEW, WES VIRGINIA • 465 TPH Coal Thermal Dryer Size #15 • 51 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction CONSOLIDATION COAL COMPANY, BUCHANAN PLANT, BUCHANAN COUNTY, VIRGINIA • 412 TPH Coal Thermal Dryer Size #10 • 35 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction TECK CORPORATION, BULLMOOSE PLANT, TUMBLER RIDGE, BRITISH COLUMBIA, CANADA • 374 TPH Coal Thermal Dryer Size #12.5 • 30 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction DENISON MINES, LTD., QUINTETTE PLANT, BRITISH COLUMBIA, CANADA • 468 TPH Thermal Coal Dryer Size #12.5 • 38 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction DENNISON MINES, LTD., QUINTETTE PLANT, TUMBLER RIDGE, BRITISH COLUMBIA CANADA • 354 TPH Coal Thermal Dryer Size #10 • 28 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction BRITISH COLUMBIA COALS, LTD., GREEN HILLS PLANT, ELKFORD BRITISH COLUMBIA, CANADA • 372 TPH Coal Thermal Dryer Size #20 • 55 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction
COAL PREPARATION AND HANDLING EXPERIENCE
52 Section 05 COAL THERMAL DRYER EXPERIENCE
JEWEL COAL & COKE COMPANY, JEWEL SMOKELESS PLANT, VANSANT, VIRGINIA • 567 TPH Coal Thermal Dryer Size #12.5 • 38 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction PEOPLES REPUBLIC OF CHINA, XINGLONGZHAUNG PLANT, XINGLONGZHAUNG SHANGDONG PROVINCE, BEIJING, CHINA • 198 TPH Coal Thermal Dryer Size #5 • 16 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction CONSOLIDATION COAL COMPANY, DENTS RUN PLANT, MANNINGTON, WEST VIRGINIA • 338 TPH Coal Thermal Dryer Size #10 • 32 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction CLINCHFIELD COAL CO., DIVISION OF PITTSTON COAL GROUP, MOSS III PLANT, SOUTH CLINCHFIELD, VIRGINIA • 350 TPH Coal Thermal Dryer Size #10 • 33 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction CLINCHFIELD COAL CO., DIVISION OF PITTSTON COAL GROUP, MOSS III PLANT, SOUTH CLINCHFIELD, VIRGINIA • 258 TPH Coal Thermal Dryer Size #7.5 • 25 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction BP CANADA, LTD., SUKUNKA COAL PROJECT PLANT • 265 Coal Thermal Dryer Size #7.5 • 27 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 53 COAL THERMAL DRYER EXPERIENCE
CARDINAL RIVER COALS, LTD., DIVISION OF LUSCAR CONSOLIDATION COAL CO., CARDINAL RIVER PLANT, LUSCAR ALBERTA, CANADA • 250 TPH Coal Thermal Dryer Size #7.5 • 16 TPH water evaporation rate • Turnkey engineering, procurement and construction ISLAND CREEK COAL CO., UPSHUR PLANT, TALLMANSVILLE, WEST VIRGINIA • 275 TPH Coal Thermal Dryer Size #10 • 35 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction CLINCHFIELD COAL COMPANY, DIVISION OF PITTSTON COAL GROUP, MCCLURE #1 PLANT, MCCLURE, VIRGINIA • 360 TPH Coal Thermal Dryer Size #10 • 33 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction ISLAND CREEK COAL COMPANY, POND FORK PLANT, BOB WHITE, WEST VIRGINIA • 179 TPH Coal Thermal Dryer Size #7.3 • 18 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction THE NEW RIVER COMPANY, MEADOW CREEK PLANT, MEADOW CREEK, WEST VIRGINIA • 341 TPH Coal Thermal Dryer Size #12.5 • 35 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction
COAL PREPARATION AND HANDLING EXPERIENCE
54 Section 05 COAL THERMAL DRYER EXPERIENCE
BADGER COAL COMPANY, DIVISION OF PITTSTON COAL GROUP, GRAND BADGER #1 PLANT, SAGO, WEST VIRGINIA • 334 TPH Coal Thermal Dryer Size #10 • 32 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction RANGER FUEL COMPANY,DIVISION OF PITTSTON COAL GROUP, BECKLEY #2 PLANT, SABINE, WEST VIRGINIA • 360 TPH Coal Thermal Dryer Size #10 • 33 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction CONSOLIDATION COAL COMPANY, AMONATE PLANT, MCDOWELL COUNTY, TAZEWELL, WEST VIRGINIA • 350 TPH Coal Thermal Dryer Size #12.5 • 40 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction EASTERN ASSOCIATED COAL GROUP, KEYSTONE PLANT, KEYSTONE, WEST VIRGINIA • 290 TPH Coal Thermal Dryer Size #7.5 • 13 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction ISLAND CREEK COAL COMPANY, GUND PLANT, PIKE COUNTY, TURKEY CREEK, KENTUCKY • 279 TPH Coal Thermal Dryer Size #12.5 • 34 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction
COAL PREPARATION AND HANDLING EXPERIENCE
Section 05 55 COAL THERMAL DRYER EXPERIENCE
THE NEW RIVER COMPANY, BECKLEY LICK RUN PLANT, MOUNT HOPE, WEST VIRGINIA • 345 TPH Coal Thermal Dryer Size #l2.5 • 33 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction PENN WEST FUELS, DOVERSPIKE PLANT, DORA, PENNSYLVANIA • 420 TPH Coal Thermal Dryer Size #7.5 • 15 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction MAPCO, PONTIKI PLANT, MARTIN COUNTY, INZE, KENTUCKY • 243 TPH Coal Thermal Dryer Size #10 • 30 TPH Water Evaporation Rate • Turnkey engineering, procurement and construction
COAL PREPARATION AND HANDLING EXPERIENCE
56 Section 05 GEOVIC
NICKEL – COBALT PROJECT, NKAMOUNA, CAMEROON
Roberts & Schaefer conducted an Optimized Feasibility Study to investigate all areas for lowering costs while concurrently advancing front end engineering design (FEED); reducing risk and establishing major construction start and completion dates. Some of the challenges facing the project team for the feasibility study are, limited local electrical supply, and very basic services and supplies. There is no telephone service, airstrip, or approved heliport, and only rudimentary medical facilities. This is extremely demanding project and one of the fi rst of its kind in this part of the African continent, apart from the above mentioned challengers there are many other issues to be overcome such as skilled labor to build & operate the mine and processing plant. There is a huge potential of future mines within the resources rich region, the joint venture team are very mind full of getting the project right to pave the way for other such ventures. The Geovic Project will be executed within a joint venture structure comprising Roberts & Schaefer, Bateman International Projects and Group 5 Projects. The Geovic Project is the fi rst of seven potential cobalt-nickel-manganese deposits to be developed and it is estimated to contain 53 million tons of proven Roberts & Schaefer has provided the and probable ore reserves at average grades of 0.24% cobalt, 0.72% nickel and complete engineering, procurement and 1.22% manganese. construction management services in The ore is concentrated by simple sizing and upgraded to 0.7% cobalt, 1.0% nickel all phases of precious and base metal and 3.5% manganese prior to processing. The project includes a shallow open pit processing facilities and crushing plants. mine, ore concentration facilities and a 2,000 metric ton per day process plant. The Geovic Project in Nkamouna is located in south-eastern Cameroon, approximately 640 kilometers east of the port city of Douala and 400 kilometers east of the capital of Yaounde.
METALS EXPERIENCE
Section 06 1 CONSTELLATION COPPER
LISBON VALLEY COPPER, MOAB, UTAH
Roberts & Schaefer Company was awarded an engineering contract for engineering to assist Constellation Copper to move an existing SXEW Copper plant from Tonopah, NV to Lisbon Valley, UT. R&S scope of work included generating the new general arrangements and design of foundations for the Primary Crusher, Reclaim tunnels, Secondary Crusher, Agglomeration system, and interconnecting conveyors. Also included was generating the general arrangement and foundation design for the new tank farm, settling areas and tank house.
METALS EXPERIENCE
2 Section 06 SATELLITE GOLDFIELDS
MODULAR GOLD RECOVERY ADR PLANT, GHANA, AFRICA
Engineering, procurement and construction assistance to provide Satellite Goldfi elds an entire process facility consisting of carbon adsorption, stripping (ambient) and electrowinning of Gold. Ancillary equipment was also provided for carbon regeneration, acid washing, conditioning and sizing. Under a design/furnish contract, all process and detailed engineering, procurement, fabrication, pre-assembly and construction supervision was provided for a modular designed 1,000 GPM ADR Plant. Work included the design of all process plumping and piping systems, carbon handling and storage, reagent mixing, storage and distribution, carbon regeneration, acid washing, sizing, atmospheric stripping,, electrowinning, and refi ning. The facility modules were designed to fi t in shipping containers for delivery to the site with minimal fi eld assembly. Modules were assembled prior to shipping with equipment mounted, tanks, pumps and piping installed, and equipment pre-wired. The Motor Control Center enclosure was fabricated and shipped complete with switchgear and wiring for quick fi eld installation. Field services included supervision of the erection, testing and commissioning of the plant.
This was the third plant of this type shipped to Ghana by Roberts & Schaefer.
METALS EXPERIENCE
Section 06 3 ROMARCO MINERALS
HAILE GOLD MINE FEASIBILITY STUDY
Complete a feasibility study with estimates of capital and operating costs. The Haile Gold Mine was in the process of being closed down, when purchased by Romarco Minerals, Inc. The purchase came after additional core drilling was completed at the site that showed signifi cant gold and silver ore reserves. To determine the feasibility of reopening the mine for new production, R&S was hired to complete a feasibility study to determine the most probable fi rst cost The study was completed within and operating costs of a new gold processing plant based upon the results of the the client’s required time frame new and extensive core sampling that had taken place. This work was coordinated and within budget. with other consultants that were more specifi cally focused on the mining and metallurgical aspects of the project. The R&S scope of work included: • Development of the process fl ow sheets • Development of the process fl ow diagrams • Material mass balances • Preparation of Piping and Instrumentation Diagrams • Process equipment selection • Preliminary design and layout of the process plant and related facilities • Determination of the infrastructure requirements • Plan and schedule for EPCM services • Development of the major equipment list and specifi cations • Identifi cation of critical path and lead times for major equipment procurement • Capital cost estimate • Operating cost estimate Engineering design was completed in suffi cient detail to support the capital cost estimate for: • Site access roads, fencing, lighting and security • Ore stockpile and reclaim material handling • Crushing and conveying ore to the process plant • Process plant grinding, gravity separation, fl otation, thickening, cyanidation, and gold recovery facilities. • Process plant support facilities • Cyanide recovery and destruction • Truck shop, warehouse, lab, powder magazine, and Admin & Engineering offi ces • Fuel/lube supply, storage and facilities • Water supply, storage and distribution facilities • Electrical supply and distribution • Waste water treatment
METALS EXPERIENCE
4 Section 06 NEWMONT MINING
FRESH WATER PUMPING PROJECT Engineering, procurement and construction management services were provided for installation of a new deep well pump and 16,000 linear feet of pipeline for fresh water feed to Newmont’s quarry mill. The project involved an initial cost study to investigate various pumping options and pipeline materials. This study involved complete cost comparisons for material, operating costs and return on investment. Final design was completed after the most cost-effective option was selected. CARBON REGENERATION AND HANDLING PROJECT Engineering feasibility services were provided for a detailed cost study for a new centralized carbon handling facility at Newmont Gold’s No. 2 Mill. The new handling system would provide a plant capable of stripping, acid washing and regeneration of 24 tons of carbon per day. The study provided equipment selection, material quantities, engineering cost and installation costs. FLASH CHLORINATION PROJECT Engineering, procurement and construction management services were provided for the addition of three fl ash chlorination vessels and associated platforms and equipment at Newmont Gold’s No. 1 Mill. The fl ash chlorination vessels are installed to conduct full-scale tests for treatment of carbonaceous ore. Associated with the work is a chlorine distribution and handling system, including complete instrumentation for data collection and test analysis. TRASH SCREEN MODIFICATION PROJECT Engineering, procurement and construction management services were provided for modifi cation to the cyclone overfl ow trash screens at Newmont Gold’s Gold Quarry Mill. The project required conceptual layout and fi nal detailed design to replace two vibrating trash screens with one 12-meter Delkor linear trash screen. The installation was accomplished during normal plant operations except for a 72-hour change-over and start-up period. Careful planning was necessary to maintain the existing operation. NEWMONT GOLD COMPANY, HEAP LEACH CRUSHING PROJECT, CARLIN, NEVADA An engineering feasibility study was completed to develop the arrangement and capital cost for a new heap leach crushing and conveying facility at Newmont Gold Company’s Gold Quarry Mine near Carlin, Nevada. The fi nal report included drawings and a cost estimate in a form suitable for presentation to the Board of Newmont Mining Corporation. The facility consisted of a truck dump station arranged with a 42" x 65" gyratory crusher, fi tted with an under crusher belt feeder to deliver 6" x 0 ore to an overland conveyor system. The conveying system allowed for the future addition of secondary crushing. Cement addition and agglomeration was accomplished through conveyor transfer stations prior to the ore reporting to a radial stacker and storage.
METALS EXPERIENCE
Section 06 5 ALASKA GOLD COMPANY (NOVAGOLD)
ROCK CREEK GOLD FACILITY, NOME, ALASKA
Engineering and estimating services to provide input to the feasibility study for the Rock Creek Project, a grass-roots gold facility to be located near Nome, Alaska. Plant design was based on processing 7,000 metric tons per day (t/d) of gold ore for approximately four years. The processing plant consisted of a conventional carbon-in-leach (CIL) and electrowinning recovery circuit. Run-of-mine ore is crushed in a primary jaw crusher, a secondary cone crusher, in two tertiary crushers and subsequently conveyed to a fi ne ore stockpile. Ore from the stockpile is reclaimed and fed, along with water, to a single ball mill. The ball mill operates in closed circuit with cyclones; coarse material in the cyclone underfl ow returns to the ball mill for further grinding, and cyclone overfl ow is processed in gravity concentrators and in a fl ash fl otation cell. Gravity concentrate, containing relatively clean gold, is refi ned into doré bars on site. Gravity tailings feed the fl ash fl otation cell and fl otation tailings feed a high density tailings thickener. Tailings thickener underfl ow is pumped to a tailings disposal area and thickener overfl ow is recycled to the milling circuits. Flotation concentrate, combined with gravity middlings, feeds a carbon-in leach (CIL) circuit where gold is dissolved with cyanide and adsorbed onto activated carbon. CIL tailings, free of gold values, is conditioned with chemicals in an agitated tank to detoxify residual cyanide and pumped to the tailings thickener. A pressurized strip circuit will desorb gold from the loaded carbon into a concentrated solution, and the gold is recovered from the concentrated solution by electrowinning onto steel wool. Gold-loaded steel wool is smelted with fl uxes to produce gold bullion.
METALS EXPERIENCE
6 Section 06 OMG APEX
TUNGSTEN RECYCLE PROJECT, ST GEORGE, UTAH
Engineering for a new Crystallizer Circuit to increase production; R&S had worked with OMG Apex previously on other upgrade projects. The scope of the project included: • Conveyor • Dryer • Feeder modifi cations • Reactor modifi cation • Crystallizer #3 • Filter Feed Tank • Belt Filter • Receiver tank silo • Bag house dust collector • Piping to integrate Crystallizer #3 with #1 and #2. • Electrical power and PLC control architecture • Platforms, access stirs, access ladders, product and maintenance lifts • All process, mechanical, structural, electrical and control engineering OMG Apex stored the magnesium scrap in their yard where it absorbed moisture awaiting processing. Their scrap deliveries were inconsistent and they were forced to purchase and store material to assure a consistent feed to the process. As a result of process fi ne tuning they were able to increase the slurry feed which required additional process equipment to convert to fi nal product. In order to properly dry the scrap material R&S designed a feed conveyor to a dryer vessel modifi ed for this purpose, and the support so the vessel could rotate. The dry material was loaded to a feed hopper which fed the calciner. The calciner could process at a higher rate since energy was not required to dry as well as break down the tungsten. The increased process fl ow required a third crystallizer which was tied into crystallizers 1 and 2. A fi lter Feed Tank, Belt Filter, concentrate tank, agitator, centrifuge, and product silo were added to fi nalize the recovery of the tungsten.
METALS EXPERIENCE
Section 06 7 CALLAHAN MINING CORP.
HEMATITE FLOTATION CONCENTRATOR, HUMBOLDT, MICHIGAN
Complete engineering, procurement and construction management services were provided to convert an existing hematite fl otation concentrator to a 2,000 TPD gold ore processing facility. The project included the addition of a new two-stage crushing plant with a jaw crusher, a cone crusher and associated screening and conveying equipment. Existing fi ne ore storage bins were reused to store crushed ore to serve each of two grinding circuits consisting of 900 HP ball mills in closed circuit with 20" cyclones. The remainder of the mill equipment included rougher and cleaner fl otation, a cyanide leach circuit, static thickeners and drum and disk vacuum fi lters. The leachate was clarifi ed in a pressure leaf fi lter prior to deaeration ahead of zinc dust precipitation. The facility utilized the Merrill-Crowe zinc precipitation process to produce dore’ bullion. Engineering services included all design phases associated with both the crushing plant and the mill including determination of suitable environmental mitigation measures, development of process fl ow sheets, P&ID and equipment specifi cations and selection. All electrical power and control design was also provided. Conversion of the existing mill to process gold ore stressed evaluation of existing equipment and the reconditioning and re-use where suitable. Re-use of existing equipment required detailed evaluation of facility design parameters. This was necessary in order to match as closely as possible the equipment available to that required by the process, and to provide an effi cient operating system at the lowest possible capital cost.
METALS EXPERIENCE
8 Section 06 WHARF RESOURCES
CRUSHING PLANT STUDY, DEADWOOD, SOUTH DAKOTA A detailed engineering feasibility study for a 550 TPH three-stage, closed circuit crushing plant. Work includes fl owsheet development, general arrangement drawings, equipment list and cost estimate. CRUSHING PLANT, DEADWOOD, SOUTH DAKOTA Complete engineering, procurement and construction management for a 550 TPH three stage closed circuit crushing plant. The new crushing plant is part of Wharf’s expansion. PROCESS PLANT EXPANSION, DEADWOOD, SOUTH DAKOTA Complete engineering, procurement and construction management for a 2,000 GPM carbon adsorption plant at an existing operation. The work includes layout and design for the total facility which includes pumping systems, carbon handling and storage, regeneration, acid washing and building design. The work also includes integration of the existing plant with the new facility electrical system which includes PLC control, new MCC and control room.
METALS EXPERIENCE
Section 06 9 KENNECOT UTAH COPPER CORPORATION
SALT LAKE CITY, UTAH The design engineering, equipment and construction specifi cation for reactor, converter and fugitive gas collection and control at the Kennecott Garfi eld Smelter. The work included: designs for the collection of high temperature dust and fumes from both reactor slag tapping and reactor matte tapping areas, collection of SO2 fumes from waste heat boilers and space pressurization to exclude fugitive gases from material handling areas. Further items involved in the work were custom hoods and enclosures with protective high temperature insulations, fans, and ductwork and associated structural and electrical systems. SALT LAKE CITY, UTAH The evaluation, design engineering, equipment specifi cation and construction specifi cation for the repair and gas fl ow improvement to four copper converter gas fl ues. Included in the project were the evaluation of the condition of the existing converter ducts and shot coolers, their alignments, expansion provisions, material selection, access catwalks and structural supports. BINGHAM CANYON, UTAH Copper ore and concentrate handling systems.
METALS EXPERIENCE
10 Section 06 MORE EXPERIENCE
AMAX GOLD, INC., GOLDEN, COLORADO Preparation of feasibility studies of several options for a gold ore crushing and processing plant were executed for Amax Gold, Inc. The work included the preparation of fl owsheets, general arrangement drawings, capital and operating cost estimates, and feasibility study reports for a heap leaching facility, a milling facility, and a combination heap leaching and milling facility. An economic analysis of the project as completed which included discounted cash fl ow, internal rate of return and net present value analysis as well as a sensitivity analysis in which the market price of gold, the gold recovery rate, project capital cost and project operating costs were varied. TEBEREBIE GOLDFIELDS, PROCESS PLANT, GHANA, WEST AFRICA The engineering, procurement, fabrication, pre-assembly and construction supervision for a complete 1,000 gpm carbon adsorption plant. Work included layout, design of process pumping and piping systems, carbon handling and storage, reagent mixing, storage and distribution, carbon regeneration, acid washing, and sizing, atmospheric striping, electrowinning and refi nery areas. The entire facility was designed to ship in overseas shipping containers with pre-assembly of larger items before shipment and modular design for areas where pumps, piping and tanks could be pre-wired, pre-piped and shipped on skids. MCC enclosure was fabricated and shipped complete with switchgear and wiring for quick fi eld installation. Field duties consist of supervision in erecting, testing and commissioning the facility.
Teberebie Goldfi elds, Process Plant, Ghana, West Africa
METALS EXPERIENCE
Section 06 11 MORE EXPERIENCE
EUROPEAN BANK OF RECONSTRUCTION & DEVELOPMENT, MURUNTAU GOLD PROJECT (NEWMONT MINING)
Independent Due Diligence Engineering Review of Newmont Mining’s Bankable Feasibility Study prepared for its Muruntau Gold Project located in Uzbekistan, CIS for the European Bank of Reconstruction and Development (EBRD). The operation included a gold heap leach followed by a Merrill-Crowe process plant, sized to process 14,000,000 TPY of low grade stockpile material from an existing mine and milling operation. The due diligence was initiated with a site visit to Uzbekistan and by meetings with the EBRD in London and in the United States. The review included an assessment of the: • defi ned capital cost • operating cost • engineering • construction, schedule, • fi nalizing performance test criteria required for the loan contract Of critical importance in the evaluation were local: • transportation • utility services • security • infrastructure • environmental considerations • permits • labor • government positions • personnel evaluations • supply contracts. A fi nal report was prepared by R&S and delivered to the EBRD and Barclays Bank of London for soliciting supplemental commercial funding. As part of the assignments, R&S made a technical/economic presentation to approximately twenty fi ve interested fi nancial institutions in London. In additional to completing the fi nal review of the Project Development Plan (Construction), R&S was assigned the responsibility of being the independent engineer by EBRD, until the performance and guarantee tests were completed and the loan was repaid.
METALS EXPERIENCE
12 Section 06 MORE EXPERIENCE
INSPIRATION MINES, INCORPORATED, AUSTIN, NEVADA Engineering design services were furnished for the Austin Gold Venture Project of Inspiration Mines, Inc., at Austin, Nevada. The facility is designed to process 1,000 TPD of highly variable ore, producing a fl otation concentrate for transport to an off-site smelter, and the casting of dore’ bullion. Crushed ore from storage is conveyed to ball mills for grinding, arranged in closed circuit with cyclones. The cyclone overfl ow is directed to a fl otation circuit, reporting to rougher cells and two stages of cleaners. Thickened concentrates are dewatered for shipment. Thickened rougher fl otation tails are pumped to a carbon-in-leach circuit, followed by electrowinning and casting. Leach tails are piped to a pond, with reclaim water returned to the leach circuit. Included in the design services were the ancillary facilities associated with the plant. These include the administrative offi ces, changehouse, laboratory, ware- house and shop area, parking and fencing. All electrical power and control design was provided, including fi nalizing of process fl ow sheets, P&ID’s, specifi cation, equipment selection and preparation of a construction document. Used equipment was incorporated into the facility where possible. Procurement and construction management services were provided under a separate contract. Design and supply of the conveyors and carbon-in-leach circuit were also furnished under a separate lump-sum contract.
SHERRGOLD INC., MACLELLAN MINE, LYNN LAKE, MANITOBA The engineering, fabrication, assembly and supply of a six stage carbon adsorption plant. The modules were shop fabricated, pre-wired, pre-piped and ready for placing. Field installation was limited to interconnecting piping and wiring. The modules were rated at 468 gallons per minute and were designed for use with 6 x 16 carbon at a fl ow rate of 33 gallon per minute per square foot.
METALS EXPERIENCE
Section 06 13 MORE EXPERIENCE
SHELL MINING COMPANY, STANDARD HILL PROJECT, KERN COUNTY, CALIFORNIA Complete turnkey services were provided to shell mining company for a 300 GPM modular carbon adsorption gold recovery plant. All process plant components were arranged on structural steel skids that were shop fabricated and assembled, prewired and prepiped ready for fi eld assembly. The skids included carbon adsorption, atmospheric strip, acid washing, thermal carbon regeneration, electrowinning, melting and associated accessories. Electrowinning and melting were housed in modifi ed shipping containers. All skids were set in the fi eld on cribbing for ease of disassembly and relocation to future sites. NEVADA GOLD MINING, INC. (AMAX), SLEEPER PROJECT, WINNEMUCCA, NEVADA Complete detailed engineering, procurement and fi eld engineering services were furnished to Nevada Gold Mining, Inc. for a new crushing, material handling and storage facility at their Sleeper Project. 1,100 TPH of ROM ore is received by trucks and dumped into a pocket fi tted with a 72" wide apron feeder feeding a 42' x 65' gyratory crusher. Primary crushed ore is stockpiled prior to being crushed in secondary and tertiary crushers. The tertiary crushers are arranged in a closed circuit producing a 5/8" product. The fi nal crushed ore is conveyed to a 45,000-ton pile formed by a radial stacker. Each crushing station incorporated structural steel support modules for ease of relocation. WESTERN ENERGY COMPANY, CHARTAM PROJECT An engineering feasibility study was prepared for Western Energy’s Chartam heap leach gold recovery plant located in Montana. The study included the crushing plant, agglomeration station, ore storage and reclaim, process plant, heap layout and associated ancillary facilities. The process plant included fi ve stages of carbon-in-column adsorption, pressure stripping, regeneration, electro- winning and casting. The study provided a narrative describing the facility, a +10% cost estimate, general arrangement drawings and equipment lists bound into a report form suitable for presentation to the company’s Board of Directors.
METALS EXPERIENCE
14 Section 06 MORE EXPERIENCE
CARLOTA COPPER, MIAMI, ARIZONA Engineering, procurement and construction; Carlota Copper is the operating company for Cambior, U.S.A. This project uses heap leach technology combined with solvent extraction and electrowinning for copper production. The copper produced is refi ned to a purity of 99.999%. This is the only new facility of its kind being designed in North America at this time. The project included all ancillary facilities, primary crushing, overland conveying, heap stacking, solution collection and pumping, solvent extraction, electrowinning, mine dewatering and pipeline systems. Also included are sewage treatment and water distribution, fi re protection, power and electrical systems. GENEVA STEEL, OREM, UTAH Roberts & Schaefer Company performed the engineering, design and construction management services for the lime handling, storage and pulverized circuit. The circuit will be used to provide fl ux material as a part of the Q-BOP furnace addition. A broad overview of the criteria used in the detailed design and engineering encompassed the following: soft burnt lime and dolomite (1" x 0) will be delivered in covered rail cars on an existing high line track and unloaded into any of 13 existing elevated rail storage bins. Material will discharge from the bins onto a belt conveyor which will transfer the burnt lime material to a surge bin. Material from the surge bin will feed to either of two pulverizing circuits each having Raymond pulverizing mills. The pulverized lime product will feed into two independent pneumatic transport systems and will be conveyed in separate parallel pipes approximately 1,000' to either a 750-ton silo or a 250-ton silo. The lime and dolomite fl uxes are then metered and injected, using high pressure oxygen into the Q-BOP furnace.
METALS EXPERIENCE
Section 06 15 MORE EXPERIENCE
HANNA NICKEL MINING COMPANY, RIDDLE, OREGON Engineering, procurement and construction were provided for the addition of a 120' rotary dryer with combustion chambers, wet venturi and dry dust collection for 150,000 CFM, and total feed and product materials handling at their existing ore plant. The electrical engineering included the design of modifi cations to their existing substation, power distribution and control center, including complete combustion chamber and materials control, instrumentation and alarm systems. Construction required coordination with existing operations to avoid plant shutdown. BP MINERALS AMERICA FALLON, RAWHIDE MINE, NEVADA Detailed engineering services were provided to BP Minerals America for the Rawhide Project. Roberts & Schaefer completed detailed design for the three-stage crushing plant and conveying system and assisted with design for 2,500 GPM Merill-Crowe recovery system. The design also included P&ID’s for the facility and the electrical control and power distribution systems.
METALS EXPERIENCE
16 Section 06 MORE EXPERIENCE
PINSON MINING COMPANY, WINNEMUCCA, NEVADA Crushing screening facility. ASAMERA MINERALS (US) INC., WENATCHEE, WASHINGTON Pressure oxidation/cyanide leaching plant. WESTERN STATES MINERALS CORP, WHEATRIDGE, COLORADO Heap leach tails recovery facility. CORTEZ GOLD MINES, CORTEZ, NEVADA Gold recovery plant services. PEGASUS GOLD CORPORATION, FLORIDA CANYON MINE, IMLAY, NEVADA Gold recovery plant services. HECLA MINING COMPANY, COEUR D’ALENE, IDAHO Republic Mill Crushing Plant services. ASARCO INCORPORATED, SALT LAKE CITY, UTAH Hayden Smelter Plant services.
METALS EXPERIENCE
Section 06 17 MORE EXPERIENCE
JONES & LAUGHLIN STEEL COMPANY, CALIFORNIA, PENNSYLVANIA Engineering feasibility study for the modernization of the coal handling system. BETHLEHEM STEEL CORPORATION, VAN, WEST VIRGINIA Turnkey project for a stacker/reclaimer facility and overland conveyor system. U.S. STEEL CORPORATION, JEFFERSON, ALABAMA Turnkey project for an overland coal conveyor for the Oak Grove Mine. LTV STEEL CORPORATION, EAST CHICAGO, INDIANA Feasibility study for the evaluation of the central waste and processing facility at the Indiana Harbor Works. REPUBLIC STEEL CORPORATION, PHILIPPI, WEST VIRGINIA Turnkey project for a coal preparation and handling facility. BETHLEHEM STEEL CORPORATION, LACKAWANNA, NEW YORK Chromore handling system. ARMCO STEEL CORPORATION, EDWIGHT, WEST VIRGINIA Turnkey project for a coal material handling and processing facility. U.S. STEEL CORPORATION, GREENE COUNTY, PENNSYLVANIA Engineering study of the coal preparation plant facilities. GENEVA STEEL, PROVO, UTAH Oxygen/argon piping systems.
METALS EXPERIENCE
18 Section 06 MORE EXPERIENCE
CF&J STEEL CORPORATION, COMSTOCK MINE, UTAH Engineering of an iron ore benefi ciation facility. HINDUSTAN STEEL LIMITED, BIHAR, INDIA Turnkey engineering, procurement and construction of a 770 TPH heavy medium cyclone and water-only cyclone coal preparation plant. HINDUSTAN STEEL LIMITED, PATHERDIHI CENTRAL COAL WASHERY, BIHAR, INDIA Turnkey engineering, procurement and construction of a 500 TPH coal preparation plant. BRAZILIAN NATIONAL STEEL COMPANY, CAPIVARI MINE, BRAZIL Engineering, procurement and supply of a 65 TPH heavy medium cyclone circuit addition to their existing coal preparation plant. CFI STEEL CORPORATION, WESTON, COLORADO Turnkey project for a coal storage facility.
METALS EXPERIENCE
Section 06 19 CARIBBEAN ISPAT LTD
DIRECT REDUCTION FACILITY III (DR3), POINT LISAS TRINIDAD & TOBAGO
Engineering, procurement and structural/mechanical erection services for the iron oxide screening, storage and reduction furnace feed system and product conveying, storage and reclaim, and shiploading feed conveyor system at the Caribbean Ispat Limited Direct Reduction Facility III (DR3). The oxide feed system consists of a series of conveyors which receive iron oxide from existing mobile hoppers, conveyors and a shipunloader. The oxide is then conveyed to either a stacker/reclaimer for storage or to a set of oxide screens. The screened fi nes are conveyed to a stockpile. The sized oxide is stored in day bins which have weigh belt feeders on the discharge of each bin. The oxide is then conveyed to the reduction furnace. The DRI product is then conveyed from the furnace to the product storage bins. The bins are equipped with vibrating feeders which feed the DRI product to a screening station which send the screened fi nes to a bin for truck loadout. The overs are conveyed to either the existing meltshop, existing product storage building or the new product storage building. The product storage consists of a traveling tripper/bridge structure and reversing shuttle conveyor system. The DRI product is automatically stored into four stockpiles within the product storage building. The DRI product is then reclaimed from the product storage building via a series of slide gates and conveyors to the dock conveyor/tripper for shiploading. This project required the use of gas tight slide gates for the product storage bins and product reclaim storage building reclaim slide gates due to the high reactivity of the DRI.
DIRECT REDUCED IRON & BRIQUETTED IRON HANDLING
20 Section 06 ILLINOIS CENTRAL RAIL
MARINE TERMINAL, ST. JAMES PARISH, LOUISIANA
Roberts & Schaefer Company provided engineering, procurement, startup and construction management services for the Illinois Central Rail Marine Terminal (ICRMT) in St. James Parish, Louisiana. Several different products are being handled at this facility, including Coal, Pet Coke, Met Coke, Iron Ore Pellets, and DRI. The facility provides iron ore pellets to the neighboring DRI facility for processing, which then conveys the processed DRI back to the handling facility for loading onto ocean vessels, river barges or trains. The project consisted of the following major systems: 1. Traveling Grab Unloader to unload river barges or ocean vessels of Met Coke or Iron Ore Pellets at a rate of 3000 TPH to a traveling stacker for storage or directly to the DRI processing facility. 2. Traveling Shiploader to load ocean vessels with DRI (1100 TPH), Pet Coke (1100 TPH), or Coal (3000 TPH). 3. Barge Loader (supplied by R&S) to load river barges with DRI (1100Tph) or Coal (1700 TPH). 4. Rotary Car Dumper to unload Coal (3000 TPH) or Pet Coke (3000 TPH) to the traveling stacker for storage or onto conveyor belts for direct loading to ocean vessels or river barges. 5. Unit Train Batchweigh Loadout to load rail cars with DRI or Pet Coke. 6. Traveling Stacker to stockpile Iron Ore, Coal, Pet Coke or Met Coke. Reclaiming was accomplished by front end loaders feeding portable conveyors or dozer traps. Due to the varying densities of the materials, variable frequency drives were utilized on many conveyors to convey the materials at the proper rate. Also, several conveyors were used to convey material both inbound and outbound, therefore they had to be reversible. There is over 16,000' of conveyor on this project. The entire process is controlled by an Allen Bradley programmable logic controller (PLC) and human machine interface (HMI) terminal in a control tower which also communicates with other PLCs aboard the machines. The PLC automatically selects the proper conveyor speed based on the material being conveyed. The control room is situated on top of a transfer tower to provide the operator with a vantage point to be able to oversee the entire system.
METALSDIRECT REDUCEDEXPERIENCE IRON & BRIQUETTED IRON HANDLING
Section 06 21 CYPRUS NORTH SHORE MINING
HEARTH LAYER PLANT, SILVER BAY PROCESSING FACILITY, SILVER BAY, MINNESOTA
Engineering, procurement and construction for the addition of a hearth layer system for pellet machines No. 11 and No. 12 at the then inactive Silver Bay processing facility in Silver Bay, Minnesota. This process was initially designed to provide taconite pellets. The installation included in this project increased plant capacity and coordinated the reactivation of the vessel. Pellets for the hearth layer are obtained from the pellet discharge chutes on ma- chines No. 11 and No. 12. Chutes are provided with a diverter gate to direct mate- rial to a process transfer conveyor or to individual collecting conveyors which transfer to the fi rst green pellet elevating conveyor. The fi rst green pellet elevating conveyor distributes to an external transfer tower to a second transfer conveyor. This conveyor elevates the material to three transfer conveyors that feed a combination feed chute and diverter gate which in turn recycles the material to either machine No. 11 or via an additional transfer conveyor to machine No. 12. The entire system is fi tted with bag house type dust collectors. A complete process control system was provided, which is tied into the existing facility. As part of the scope of our supply, the entire existing facility was restarted in conjunction with the new hearth layer system. Extreme time restraints required this project to utilize pre-assembly conveyor structures, duct work, chute work, and piping in order to minimize fi eld assembly. The entire project was completed in four and a half months.
DIRECT REDUCED IRON & BRIQUETTED IRON HANDLING
22 Section 06 POSVEN
HOT BRIQUETTED IRON PLANT PUERTO ORDAZ, VENEZUELA
Engineering and procurement for the ore/pellet feed and blending system and HBI (Hot Briquetted Iron) stockpile, screening and train loadout system at Posven HBI Plant. The process consists of an iron ore/pellet feed system from either an open ore/pellet reclaim hopper or a pellet feed conveyor system. The ore/pellets are stored in separate bins which have weigh belt feeders on the discharge of each bin. The weigh belt feeders then feed double deck screens. The oversize lumps (+38mm) are conveyed to a stockpile. The screened fi nes (-6.35 mm) are conveyed to two ore/pellets fi nes bins which provide truck loadout. The sized (+6.35 mm to -38mm) ore/pellets are then conveyed in a controlled ration of ore/pellets/HBI fi nes to the reactor reduction system and briquetter machines. The briquettes are then conveyed along product cooling conveyors to two screens. The screened HBI fi nes are then transported by conveyor to an HBI fi nes bin in the ore/pellet blending system which are then sent back through the process. The overs from the screens are conveyed to either the train loadout system or stockout pile. The use of pocket conveyors and standard conveyor systems are used throughout the system due to space considerations. The process also included dust collection, cooling water spray, sampling and dust suppression systems. The entire system is controlled through a programmable logic control (PLC) system and human machine interface (HMI) computer terminal.
METALSDIRECT REDUCEDEXPERIENCE IRON & BRIQUETTED IRON HANDLING
Section 06 23 CROWN ASPHALT RIDGE COMPANY
OIL SANDS EXTRACTION PLANT IMPROVEMENTS, VERNAL, UTAH
Mineral: Oil Sands Engineering, procurement, and construction to improve Bitumen recovery. Crown Asphalt Ridge, LLC Korean Technology Industry America-KTIA) proposed to modify existing facility and install new processing equipment in the existing Crown Asphalt Ridge Oil Sands Processing Circuit in order to increase Bitumen recovery. Modifi cation of the Processing Circuit indicated a potential to increase oil plant recoveries to 800 barrels per day (BPD). The new circuit includes the following: • Relocation and refurbishment of several critical pieces of processing equipment. • Design the new screening / crushing tower. • Design new Blade Mill Feed and Delumper Discharge Conveyors. • Upgrade and modify Froth Settler and Tailing Solvent Recovery Unit. • Design of new froth Cells • Design of new centrifuges and heat exchangers. • Upgrade existing MCC with new switchgear. • A demolition plan to accommodate removal of existing equipment systematically without interrupting existing plant operations. • Removal and modifi cations to existing tanks, adding launders and internals to convert to Primary and Secondary Settler Tanks. • Design new conditioning tanks with agitators. • Install new piping, re-route existing piping where necessary, remove existing piping where it is no longer needed • Upgrade Pumps and Motors • Design new thickener and clarifi er. The following describes the engineering deliverables for the project: • Site Investigation • General Arrangement Drawings • Piping Routing Drawings • Electrical Modifi cations and Design • Control System Design • Structural Drawings • Concrete Design • Cost Estimates Project substantial completion is expected in the fi rst quarter of 2010, with commissioning following immediately thereafter.
INDUSTRIAL NON-METAL MINERALS EXPERIENCE
24 Section 06 SGS CANADA
OIL SANDS EXTRACTION PLANT, FORT MCMURRAY, ALBERTA, CANADA
Mineral: Oil Sands Engineering and procurement services for the material handling system, oil extraction skids and froth treatment skids for their pilot plant facilities. SGS is a world renowned third party testing services company. In an effort to establish themselves in the oil sands industry, started building their pilot plant for fi rst oil sands client , Synenco Energy in 2007. Synenco contracted SGS to provide testing facilities to test their patented spiral drum extraction technology using the ore from their oil sands lease. SGS contracted R&S to engineer and procure the material handling system and work with Synenco to develop a pilot scale version of their extraction drum. The 2 MTPH material handling system consisted of a crushing station which reduced the ore to 2" minus. It is then conveyed to a metering station that uses an apron feeder to meter the ore going into the extraction area. Once the sand has been separated from the oil, it is removed by the tailings stacking conveyor. The crushing and metering stations are all located in the ore storage building that is maintained at -15° C year round. The extraction system involved the patented extraction drum and various process skids consisted of tanks, pumps, fl oatation columns, thickeners and instrumentation. Upon successfully delivering the fi rst job, R&S was sole sourced to reconfi gure the extraction process equipment, design and deliver 3 froth treatment skids for SGS’s second customer Teckcominco/ UTS. The extraction drum drive was completely redesigned and the froth treatment skids included a CCD (counter-current decantation) system, TSRU (tailings solvent recovery unit), and a SRU (solvent recovery unit). separate from the railcar loadout system.
METALSINDUSTRIAL EXPERIENCE NON-METAL MINERALS EXPERIENCE
Section 06 25 WESTERN OIL SANDS
MODULAR ASPHALTENE RECOVERY PLANT, FORT MCMURRAY, ALBERTA, CANADA
Mineral: Asphaltene Engineering, procurement, and Construction Assistance, for a modular Asphaltene recovery pilot plant to process tailings from a tar sands solvent extraction unit. The work included conceptual design, detailed engineering, procurement, fabrication and construction of a modular pilot plant that was assembled in a fabrication shop in Utah, USA and shipped to Fort McMurray, Alberta, Canada for module re-assembly and tie-in to utilities and the tailings supply line. The project included a series of unit operations process equipment that were skid-mounted. The structural steel support skids were fabricated in a steel fabrication facility in the Salt Lake City, Utah area. All mechanical equipment, electrical components and piping were assembled to the maximum extent possible in the steel fabrication / assembly facility and trial fi t prior to shipment to the fi nal project site in Canada. This project incorporated approximately 13 skids to support the process equipment, a motor control center (MCC) enclosure, a modular control room, pipe and cable tray supports, and ancillary equipment. The plant was powered by rented diesel-powered generators. The equipment skids were assembled at the fi nal processing site on a concrete containment slab. Field work included structural assembly, interconnecting piping, and making fi nal electrical connections from the motor control center to the power and control panels on the skids.
INDUSTRIAL NON-METAL MINERALS EXPERIENCE
26 Section 06 GREAT SALT LAKE MINERALS CORPORATION
MULTI-SITE PLANT UPGRADES, OGDEN, UTAH
Mineral: Salt and Sulfate of Potash Project Development, Engineering, procurement & construction of plant upgrades. Work included initial evaluation and prioritization of projects, developing initial concepts for each project, completing a conceptual/preliminary design and capital cost and a procurement/construction schedule suffi cient enough to develop the funding CAR. Once funding was approved, the work included developing fi nal engineering design, procurement, construction and construction management. The owner had twelve separate projects at its Salt Plant and thirteen projects at its SOP (Sulfate of Potash) Plant. The work was varied, including: • Scrubbers • Dust collection and dust control • Bucket elevator replacement • Mineral mixing • Automated baggers • Material handling • Wood & Steel Bin replacement • Pellet Presses • Material drying • Tanks and agitators • Platform modifi cations • Burner replacement The detailed engineering phase included the detailed designs of mechanical equipment, structural, civil and electrical design. Engineering deliverables included: • Design Basis to provide a complete technical description of the project • Layout drawings • Structural Design and Drawings • General Civil work, foundations, drains, etc. • Piping and Mechanical design • Electrical Motors switchgear, P&ID’s, Electrical One Lines and MCC’s. • Specifi cation Sheets for Mechanical, Electrical, Civil and Structural design. • Operating manuals to provide detailed step by step instructions for the operation of the process and equipment. Roberts & Schaefer will also specify, purchase and procurement of raw materials and equipment necessary for construction and completion of the projects.
METALSINDUSTRIAL EXPERIENCE NON-METAL MINERALS EXPERIENCE
Section 06 27 INTER-ROCK MINERALS
MIN-AD DOLOMITE FACILITY, HUMBOLDT COUNTY, NEVADA
Mineral: Dolomite Detailed Engineering, Design, procurement and Construction to expand the capacity of its MIN-AD, Inc. dolomite facility near Winnemucca, Nevada. The existing plant contained many moving parts, was labor intensive and required very high maintenance. R&S developed the process design criteria, fl ow sheets, equipment list, general arrangement drawings, plot plan and single line electrical diagrams for the development of the expansion of the facility. The expansion process was designed to increase capacity from 70,000 to 105,000 tons per year of ore and reduce maintenance. The expanded plant was designed on the basis of: • 30 tons per hour • 20 hours per day • Five days per week • Fifty weeks per year • A conservative availability factor of 70%. The proposed modifi cations consisted of: • Dumping all the ore into a sunken hopper( 40 ton) and conveying it to covered coarse ore storage sheds (12,000 tons). • Reclaiming the ore from the covered sheds by conveyor and transporting it to a milling circuit feed bin. • Feeding two roller mills (in parallel) with screw feeders (30 ton capacity) • Drying the ore while simultaneously grinding it in the roller mills. • Pneumatically conveying the dried milled products (standard and fi nes grades). • Installing a truck loadout system (2-400 ton silos) separate from the railcar loadout system.
INDUSTRIAL NON-METAL MINERALS EXPERIENCE
28 Section 06 ARGYLE DIAMONDS
ARGYLE UNDERGROUND EXPANSION PROJECT, WESTERN AUSTRALIA
Mineral: Diamonds Roberts & Schaefer, under a service agreement with Laing O’Rourke, were engaged to carry out engineering design on the Argyle Underground Expansion Project. The design incorporated conveyor systems under two separate ore passes via an underground crushing & screening plant through to existing secondary crushing station and stockpile. The design consisted of three underground conveying systems totaling approximately 3km long, lifting 8 MTPA of ore nearly 600m to the surface. Aboveground the ore is transferred to a 1200mm wide overland belt conveyor via a purging shuttle head. A gantry/ trestle conveying system approximately 1 km long was designed to move the ore up the side of a hill nearly 85m in elevation fi nishing at existing crushing station and stockpile.
METALSINDUSTRIAL EXPERIENCE NON-METAL MINERALS EXPERIENCE
Section 06 29 KRUPINITE CORPORATION
MODULAR PRODUCTION PLANT
Mineral: Tantalum and Niobium Detailed Design & Engineering (Construction to follow when location is found) Roberts & Schaefer Company worked with a newly formed company, Krupinite Corporation to design and build a modular tantalum/niobium production plant with throughput of 100 metric tons per month, to verify and refi ne the new recovery process for commercialization. To date the design engineering has been completed and the construction of the modules is awaiting the owner’s selection of a location to place the new facility. The new technology, called the Krupinite Process, has been developed to recover tantalum and niobium from ores, wastes, process residues, concentrates, and other similar materials. Although tantalum and niobium recovery processes are not new, present methods use highly corrosive and hazardous reagents and produce harmful waste streams. For example, the procedure currently being used consists of the following basic steps: 1. Dissolving tantalum and niobium from materials with hot hydrofl uoric acid. 2. Separating the liquid (dissolved tantalum / niobium) from the solids. 3. Precipitating the metals from the aqueous solution with ammonia. 4. Calcining the precipitate to produce tantalum and niobium oxides. The main disadvantage of the old technology is that it produces a large amount of wastewater containing ammonium fl uoride and a solid waste containing fl uorides and residual hydrofl uoric acid. Elaborate and expensive neutralization and precipitation steps are therefore required before any of these waste streams can be disposed of. Another disadvantage is that fresh hydrofl uoric acid has to be added on a continuous basis to make up for the acid compounds lost to the waste streams. The Krupinite Process drastically reduces the volume of hazardous waste streams generated by the current processes. The steps involved in this new process are similar to current procedures except that in Step 1, the metals are dissolved in a heated solution of ammonium fl uoride instead of hydrofl uoric acid. Fluoride ions that would normally end up in the waste streams with present extraction procedures are instead, through a series of scrubbers and condensers, recovered, regenerated and recycled into the process. In Step 3, ammonia used to precipitate the metals is also recovered, regenerated and recycled into the process. Additionally, waste piles from existing operations can serve as the feedstock in the recovery of contained metal values without disturbing additional land by mining. Reclaiming the nonrenewable resources such as tantalum and niobium would also reduce the volume of existing waste piles.
INDUSTRIAL NON-METAL MINERALS EXPERIENCE
30 Section 06 MOBIL MINING AND MINERALS COMPANY
SOUTH FORT MEADE MINE BENEFICIATION PLANT, NICHOLS, FLORIDA
Mineral: Phosphate Roberts & Schaefer Company has been selected by Mobil Mining and Minerals Company to provide complete project management, detailed engineering, procurement and all construction under a turnkey lump sum contract for the South Fort Meade Phosphate Rock Benefi ciation Plant and associated facilities. The new facility will process 2,800 tons per hour of raw phosphate matrix received via slurry pipeline from an off-site mining operation. The raw phosphate matrix will be processed by trommel and vibrating screens, primary and secondary logwashing and two stages of fl otation. This will produce four sizes of phosphate concentrate for direct application as fertilizer, or the production of phosphoric acid. Also included in the benefi ciation plant is a heavy media circuit to concentrate the 3/4" x 3 mesh matrix feed. The facility incorporates product storage in multiple storage tanks for the sizer rock, coarse concentrates and fi ne concentrates, with additional open storage for 500,000 tons of wet rock product. High capacity rail loading is provided to load 100 ton capacity rail cars at a rate of 4,000 tons per hour. The operation will be completely automated by Roberts & Schaefer’s Process Control and Automation Group using open distributed control system technology. In addition to the benefi ciation plant, the project includes complete site development, distribution of utilities, storage of reagents, warehouse, Roberts & Schaefer has provided a variety shop and maintenance facilities, offi ces, parking and roads, reservoirs of facilities with sound basic engineering for plant water and drainage and all site drainage. expertise to meet overall objectives. Industrial mineral facilities generally require one or more of the major steps in mineral processing, that is: size reduction, liberation, concentration, benefi ciation and refi ning.
METALSINDUSTRIAL EXPERIENCE NON-METAL MINERALS EXPERIENCE
Section 06 31 MORE EXPERIENCE
J.R. SIMPLOT COMPANY, PLANT RETROFIT, VERNAL, UTAH
Mineral: Phosphate Engineering Only for a retrofi t of a nearly fi fty-year old phosphate concentration plant at their Vernal Phosphate mine on the slopes of the Uinta Mountains in eastern Utah. This project consisted of providing Scope Defi nition services, Process Criteria documents, process fl ow diagrams, calculations, and both preliminary and detailed The project was completed on engineering drawings to allow the customer to replace the existing eight fl otation schedule and under budget largely cells with new and larger capacity cells. due to Roberts & Schaefer’s use The R&S project team was tasked with developing an engineering plan that of rigorous earned value project enabled the plant to remain operational throughout construction. control techniques (metrics). The team prepared a set of phased engineering drawings to achieve this requirement. The engineering drawings consisted of process diagrams, phased layouts, piping schematics, electrical one-line diagrams, electrical device physical layouts, structural support details, and concrete foundations suffi cient to allow the customer to proceed with equipment procurement and construction.
INDUSTRIAL NON-METAL MINERALS EXPERIENCE
32 Section 06 MORE EXPERIENCE
ASARCO, INC., OMAHA, NEBRASKA
Mineral: Antimony Oxide The design engineering and equipment specifi cations for an oxide fuming plant to produce antimony oxide as a by-product in the refi ning of lead. The work included designs for the collection of high temperature dust and fumes, the conveying of fi ne particulate antimony oxide with bucket elevators and screw conveyors, the blending of alternative products with ribbon-type blenders, the storage of additives and products, and a product bagging system. Included in the work was the design of ductwork, power supply and distribution and instrumentation and the preparation of specifi cations for equipment and electrical components. ASARCO, INC., HILLSBORO, ILLINOIS
Mineral: Zinc Oxide The design engineering for a zinc-oxide fuming plant for upgrading impure zinc oxide dust by reduction in a coal fi red furnace, and subsequent rapid oxidation to produce a pure zinc-oxide product. The design included the furnace with cooling system, pneumatic conveying of pulverized coal, special conveying of fi ne products and storage bins. It provided the electrical designs and complete furnace instrumentation and control. FMC CORPORATION, GREEN RIVER, WYOMING
Mineral: Soda Ash This project provided the design of a soda ash automatic bagging and palletized facility and a product storage facility warehouse. Included was engineering for equipment layout and foundation design, building foundations, building construction, inter-connecting piping and tie-ins to the existing system and building.
FMC Corporation, Green River, Wyoming
METALSINDUSTRIAL EXPERIENCE NON-METAL MINERALS EXPERIENCE
Section 06 33 MORE EXPERIENCE
C.E. BASIC REFRACTORIES, GABBS, NEVADA
Mineral: Magnesium Oxide Basic Refractories, a Division of Basic Incorporated, awarded an engineering and procurement assistance contract to Roberts & Schaefer to design the addition of a fi fth Herreshoff furnace circuit to their facility at Gabbs, Nevada. Magnesite is mined and processed producing magnesium oxide (MgO) for use in refractory brick. The new facility includes increased secondary crushing using a short-head cone crusher, modifying the existing raw material handling and storage system, adding a controlled feed system to direct raw stone to a new 14 hearth, Herroshoff furnace, (fi red with either heavy oil or natural gas), a cooler to cool the calcined product from the furnace, and handling facilities to transport the material to storage. A 45,000 ACFM bag house dust collector (1:1 air to cloth ratio) provides collection to meet air quality standards for the furnace and material handling system. Dust is pneumatically returned to the furnace using a low pressure air system. Versatility is designed into the circuit to allow calcined material from the other Herreshoff circuits to be directed into the storage system or raw stone to be removed from the circuit and trucked to any other circuit. The facility was located within a very confi ned area, requiring precise planning, layout and sequencing of construction activities to assure successful completion of the project. J.R. SIMPLOT COMPANY, POCATELLO, IDAHO
Mineral: Phosphate Rock Roberts & Schaefer Company provided the total engineering required to convert a phosphate plant from gas to coal fi red. Work included site visits to determine the best way to install the new equipment, fi eld measuring and evaluations. Prepared all general arrangement and detailed drawings to complete the work.
INDUSTRIAL NON-METAL MINERALS EXPERIENCE
34 Section 06 MORE EXPERIENCE
KAISER ALUMINUM & CHEMICAL CORPORATION, WENDOVER, UTAH
Mineral: Potassium Chloride Three design studies and the subsequent construction of additions and moderniza- tion at a potassium chloride processing plant in Western Utah. The studies includ- ed the preparation of general arrangement and layout drawings, cost estimates and construction schedules for venturi-type dust collection at a kiln and compactor addition, the projection of increased processing capacity through the addition of new conveyors, grinding mills and fl otation cells, and the cost and schedules to rebuild enclosed storage buildings including the conveyor systems that were failing from foundation deterioration. UTAH SALT COMPANY, WENDOVER, UTAH
Mineral: Salt Design and construction of a salt processing and handling plant. Included was drying of the product utilizing an oil fi red rotary dryer, size classifi cation with screens, dust collection with cyclones, bagging and product storage. Ancillary facilities included a shop-offi ce-warehouse complex adjacent to the plant facility. PACIFIC CORP, SALT LAKE CITY, UTAH Pyrite removal system. WESTERN AGGREGATE MINERALS COMPANY, CARLSBAD, NEW MEXICO Langbenite compaction feasibility study. BRUSH WELLMAN COMPANY, DELTA, UTAH Ammonia recovery system. PLEXUS RESOURCES, SALT LAKE CITY, UTAH Bornite project services. MONSANTO COMPANY, SODA SPRINGS, IDAHO Phosphate ore handling services-Enoch Valley Tipple.
METALSINDUSTRIAL EXPERIENCE NON-METAL MINERALS EXPERIENCE
Section 06 35 DOLNOSLASKIE SUROWCE SKALNE (DSS)
PILAWA QUARRY PROCESSING PLANT, PILAWA, POLAND
Engineering and procurement for a 1,000 MTPH capacity, green-fi eld site quarry processing plant. The project involves three stages of crushing/screening utilizing Sandvik and Metso primary jaw crushers and Sandvik and Metso secondary and tertiary cone crushers to provide several different grades of aggregate product. Screening is accomplished with Powertec and Fintec screens. The storage yard consists of several product stock-piles; reclaim system and a truck weighing scale and a loading hopper. An obstacle to effi cient plant operation was the severely limited siding availability for unit train loading. R&S was awarded a turnkey contract to build an innovative train loading system developed by R&S that permitted the loading of up to 16 shuttle unit trains (25 each) per 24 hours. The train loader is a traveling tripper type using a reversible feeder at discharge to direct material to cars on either side of central belt. A PLC system controls the loading via belt scale, automated bin gates and provides servo drive control of the tripper. System loads a 25 car shuttle in 90 minutes. The plant and train load-out became operational in early 2009; the plant operates 24 hours a day at a rate of 4 million tons annual throughput.
The Pilawa Quarry is now one of the largest and most effi cient plants of its type in Europe.
AGGREGATE EXPERIENCE
Section 07 1 KWB BELCHATOW
AGGREGATE & SAND PLANT, SZCZERCOW, POLAND
Engineering and construction management for a 450,000 MTY sand/aggregate plant at a lignite open cast mine at the Belchatow Electric Generating Station in Poland. The feed stock is the overburden from the open cast mine, composed of layers of sand and smaller, aggregate quality rock. Plant operates 16h/day and an avgerage of 160 days/year. The project involved engineering two production lines, one for multiple grades of sand, second line for road aggregate production, utilizing a mobile crushing/screening plant with multiple deck screens to separate and size the sands and a single stage cone crushing system to provide aggregate grades. Overburden is selectively stockpiled, divided into sand and rock. Sand production line for 5 grades of sand: • (14) 800 mm wide belt conveyors • 6 x 18 Dual deck screen, 5x12 dual deck screen • Underfl ow sump/pump system • (2) 400mm classifying hydrocyclones • 3 x 4 sieve bends • Rotary bucket dewaterizer Sand and Aggregate stockpiles designed • 17' dia. conical thickener for a 15 production day capacity. The Aggregate production line for 3 grades of product: plants are controlled by two independent • (2) 6x18 dual deck vibratory screen, (1) 5 x 12 dual deck screen PLC systems. The process water circuit is • Vacuum fi lter dewaterizer a closed type with make-up water from • PH balance system • Slurry sump/pumps local streams and PH balancing . • 17' dia. conical thickener • (2) 7TPH Belt fi lter Presses • Mobile crushing/screening system with jaw and cone crusher, dual deck screen • (6) 800mm Belt conveyors • Flocculant system Product Loading system: • (2) belt conveyors • Product blending station • Belt scales • Truck loading conveyor/truck scale • Truck wash-down system
AGGREGATE EXPERIENCE
2 Section 07 TARMAC UK
WISNIOWKA QUARRY, WISNIOWKA, POLAND
Engineering, procurement and construction of a 500 MTPH aggregate processing plant, storage and rail load-out facilities. The plant is fed via a truck dump hopper with a grizzly screen, primary jaw crusher, and a conveyor. The facility has a primary and a secondary crushing and sorting system, providing 10 different product sizes ranging from 0-5mm to 25-63 mm size. Product is distributed to and stored in 10 - 5000 ton conical stockpiles, from which the product is reclaimed and sent to a remote rail load-out via a belt conveying system. The plant has full dust collection and suppression system, as well as noise abatement features to minimize impact to surrounding community.
AGGREGATE EXPERIENCE
Section 07 3 GRANIT
STRZEGOM QUARRY, POLAND
Engineering, procurement & construction of an 450 MTPH addition to the Strzegom Quarry aggregate processing plant, and storage yard. R&S was contracted for a 150 MTPH addition to the existing 300MTPH quarry processing plant, and yard facilities. The objective was to provide three additional sales products to the product mix and increase in overall output. Aggregate produced is a high quality cubic asphalt additive. All structures were to be of open construction. The plant was designed for two shifts, 16hr /day, 6 day/week operation. 35 ton mine trucks deliver the raw aggregate to the dump hopper. Yard addition consists of: • Truck dump hopper with a 100mm grizzly screen • Collecting and re- circulating conveyors • Primary jaw crusher • Plant feed conveyor • Magnetic separator The plant addition consists of: • Surge bin with a vibrating feeder • 180 MTPH capacity H4800 cone crusher. • Three deck screen with 63mm, 32mm and a 5mm decks • Stockpile feed conveyors and stockpiles • Loadout conveyor with a PLC controlled belt scale • Wet dust suppression system at stockpiles and all transfers
AGGREGATE EXPERIENCE
4 Section 07 GRANITE ROCK COMPANY
LOGAN QUARRY AGGREGATE PLANT RENOVATION, AROMAS, CALIFORNIA
Engineering, procurement and construction management for expansion of Granite Rock’s Logan Quarry. The project consists of dry screening, tertiary crushing, wet screening, sand classifi cation, reclaim, blending, rinse and loadout facilities. Design rates for the plant is 1,550 TPH for the dry circuit, 1,500 TPH for the wet circuit, and an average of 2,500 TPH for the reclaim and loadout. Fractured granite is mined from an open pit quarry, fed to a mobile primary crushing unit located in pit and conveyed to the plant for further crushing, screening and washing. Sized materials produced in the plant are reclaimed from storage piles and blended to produce various concrete, asphalt, drain and fi ll specifi cation products. Material entering the plant is screened into fi ne rock and coarse fractions. The coarse rock is secondary crushed and dry screened to produce sized materials ranging from 2" ballast to #8 Mesh dust. Oversize from the dry screening reports to a tertiary closed circuit crushing system. Gate positioning and crusher settings can adjust the production rates of the various sizes to match sales and balance inventory. A special line of dry screening is provided to produce premium “chip” products. Fine rock is wet screened to produce sized materials ranging from 1" to 1/4". The #8 mesh screen underfl ow is classifi ed to produce specifi cation grade sand. Feed to the sand circuit can be supplemented with dust from the dry screening. The sized materials are reclaimed from the product stockpiles and proportionally blended to produce ASTM, California state and county specifi cation grade products for concrete, asphalt, road base, railroad ballast, drain rock and sand. Blended products are conveyed and stored in elevated bin compartments located over truck loading lanes and a rail loading conveyor. The bin compartments are sequentially fi lled upon demand with the various products. Truck scales running the length of the loadout lanes allow accurate loading to a targeted weight.
AGGREGATE EXPERIENCE
Section 07 5 ROC-SAN GRAVEL COMPANY
AGGREGATE PLANT, LODI, CALIFORNIA
Detailed engineering services, procurement assistance and fi eld engineering services were provided for a 800 tph aggregate and sand plant, including a placer gold recovery circuit to remove the goal values from the fi ne material. Pit-run material is delivered to a receiving station and conveyed to a scrubbing station. The scrubber material discharges onto dewatering screens, separating the 4" x 1-1/2", the 1-1/2" x 3/16" and the minus 3/16" fractions. The minus fraction reports to the sand plant and the other fractions reports to separate plant surge pile. A complete crushing, screening and conveying facility produces a variety of aggregates and sand for the concrete market, and decorative rock for the landscaping market.
AGGREGATE EXPERIENCE
6 Section 07 WESTERN AGGREGATE
IDEAL CEMENT PLANT, JEFFERSON COUNTY, COLORADO
Engineering, specifying, procurement and construction management for a new light-weight aggregate plant. Includes near pit crushing, conveying, storage, load-out, kiln/cooler and associated off-gas processing. R&S did all hardware engineering/installation, integration of several different support systems, cell control, programming and start-up. This plant is operating at the forefront of technology for its industry and benefi ts daily in the area of process and quality control of a highly delicate product. The control system operates a process plant with a very high number of process control loops and equipment diagnostic temperatures and pressures. A complete off-gas scrubber dynamics profi le is given. Plant reports are generated and historical trends are plotted on demand. Scope items worthy of note include: • System architecture design • Specifi cation and procurement of hardware/software • Control panel design and fabrication • Control room design and construction • Field devices and electrical • PLC programming • I/O panel design and fabrication • Cell control Graphics programming • Higher level programming and MIS integration • Special plant-customer (man-machine) interfaces • Programming start-up and commissioning • Distributed control system retro-fi t • Implemented micro-processor based distributed PID controllers • Special programming for high-dynamic applications.
AGGREGATE EXPERIENCE
Section 07 7 MORE EXPERIENCE
KAISER CEMENT CORPORATION, PERMANENTE AGGREGATE, CUPERTINO, CALIFORNIA Engineering Services were performed for Kaiser Cement Corporation to prepare a feasibility study for the modernization of their existing sub-base and coarse aggregate plant. The plant modernization objective was to produce concrete aggregate, sand and the variety of sub-base products to serve the location area. The new plant was designed to produce 2,100,000 tons per year. The new facility begins at the tie into the existing coarse aggregate stockpile and conveying system. It provides crushing and screening facilities to produce the custom blending of ASTM and California State Highway specifi cation products, concrete sand, base rock and asphalt rock. Washed and rinsed aggregate products reclaimed from storage are automatically weighed and loaded into customer trucks. Signifi cant development work was involved in arranging the new facility into the restricted existing site location, and maintaining operations of the existing facilities. ASH GROVE CEMENT WEST, LEHI, UTAH Portable crushing and conveying. TRI COUNTY ASPHALT CORPORATION, LAKE HOPATCONG, NEW JERSEY Aggregate facility. GRANITE ROCK COMPANY, WATSONVILLE, CALIFORNIA Hollisters and plant. CENTEX CEMENT ENTERPRISES, INC., DALLAS, TEXAS Yuba placer dredge sand recovery system.
AGGREGATE EXPERIENCE
8 Section 07 LEHIGH CEMENT COMPANY
CEMENT FACILITY, UNION BRIDGE, MARYLAND
Engineering, procurement and construction for a material handling system by Lehigh Portland Cement Company at their Union Bridge, Maryland, cement facility. The project consisted of a series of conveyors to accept either rail or truck delivered coal, coke, iron, steam coal and sand. The products were stockpiled by a longitudinal stacker and reclaimed by a scraper reclaimer. Once reclaimed, the material is conveyed to storage bins for use in the kiln process. The existing limestone system was also extended by a series of conveyors and stored in a new 52,000 MT storage dome. The limestone is reclaimed by pan feeders and conveyed to storage bins. Clinker from the kilns was also stored in new silos and conveyed to the existing conveyor system for grinding and distribution as a fi nal product. Throughout the facility, dust collection and dust suppression systems were provided.
Roberts & Schaefer has provided feasibility studies, engineering design, procurement and construction management services for numerous crushing, screening and material handling plants for a variety of materials.
AGGREGATECEMENT EXPERIENCE EXPERIENCE
Section 07 9 NATIONAL CEMENT COMPANY OF CALIFORNIA
PLANT 2 MODERNIZATION, LEBEC, CALIFORNIA
Engineering & Procurement of Conveyors and Dust Collection Equipment. This included the belt conveyors, stackers, weigh scales, magnet, metal detector, dust collectors, belt weigh feeders, chutes, and belt conveyor instrumentation. Belt conveyor capacities ranged from 150 TPH to 2000 TPH. More specifi cally the work included: • Eleven transfer conveyors • Seven transfer stations • Seven belt weigh feeders for limestone, iron, silica, clay, gypsum & clinker • Nine dust collectors • Two stacker conveyors • All associated diverter gates, belt scales, metal detectors, magnets & tipping valves • Computer controls and instrumentation
CEMENT EXPERIENCE
10 Section 07 CALAVERAS CEMENT COMPANY
QUARRY CRUSHING SYSTEM, TEHACHAPI, CALIFORNIA
Roberts & Schaefer Company was awarded the engineering services for a new Crushing Circuit Upgrade project. The main function of the new construction was to connect a new owner provided Hazemag crusher with the existing cable supported overland conveyor. Within this circuit, the owner desired to install an in line real time atomic analyzer and to separate the useful limestone material from the undesirable decomposed granite (DG). In order to get a proper silica additive, some of the DG had to be added to the limestone which was accomplished automaticallyfrom a feeder at the DG hopper. R&S was in charge of all civil work on the site, the structural, mechanical and electrical engineering for the conveyors, screens and bins, the MCC/generator building, and the analyzer building. The Hazemag crusher had a minus 4" vibratory screen prior to the crusher to separate the DG (99% minus 1") and undersized limestone. In order to process the screened material we provided a 48"conveyor at the unders screen, a 90° transfer, and a 36" conveyor to the top of a 3 deck screen. The screen separates the smaller limestone which is put back on the main conveyor via rock box chute work. The remaining DG falls in to a pant leg hopper. One leg automatically blends DG back in to the main product chute, via a feeder belt, based on signals from the analyzer. The other leg feeds a stacking conveyor which discharges near the DG waste pile. The plus 4" material is fed through the Hazemag crusher and is discharged on to a 48" product conveyor. This conveyor feeds a load cell supported controlled feed bin. In order for the analyzer to produce accurate results, consistent feed is required. The feeder conveyor under the bin automatically adjusts the feed on the belt going through the analyzer. The fi nal product is transferred to the existing overland conveyor via a transfer station. The transfer station includes an emergency fl op gate to direct material to the ground in case there is a disruption on the overland conveyor.
AGGREGATECEMENT EXPERIENCE EXPERIENCE
Section 07 11 ASHGROVE CEMENT COMPANY
CEMENT PROCESSING FACILITY, MOAPA, NEVADA
Engineering, Costing and Specifi cations with Cement Performance International (CPI) for the preliminary engineering, facility general arrangements, EPC schedule, mechanical and construction specifi cations, and capital cost estimate for the Firebird Project proposed by Ashgrove Cement Company,Inc. The project consisted of the following: • A 1,500,000 short ton per year cement processing facility. The process included quarry, crushing, overland conveying, pyro-processing, clinker grinding, raw material and fuel preparation facilities, raw material transport and storage, fi nish mill, product transport and storage, and load-out facilities. • Water supply, storage and distribution. • Plant mobile equipment. • Fire protection water system. • Plant roads. • Ancillary facilities (Warehouse, Truck Shop, Admin Bldg., Lab, Fuel Storage and Power Distribution) Roberts & Schaefer Company prepared the fi nal RFP documents. The project deliverables included: • Overall Site Plan Drawing (showing plant, roads, power, water supply). • General Arrangement Drawings for Ancillary Facilities. • Crushing, Ore Storage & Blending Facility Plan. • General Arrangement Drawing for Quarry Crushing Plant. • General Arrangement Drawings for Raw Kiln Feed Grinding and Storage. • General Arrangement Drawings for Kiln and Preheater. • General Arrangement Drawings for Coal Grinding and Storage. • General Arrangement Drawings for Clinker Cooler. • General Arrangement Drawings Cement Silos and Grinding Circuit. • Preliminary Electrical Load List. • Material Balances • Plant Design Criteria • Preliminary Flow sheets. • Preliminary Equipment List • Data Supporting Material Take offs. • Mechanical and Construction Specifi cations. • Capital Cost Estimate • Construction Plan and EPC Schedule. • Training Schedule and Outline. Roberts & Schaefer Company provided the preliminary design engineering and the mechanical and construction specifi cations described above for the project.
CEMENT EXPERIENCE
12 Section 07 SOUTHDOWN CALIFORNIA CEMENT
CEMENT LOADOUT FACILITY, VICTORVILLE, CALIFORNIA
Engineering and procurement of a new Bulk Cement Truck Loadout Facility at the River. The project consisted of the addition of three new truck loading lanes, including three new truck scales, a new 150-ton surge bin, new 850 ton per hour (TPH) bucket elevator, and new air slides to transfer cement from the existing silos to the new bucket elevator and surge bin. It included the tie-in from the existing airslides to the new cement handling system, and a new dust collection system. A new motor control center was designed to provide power to the new system. The existing control system was upgraded/modifi ed to coordinate the new equipment with the existing equipment that reclaims cement from the existing silos. R&S provided layout, mechanical, piping, civil, concrete, structural steel, chutework, and electrical engineering.
AGGREGATECEMENT EXPERIENCE EXPERIENCE
Section 07 13 LAFARGE
SUGAR CREEK FACILITY, SUGAR CREEK, MISSOURI
Detailed engineering of design of changes to Clinker Handling System. Lafarge Corporation had the need to install a new clinker handling system at its Sugar Creek Cement Plant. The existing storage silos at the plant store raw materials and gypsum as well as clinker. This project provided a new clinker dump hopper and handling facilities that will convey the clinker from the haul truck dump hopper to the bucket elevator and for dispersion to the silo as selected by the operator. Future provision for slag handling was also a consideration for the project. The gypsum system had to remain in service in its present confi guration during construction. The objective of the project was to meet or exceed the 250 tons per hour material movement requirement while providing effective dust control for the Sugar Creek Plant. Dusty conditions are to be minimized while providing a system to meet the Plant’s needs. The work included detailed engineering design plus the creation of design drawings including: • General Arrangement drawings • Flow sheets • Site plans • Power distribution
CEMENT EXPERIENCE
14 Section 07 BLUE CIRCLE, INC.
ROBERTA CEMENT AND LIME PLANT, CALERA, ALABAMA
Engineering design, procurement and construction management services were provided for Blue Circle Inc.’s Roberta Plant, a major producer of cement and lime. The project consists of a complete new raw material facility to serve the production plant, designed to produce raw material feed stock at a rate of 1,200 TPH. Selective mining procedures deliver run-of-quarry rock to a truck dump and primary crushing station located in the quarry pit. The facility also provides means to Primary crushed limestone rock is conveyed from the pit to a location adjacent handle clay/shale and dirty rock materials to the cement and lime production circuits. The limestone rock is further crushed directly to the cement production plant. in a secondary crusher before reporting to a primary screening station for sizing. The facility incorporates the most modern Based upon the grade of limestone being processed, oversize material reports to of process technology. a tertiary crusher arranged in closed circuit and after crushing, is recombined with the primary screen station feed. When producing cement grade limestone, two grades of limestone are produced and report to separate storage stations. When producing lime grade limestone, a secondary screening station sizes the limestone in the variety of size fractions required for each grade, and delivers the fi nished products to separate storage stations. All materials are reclaimed from storage, reporting to each production plant.
AGGREGATECEMENT EXPERIENCE EXPERIENCE
Section 07 15 CHEMICAL LIME
APEX PLANT, APEX NEVADA
Engineering, procurement, construction and commissioning for the design, supply and construction of a lime processing facility addition at the Apex Plant in Nevada. A diverter gate was installed below an existing conveyor to divert the Lime to the existing system or onto a new belt conveyor BC-8001. Conveyor BC-8001 feeds a new bucket elevator which transfers the lime to a new lime storage silo. The new silo has a capacity of 5000 Tons. A weigh belt feeder under the silo feeds the lime onto new belt conveyor BC-8002 and into another diverter gate, DG-8002. Diverter Gate DG-8002 distributes the lime onto one of two existing quicklime conveyors, BC-0505 or BC-0507. A dust collection system was installed to pick up fugitive dust at the transfer points to the new conveyors and convey the dust through two new screw conveyors and then back onto the BC-0505 or BC-0507 conveyors. A bin vent fi lter was installed on top of the new 5,000 ton lime silos to vent the displaced air and to capture fugitive dust, returning the dust back into the silo.
LIMESTONE HANDLING EXPERIENCE
16 Section 07 DRAVO LIME COMPANY
BLACK RIVER PROCESSING PLANT, BUTLER, KENTUCKY
Design, furnish, install and commission a turnkey limestone, coal and coke material handling system. The limestone handling included the addition of new conveyors and equipment to crush, wet screen, classify and stockpile limestone into fi ve stockpiles of the various sizes. Crushing consisted of two secondary cone crushers rated at 350 TPH that accept the oversize from two triple deck screens and, once crushed, recycle this material back to the screens. The material from the other screen decks is conveyed to the appropriate stockpile. The undersize from the screens is sent to a spiral classifi er which in turn feeds a radial stacker. The limestone is reclaimed from the stockpiles by vibrating feeders which send the limestone via conveyors to the limestone feed bins. The coal handling system consisted of a new 50-ton truck dump, vibrating feeders and a 450 TPH conveying system to feed petroleum coke and coal to three silos. All processes are controlled from the kiln control room from computer interface terminals and a new programmable logic controller (PLC).
AGGREGATE EXPERIENCE
Section 07 17 CAREMUSE LIME COMPANY
LIMESTONE HANDLING FACILITY, MAYSVILLE, KENTUCKY
Engineering, procurement and construction of a limestone handling facility. The new limestone handling facility began with the installation of new 1000TPH, 42" feeder located within an existing transfer structure. The new feeder was fed from the existing conveyor system. From the new feeder, a new stockpile conveyor with travelling tripper was furnished to create a 75,000T limestone stockpile. The new stockpile conveyor was located near the existing reclaim tunnel to utilize the existing reclaim feeders and tunnel. New concrete support tubes were installed to support the stacking conveyor. Four new vibrating feeders were installed in the existing tunnel to allow for increase reclaiming capacity. A new escape tunnel was provided for the existing reclaim tunnel.
LIMESTONE HANDLING EXPERIENCE
18 Section 07 GENERAL DYNAMICS CORP.
GRINDING MILL PLANT, BUFFINGTON, INDIANA
Engineering, procurement and construction of a grinding mill system at the Marblehead Lime kiln and plant. The scope of supply began with the installation of a fi ne storage tank for the processed 1/4" x 0 fi nes. The material was reclaimed by use of a fi xed rate screw feeder ahead of an elevator rated at 25 TPH. Material was then transported by two 14" diameter screw conveyors to a 24" fi nes transfer belt. This belt also This system is electrically interlocked and received 1/4" x 0 material from the existing facilities. controlled from the existing plant control The 24" fi nes transfer belt delivers the 1/4" x 0 material to a 490-ton storage system. This installation was completed tank. Material from the storage tank has the options of being directly loaded in approximately 13 months. onto railroad cars or conveyed via a 20" diameter screw conveyor to a new mill surge bin. Downstream from the new mill circuit addition, a 30" lime transfer conveyor returns the 170 TPH coal and transported lime to a crusher feed belt. The material is passed through a railroad crusher to make a nominal 3/4" x 0 size. This material is delivered to a 108-ton storage tank. The material from the storage tank is reclaimed by a pebble feeder which discharges to the mill storage bin. The product collects in the mill storage bin and is now fed to two Whizzer 400 HP mills, complete with exhausters and oil pumps. The product from the air-swept Whizzer mills is collected in two independent cyclone circuits; each cyclone discharging to a separate 720-ton tank. A common dust collection system is used for the two cyclones. The dust collection product discharges to a third 720-ton tank or via the 24" line screw conveyor to a 600 ton, 150 mesh storage tank. The fi nal product collects in a total of six storage tanks for the various sizes. Truck loading spouts are provided for each tank, in addition to 24" loadout screws for conveying the material to a railroad car loading facility.
AGGREGATELIMESTONE HANDLINGEXPERIENCE EXPERIENCE
Section 07 19 OMYA CALIFORNIA
OPTICAL SORTER IMPROVEMENTS, LUCERNE VALLEY, CALIFORNIA
Detailed design engineering services for enhancement to the Optical Sorter project. OMYA California, Inc. installed a new optical ore sorter, underground reclaim tunnel including conveyor and feeder, and multiple belt conveyors to handle both accepted and rejected materials from the sorter. Ancillary equipment to be installed included an air compressor, MCC section, remote IO cabinet, communications equipment and cables, and water piping. In addition to the above equipment and materials, a new vibrating screen, support structure, and related materials were to be installed at a location prior to the new optical sorter. R&S performed the detailed engineering for the new vibrating screen, optical sorter, and associated material handling equipment. The engineering was completed in two phases, preliminary design and detailed design. R&S also prepared the design for the new reclaim tunnel and escape tube to be located under the new Sorting Stockpile No. 7. The reclaim conveyor accepted material from the new vibrating feeder at a maximum capacity of 100 TPH and included a new belt scale. R&S prepared all design calculations, drawings, and material and installation specifi cations for the items listed below. • Site Plan • General Arrangements • Piping • Structural • Plate work • Concrete • Civil • Electrical and Instrumentation
LIMESTONE HANDLING EXPERIENCE
20 Section 07 OMYA CALIFORNIA
CRUSHER PROJECT, LUCERNE VALLEY, CALIFORNIA
Engineering Study to fully develop the concept for the new crushing and stockpiling system. R&S worked with OMYA to fi nalize the fl owsheet for the project, and prepare preliminary site plans and general arrangement drawings in suffi cient detail to allow for the completion of a project capital cost estimate with an accuracy of ±10%. In addition, R&S reviewed the existing electrical system and included the modifi cations required to integrate the new project into the existing plant electrical system. Deliverables included: • Review the conceptual design of the project completed to date by OMYA • Finalize the fl owsheet for the project. • Develop of the fi nal site plan. • General arrangement drawings. • Preliminary calculations to size the belt conveyors, dust collectors, and stilling shed for the primary truck dump hopper. • Finalize Equipment List • Power Study • Plans for Dust control (fugitive dust control at truck dump and dustless transfers) • Geotechnical specifi cations for borings, testing requirements, and required recommendations • Capital Cost Estimate • Final Report
AGGREGATELIMESTONE HANDLINGEXPERIENCE EXPERIENCE
Section 07 21 MARBLEHEAD LIME CO.
BUFFINGTON PLANT, BUFFINGTON, INDIANA
Engineering, procurement and construction of rotary kiln installation at the existing Buffi ngton Plant. The existing facility at Buffi ngton, Indiana, had three operating kilns, and the scope of supply on this project included furnishing and installation of two additional kilns, complete with all ancillaries. The limestone is stored in two silos (one new and one existing) each with a This project proved challenging in that 1,600-ton capacity. The limestone is reclaimed by variable speed weigh feeders a major portion of the equipment from the new silo, and via a splitter gate and a variable speed feeder from the used in the project had been previously existing limestone storage silo. Two new kiln feed belts were provided to feed used, and on-site refurbishing and kiln No. 4 and kiln No. 5. testing was required. The entire The coal is also stored in two silos, one new and one existing. Each coal silo has project took approximately 16 months a 750-ton capacity. The coal is reclaimed from the new coal storage silo by belt to become operational. feeders and by means of a splitter gate from the existing coal storage silo on twin weigh belt feeders. Each unit feeds 200 HP coal pulverizer mill for fuel supply. Two kilns were provided—each 16'-6 diameter by 300' long, complete with drive trunnions, lubrication system and cooling chamber. Each kiln had a separate dust collection system, consisting of a refractory lined expansion changer, dust housing, exhaust gas fan and kiln gas bag house, complete with reversing fan air locks, fi re protection and heat tracing. The processed material is collected on the existing product conveying system, modifi ed to handle the increased capacity. In addition to the kiln installation, modifi cations were done in the existing facility including the addition of a 24" reversible fi nes belt, a fi nes recycling system consisting of bucket elevators, screw conveyors and transfer belt conveyors for recycling of kiln or process fi nes. Screening and presizing for lime and pebble products also was part of the project scope along with a complete truck loading and product compacting system.
LIMESTONE HANDLING EXPERIENCE
22 Section 07 MORE EXPERIENCE
MARBLEHEAD LIME, PLEASANT GAP, PENNSYLVANIA Limestone handling facility. FRU-CON CONSTRUCTION, NORTH BRANCH PROJECT, BAYARD, WEST VIRGINIA Roberts & Schaefer’s broad engineering Engineering and procurement of a limestone handling system. capabilities give it the distinct advantage of being more responsive to customers. MARBLEHEAD LIME, GARY, INDIANA Kiln renovation. MARBLEHEAD LIME, CHICAGO, ILLINOIS Engineering services and bid preparation for a two-kiln line plant. JONES & LAUGHLIN CORPORATION, HARPER’S FERRY, VIRGINIA Limestone cleaning and crushing plant; engineering, procurement and construction.
AGGREGATELIMESTONE HANDLINGEXPERIENCE EXPERIENCE
Section 07 23 SAND HANDLING PROJECTS
PCC RAIL, SAND & GRAVEL PLANT, JAWORZNO, POLAND Engineering, Procurement & Construction for an addition to the sand and gravel plant in Jaworzno to wash and classify ultra fi ne industrial sand. The project involved the installation of two primary sizing screens, storage piles, reclaim feeders and conveyors, two batteries of classifying cyclones and 5 deck screens with the associated pumps, sumps and piping systems. ISOVER S.A., MINERAL WOOL PLANT, GLIWICE, POLAND Scope: Engineering, Procurement & Construction for an addition to the sand receiving yard and plant supply system. The project involved the installation of a new storage bin equipped with discharge side dosing batch weigh feeder providing very accurate batch sizes. Batches of sand were conveyed via a box type belt conveyor to melting furnaces. System was totally automated. R&S received a quality citation from ISOVER S.A. for excellence in engineering and execution. Above: PCC Rail, Sand & Gravel Plant, Jaworzno, Poland
Below: ISOVER S.A, Mineral Wool Plant, Gliwice, Poland
SAND HANDLING EXPERIENCE
24 Section 07 MORE EXPERIENCE
EAGLE ROOFING TILE PLANT, RIALTO, CALIFORNIA
Roberts & Schaefer Company was awarded a lump sum contract by Duncan Brothers for Burlingame Industries to provide detailed engineering services and mechanical and electrical equipment supply for a sand storage conveying system. The purpose of the project was to double the existing sand storage capacity for the Eagle Roofi ng tile plant near in Rialto, California. The system included Roberts & Schaefer Company’s an approximately 2,000-ton, above-ground storage bin to contain damp sand, commitment to the sand industry and 24"-wide belt conveyors to convey the sand from the existing drive-over includes complete engineering design storage bins to the new above ground bin. Additional belt conveyors were and construction services for handling included to reclaim sand from the new bin for transport to existing conveyors and processing of sand. that fed two existing roofi ng tile manufacturing plants. Three new conveyors and the extension or modifi cation of two existing conveyor were required.
AGGREGATESAND HANDLING EXPERIENCE EXPERIENCE
Section 07 25 MORE EXPERIENCE
PENNSYLVANIA GLASS & SAND CORPORATION BERKELEY SPRINGS, WEST VIRGINIA Engineering layouts, design and construction and installation screen tower(s) additions & personnel elevator. WEDRON SILICA, PRAIRIE STATE SILICA PLANT TROY GROVE, ILLINOIS Engineering layouts, design and construction of drying system, sand handling, storage and reclaim system. PENNSYLVANIA GLASS & SAND CORPORATION PACIFIC, MISSOURI Engineering layouts and estimate for slurry pumping system. AMERICAN STEEL FOUNDRIES ALLIANCE, OHIO Engineering layout and design—foundry sand reclamation—washing, drying and cooling. SILICA PRODUCTS COMPANY GUION, ARKANSAS Engineering and estimate study—sand screening, storing and handling. PENNSYLVANIA GLASS & SAND CORPORATION BERKELEY SPRINGS, WEST VIRGINIA Engineering layouts—boiler house bottom ash removal. PENNSYLVANIA GLASS & SAND CORPORATION MAPLETON DEPOT, PENNSYLVANIA Engineering layouts—dust collection at micron bagging station. PENNSYLVANIA GLASS & SAND CORPORATION MILL CREEK, OKLAHOMA Engineering layouts and design for two mill silica fl our grinding system including bulk storage, rail and truck loading.
SAND HANDLING EXPERIENCE
26 Section 07 MORE EXPERIENCE
PENNSYLVANIA GLASS & SAND CORPORATION BERKELEY SPRINGS, WEST VIRGINIA Engineering layouts and sand loadout system—furnished structural, mechanical and fabricated items. PENNSYLVANIA GLASS & SAND CORPORATION MAPLETON DEPOT, PENNSYLVANIA ENGINEERING Engineering layouts—dust collection at old screen tower. PENNSYLVANIA GLASS & SAND CORPORATION BERKELEY SPRINGS, WEST VIRGINIA Engineering layouts, design and construction rod mill installation— wet reduction of silica sand. PENNSYLVANIA GLASS & SAND CORPORATION MAPLETON DEPOT, PENNSYLVANIA Layouts and design, and installation slurry pumping system. PENNSYLVANIA GLASS & SAND CORPORATION MAPLETON DEPOT, PENNSYLVANIA Engineering layouts and design, and installation rod mill wet reduction system. AMERICAN STEEL FOUNDRIES GRANITE CITY, ILLINOIS Engineering layouts and design of foundry sand reclamation—washing, drying, cooling, chrome and sand extraction and water clarifi cation.
AGGREGATESAND HANDLING EXPERIENCE EXPERIENCE
Section 07 27 MORE EXPERIENCE
COLORADO LEIN WILLIAM R. BARNES COMPANY LAPORTE, COLORADO WATERTOWN, ONTARIO, CANADA 30 TPH Sand Dryer 10 TPH Sand Heater-Cooler COLUMBIANA FOUNDRY MILLWOOD SAND COMPANY COLUMBIANA, OHIO MILLWOOD, OHIO 10 TPH Sand Dryer-Cooler 65 TPH Sand Dryer KINGS MOUNTAIN FLORIDA ROCK INDUSTRIES MICA COMPANY INTERLACHEN, FLORIDA KINGS MOUNTAIN, 55 TPH Sand Dryer NORTH CAROLINA NOVA SCOTIA SAND & GRAVEL 20 TPH Dryer SHUBENACADIE, NOVA SCOTIA PRODUVISA SERVICIDOS, S.A. 50 TPH Sand Dryer-Cooler GARACAS, VENEZUELA CAROLINA SILICA, INC. 45 TPH Sand Dryer MARSTON, NORTH CAROLINA OTTAWA SILICA 90 TPH Sand Dryer OTTAWA, ILLINOIS 10 TPH Sand Dryer-Cooler OWENS ILLINOIS IONE, CALIFORNIA 120 TPH Sand Dryer-Cooler WEDRON SILICA CORPORATION WEDRON, ILLINOIS 60 TPH Sand Cooler
FLUID BED SAND DRYERS/COOLERS EXPERIENCE
28 Section 07 MORE EXPERIENCE
METALLURGIMPORT WARD IRON WORKS MOSCOW, RUSSIA (HOLMES FOUNDRY) 100 MTPH Sand Dryer WELLAND, ONTARIO, CANADA 25 TPH Sand Dryer-Cooler PENNSYLVANIA GLASS & SAND CORPORATION CAROLINA SILICA, INC. BRADY, TEXAS MARSTON, NORTH CAROLINA 115 TPH Sand Dryer 60 TPH Sand Dryer LYMAN-RICHEY SAND SOBIN CHEMICAL & GRAVEL COMPANY COMPANY (DIV. IMC) VALLEY, NEBRASKA SPRUCE PINE, NORTH CAROLINA 50 TPH Sand Dryer-Cooler 6 TPH Sand Dryer METALLURGIMPORT WEDRON SILICA COMPANY MOSCOW, RUSSIA BYRON, CALIFORNIA 30 MTPH Sand Dryer-Cooler 60 TPH Sand Dryer METALLURGIMPORT HARDY SAND MOSCOW, RUSSIA TUSCALOOSA, ALABAMA 10 MTPH Sand Dryer-Cooler 65 TPH Sand Dryer and Separate 65 TPH Sand Cooler WEDRON SILICA COMPANY EMMETT, IDAHO WEDRON SILICA COMPANY 60 TPH Sand Dryer LUGOFF, SOUTH CAROLINA 60 TPG Sand Dryer
AGGREGATEFLUID BED SAND EXPERIENCE DRYERS/COOLERS EXPERIENCE
Section 07 29 MORE EXPERIENCE
WHITEHEAD BROS. COMPANY ENGINEERING ONLY LUGOFF, SOUTH CAROLINA MONTEREY SAND COMPANY 75 TPH Sand Dryer MONTEREY, CALIFORNIA 50 TPH Sand Dryer SNC SERVICE LTD. ALGERIA SILICA PRODUCTS COMPANY 25 MTPH Sand Dryer-Cooler GUION, ARKANSAS 75 TPH Sand Dryer-Cooler COLUMBINE MINERALS WHEATRIDGE, COLORADO WEDRON SILICA PRAIRIE 25 TPH Sand Dryer STATE SILICA PLANT TROY GROVE, ILLINOIS ACME RESIN COMPANY 75 TPH Sand Dryer-Cooler OREGON, ILLINOIS 37 TPH Sand Cooler
FLUID BED SAND DRYERS/COOLERS EXPERIENCE
30 Section 07 FERTECO MINERACAO S.A.
SEPETIBA BAY, BRAZIL
Ferteco Mineracao S.A. (“Fertico”) the then third largest producer of iron ore of Brazil engaged Soros Associates, Inc. to undertake feasibility and later detailed design, supervision of fabrication and erection of a Dual Linear Loader (“DLL”) at its port terminal located at Sepetiba Bay, Brazil. Soros was initially engaged to undertake a feasibility study in that was later upgraded to a bankable study. Then Ferteco, after achieving compliance with then Brazilian Port Legislation, received authorization to proceed to implement and operate its own iron ore export terminal at Sepetiba Bay, approximately 80kms west of Rio de Janeiro. Through the feasibility study, Soros had identifi ed and recommended that a DLL would be the most economical loader design with respect to meeting the project requirements of loading up to Cape Size bulk carriers. Ferteco formed a new subsidiary, Companhia Portuaria Baia de Sepetiba (“CPBS”) who then engaged Soros to undertake the engineering of the DLL. This engagement was then expanded to include supervision of fabrication and erection of the DLL. The principal components of a DLL are the rear and front portals, bridge, shuttle, mast and boom. The DLL is an improved version of earlier Linear Loaders developed by Soros during the 1970’s. The Sepetiba DLL was developed by Soros to load up to 20Mtpa of iron ore exports into bulk carriers ranging from 30,000 to 230,000 DWT. The loader is designed with for continuous heavy-duty operation rated at 10,000tph. The boom luffs and shuttles in and out, in order to optimize hatch loading and minimizing free fall of product, thereby also assisting in achieving the required load rate. After completing a tender package based on the Basic Design of the DLL, Soros recommended a shortlist of worldwide experienced manufacturers (incl. Brazilian based manufacturers) and participated in the interview of the shortlisted parties. The contract was awarded to Bardella Industrias Mecanicas S.A. located in Guarulhos, Sao Paulo, Brazil.
PORT AND MARINE EXPERIENCE
Section 08 1 BATU HIJAU MINING PROJECT
PT NEWMONT NUSA TANGARRA, SUMBAWA, INDONESIA
Scope: Engineering, supply and commissioning of a concentrate feed conveyor and shiploader at the port, and a coal barge unloading and stockpile system at the power plant. The project consisted of a 1450 TPH, 36-inch-wide, 1417-foot-long, copper concentrate conveyor and shiploader. The copper concentrate conveyor is fed by two variable speed reclaim feeders located in the copper concentrate building. The reclaim feeders are fed by front end loaders. The copper concentrate conveyor feeds the shiploader. The shiploader slews through a 285-degree arc and incorporates a shuttling type boom and conveyor. The shuttling boom can provide reach from 41 feet out to 135 feet from the shiploader pivot. The shuttling boom conveyor transports the copper concentrate to the ship through a telescopic loading spout. An operator’s cab is provided on-board the shiploader with a radio control unit that permits remote operation. The project consisted of a 440 TPH coal barge unloading and stockpiling system, featuring a 165-foot-long unloading conveyor with a hopper that is fed from a front end loader. The hopper is located on the fl oating dock. The coal barge unloading conveyor is pivoted to allow vertical movement for varying tide levels. The coal barge unloading conveyor feeds a 2160-foot-long coal stockpiling conveyor with a stacking tube located at the head end. The conveyors are controlled from a control panel located near the dock.
PORT AND MARINE EXPERIENCE
2 Section 08 SERCO SODEXO DEFENCE SYSTEMS
ANNUAL CONDITION ASSESSMENT AND REPAIR & MAINTENANCE REPORTING
North Queensland Department of Defence – Five Year Term Contract. Serco Sodexho Defence Systems (“SSDS”) is a dedicated Prime contractor to the Australian Defence Organisation, directly employing and engaging Industry Providers for direct service delivery under contract bases for supplies, equipment and a range of other services including engineering works. Soros has a fi ve year term agreement with SSDS for the provision of engineering services associated with annualized condition assessment and reporting and planning of repairs and maintenance. Soros recently completed the 2009 annual engineering inspection of Defence facilities at Townsville (Ross River Army Base), Cairns (RAN Patrol Boat Base “HMAS Cairns”) and Thursday Island (Navy Wharf). In conjunction with its dive services partner Dermody Diving both the topside and underwater structures of the wharves were investigated, providing a thorough audit of all possible degradation and failure of structures. Audit and inspections were undertaken in accordance with Defence procedures for OH&S and for compliance with Australian and International Standards for condition and rating. Soros then completed the inspection report providing a number of options and recommendations as well as a program for repairs and maintenance including: • Further detailed investigative studies; concrete borehole sampling, structural analysis of failed concrete sections; • Remedial repair options, offering a number of solutions each offering different solutions itemised by cost • Maintenance Schedule for Structural and non-structural furnishings
PORT AND MARINE EXPERIENCE
Section 08 3 CARIBBEAN ISPAT LIMITED
DIRECT REDUCED IRON (DRI) MATERIAL HANDLING FACILITY, PORT LISAS, TRINIDAD
Engineering, procurement, construction, start-up and commissioning. Roberts & Schaefer Company was awarded a design and supply contract from LGZ Steel Partners for a direct reduced iron (DRI) material handling system in Port Lisas, Trinidad and Tobago for Caribbean Ispat Limited. The project included a conveying system that would accept iron oxide at a rate of 2800 Tons/Hr and transport it to a screening station where the material is sized and conveyed to a series of fi ve-day bins. From the day bins, the material is conveyed to a MIDREX furnace and the product becomes direct reduced iron. The DRI is then conveyed to three gas-tight silos that feed a series of conveyors that transport the DRI to the melt shop or a product storage building. The material is stored in the product storage building by a tripper and traveling bridge structure that forms DRI piles within the product storage building. The DRI is reclaimed at a rate of 2,000 TPH through a series of slide gates and reclaim conveyors and sent to the dock where the material is loaded into ships by a dock conveyor and traveling tripper.
PORT AND MARINE EXPERIENCE
4 Section 08 ALCOA
CONDITION ASSESSMENT OF A RADIAL SHIPLOADER
Condition assessment services were provided to Alcoa’s Surinam operations and the related radial shiploader located at Paranam on the Surinam River, Suriname (South America). This work was commissioned on the basis of Soros’ ongoing relationship with the operations in Suriname that had previously included provision of: • The original design and construction drawings of the radial loader, along with client representation through the engineering, construction, and the commissioning phases; and • Structural and mechanical design for the modifi cation for the inclusion of a dust collector system, and fi eld supervision for this addition. The design work provid- ed included strengthening the existing boom structure, supporting shuttle frame. Leveraging this previous experience with the Alcoa operation and specifi cally the shiploader, Soros was then engaged to work in conjunction with Hatch Associates, and provided the following condition assessment services that comprehended: • Structural review of structural joint separation, deformity of the portal frame and traverse trucks; • Bird nesting of the drum hoist rope; • Boom pivot pin not working resulting in keeper plate bolt failure; and • General overall condition assessment of the radial boom. • After completion of the visual inspections, in non-operating mode noting the poor condition of the machine at the time, design detail drawings were developed to correct all structural problems, along with drawings to show how the structure was to be supported to carry out joint replacement and strengthen truss members. The on-site component of the work had duration of one week, and the reporting, procedure writing and repair programming duration was around one month. The documentation was furnished to Hatch Associates, who were then charged with completing the remedial and corrective works in accordance with the reports.
PORT AND MARINE EXPERIENCE
Section 08 5 ILLINOIS CENTRAL RAIL MARINE TERMINAL
ST. JAMES PARISH, LOUISIANA
Engineering, procurement, startup and construction management services, Several different products are handled at this facility, including coal, petroleum coke, metallurgical coke, iron ore pellets and direct reduced iron (DRI). The project required more than 16,000 feet of conveyor with inbound/ outbound reversibility, as well as: a travelling grab unloader to unload metallurgical coke and iron ore pellets from river barges and ocean vessels at a rate of 3000TPH to either a travelling stacker or the neighboring DRI facility; a travelling shiploader to load ocean vessels with DRI (1100TPH), petroleum coke (1100TPH) and coal (3000TPH); a barge loader (supplied by Roberts & Schaefer) to load river barges with DRI (1100TPH) and coal (1700TPH); a rotary car dumper to unload coal (3000TPH) and petroleum coke (3000TPH) to the travelling stacker storage or onto conveyor belts for direct loading to ocean vessels and river barges; a unit train batch weigh loadout to load rail cars with DRI and petroleum coke; and a travelling stacker to stockpile iron ore, coal, petroleum coke and metallurgical coke. Reclaiming was accomplished by front end loaders feeding portable conveyors and dozer traps.
PORT AND MARINE EXPERIENCE
6 Section 08 AES – PUERTO RICO
TOTAL ENERGY PLANT, GUAYAMA, PUERTO RICO
Engineering, procurement, construction, start-up and commissioning of the coal, limestone and aggregate material handling systems included ship loading and unloading; the contract was awarded by Duke/Fluor Daniel. The coal and limestone are received in self-unloading ships. The ash is shipped out in geared ships or ocean barges. The dock area consists of the coal/limestone receiving hopper with belt feeder and the aggregate ship loader. The single path series of conveyors with a length of 3,600 feet from the dock to the material handling areas are reversing conveyors and handle all three materials. The coal or limestone is conveyed from the 50,000-ton capacity ships at 3,000 TPH to the storage areas and the aggregate is conveyed at 1,800 TPH from the storage area to the 9,000-ton capacity ocean barges. The coal handling stockout and reclaim system consists of two stacking tubes with a total pile capacity of 98,000 tons and a series of ten variable rate vibratory feeders located below the piles for reclaim at 720 TPH. The limestone stockout and reclaim system consists of a conveyor from the second coal stacking tube to the limestone stacking tube enclosed in a dome for dust and moisture control. The bottom and fl y ash are combined from the ash silos and conveyed to the initial storage area. This manufactured aggregate (ash product) is reclaimed by mobile equipment to a hopper with a 1,800 TPH feeder breaker and sent to the ship loader via the reversing conveyor system. The shiploader is equipped with a telescopic spout and a retractable boom conveyor. The aggregate systems include wet suppression for dust control. All unloading, stockpiling, reclaiming, crushing, and ship loading operations are controlled by a series of programmable logic controllers (PLCs).
PORT AND MARINE EXPERIENCE
Section 08 7 DANSKAMMER GENERATING STATION
COAL HANDLING SYSTEM, MARLBORO, NEW YORK
Scope: Engineering, procurement, construction, start-up and commissioning, The project is comprised of self-unloading vessels (30,000 ton DWT class) which deliver coal to the existing Roseton Dock. This tonnage is three times the amount now delivered by rail. The dock was modifi ed to receive additional coal. The coal receiving hopper and a belt conveyor were installed on a marine cell in which the vessel unloads at rates up to 2,000 metric TPH. The hopper is enclosed to contain fugitive dust. The self-unloading vessel with coal is breasted against the existing dock. The unloading conveyor boom is positioned over the receiving hopper and inside the enclosure. Conveyor BC-1, located under the receiving hopper, conveys coal to Transfer Tower 1, then the coal transfers to Conveyor BC-2 at the rate of 2,000 MTPH. Conveyor BC-2 travels to Transfer Tower 2, where the coal is proportioned between the existing stockout (500/1,000 MTPH rating) via Conveyors B-3 and BC-4.
PORT AND MARINE EXPERIENCE
8 Section 08 PORT OF BRISBANE
NEW HOPE CORPORATION LIMITED
Scoping Study for Upgrade or Replacement of Shiploader, QBH Coal Terminal, Port of Brisbane (QLD), Australia Soros undertook a condition inspection of the shiploader, which comprehended: • Interviews with QBH management, operations and maintenance personnel using a set questionnaire; • Review of maintenance and operating records; • Review of maintenance access (especially to jetslinger) and related safety matters; • Review of drawings (as-built through to modifi cations) and associated reports for the condition assessment and wharf capacity analysis; • Observation of the machine both in working and static modes, along with recording of notes and photographs; and • A detailed report identifying key issues associated with safety, environmental and operating matters. Soros was able to establish a solid justifi cation for the replacement of the existing ship loader and the next phase of work required Soros to complete the scoping of replacement design options and provide a capital cost estimate for such options and also benchmark the estimate against other designs. The QBH wharf is narrow by modern standards and the elevated feed conveyor running parallel to the wharf is to remain in-situ. These constraints in which the new shiploader design must fi t mean that the replacement of the shiploader will see a custom applied design. Soros is continuing to work with QBH to deliver a suitably designed shiploader to meet these requirements and the overall design criteria.
PORT AND MARINE EXPERIENCE
Section 08 9 NORTH CAROLINA STATE PORTS AUTHORITY
CONDITION ASSESSMENT & REPORTING OF DRY BULK AND LIQUID HANDLING MARINE TERMINALS, MOREHEAD CITY, NORTH CAROLINA
Soros was awarded a three year term contract for the provision of condition assessment and reporting at the Morehead City Terminal. Soros’ fi nal report addressed: • Problem areas and recommended solutions for each (including environmental issue such as dust emission and bird excrement); • Items requiring repair or remediation, and associated priority ranking; • Time schedule and budget cost to repair/modify each problem item; and • Improvements that would aid it the operation and maintenance of the facility and budget cost for such improvements and the benefi t each contribute. With a range of issues and items being reported throughout the contract period, some of the issues and items reported included: • Use of a front end loader for reclaim in the dome storage, and the related dust; • A tripper rail lifting off from the concrete fl ooring; • Corrosion due to product build-up in conveyor A-frames; • Thickness testing for tanks; • Defi cient electrical drawings and the need to produce a new, overall single line diagram; • The need to acquire inventory of soon to be obsolete Allen-Bradley processors.
PORT AND MARINE EXPERIENCE
10 Section 08 BALTIMORE GAS & ELECTRIC COMPANY
BRANDON SHORES, UNITS 1 AND 2, ANNE ARUNDEL COUNTY, MARYLAND
Complete project management, detailed engineering, procurement and construction services were provided under a turnkey contract. This contract covered the major coal handling facilities serving two new 620 MW units of the Brandon Shores Power Plant on the Patapso River. A major feature of the coal handling facility is a system to receive coal by 7,000-ton capacity barges. This installation involved extensive marine works, including a 3-barge dock, jetty way and a barge haul system to move the barges during unloading. A high capacity 4,000 TPH continuous bucket elevator barge unloader was installed on the new jetty way. An innovative construction method was developed for the assembly of the barge unloader. The entire machine was pre-assembled on shore and shipped in one piece on a fl oating barge crane. The barge unloader discharges to a high capacity 72" collecting conveyor. The conveyor is in a fully enclosed ventilated gallery. Coal is conveyed over the water and inland to a transfer station some 2,100' away (of which 1,700' are over water). Once the coal is delivered on shore it is sampled at a transfer station. It is then either directed to a radial stacker (discharging to a ground storage system serving the existing Wagner Station), or onto another conveyor serving the main coal storage stockpile system for Units 1 and 2. This conveyor discharges to another transfer station. From here coal is directed to either the inactive storage pile (by a cantilevered conveyor fi tted with a telescopic chute), or the active storage pile (by the yard belt for delivery to a stacker reclaimer). The stacker reclaimer has a 20' diameter bucket and is fi tted with a trailing tripper and stacking slewing boom. 4,400 TPH of coal handling capability.
PORT AND MARINE EXPERIENCE
Section 08 11 PORT OF LYTTELTON
CHRISTCHURCH, NEW ZEALAND
Soros was engaged by Opus International Consultants Ltd, NZ (“Opus”) to undertake an investigation into the means of achieving an increase in throughput from 18,000tpd to 25,000tpd and the capability to load larger vessels that the existing Panamax bulk carriers. Alternative concepts for the upgrade of the terminal were prepared and compared. The 30 year old shiploader was examined and upgrade measures and repair works were identifi ed. The outreach and throw of the machine were investigated in order to facilitate loading of larger vessels, with the latter being the solution that was eventually implemented. Individual measures to upgrade the electrical and control systems of the terminal, conveyors, train unloading and reclaim system were identifi ed and implemented. The initial study work completed by Soros looked at various options for the upgrade and the respective equipment. An opportunity was identifi ed to utilize second hand coal handling equipment. Soros then re-engineered to construction level the equipment to suit its application in the Lyttelton stockyard. Soros also produced specifi cations to procure replacement/new equipment and provided the consulting support during the procurement, fabrication and construction phases of the project. Detailed shiploader modeling identifi ed the need to add a telescopic chute and jet-slinger, along with increasing belt speed, adding a motorized cable reeling system and associated controls. Soros was also called upon to assist and report on a commissioning troubleshoot brief. In 2008 Soros and Opus agreed to jointly work together to deliver to LPC and its client Solid Energy New Zealand Ltd further consultancy services for the upgrade and expansion of the coal terminal at the Port of Lyttelton. The objective of the consultancy services was to identify and assess plausible options for expansion of the materials handling systems (“MHS”) in accordance with proposed plans for the overall expansion of the stockyard and any possible development staging. Soros provided its services through three stages of the project: • An ideas defi nition phase • Prefeasibility which required conceptual design and ±30% capital estimates; and • Feasibility which required preliminary design with ±20% capital estimates.
PORT AND MARINE EXPERIENCE
12 Section 08 CINERGY SERVICES
ZIMMER PLANT, MOSCOW, OHIO
Engineering, procurement, construction, start-up, and commissioning of the gypsum handling and barge loading system. The gypsum handling and barge loading system is designed to receive the gypsum at the barge loader conveyor from either the existing radial stacker or by front-end loaders into a dozer trap. The 36-inch barge loader conveyor has a capacity of 600 TPH and is 1,014-foot long. The conveyor has a 320-foot span over the existing 200-foot diameter thickener and pump house. The conveyor transports discharges the gypsum into a moveable-loading chute with a telescoping spout. The chute/spout is designed to fi ll covered barges through open hatches, which requires that the chute/spout be able to move laterally and extend and retract. A certifi ed belt scale weighs the amount loaded into each barge. A new barge haul system positions the barges. A new river cell was constructed as part of the project to support the conveyor structure and the barge haul equipment. A programmable logic controller (PLC) controls the entire operation.
R&S/Soros has unmatched experience in the loading and unloading of ships and river barges and designing the marine infrastructure to support it.
PORT AND MARINE EXPERIENCE
Section 08 13 COMPANHIA MINERA DOÑA INES DE COLLAHUASI
CONDITION ASSESSMENT & REPAIR OF CONCRETE MARINE AND LANDSIDE STRUCTURES, PUERTO PATACHE, CHILE
The client had noticed that deterioration of the reinforced concrete structures was occurring in both landside (shed slab) and marine installations. CMDI retained Soros Associates, Arze Recine y Asociados, and Wiss, Janney, Elstner Associates (S.A.W.) to undertake a four phased investigation to identify the cause and make a recommendation as to how best to correct the ongoing problem. Soros’ investigation and report indicated that serious reinforcement bar corrosion had occurred and that the client could expect if this problem was not corrected that serious failure of the supporting structure would also occur. Further into the investigation Soros returned to site and assessed the extent of reinforcement bar corrosion. In some samples it was found that loss due to corrosion was as high as 50%. The inspection of all foundations showing signs of failure was undertaken, and each site of corrosion was then classifi ed according to criticality and potential failure, with a scale ranging from in need of repair through to replacement. Soros also provided a cost estimate and supporting schedule of the engineering and repair work to be done. The work required included routing and sealing of cracks, repair of delaminations, coating marine structures, installation of cathodic protection as well as demolition of some structures and complete replacement. Soros’ fi ndings were discussed with the CMDI, who then engaged Soros and its Chilean partners to provide further assistance by way of: • Defi ning the scope of works for the required repair and remedial works; • Assist with tender documentation and review of submissions and respondents, and make recommendations for contractors; • Field supervision, construction inspection and quality control.
PORT AND MARINE EXPERIENCE
14 Section 08 PT FREEPORT
INVESTIGATION OF STEEL CORROSION, PRODUCT SPILLAGE AND UPGRADE OF COPPER CONCENTRATE RECLAIM AND LOADER, PORT OF AMAMAPARE (PAPUA), INDONESIA
Due to a number of conditions such as surge loading, off centering loading, impact loading, under-designed system, and the transloading operation, a considerable loss of unrecovered product was resulting. Although there was no execting method to accurately assess the loss, it was estimated to be 0.5% to 1% of the yearly throughput, which amounts to a loss of US $10M to $15M per year. In order to reduce the loss of product, PT Freeport had decreased the handling rate from 2,000tph to 1,400tph. At the request of PT Freeport Indonesia, Soros carried out a site investigation of PT Freeport’s copper concentrate shiploading and reclaim system. The objective of this site visit was to: • Assess current cause of spillage of copper concentrate; • Determine and recommend feasible options for containment and recapturing of spillage; • Assess adequacy of the existing system; • Provide a short term improvement plan; • Provide a long term solution plan; • General assessment of structural steel corrosion; and • Provide a budget cost estimate for a new shiploader capable of loading vessels up to 55,000 DWT without the need to shift the vessel Soros undertook a detailed inspection and observation of the plant, both under load and static modes. Soros also met with key operating and maintenance personnel and review all associated documentation. Based on Soros’ observations of the system under load and no load conditions, Soros made a number of recommendations and when implemented will improve operations, reduce maintenance and loss of product.
PORT AND MARINE EXPERIENCE
Section 08 15 OXBOW CORPORATION (FORMERLY AIMCOR)
CONDITION ASSESSMENT OF A PET COKE LOADING FACILITY, PORT OF TEXAS CITY, TEXAS
Soros provided to Aimcor a structural assessment of the existing loader which included: • Review of existing design drawing and calculations; • Site evaluation Inspection; • Determination of condition of the main and secondary members including all critical joints; • Due to the extent of corrosion, carried out a material thickness check of all main structural members; • Based on fi eld measured material thickness recalculated the member strength to determine its suitability for the imposed load/ stress; • Prepared structural modifi cation drawings for all over stressed members; • Prepared reinforcement / replacement joint detail drawings; • Prepared fi eld structural installation instruction; • Expected useful life with and without repairs; • Estimated cost for structural repairs; • Estimated outage period to carry out structural modifi cations; and • Cost of new replacement and including a temporary system to continue their loading operation.
PORT AND MARINE EXPERIENCE
16 Section 08 CREDIT LYONNAIS SINGAPORE
ANNUAL EVALUATION OF COAL BARGING TRANSPORT INFRASTRUCTURE, KALIMANTAN AND JAVA, INDONESIA
Soros was appointed to a six year term contract by Credit Lyonnais Singapore to undertake annual inspection of the coal barging transport infrastructure. The objective of these inspections was to carry out detailed assessment of the transport chain to ensure reliability of the supply chain to the power plants. The Soros program of activities included: Retrieve background information to compare original project objectives, last fi ndings report results and this report fi ndings; Prepare an activity check list of items that need to be investigated for each link of the coal transportation system; Dispatch marine and material handling specialist to the site; Meet with the onsite project manager and obtain his input as the current situation and to determine what changes and or improvements were made; Meet with operations and maintenance personnel at each coal handling transfer and obtain their input; Obtain and assess yearly operating and maintenance records for the complete transportation link including; barge operation and river data; Record all data and prepare a daft fi ndings report including suggested improvements that will reduce cost and improve the operation; Review draft fi ndings report with project manager and record his comment; and Furnish a fi nal report which outlines the fi ndings of the assessment. With the various elements of the transport chain being examined annually to assure adequate coal supply to the Paiton Power Plant, aside from truck transportation and barge transportation, particular consideration and assessment was given to the shipping channel at the exit of the river and the availability of the berths at the Pulau Laut Terminal. In all the reports the coal transport was reconfi rmed to be adequate and reliable for the next 20 years. It was learned that another company crossed the open sea to Java directly with river barges. Therefore Soros was asked to examine that Alternative, which eliminated the need of transhipment of coal from barges to Handymax at the Pulau Laut Coal Terminal. The outcome of this investigation [which included wind, waves and weather related research at the Java sea], confi rmed that direct shipment of coal in barges was a viable alternative.
PORT AND MARINE EXPERIENCE
Section 08 17 CARGILL CROP NUTRITION
CARGILL CATFISH
In early 2003, Cargill Crop Nutrition commenced a study for the upgrade of their existing bulk handling dock to accommodate Panamax sized ships, additional truck and rail unloading of dry products, and increase the export of dry products to a rate 5M tons per annum over a 3 to 7 year period Roberts & Schaefer was awarded the contract to complete the feasibility study. Staff from R&S and Soros visited the site to obtain preliminary information and discuss project objectives. Further visits were to observe the loading of two bulk carriers and the unloading of a sulphur barge. The scope of work required R&S and Soros to assess options for handling the increased freight task in each stage and provide design and cost estimates. Phase 1 of the study was to determine the best means and methods for allowing the import of 500,000 tons per annum of dry products by truck and then exporting 2.5Mtpa via Panamax or Handymax vessels from the facility. Phase 2 would see an increase in the export of dry products to 5Mtpa by receiving 2.5Mtpa of dry products by rail from Bartow and Green Bay plants. Also included in the study was a site and logistical review of existing systems and truck paths for the added truck traffi c resulting from implementation of the project. With the increased traffi c into the Riverview plant, a review of the entrance into the plant was also completed. The then current dock facilities, including the existing ship loader, the depth of the channel, and the length and depth of the berth, were not capable of accommodating Panamax sized vessels. The study included methods and means for upgrading to allowing the use of Panamax vessels (deepening dredging of berth pocket and turning basin while keeping the existing facility operational. The existing ship-loading rate was approximately 750tph and it was planned to remain at this rate in Phase 1. This tonnage rate was then to be increased to 2,000tph by way of introducing a new shiploader in Phase 2, thereby providing faster loading of Panamax vessels. Due to the increased volume of product being shipped, a review of adding an additional 150,000 tons of dry products storage was also completed which resulted in modifi cations to the shed and conveyor systems.
PORT AND MARINE EXPERIENCE
18 Section 08 SAVAGE RIVER MINES LIMITED
PORT LATTA OPEN SEA ORE TERMINAL TASMANIA
The project was an open sea loading berth for magnetite ore pellets at Port Latta, in northwest Tasmania. The facility enabled the development of the magnetite deposit at Savage River for Savage River Mines Limited. An open cut mine, concentrator plant and township were developed at Savage River, 100 km south west of Burnie. A pipeline was constructed from the concentrator to a palletizing plant and dedicated port facilities at Port Latta. Production commenced in 1966 supplying Japanese steel mills with 45 million tons of palletized magnetite ore over a 20 year period Soros was responsible for the feasibility study and complete detailed design of the facility which comprises a 1.8 km approach trestle and dual radial shiploaders for the continuous loading of ore carriers up to 125,000 DWT at a rate of 3,500 tons per hour. The ore stockyard utilized a rail mounted stacker and two crawler mounted bucketwheel reclaimers. An auxiliary harbor with breakwater for tugs, lineboats and maintenance barges also accommodated fl oating construction equipment. A large crane barge was mobilized from San Francisco and towed 16,000 km to the site. The marine structures were prefabricated steel jackets and precast concrete caps. Initially a temporary outer jacket with spud legs was installed and leveled. Then followed the second permanent jacket, through which rock sockets were drilled into the bedrock for the insertion of pin piles that were subsequently grouted.
PORT AND MARINE EXPERIENCE
Section 08 19 ALCOA
BUNBURY ALUMINA LOADER WESTERN AUSTRALIA
Soros provided complete detailed design engineering for a shiploader and marine facilities at Bunbury, Western Australia, for Alcoa. The alumina loading facility includes a linear loader delivering 2,000 tons per hour of alumina to vessels up to 50,000 DWT. The structures comprise four berthing dolphins, unloader support platform and an approach bridge. The linear loader was invented and patented by Soros in the 1970’s to increase the ship coverage obtained for a given overall shiploader length, compared with a radial (or quadrant) loader which was also developed by Soros in the 1960s. The linear loader has a variable span slewing bridge supported at the front on a turntable that travels on a linear track parallel to the vessel. The support at the rear pivot allows the bridge to rotate and slide. The loader was designed with a high effi ciency collection system for dust free operation. The marine structures are supported on steel tubular piles anchored to the rock seabed with drilled in spuds. This was the fi rst fully enclosed bulk loading facility in Australia, an environmental ‘fi rst’ at the time and the shiploader design was later recognized with an award refl ecting this advancement.
PORT AND MARINE EXPERIENCE
20 Section 08 NEW SOUTH WALES DEPARTMENT OF PUBLIC WORKS
PORT KEMBLA COAL TERMINAL PORT KEMBLA, NEW SOUTH WALES
Soros Associates, in collaboration with Soros Longworth and McKenzie, provided to the New South Wales Department of Public Works complete project management services which included feasibility study, operational simulation, detailed engineering design of all civil works and structures, bid evaluation, assistance with construction supervision, inspection and start-up. The Port Kembla Coal Terminal development featured dredging, seawall and reclamation, onshore foundations, marine structures, site civil and road works, rail car and truck dump facilities, conveyor system, stackers, reclaimers, shiploaders, environmental services and controls and service and administration buildings. The project commenced in 1979 and was completed in 1982. Phase 1 of the development catered for an annual capacity of 16 million tons for 16 grades of coal, with provision for expansion to 22 million tons in Phase 2. An interesting note is that PKCT has performed at 18 million tons per annum (Mtpa) (on a monthly annualized basis) in recent times. Vessels to be loaded in Phase 1 were 120,000 DWT to full draft and 160,000 DWT to partial draft. During March 2007, a record performance at PKCT was achieved with loading the largest cargo uplift of 166,000 tons onboard the Sen-Oku and achieving a displacement of 206,000. Phase 1 provided: • 5 km of high capacity conveyors • train unloading within one hour • 3 lane road over a covered slot storage enabling 9 trucks to unload simultaneously • automatic washing of trucks before leaving the terminal • multiple stackers to eliminate train unloading delays • coal reclamation by two 6600 tph bucketwheels • two travelling shiploaders fed by a single 6600 tph conveyor • automatic stockpile dust suppression spray system actuated by inventory, wind speed and direction • designed system redundancy allowing operation with any single major machine out of service • open deck wharf minimizing cost of marine construction SLM received an Award of Merit from the Association of Consulting Engineers Australia for its work on the Port Kembla Coal Terminal project. Current throughput at PKCT is 11.7 Mtpa of coal and capacity of 16-18 Mtpa. As a result, PKCT has spare capacity of 6 million tons available, which is unique compared with other coal terminals on the Eastern Seaboard of Australia.
PORT AND MARINE EXPERIENCE
Section 08 21 MARITIME SERVICES BOARD OF NEW SOUTH WALES
KOORAGANG COAL TERMINAL NEWCASTLE, NSW
Preliminary concept designs and cost estimates for the Kooragang Coal Terminal at Newcastle were provided to the Maritime Services Board (“MSB”) of NSW by Soros Associates and its affi liate Soros Longworth & McKenzie. Later, the detailed engineering contract initially entered into with the MSB was assigned over to BHP Company Pty Ltd (“BHP”), who had been appointed as project managers. The project featured geotechnical investigations and pre-loading concepts, conceptual design and master planning of the staged development, preliminary engineering, cost estimates, detailed design and contract documentation for marine and civil works, foundations, structures, services, environmental controls and conveyor equipment contracts, tender documents and bid evaluation for shiploaders, reclaimers and stackers. Construction support was also provided to the project manager, BHP. The state of the art coal terminal was designed for an initial capacity of 15 Mtpa with 40 different grades of coal and for expansion to 50 Mtpa with 100 grades. Other principal design features included: • Unloading of trains with 3200t payload in 30 minutes at a rate of 7300 tph (then a record) • Shallow railway unloading pit used a 6,600 tph belt feeder 3.2m wide, VVVF drive (then a record belt width) • Multiple 7,300 tph stackers to eliminate waiting time between trains with different grades • Coal reclaimed by 8,800 tph bucketwheel reclaimers, then the world’s largest • Shiploading system with a booster bin, fed by over 3.6 km of high capacity conveyors, achieved a peak shiploading rate of 12,000 tph into vessels ranging from 25,000 DWT to 180,000 DWT • Open deck wharf minimized cost of marine construction • Dredged pull off waiting basin enabling tidal departures, increasing berth availability (later covered with second and third stage berths and loaders) • Access provision for main conveyor duplication (in later years completed) • Extensive environmental safeguards including covered conveyors, noise control, coal pile spray systems and landscaping.
PORT AND MARINE EXPERIENCE
22 Section 08 MORE EXPERIENCE
CONSTELLATION ENERGY, BRANDON SHORES POWER STATION, BALTIMORE, MARYLAND Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; the contracts was awarded by URS Washington Group. The limestone handling system is designed to receive limestone from 2,000 or 4,000-ton capacity barges with a rotary clamshell bucket crane. The material is unloaded and conveyed at 1,500 TPH through a series of transfer towers to either a storage dome or a stacking tube (inactive storage pile).
Above: Constellation Energy, Brandon Shores Power Station, AMERICAN ELECTRIC POWER, MITCHELL PLANT, Baltimore, Maryland CRESAP, WEST VIRGINIA Below: American Electric, Power, Mitchell Plant, Engineering, procurement, construction, startup and commissioning Cresap, West Virginia of the limestone and gypsum handling systems; the contract was awarded by E & C Group, Inc. The limestone handling system is designed to receive limestone from 1,000 to 2,000-ton barges with a rotary clamshell bucket crane. The receiving hopper is provided with fog type dust suppression. Gypsum is reclaimed from the storage building with a traveling portal scraper reclaimer and conveyed at 1,000 TPH to either barge loadout or the wallboard storage building. Barge loadout is through a transfer house and onto a barge loadout shuttle conveyor equipped with a telescopic chute.
PORT AND MARINE EXPERIENCE
Section 08 23 MORE EXPERIENCE
SOUTHERN INDIANA GAS & ELECTRIC, CULLEY STATION, NEWBURGH, INDIANA Engineering, procurement and construction of a limestone unloading, storage and reclaiming system. The limestone is delivered on river barges and unloaded by a clam-shell type barge unloader. The unloaded material is delivered to a receiving hopper located on a fl oating barge. The barge is fi tted with drainage pump and is anchored to two 20’ diameter concrete capped river cells.
TVA GALLATIN, FOSSIL PLANT, GALLATIN, TN Southern Indiana Gas & Electric, Culley Station, Newburgh, Indiana A complete design-build contract for a 1400 TPH Barge Unloading Facility including the associated material handling system. Complete marine facilities to dock and unload barges, as well as tugboat moorings are included. The project also includes a clamshell barge unloader, double-roll crusher, and a sampling and service building. The turnkey project is based on a feasibility study completed earlier by R&S. DAYTON POWER & LIGHT, STUART GENERATING STATION, ABERDEEN, OHIO Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems. The limestone handling system is designed to receive limestone from barges and convey the limestone at 1,000 TPH through a series of transfer towers to either an elevated stockout conveyor with a traveling tripper or to divert some limestone to the storage bins at the limestone preparation building. The gypsum is conveyed at 500 TPH to the barge loadout area and onto a barge loadout shuttle conveyor equipped with a telescopic chute. Alternately, gypsum can be directly transferred from the radial stacker through a transfer hopper and conveyors to the barge loadout shuttle conveyor.
PORT AND MARINE EXPERIENCE
24 Section 08 MORE EXPERIENCE
WALLARAH COAL COMPANY, CATHERINE HILL BAY COAL LOADER, NSW The Catherine Hill Bay Colliery south of Newcastle supplied much of the coal to Balls Head in vessels called “60 milers”. Part of the pier and loader were severely damaged in storm conditions, Soros designed repairs to rehabilitate both pier and loader. COAL & ALLIED LIMITED, COAL TRANSSHIPMENT TERMINAL, BALLS HEAD BAY, SYDNEY A low cost solution to modernizing an existing facility (then over 70 years old) made maximum reuse of the existing stockpile and reclaim structure. The jetty was reconstructed and the work included remote-controlled bin gates, travelling feeders, reclaim conveyors, twin wharf conveyors and a new 2000 tph travelling loader for the loading of 30,000 DWT coal carriers. The construction works for the upgrade of the transshipment facility were undertaken by Malco Industries of Adelaide, who later received an award for Excellence in Engineering from the Institution of Engineers Australia. MT NEWMAN MINING CO. PTY LTD, IRON ORE SHIPLOADING TERMINAL, PORT HEDLAND, WESTERN AUSTRALIA Soros conducted a study to identify existing bottlenecks at the terminal, Wallarah Coal Company, Catherine Hill Bay Coal Loader, NSW recommend solutions for product quality improvement, loading larger cargoes, improved shiploading rate and expanded stockyard. Signifi cant improvements were the expansion of the stockyard area from 4.8 to 6.5 million tons and an increase of system capacity from 36 Mtpa to 46 Mtpa. CYNERGY SERVICES, MIAMI FORT STATION, NORTH BEND, OHIO R&S was awarded a turnkey contract from Cinergy Services for a limestone and gypsum material handling system at the Miami Fort Station. The limestone is received from a barge unloading station and conveyed to a limestone stockout pile at 700 TPH. Limestone is reclaimed with two hoppers and belt feeders to two day bins in the limestone preparation building. The gypsum is received from the dewatering building vacuum belt feeders. From there it is conveyed at 160 TPH to a stockout pile or an emergency stockpile. Gypsum is reclaimed with a reclaim hopper and belt feeder and conveyed to a barge loadout station.
PORT AND MARINE EXPERIENCE
Section 08 25 MORE EXPERIENCE
AMERICAN ELECTRIC POWER, CARDINAL PLANT, BRILLIANT, OHIO Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; the contract was awarded by Black & Veatch The limestone handling system is designed to receive limestone from river barges at a receiving hopper with a vibratory feeder. The limestone is conveyed at 1,000 TPH to a 27,000-ton limestone storage pile and discharged through a telescopic chute. One conveyor with telescopic chute conveys the gypsum to a 6,800-ton waste gypsum stockpile. The other conveyor transfers the gypsum to an enclosure to form a 16,000-ton commercial gypsum stockpile. Gypsum is reclaimed from the commercial pile by two hoppers with belt feeders and conveyed at 1,000 TPH to a traversing hopper with telescopic chute for barge loadout.
HAMERSLEY IRON PTY LTD IRON ORE TERMINAL, American Electric Power, Cardinal Plant, Brilliant, Ohio PORT DAMPIER, WESTERN AUSTRALIA A master plan study was undertaken by Soros for the phased expansion of East Intercourse Island and Parker Point iron ore terminals from 45 to 90 Mtpa. Comprehensive computer simulation was developed to encompass all aspects of port operations from rail unloading to determine the effects on terminal throughput of proposed improved operating practices and the supply of ore from new mines. Development of port facilities was recommended to meet increasing throughput by systematic modifi cations and/or additions for least capital and operating costs. NOYES BROS PTY LTD OFFSHORE CLINKER AND CEMENT TERMINAL, GLADSTONE, QUEENSLAND A study was undertaken to evaluate the feasibility of importing clinker and exporting cement over an offshore terminal. TEXAS GULF SULPHUR COMPANY OFFSHORE IRON ORE TERMINAL, NORTHWEST WA Under a joint feasibility study to develop Hancock & Wright’s iron ore tenements, Soros studied the export of iron ore from the mainland by tug and barge to nearby Delambre Island where a stockpile was to be established. The island had deep water close to its western shore and a loading facility with short trestle was proposed. As the iron ore market weakened not long after the study, the project did not proceed.
PORT AND MARINE EXPERIENCE
26 Section 08 MORE EXPERIENCE
NEW SOUTH WALES DEPARTMENT OF PUBLIC WORKS & COLLIERY PROPRIETORS ASSOCIATION, OFFSHORE COAL TERMINAL, COALCLIFF The New South Wales Department of Public Works & Colliery Proprietors Association engaged Soros to undertake a feasibility study for the transport of coal from Burragorang by private railway to the top of the plateau and then to an offshore loading facility catering for 18 Mtpa in 150,000 DWT vessels. Low availability of the facility due to prevailing weather conditions and lack of interest in the private railway became the key features of this study and the challenge for development of the facilities. OFFSHORE COAL TERMINAL, PORT KEMBLA South of Port Kembla, the group of islands known as Five Islands provides some attenuation to sea conditions. A proposed offshore facility for the loading of 18 Mtpa of coal into 150,000 DWT vessels was studied at this site. The structural and foundations concepts for an offshore coal loading facility were undertaken as part of this study. Later, the dredging of Port Kembla to enable vessels of 120,000 DWT to be accommodated encouraged Other Key Soros Projects Soros has been engaged in a number of other interesting and diverse projects apart from its signature projects. The following is a selection of projects that further demonstrate Soros’ breadth of experience throughout the last 40 years. the development of the Port Kembla Coal Terminal, for which Soros was engaged in the study and design phases. CLUTHA DEVELOPMENTS LIMITED, MARITIME SERVICES BOARD OF NSW & COMBINED COLLIERY OPERATORS, COAL TERMINAL, BOTANY BAY Operational and engineering studies were conducted for a 10 Mtpa terminal for Illawarra coal with a covered storage facility in Botany Bay south of the existing airport runway. DARWIN PORT AUTHORITY, CONTAINER CRANE, PORT OF DARWIN, NORTHERN TERRITORY Soros was engaged to undertake a structural check of the design of a new container crane being designed and erected by IHI Ltd of Japan. The crane was to service the container trade to Darwin and had a boom length of 35m, safe working load of 35t under the spreader and a heavy lift capacity of 70t. It also had the fl exibility to act as a grab crane for bulk materials such as gypsum. Erection supervision of the crane structure was also provided.
PORT AND MARINE EXPERIENCE
Section 08 27 MORE EXPERIENCE
ALCAN SOUTH PACIFIC PTY LTD, BAUXITE LOADING FACILITY, CAPE YORK, QUEENSLAND Bauxite from the Ely Mining Project was to be exported from the Pennefather River area via an unprotected berth connected to the shore by a trestle. Soros conducted a prefeasibility study including layout and berth orientation, mechanical systems, structural supports, berthing structures and approach trestle. Different types of shiploaders were evaluated for the loading of 72,000 DWT bulk carriers. A radial (quadrant) loader was found to be the most appropriate and economical. Design, detailed specifi cations and tender documents for the shiploader were prepared. NONOC ISLAND, PHILIPPINES Study and design of coal unloading port and coal handling facility for power generation at a nickel refi nery. PORT DICKSON, MALAYSIA Port planning, engineering economics and preliminary design of a multi-purpose dry cargo facility. VICTORIA Engineering study for 8 Mtpa coal unloading facility for power station. PORT KELANG, MALAYSIA Studies for a palm oil kernel loading facility. The study included the design of a conveyor system and covered storage within the established port of Port Kelang. PARKER POINT, DAMPIER, WA Feasibility study and detailed design of repairs and strengthening to existing 40,000 DWT service wharf.
PORT AND MARINE EXPERIENCE
28 Section 08 MORE EXPERIENCE
CAPER CUVIER, WA Feasibility study for upgrading of mooring system at an offshore salt loader. TAIPEI MARINA Master Planning study and preliminary engineering design. LOY YANG VICTORIA Tender design and documentation of coal handling system of No 3 open cut-mine. CAPE LAMBERT, WA Feasibility study for upgrading offshore berth to handle 250,000 DWT bulk carriers. DAMPIER, WA Design of modifi cations to tendering system for a salt loading installation. NEWCASTLE, NSW Feasibility study and cost estimate for 250,000 DWT offshore coal loading facility. NEWCASTLE, NSW Feasibility study and cost evaluation of dredging Newcastle harbor to permit vessels of up to 250,000 DWT.
PORT AND MARINE EXPERIENCE
Section 08 29 MORE EXPERIENCE
Port Options Study assessment of three potential port sites (coastal and inland waterway) and assessment of various related equipment options for import of coal, limestone, fuel oil, caustic soda and the export of bauxite and alumina, South East Africa for a major international bauxite mining company. Site inspection and capital cost estimate for expansion of existing port and cement handling facilities to accommodate up to Panamax size bulk carriers. Kharo Creek, Gujarat, India, for Sanghi Cement Limited. Site inspection and capital cost estimate for development of an iron load-out and multipurpose facility (cement and general cargoes) for Port of Lobito Authority, Angola. Port Options Study assessment of four potential port sites (coastal and inland waterway) and assessment of various related equipment options for export of bauxite, Australia for a major international bauxite mining company. Project management services for design and review of breakwater and materials handling at Port of Gangavaram, India, for Consulting Engineering Services, India.
Due diligence assessment of a container terminal in Above: Port of Gangavaram, India Shekou, China, for P&O Ports. Below: Container terminal in Shekou, China Road to rail coal transfer facility and coastal shipload facility at Ikamatua & Greymouth, New Zealand, for P&O Maritime Services. Design of barge berth for aggregate loading, Alaska USA, for Metlakatla Indian Community. Design of coal unloading wharf and materials handling systems, Prony Bay, New Caledonia, for Prony Energies. Assistance with tendering for expansion of Laem Chabang Container Terminal, Thailand, for P&O Ports. Concept design of short term coal barging facilities in East Kalimantan, Indonesia, for PT Kaltim Prima Coal. Advice on seismic upgrade of container wharves at South Harbour, Manila, Philippines, for P&O Ports. Site selection for coal barging in East Kalimantan, Indonesia, for PT Tanito Harum.
PORT AND MARINE EXPERIENCE
30 Section 08 MORE EXPERIENCE
Condition assessment of four wharves at Picton, New Zealand, for Port Marlborough Limited. Concept design of coal stockpile and barge loading facilities at Port of Greymouth, New Zealand, for Grey District Council. Concept design of barge unloading facility for bulk concentrate at Gladstone, QLD Australia, for P&O Maritime Services. Feasibility study for upgrade of marine facilities at fertiliser plant in Tampa, Florida, USA, for Cargill Crop Nutrition.
Above: Picton, New Zealand
Below: Cargill fertiliser plant in Tampa, Florida
PORT AND MARINE EXPERIENCE
Section 08 31 MORE EXPERIENCE
Due diligence assessment of a container terminal in Qingdao, China, for P&O Ports. Feasibility study of wharf facilities for shipping of aggregate from Punta Cana in the Dominican Republic to San Juan, Puerto Rico, for Grupo Carmelo. Consulting advice for design and development of an alumina shiploader to be located at No.6 Berth in the Port of Bunbury, WA, Australia, for Bechtel. Preliminary design of naval wharf at Kuching, Malaysia, for EDS Konsultant Sdn Bhd. Feasibility study for sand barge loading facility at North Stradbroke Island, QLD Australia, for Unimin Australia Ltd. Design review of an oil loading wharf at Labuan, Malaysia, for EDS Konsultant Sdn Bhd. Preliminary design of berth for methanol vessels at Labuan, Malaysia, for Petronas. Evaluation of coal ship loader and coal terminal upgrade, with subsequent detailed design at Lyttelton, New Zealand, for Lyttelton Port Company. Above: Feasibility study of wharf facilities, Punta Cana in the Evaluation of new wharf and coal shiploader options at Lyttelton, Dominican Republic to San Juan, Puerto Rico New Zealand, for Lyttelton Port Company. Below: Study of coal supply system from mine to power station, Design specifi cation, in support of tender bid, for an alumina ship loader Indonesia, for Credit Lyonnais Bank to be located at Fisherman’s Landing No.2 Berth in the Port of Gladstone, QLD, Australia, for Bechtel. Concept design for a LNG transshipment terminal, Bahamas, for Chicago Bridge and Iron. Front end engineering design for a LNG import terminal at Bataan, Philippines, for Chicago Bridge and Iron. Feasibility study for a ferry landing at North Stradbroke Island, QLD, Australia, for Redland Shire Council. Annual due diligence study of coal supply system from mine to power station, Indonesia, for Credit Lyonnais Bank.
PORT AND MARINE EXPERIENCE
32 Section 08 HEXCEL
CARBON MANUFACTURING LINES, SALT LAKE CITY, UTAH
R&S was awarded a time and materials contract from Hexcel to engineer a new carbon fi ber manufacturing line #10 to be attached to the existing carbon fi ber manufacturing line #8 facilities. Our work on this project included: • Architectural design and engineering of a 700' x 80' manufacturing building including ancillary annexes. • All civil, structural, mechanical, piping, HVAC, electrical and control engineering • Mirrored mechanical drawings for $15 M worth of conveyor roll stands and fi ber enhancement equipment • Integration of vendor supplied equipment for a complete operating fi ber line • Fabrication and construction engineering support • Integration of controls and automation with the other fi ber lines. The construction and equipment installation was completed on time. The start-up period was as anticipated and Hexcel was able to begin full manufacturing less than one month after completion of construction R&S was subsequently awarded an engineering contract for Fiber lines #11 and #12 that were designed for 30% greater through-put than any previous lines. They were also designed to be more Roberts & Schaefer knows how to apply fl exible to the type of fi ber that can be produced. The building was located and its skills and experience to any type of utilities designed to accommodate the future carbon fi ber lines. processing or resource handling project, Our work on this project included: regardless of size or scope. • Architectural design and engineering of a 850' x 160' manufacturing facility including ancillary annexes. • All civil, structural, mechanical, piping, HVAC, electrical and control engineering • Mechanical drawings for $40 M worth of conveyor roll stands and fi ber enhancement equipment • Integration of vendor supplied equipment for a complete operating fi ber line • Fabrication and construction engineering support • Integration of controls and automation with the other fi ber lines.
SPECIALTY PROJECT EXPERIENCE
Section 09 1 DTE UTAH SYNFUELS
MATERIAL HANDLING SYSTEM UPGRADE, PRICE, UTAH
Engineering, procurement and construction of a replacement and upgrade to its material handling systems at its facility in Price, Utah. The purpose of the project was to increase productive capacity to 1.4 million tons of synthetic fuel per year. The new, upgraded facility was designed to operate 365 days per year, 24 hours per day at 91% availability. Feed conveyors to and from the synfuel plant were sized at 225 tons per hour to assure a continuous supply of coal to the synfuel process plant. The new system included: • Runoff contained ground storage for two types of waste coal • New feed hopper and screening • Crushing of oversized waste coal • Sampling of waste coal feed • Sampling of the fi nal synfuel product • Storage via radial stacker • New truck loadout hopper • All related conveying systems • Computer process control • Perimeter ditches, runoff control, sediment entrapment and enlargement of an existing sediment pond. The new system was constructed during 2003 at an operating plant and was designed to minimize impact to existing operations. The work was completed on time and within budget.
SPECIALTY PROJECT EXPERIENCE
2 Section 09 KOMBINAT KOKSOWNICZY W ZABRZU, S.A.
COKE PRODUCTION PLANT, DEMBIENSKO, POLAND Engineering contract to modernize and increase the capacity of the existing coke production facility. The project was divided into four separate phases. The fi rst phase involved mod- ernization and automation of the rail load-out facility to eliminate direct coal dumping onto takeoff conveyor via the use of in-ground hopers. The second phase involved the installation of a new coker area bunker. The third phase involved the reconstruction and increasing capacity of the conveying system and coking plant day bunkers, allowing bunker by-pass to the coking batteries and push cars. As the plant is within city limits, the coal storage yard had to be covered, including a dust collection system. The fi nal phase involved engineering a complex fi re protection system for the entire facility and a coke sizing and crushing system. COKE PRODUCTION PLANT, RADLIN, POLAND Engineering for the expansion of capacity of the existing grinding facility, expansion of the coal storage yard and the construction of a new conveyor system. New coal bunkers were designed for different coal grades. A separate coarse coal conveying and storage system was designed.
The plant also received a new coker battery. Coke Production Plant, Dembiensko, Poland
SPECIALTY PROJECT EXPERIENCE
Section 09 3 ZAKLADY KOKSOWNICZE VICTORIA S.A.
COKE PRODUCTION PLANT, WALBRZYCH, POLAND
Engineering for the expansion of the existing coal grinding building and additional equipment to enable grinding of coal of up to 20mm diameter and increasing the Victoria plant capacity. The coal storage yard and rail load-out is extremely constrained, therefore R&S designed 18 new bunkers with 1500MT capacity each, for overall 33,000 MT capacity for four different coal grades. The client required the construction of a coal rail car defrosting building with 10 rail car capacity. Rail unloading at 180 MTPH is being accomplished with a clamshell and a gantry. The unloading system also contains a frozen coal breaker.
SPECIALTY PROJECT EXPERIENCE
4 Section 09 NEWMONT MINING
TRUCK MAINTENANCE & WASH FACILITY, CARLIN, NEVADA
Roberts & Schaefer Company has worked for Newmont Gold Company for over 30 years on a variety of mining related material handling and processing projects. When the need arose to build a new maintenance and wash facility for their large haulage trucks at their Gold Quarry Mine near Carlin, Nevada, they looked to R&S to help. Newmont contracted with R&S to complete a feasibility study to determine the ex- acting requirements for a new haul truck maintenance facility and was ultimately awarded the turnkey contract to engineer, procure and construct the facility. The fi nal design included 6 repair bays and one wash bay with plans so that additional repair bays could be added at a later date. The shop was designed to accommodate the larger 797 haul trucks with beds full up. Crane hook clearance was set at 52 feet. Roberts & Schaefer stepped up to the challenge of a diffi cult schedule and delivered the new shop on budget, with zero lost time injuries, and only one week behind the allotted 63-week schedule. As many as 15 separate subcontractors at one time were managed on-site by R&S to accomplish this goal. The 53,000 SF pre-engineered steel building truck shop included the following features: • Six repair bays with drive through capability Roberts & Schaefer can engineer ancillary • 18-inch thick repair bay concrete fl oors with centerline drain trench facilities for utility, mining and industrial • 36' x 30' rubber break-away overhead doors operations to meet a variety of needs and • Two 40-ton bridge cranes with 10-ton auxiliary hoists (64' 8" span) operational requirements. • One wash bay with 4 wash systems (undercarriage, water cannons, Hotsy and high pressure hose) • Lubrication tank farm and pneumatic pressurized lube system • Fire suppression throughout • Exterior sedimentation basin with oil skimming and recirculation water
SPECIALTY PROJECT EXPERIENCE
Section 09 5 US BORAX
TRUCK MAINTENANCE & WASH FACILITY, BORON, CALIFORNIA
U.S. Borax was in critical need of a new truck shop to accommodate a fl eet of 27 new mine trucks. The trucks were purchased for both open pit mining and to expedite removal of overburden created when a major portion of the existing pit collapsed onto the ore body. Time was of the essence as Borax did not have a building with high enough doors and cranes or a thick enough slab to accommodate repair and maintenance of the new trucks. The scope of the project included 5 repair bays for 240 ton mine trucks, two 30/5-ton overhead cranes, four high volume lube racks, concrete lube bay with six lubricant tanks, six closed offi ces, one supervisors offi ce, a lunchroom, bathrooms and showers. The existing offi ces were remodeled and separation walls installed where required. New concrete aprons were installed and a slab was poured at the tire shop. Land was limited and Borax wanted to integrate the shop with their existing facility. In the fi nal solution the new building mirrored the largest existing building. The existing sectional doors were removed resulting in a 10 bay shop. Modifi cations were made to the existing buildings to improve the working environment and to meet fi re codes. The fi re code issue was especially diffi cult due to the enormous size and height of the building. Numerous meetings were held with Kern county to resolve the fi re issue. A new truck wash facility was built to replace the antiquated system in place. The new wash area is open air with 40' high concrete walls as wind protection. Eight water cannons can be directed from fl oor level and an 18' high walk way. High-pressure steam, hot water, and detail hoses are also available. The recycle pond is four stage but due to the nature of boron, settling of the sediment is diffi cult. Approximately 30% of the water is replaced automatically during use.
SPECIALTY PROJECT EXPERIENCE
6 Section 09 MORE EXPERIENCE
THYSSEN KRUPP FORDERTECHNIK, FERTILIZER CONVEYING SYSTEM SUPPORT STEEL, ODESSA, UKRAINE Engineering and procurement of a fertilizer conveying system support steel, including trusses, transfer stations and mechanical systems for their Odessa, Ukraine fertilizer port terminal project. The project involved the design, fabrication and export packaging of the components with the approx weight of 190MT UNITED ENGINEERS & CONSTRUCTORS, CLIVE INCINERATION FACILITY, WESTERN UTAH Roberts & Schaefer’s involvement was the design, purchase and supply of all front end material handling, and back end ash handling equipment. The purpose of this facility is to incinerate, and make inert, hazardous materials in the form of soil, concrete, sludge, drums, boxes, clothing, liquids, or metal in any shape. This involved vibrating screens, feeders and conveyors, shredders, augers, bucket elevators, roller, screw, drag, fl exwall, pan and en-masse conveyors, hydraulic power units, bins, chutes, hoppers, ducting, baghouses with fans and collections systems, slide gates, loading spouts, rotary valves, weigh scales, lifts, supporting structural, ladders, stairways & platforms and local system controls. Temperature of material handled ranges up to 1,000°F. Vendor inspection and review of their QA programs was performed. Field service to support facility start-up will be accomplished. STABILIZATION FACILITY, GRASSY MOUNTAIN, USPCI, WESTERN UTAH These facilities include dumping pits for solid waste, liquid waste unloading and storage, drum receiving and dumping, screen/shredder, waste mixer, reagent addition, reagent storage and pneumatic transport, air compressor, industrial ventilation and dust collection, building enclosure with HVAC, system PLC control and interactive graphics and instrumentation. The detailed design services include the expansion of initial drawings and the fi nalization of process fl owsheets, piping and instrument diagrams, overall facility layout, facility plot plans. Further, the preparation of equipment and material specifi cations, construction packages, overall schedule for engineering, procurement, deliveries and construction.
SPECIALTY PROJECT EXPERIENCE
Section 09 7 MORE EXPERIENCE
LANDFILL, REMEDIATION AND CLOSURE, NEW YORK The project includes mining, geotechnical, environmental and processing (consolidation of hazardous waste). The project encompasses excavation and segregation/disposal of hazardous waste into landfi ll cells. Further, a closure cover along with slope regrading and benching, leachate collection and treatment, and erosion and sediment control. Guiding factors were the maximum safety for personnel and the environment during processing and all remedial activities. IDEAL BASIC INDUSTRIES The contract required all engineering, procurement and construction services necessary to complete the project. Roberts & Schaefer Company provided the engineering and procurement portion. The project consists of collecting hot exhaust bases from two clinker cooler drag conveyors, serving kiln lines 1 and 2. The exhaust air is directed to two air gas heat exchangers, to cool the air to approximately 250°F prior to entering pulse type dust collectors. The clean air discharge from the dust collectors is routed to a single stack and vented to atmosphere. The clinker dust collected is returned to an existing drag conveyor and back to the plant process. Complete instrumentation and controls provide automatic operation and monitoring of all system functions to assure safe and proper operating conditions. The installation required removal of an existing cyclone dust collector system, fans, ducting and all associated accessories, and interfacing the new system into the existing structure.
SPECIALTY PROJECT EXPERIENCE
8 Section 09 MORE EXPERIENCE
BIOGEN POWER FACILITY, SYSTEMS ENGINEERING Engineering design and procurement services were provided for construction of a truck-receiving, coal and sorbent storage and reclaim system, and ash recovery and truck loadout system. Work included the design of a truck dump to receive 25-ton capacity highway truck-trailers, delivering coal or sorbent to a receiving pocket fi tted with a screw reclaim feeder. Received material is transported to a 980 ton capacity coal storage bin, 40-ton capacity coal day bin or 55-ton capacity sorbent storage bin via a 24" diameter screw conveyor, bucket elevator and diversion gates at a rate of 160 TPH. All storage and day bins are fi tted with reclaim screw feeders which deliver on demand coal and sorbent to a fl uid bed combustor. High tempera- ture bed ash (600°F) and fl y ash (380°F) produced by the combustor are collected and transported to a loadout station via screw conveyors and bucket elevators. In route to the loadout station storage bins, the ash passes through hollow fl ight type water cooled screw conveyors for ash temperature control prior to storage and loadout. Telescoping loadout chutes deliver bedash and fl yash from 225-ton capacity storage bins to highway trucks for material removal from the facility. A programmable logic controller provides the control means for automatically receiving, storing and reclaiming both coal and sorbent. Lihue Plantation Company, Ltd., Lihue Kauai, Hawaii INDUSTRIAL MINERA MEXICO, NUEVA ROSITA, MEXICO Roberts & Schaefer Company in a joint venture with Pennsylvania Coke Technology (PACTI) designed and built a non-recovery coke making demonstration facility for Industrial Minera Mexico in Nueva Rosita, Mexico. This facility produces approximately 6,000 TAY of high quality coke. The “PACTI” oven produces no toxic emissions because all the volatile coal content is incinerated within the oven system. LIHUE PLANTATION COMPANY, LTD., LIHUE KAUAI, HAWAII The Lihue Plantation Company, Ltd. of Lihue, Kauai Hawaii awarded Roberts & Schaefer Company a contract to provide engineering, equipment and materials, and construction management for a new cut sugar cane conveyor system. A fl ume system originally sluiced the cut sugar cane from the raw cane cleaning and cutting station to the sugar mill for processing. The project included a unique 1,600' long, 60" wide belt having two horizontal curves. All conveyor components incorporated into the horizontal curves are standard manufactured items. With this concept, we were able to use the existing fl ume superstructure resulting in considerable cost and time savings.
SPECIALTY PROJECT EXPERIENCE
Section 09 9 MORE EXPERIENCE
ARCO, DENVER, COLORADO Total engineering for a refi t of a pollution control system for a coal mine. The project consisted of fi eld measuring to determine the best way to fi t the new hardware into existing facility, and the writing of specifi cations for procurement of equipment. ASARCO INC., OMAHA, NEBRASKA Provided design engineering and equipment specifi cations for an oxide fuming plant to produce antimony oxide as a by-product in the refi ning of lead. The work included designs for the collection of high temperature dust and fumes, the conveying of fi ne particulate antimony oxide with bucket elevators and screw conveyors, the blending of alternative products with ribbon-type blenders, the storage of additives and products, and a product bagging system. Included in the work was the design of duct work, power supply and distribution, and in- strumentation and the preparation of specifi cations for equipment and electrical components. ASARCO INC., HILLSBORO, ILLINOIS The design engineering for a zinc-oxide fuming plant for upgrading impure zinc oxide dust. This is done by reduction in a coal fi red furnace and subsequent rapid oxidation to produce a pure zinc-oxide product. The design included the furnace with cooling system, pneumatic conveying of pulverized coal, special conveying of fi ne products and storage bins. It provided the electrical designs and complete furnace instrumentation and control.
SPECIALTY PROJECT EXPERIENCE
10 Section 09 MORE EXPERIENCE
C.E. BASIC INDUSTRIES, GABBS, NEVADA Basic Refractories, a Division of Basic Incorporated, awarded an engineering and procurement assistance contract to Roberts & Schaefer Company to design the addition of a fi fth Herreshoff furnace circuit to their facility at Gabbs, Nevada. The new facility includes increased secondary crushing using a short-head cone crusher, modifying the existing raw material handling and storage system, adding a controlled feed system to direct raw stone to a new 14 hearth, Herreshoff furnace, (fi red with either heavy oil or natural gas), a cooler to cool the calcined product from the furnace and handling facilities to transport the material to storage. A 45,000 ACFM bag house dust collector (1:1 air to cloth ratio) provides collection to meet air quality standards for the furnace and material handling system. Dust is pneumatically returned to the furnace using a low pressure air system. Versatility is designed into the circuit to allow calcined material from the other Herreshoff circuits to be directed into the storage system, or raw stone to be removed from the circuit and trucked to any other circuit. The facility was located within a confi ned area, requiring precise planning, layout and sequencing of construction activities to assure successful completion of the project. J.R. SIMPLOT, SYSTEMS ENGINEERING Total engineering required to convert a phosphate plant from gas to coal fi ring. Work included site visits to determine the best way to install the new equipment, fi eld measuring and evaluations. Prepared all general arrangement and detailed drawings to complete the work.
SPECIALTY PROJECT EXPERIENCE
Section 09 11 MORE EXPERIENCE
REMINGTON ARMS COMPANY, LONOKE AMMUNITION MANUFACTURING PLANT, ARKANSAS This facility is one of the most unusual material handling projects undertaken by Roberts & Schaefer. We were commissioned by Remington Arms Company to relocate a 22-caliber ammunition manufacturing facility known as the Rimfi re Process, from an existing facility in New England to a new location in Arkansas. Our scope of supply included engineering, procurement and construction management services. Roberts & Schaefer reviewed the existing facility drawings, and dispatched a staff of fi eld engineers to examine, measure and interview the operating personnel relative to the assembly, manufacturing and conveying systems. The housing at the new location was designed and built as relocation of the existing equipment and machinery was undertaken. Process modifi cations were included during this relocation to improve production and plant effi ciency. Foundations for the relocated equipment were completed using fi eld measure- ments, since available drawings were quite limited. A complete control system was designed, and new automation procedures were introduced along with additional maintenance and repair facility. This was a fast track project, since the only available time to reactivate the plant in its new location was that allowed by previously built-up inventories. Roberts & Schaefer activated the relocated facility within four months from award of contract. CLIVE TANK FARM, USPCI, WESTERN UTAH The Clive incineration facility is designed for a waste fuel tank farm. The waste fuel farm will be used to store & blend waste fuels prior to being shipped off-site for energy recovery, incineration or burned as a fuel in the Clive incinerator. Engineering & detailed design consisted of structural, civil, piping, mechanical and electrical.
SPECIALTY PROJECT EXPERIENCE
12 Section 09 MORE EXPERIENCE
CYPRUS NORTH SHORE MINING, HEARTH LAYER PLANT, SILVER BAY PROCESSING FACILITY, SILVER BAY, MINNESOTA Engineering, procurement and construction for the addition of a hearth layer system for pellet machines No. 11 and No. 12 at the then inactive Silver Bay processing facility in Silver Bay, Minnesota. This process was initially designed to provide taconite pellets. The installation included in this project increased plant capacity and coordinated the reactivation of the vessel. Pellets for the hearth layer are obtained from the pellet discharge chutes on machines No. 11 and No. 12. Chutes are provided with a diverter gate to direct material to a process transfer conveyor or to individual collecting conveyors which transfer to the fi rst green pellet elevating conveyor. The fi rst green pellet elevating conveyor distributes to an external transfer tower to a second transfer conveyor. This conveyor elevates the material to three transfer conveyors, that feed a combination feed chute and diverter gate which in turn recycles the material to either machine No. 11 or via an additional transfer conveyor to machine No. 12. The entire system is fi tted with bag house type dust collectors. A complete process control system was provided, which is tied into the existing facility. As part of the scope of our supply, the entire existing facility was restarted in conjunction with the new hearth layer system. Extreme time restraints required this project to utilize pre-assembly conveyor structures, duct work, chute work and piping in order to minimize fi eld assembly. The entire project was completed in four and a half months. ROCKY MOUNTAIN BANK NOTE, SALT LAKE CITY, UTAH Engineering for a waste paper collection and pneumatic conveying system for an incinerator. The project included solids collection, compaction and baling. MUNICIPAL SOLID WASTE FACILITY, RIVERSIDE, MICHIGAN Conceptual engineering and design of a 20 TPD commingled container and mixed paper processing facility.
SPECIALTY PROJECT EXPERIENCE
Section 09 13 MORE EXPERIENCE
BETHLEHEM STEEL CORPORATION, LACKAWANNA, NEW YORK Chromore handling system. ADVANCED TRANSFORMER, INC., MONROE, WISCONSIN Engineering, procurement and start-up services for asphalt handling facility. UTAH POWER & LIGHT COMPANY, SALT LAKE CITY, UTAH Resin recovery study. THIOKOL CORPORATION, BRIGHAM CITY, UTAH HMX grinding circuit facility. UTAH POWER & LIGHT, SALT LAKE CITY, UTAH Bottom ash handling system. JAMES GORES & ASSOCIATES, RIVERTON, WYOMING Soda ash handling system. APTUS ENVIRONMENTAL SERVICES, SALT LAKE CITY, UTAH Waste incineration facility, fi eld engineering services. CABLE BELT CONVEYORS, INC., NASHVILLE, TENNESSEE Overland conveyor system services. CITIZEN’S GAS & COKE UTILITY, INDIANAPOLIS, INDIANA Engineering for a coke truck loading facility.
SPECIALTY PROJECT EXPERIENCE
14 Section 09 MORE EXPERIENCE
WILLAMETTE INDUSTRIES, INC. PORTLAND, WASHINGTON The project consists of a 36" digester feed conveyor belt. This conveyor is housed in an 11'-0 diameter tubular gallery and handles wood chips to the plant’s digester building. All conveyor components are galvanized. WILLAMETTE INDUSTRIES, HAWESVILLE, KENTUCKY Through the years Roberts & Schaefer has completed a myriad of projects Design, engineering, procurement, delivery and commissioning of material relating to the pulp and paper industry. handling system to transfer 325 TPH of hardwood chips to digester feed. System incorporated 10' diameter tube enclosing 30" walkway, conduit and pipe racks and 36" conveyor. The 600' long conveyor is elevated 154' over existing paper mill operations. RIVERWOOD INTERNATIONAL PAPER MILL, MACON, GEORGIA The project consists of the modifi cations of existing conveyors and the addition of new conveyors to increase the capacity of the facility. All conveyors handle wood chips. BROWN AND ROOT, MACO, GEORGIA Design, engineer, procurement, delivery, construction management and commissioning a woodyard modifi cation and digester feed system for Riverwood International. The modifi cations to the existing chip handling included adding a chip chain reclaimer, 5 new conveyors totaling nearly 700 linear feet, disc sizing screen, transfer stations, dual shuttle conveyor automated for loading nine continuous digesters and modifi cations to existing systems while in operation. A unique feature of this project involves “piggy back” gallery above existing elevated gallery to digester feed head house. Conveyors ranged in widths between 42" and 48" and utilized motorized drive pulleys. PENTAIR PAPER (SARGENT & LUNDY), ST. PAUL, MINNESOTA Preliminary engineering design and cost estimating for a wood and coal handling system. BARR MURPHY INDUSTRIES, CARIBOU, MAINE 20 TPH potato starch plant. Turnkey process system including feed, desliming, conveying, size reduction, pulping, refi ning, digesters, drying and bagging.
SPECIALTY PROJECT EXPERIENCE
Section 09 15 ANOTHER LOOK
Roberts & Schaefer provides all phases of engineering design, procurement and construction management services to provide you with comprehensive project responsibility. We can also exercise specifi c engineering disciplines according to your requirements. Our design, scheduling, cost control and project management capabilities provide you with effi cient and effective performance. Our technical capabilities, commitment to quality, breadth and depth of experience, and professional standards enable us to produce work of the highest caliber for you. For over a century, Roberts & Schaefer has engineered solutions to process and handle the world’s resources—with a spirit of innovation, a dedication to quality and a skill for management. With major engineering offi ces around the world, our company is known domestically and internationally for its emphasis on quality engineering, professional management, responsiveness to customers, on-time completion and the overall added value of our totally integrated approach. Roberts & Schaefer is comprised of a highly dedicated team of experienced management, engineers, project managers and construction managers. We are successful in performing a wide range of applications in many diverse industries because we bring a world of unyielding engineering and contracting performance. At Roberts & Schaefer, we believe our outstanding performance speaks for itself in an ever expanding industrial marketplace. We hope this Company Profi le was helpful in bringing to light who we are. Thank you for taking the time to fi nd out about us, and we hope you will call on us with any questions or comments you may have. For more information on how we can specifi cally assist you, or for a quotation on your project, please contact your nearest Roberts & Schaefer offi ce.
DEDICATED TO QUALITY ENGINEERING SINCE 1903
Section 10 1 ANOTHER LOOK
Chicago Indonesia 222 South Riverside Plaza Sequis Center; 7th Floor Chicago, IL 60606-3986 Jl. Jenderal Sudirman Kav. 71 TEL: 312-236-7292 Jakarta, Indonesia 12190 FAX: 312-726-2872 TEL: +62-21-252 4177 Email: [email protected] FAX: +62-21-252 4138 Email: [email protected] Salt Lake City Poland 10150 South Centennial Parkway Suite 400 UI. Bojkowska Sandy, Utah 84070 44-100 Gliwice, Poland TEL: 801-984-0900 TEL: +48-32-461-2722 FAX: 801-984-0909 FAX: +48-32-461-2720 Email: [email protected] Email: [email protected]
Australia India Level 5, 35 Boundary Street 20 White House, C G Road South Brisbane, Australia 4101 Ahmedabad - 380 006, India TEL: +61 (0) 7-3234-9555 TEL: +91 79 40328000 FAX: +61 (0) 7-3234-9595 FAX: +91 79 40328001 Email: [email protected] Email: [email protected]
DEDICATED TO QUALITY ENGINEERING SINCE 1903
2 Section 10 ROBERTS & SCHAEFER EXECUTION SUMMARY
As an Engineering, Procurement and Construction company, Roberts & Schaefer’s execution goal is straightforward: To deliver each and every project in a quality manner, on schedule and on budget. “Quality manner” means meeting or exceeding all required client specifi cations, as well as for those items not specifi cally called out by the client. The company is structured, and our processes are established, with this execution goal in mind. Our organization is set up to optimize effi cient performance of project tasks while maintaining management oversight. Our dedicated staff has deep experience in our markets: bulk material handing (BMH) and material processing solutions. All of our processes, from pre-award through construction, are geared to achieving this goal. The Roberts & Schaefer organization consists of Power and Mining Profi t & Loss (P&L) centers. This allows the company to align with our principle clients. We are a “strong matrix” organization; meaning we have full-time dedicated project management and controls while maintaining functional oversight of deliverables.
An upper level view of the Roberts & Schaefer organization follows:
Power/Mining (typical)
Project Sales and Estimating Engineering Procurement Construction Admin Management Marketing
HOW THE WORLD PROCESSES ITS RESOURCES
Section 10 3 3 ROBERTS & SCHAEFER EXECUTION SUMMARY
Each project is assigned a Project Manager who is responsible for all aspects related to the project (meeting the execution goal) and is the primary interface with client management. Task management, process standards and guidance are provided by designated functional managers. Overall management oversight and control is provided by senior management. In addition to a standard Microsoft Offi ce software toolkit, Roberts & Schaefer employs the following: • CCAS software for accounting and cost tracking functions • Adept for documentation control • AutoCAD for Engineering design • Bentley for 3D Engineering design • Primavera Scheduling Program Roberts & Schaefer recognizes the critical importance of proper staffi ng. Each P&L is led by a President who is a proven, experienced EPC business leader. These Presidents are responsible for overall performance, operation and administration of the P&L. Roberts & Schaefer also uses Senior Vice Presidents (SVP) as process guides. SVPs are typically very experienced leaders who serve as mentors to help resolve issues and, most importantly, to prevent problems and improve project performance. Vice Presidents lead each of the key disciplines at Roberts & Schaefer. VPs are established for areas including: • Project Management • Engineering • Procurement • Construction • Estimates • Sales/Marketing These VPs provide direct guidance and oversight for their specifi c areas as well as overall process interface with the rest of the business. The VPs often serve as overall functions leaders for their respective areas. The functional role cuts across the P&Ls (Power and Mine) to help ensure maximum uniformity of process. The functional purpose is to consistently apply best practices across the business. Project Managers are the single point of contact, internal and external, responsible for all aspects of the projects. Roberts & Schaefer applies industry standard project management techniques based on Project Management Institute guidelines (PMBOK). Project Managers are expected to ultimately obtain PMP certifi cation.
HOW THE WORLD PROCESSES ITS RESOURCES
4 Section 10 ROBERTS & SCHAEFER EXECUTION SUMMARY
Other management positions exist for specifi c disciplines, including: • Structural • Mechanical • Piping • Electrical • Engineering Services • Accounting • Procurement • Construction • Startup and Commissioning These positions are staffed with individuals based on their knowledge, experience and licenses (e.g., Structural Professional Engineer). As illustrated in the project lifecycle diagram below, Roberts & Schaefer provides a full range of services, enabling the company to offer customers and clients a scope of work tailored to their unique needs and circumstances. Roberts & Schaefer has demonstrated capabilities across all facets of material handling and processing, that provide a compelling value proposition to customers as a single-source service provider. The company’s service scope offerings include: • study and planning • engineering and design (“E”) • engineering, design, and procurement (“EP”) • engineering, design, procurement, and construction management (“EPCM”) • complete engineering, procurement, and construction (“EPC”) services, including responsibility for construction labor • testing and commissioning operations and maintenance (“O&M”)
Study & Engineering Operations & Planning & Design Procurement Construction Commissioning Maintenance
HOW THE WORLD PROCESSES ITS RESOURCES
Section 10 5 ROBERTS & SCHAEFER EXECUTION SUMMARY
Successful project execution starts with the pre-award process. This is the primary focus of the Sales and Estimating groups. Critical considerations in the pre-award process are establishment of baseline scope (division of responsibility), baseline schedule, proper budget and client-specifi c technical requirements. The Sales and Estimating group’s key functions are: • Identifi cation of opportunities • Negotiations with clients • Preparation of budgetary estimates • Preparation of formal proposals • Interface with other Roberts & Schaefer departments • Brief and obtain formal approval of senior management Once a project is won, the Engineering process comes into play. While each project is unique, the general fl ow of engineering development is as follows: • Layouts: establish the overall process and general area confi guration that will meet the needs of the project in the most effi cient manner possible • Structural: design the structure that supports the BMH system • Mechanical: design the mechanical system that carries out the BMH function • Piping: the design the ancillary piping that is necessary for the BMH system • Electrical: the design the electrical system that powers and controls the BMH system Roberts & Schaefer sometime uses subcontracted engineering services as a variable workforce to augment our own engineering resources. Relationships with these engineering subcontractors have been established over the years and they function seamlessly with in-house engineering. Roberts & Schaefer recognizes the critical nature of documentation and proper submittals. The Engineering Services group focus is on this need. Engineering ties directly into procurement. The Procurement group maintains approved vendor and subcontractor lists. The group continuously reviews performance via a scorecard system to ensure that quality and delivery milestones are met. The group also reviews and negotiates contracts and purchase orders, issues the contracts, monitors progress and closes out the contracts/purchase orders once the task is complete.
HOW THE WORLD PROCESSES ITS RESOURCES
6 Section 10 ROBERTS & SCHAEFER EXECUTION SUMMARY
Roberts & Schaefer maintains a very experienced construction management (CM) staff with average experience of more than 25 years. The CM group manages mobilization of all equipment, materials and staff necessary to complete the project implementation in the fi eld. The mobilization effort requires interface with overall client project management on-site to coordinate activities. Our CMs typically have an offi ce manager/administrative assistant to support documentation and may have assistant CMs and/or Field Engineers as well, depending on the size and complexity of the specifi c project. The CM staff manages and coordinates each phase of construction including: • Civil / Earthwork • Concrete • Steel Erection • Electrical • Completion of punch list items • Startup/Testing and Commissioning • Client training On completion of site construction activities, the CM will coordinate demobilization of Roberts & Schaefer-related equipment and materials. Roberts & Schaefer is committed to being a continuous learning organization. At the project level, an extensive lessons learned database is maintained. Procurement evaluation scorecards are maintained and evaluated to ensure best possible performance from vendors and subcontractors. Roberts & Schaefer also does benchmarking and seeks innovative industry best practices to improve performance and effi ciency. Roberts & Schaefer believes its most valuable asset is our staff who are committed to maintaining and improving performance. PMs are expected to ultimately achieve and maintain PMP certifi cation status; engineers obtain and maintain PE licenses. Staff attend classes and perform self-study to improve business-related knowledge and skills. Roberts & Schaefer has implemented a goal-oriented performance review and appraisal process to ensure personnel development aligns with the needs of the business. Serving the needs of clients by delivery of high quality products and services, on schedule and on budget refl ects the heritage and reputation of Roberts & Schaefer—a reputation that is precious to us as we continually seek ways to uphold and improve it.
HOW THE WORLD PROCESSES ITS RESOURCES
Section 10 7 INDEX
A.B.B. Taiwan ...... 04-25 American Electric Power, John W. Turk Power Plant, Fulton, Arkansas ...... 02-21 Acme Resin Company, Oregon, Illinois ...... 07-30 American Electric Power, Mitchell Plant, Advanced Transformer, Monroe, Wisconsin ...... 09-14 Cresap, West Virginia ...... 04-2, 08-23 AES – Barbers Point, Cogeneration Plant, American Electric Power, Zimmer Coal Plant, Barbers Point, Hawaii ...... 04-21 Moscow, Ohio ...... 04-25 AES – Barbers Point, Oahu, Hawaii ...... 02-30 American Steel Foundries, Alliance, Ohio ...... 07-26 AES - Puerto Rico, Total Energy Plant, American Steel Foundries, Granite City, Illinois ...... 07-27 Guayama, Puerto Rico ...... 02-8, 08-7 Amonate Plant, McDowell County, AES, Warrior Run Power Station, Tazewell, West Virginia ...... 05-55 Cumberland, Maryland ...... 02-42 Amos Plant, Winfi eld, West Virginia ...... 04-14 Aggregate & Sand Plant, Szczercow, Poland ...... 07-2 Apex Plant, Apex Nevada ...... 07-16 Aggregate Plant, Lodi, California ...... 07-6 Aptus Environmental Services, Alabama Power Company, J.H. Miller Steam Plant, Salt Lake City, Utah ...... 09-14 West Jefferson, Alabama ...... 02-44 Arch Coal Company, Black Thunder Mine, Alaska Gold Company (Novagold), Wright, Wyoming ...... 05-3 Rock Creek Gold Facility, Nome, Alaska ...... 06-6 Arch Minerals, Cave Branch Prep Plant, Alcan South Pacifi c, Bauxite Loading Facility, Lynch, Kentucky ...... 05-42 Cape York, Queen sland ...... 08-28 Arch of Illinois, Captain Mine Preparation Plant, Alcoa, Bunbury Alumina Loader Western Australia ...... 08-20 Percy, Illinois ...... 05-41 Alcoa, Condition Assessment of Radial Shiploader ...... 08-5 Arco Coal Company, Beaver Creek Mine, Allegheny Power Service Corporation, Willow and Price, Utah ...... 05-37 Pleasants Island, Parkersburg, West Virginia ...... 02-49 Arco, Denver, Colorado ...... 09-10 Allen Fossil Plant, Memphis, Tennessee ...... 02-15 Argyle Diamonds, Underground Expansion Project, Amax Coal Company, Belle Ayr Mine, Western Australia ...... 06-29 Gillette, Wyoming ...... 05-34 Armco Steel Corporation, Edwight, West Virginia ...... 06-18 Amax Coal Company, Eagle Butte Mine, Armco Steel Corporation, Sundial, West Virginia ...... 05-46 Gillette, Wyoming ...... 05-35 Asamera Minerals, Wenatchee, Washington ...... 06-17 Amax Gold, Golden, Colorado ...... 06-11 ASARCO, Hillsboro, Illinois ...... 06-33, 09-10 Amax, Wabash Mine, Keensburg, Illinois...... 05-21 ASARCO, Omaha, Nebraska ...... 06-33, 09-10 Ameren Energy, Coffeen Generation Station, Coffeen, Illinois ...... 02-18 ASARCO, Salt Lake City, Utah ...... 06-17 Ameren Energy, Duck Creek Power Station, Ash Grove Cement West, Lehi, Utah ...... 07-8 Canton, Illinois ...... 02-19 Ashgrove Cement Company, Ameren Energy, Edwards Power Station, Cement Processing Facility, Moapa, Nevada ...... 07-12 Bartonville, Illinois ...... 02-19 Ashton Mine, Hunter Valley, Australia ...... 05-9 American Electric Power, Amos Plant, Associated Electric Cooperative, Winfi eld, West Virginia ...... 04-14 High Capacity Stacker, New Madrid, Missouri ...... 02-43 American Electric Power, Cardinal Plant, Associated Electric Cooperative, Moberly, Missouri ...... 05-44 Brilliant, Ohio ...... 02-33, 04-14, 08-26
Index 1 INDEX
Associated Electric Cooperative, New Madrid Plant, Belle Ayr Mine, Gillette, Wyoming ...... 05-34 New Madrid, Missouri ...... 02-50 Beth Energy Mines, Cambria Mine 133, Associated Southern Engineering Co., California Ebensburg, Pennsylvania ...... 05-51 Biogen Power Facility, San Bernardino County ...... 02-39 Bethlehem Mines Corporation, Atlantic City Electric, Coal Yard Addition and Ebensburg, Pennsylvania ...... 05-39 Upgrade, Beasley’s Point, New Jersey ...... 02-47 Bethlehem Steel Corporation, Atlantic Energy, B.L. England Generating Station, Drennan, West Virginia ...... 05-44 New Jersey ...... 03-12 Bethlehem Steel Corporation, Austral Coal (Xstrata) Tahmoor Mine, Lackawanna, New York ...... 06-18, 09-14 New South Wales, Australia ...... 05-12 Bethlehem Steel Corporation, B.L. England Generating Station, New Jersey ...... 03-12 Van, West Virginia ...... 06-18 Badger Coal Company, Grand Badger #1 Plant, BHP Billiton, Maruwai Mine, Sago, West Virginia ...... 05-55 Central Kalimantan, Indonesia ...... 05-15 Bailey Generating Station, Chesterton, Indiana ...... 04-25 BHP Billiton, Mt Arthur North Mine, Hunter Valley, Australia ...... 05-13 Bailey Mine Coal Preparation Plant, Enon, Pennsylvania ...... 05-26 BHP Blackwater Mine, Bowen Basin, Australia ...... 05-8 Bailey Mine, Green County, Pennsylvania ...... 05-51 Biogen Power Facility, Systems Engineering ...... 09-9 Baldwin Power Station, Baldwin, Illinois ...... 02-22 Birchwood Project, King George County, Virginia ...... 02-38, 02-44 Baltimore Gas & Electric Company, Brandon Shores, Units 1 and 2, Black Bear Preparation Plant, Anne Arundel County, Maryland ...... 02-27, 08-11 Mountaineer Mine, Gilbert, West Virginia ...... 05-22 Baltimore Gas & Electric, C.P. Crane Station, Black Dog, Riverside and Highbridge Baltimore, Maryland ...... 02-42 Generating Stations, Minneapolis, Minnesota ...... 02-38 Barbers Point, Oahu, Hawaii ...... 02-30 Black Hills Corporation, Coal Yard Upgrade, Gillette, Wyoming ...... 02-50 Barr Murphy Industries, Caribou, Maine ...... 09-15 Black Hills Power and Light, Basin Electric Power Cooperative, Neil Simpson Station, Gillette, Wyoming ...... 02-34 Dry Fork Station & Mine, Gillette, Wyoming ...... 02-10 Black River Processing Plant, Butler, Kentucky ...... 07-17 Batu Hijau Mining Project, PT Newmont Nusa Tangarra, Sumbawa, Indonesia ...... 02-48, 08-2 Black Thunder Mine, Wright, Wyoming ...... 05-3, 05-20 Bauxite Loading Facility, Blackwater Mine, Bowen Basin, Australia ...... 05-8 Cape York, Queen sland ...... 08-28 Blue Circle, Inc., Roberta Cement and Bay Shore Station Repowering Project, Lime Plant, Calera, Alabama ...... 07-15 Oregon, Ohio ...... 04-19 Blue Resources, Inc., J.W. Cornett Beaver Creek Mine, Price, Utah ...... 05-37 Preparation Plant, Leatherwood, Kentucky ...... 05-25 Bechtel Construction Company, Bowie Resources, No. 2 Mine Expansion, Mt. Poso Cogeneration Project Fluidized Bed Boiler ...... 02-45 Paonia, Colorado ...... 05-29 Bechtel Power Corp., Morgantown Energy BP Canada, LTD., Sukunka Coal Project Plant ...... 05-53 Project, Morgantown, West Virginia ...... 02-29 BP Canada, Ltd., Sukunka Coal Project Plant, Beckley #2 Plant, Sabine, West Virginia ...... 05-55 Chetwynd, British Columbia, Canada ...... 05-48 Beckley Lick Run Plant, Mount Hope, West Virginia ...... 05-56
2 Index INDEX
BP Minerals America Fallon, Carbon Manufacturing Lines, Rawhide Mine, Nevada ...... 06-16 Salt Lake City, Utah ...... 09-1 Brandon Shores Power Station, Carbon Regeneration and Baltimore, Maryland ...... 04-1, 08-23 Handling Project ...... 06-5 Brandon Shores, Units 1 and 2, Cardinal Plant, Brilliant, Ohio ...... 02-33, 04-14, 08-26 Anne Arundel County, Maryland ...... 02-27, 08-11 Cardinal River Coals, Brazilian National Steel Company, Cardinal River Plant, Capivari Mine, Brazil ...... 05-49, 06-19 Luscar, Alberta Canada ...... 05-49, 05-54 Bremo Station, Richmond, Virginia ...... 02-49 Cardon Refi nery Project, Cardon, Venezuela ...... 03-5 British Columbia Coals, Ltd., Caremuse Lime Company, Green Hills Plant Elkford, Limestone Handling Facility, British Columbia, Canada ...... 05-48, 05-52 Maysville, Kentucky ...... 07-18 Brown and Root, Maco, Georgia ...... 09-15 Cargill Crop Nutrition ...... 08-18 Brush Wellman Company, Delta, Utah ...... 06-35 Caribbean Ispat Limited, Direct Reduced Iron (DRI) Material Handling Facility, Buchanan Plant, Buchanan County, Virginia ...... 05-52 Port Lisas, Trinidad ...... 08-4 Buffi ngton Plant, Buffi ngton, Ind iana ...... 07-22 Caribbean Ispat Ltd., Direct Reduction Bullmoose Plant, Tumbler Ridge, Facility III (DR3), Point Lisas Trinidad & Tobago ...... 06-20 British Columbia, Canada ...... 05-52 Carlota Copper, Miami, Arizona ...... 06-15 Bunbury Alumina Loader Western Australia ...... 08-20 Carolina Silica, Inc., C.E. Basic Industries, Gabbs, Nevada ...... 09-11 Marston, North Carolina ...... 07-28, 07-29 C.E. Basic Refractories, Gabbs, Nevada ...... 06-34 Carter Mining Company, Gillette, Wyoming ...... 05-33 C.P. Crane Station, Baltimore, Maryland ...... 02-7, 02-42 Catherine Hill Bay Coal Loader, NSW ...... 08-25 Cable Belt Conveyors, Nashville, Tennessee ...... 09-14 Cave Branch Prep Plant, Lynch, Kentucky ...... 05-42 Calaveras Cement Company, Cayuga Generating Station, Cayuga, Indiana ...... 04-10 Quarry Crushing System, Tehachapi, California ...... 07-11 Cement Facility, Union Bridge, Maryland...... 07-9 California Biogen Power Facility, Cement Loadout Facility, Victorville, California ...... 07-13 San Bernardino County ...... 02-39 Cement Processing Facility, Moapa, Nevada ...... 07-12 Callahan Mining Corp., Hematite Flotation Concentrator, Humboldt, Michigan ...... 06-8 Centex Cement Enterprises, Dallas, Texas ...... 07-8 Camberwell Mine, Hunter Valley, Australia ...... 05-16 Central Generadora Electrica, San Jose Power Station, Guatemala City, Guatemala ...... 02-37 Cambria Mine 133, Ebensburg, Pennsylvania ...... 05-51 Central Hudson Gas & Electric, Danskammer Cambria Prep Plant, Generating Station, Newburgh, New York ...... 02-48 Somerset County, Pennsylvania ...... 05-51 Central Hudson Gas & Electric, Cape Lambert, WA ...... 08-29 Danskammer Point Steam Electric Caper Cuvier, WA ...... 08-29 Generating Station, New Jersey ...... 02-49 Capivari Mine, Brazil ...... 06-19 CF&J Steel Corporation, Comstock Mine, Utah ...... 06-19 Captain Mine Preparation Plant, Percy, Illinois ...... 05-41 CFI Steel Corporation, Weston, Colorado ...... 06-19 Carbon Coal Company, Mentmore Mine, Gallup, New Mexico ...... 05-40
Index 3 INDEX
Chalk Point Generating Station, Coal Tailings Reprocessing Facility, Eagle Harbor, Maryland ...... 02-40 Rybnik, Poland ...... 05-11 Chalk Point Power Generation Station, Coal Transshipment Terminal, Washington, D.C...... 02-38 Balls Head Bay, Sydney ...... 08-25 Chalk Point, Dickerson, Morgantown Stations, Coffeen Generation Station, Coffeen, Illinois ...... 02-18 Maryland ...... 04-16 Cogen South Plant, Chartam Project ...... 06-14 Charleston, South Carolina ...... 02-41, 03-13 Chemical Lime, Apex Plant, Apex Nevada ...... 07-16 Cogeneration Facility, Fort Drum, New York ...... 02-32 Chesterfi eld Power Station, Chester, Virginia ...... 04-5 Cogeneration Plant, Barbers Point, Hawaii ...... 04-21 Chevron Mining, Elkol Tipple Upgrade, Coke and Sulfur Handling Systems, Kemmerer, Wyoming ...... 05-14 Jose, Venezuela ...... 03-6 Chevron, El Segundo Refi nery, Coke Production Plant, Dembiensko, Poland ...... 09-3 El Segundo, California ...... 03-2 Coke Production Plant, Radlin, Poland ...... 09-3 China National Technical, Xinglongzuang, Coke Production Plant, Walbrzych, Poland ...... 09-4 Shandong Province, P.R.C...... 05-49 Colbert Steam Plant, Tuscumbia, Alabama ...... 02-50 Cinergy Services, Gibson Generating Station, Owensville, Indiana ...... 04-11 Coleman Station, Hawesville, Kentucky ...... 02-12, 04-13 Cinergy Services, Miami Fort Station, Colorado Lein, Laporte, Colorado ...... 07-28 North Bend, Ohio ...... 04-11 Columbiana Foundry, Columbiana, Ohio ...... 07-28 Cinergy Services, Zimmer Plant, Columbine Minerals, Wheatridge, Colorado ...... 07-30 Moscow, Ohio ...... 04-12, 08-13 Comanche Station (Unit 3), Pueblo, Colorado ...... 02-2 Citizen’s Gas & Coke Utility, ComEd, Fisk Station, Waukegan Station Indianapolis, Indiana ...... 09-14 and Joliet No. 9 Station ...... 02-41 City of Owensboro, Kentucky ...... 04-25 Companhia Minera Doña Ines de Collahuasi, City Utilities, James River Power Station, Puerto Patache, Chile ...... 08-14 Springfi eld, Missouri ...... 02-31 CONSOL Energy, Robinson Run Mine, Cliffside Station, Cliffside, North Carolina ...... 02-24 Mannington, West Virginia ...... 05-4 Clinchfi eld Coal Company, Moss III Plant, CONSOL Pennsylvania Coal Company, South Clinchfi eld, Virginia ...... 05-53 Bailey Mine, Green County, Pennsylvania ...... 05-51 Clinchfi eld Coal Company, McClure #1 Plant, CONSOL, Bailey Mine Coal Preparation Plant, McClure, Virginia ...... 05-54 Enon, Pennsylvania ...... 05-26 Clive Incineration Facility, Western Utah ...... 09-7 Consolidation Coal Company, Amonate Plant, Clive Tank Farm, USPCI, Western Utah ...... 09-12 McDowell County, Tazewell, West Virginia ...... 05-55 Clutha Developments, Maritime Services Consolidation Coal Company, Board & Combined Colliery Operators, Blacksville, West Virginia...... 05-45 Coal Terminal, Botany Bay ...... 08-27 Consolidation Coal Company, Buchanan Plant, Coal & Allied Limited, Coal Transshipment Buchanan County, Virginia ...... 05-52 Terminal, Balls Head Bay, Sydney ...... 08-25 Consolidation Coal Company, Dents Run Plant, Coal Ground Storage Facility, Mannington, West Virginia ...... 05-53 Isle of Wight County, Virginia ...... 05-32 Consolidation Coal Company, Enon, Pennsylvania ...... 05-46
4 Index INDEX
Consolidation Coal Company, Loveridge Plant, Danskammer Point Steam Electric Fairview, Wes Virginia ...... 05-52 Generating Station, New Jersey ...... 02-49 Constellation Copper, Lisbon Valley Copper, Darwin Port Authority, Container Crane, Moab, Utah ...... 06-2 Port of Darwin, Northern Territory ...... 08-27 Constellation Energy, Brandon Shores Dave Johnston Power Station, Glenrock, Wyoming ...... 02-40 Power Station, Baltimore, Maryland ...... 04-1, 08-23 Dayton Power & Light, Killen Constellation Energy, C.P. Crane Station, Generating Station, Manchester, Ohio ...... 04-7 Baltimore, Maryland ...... 02-7 Dayton Power & Light, Stuart Generating Continental Energy Associates, Hazleton Station, Aberdeen, Ohio ...... 04-6, 08-24 Gasifi cation Project, Hazleton, Pennsylvania ...... 02-47, 03-11 Denison Mines, Ltd., Quintette Plant, Cortez Gold Mines, Cortez, Nevada ...... 06-17 British Columbia, Canada ...... 05-52 Cottonwood Mine, Orangeville, Utah ...... 05-43 Denison Mines, Ltd., Quintette Plant, Tumbler Ridge, British Columbia, Canada ...... 05-49 Credit Lyonnais Singapore, Kalimantan and Java, Indonesia ...... 08-17 Dents Run Plant, Mannington, West Virginia ...... 05-53 Cross Station, Cross, South Carolina ...... 04-17 Direct Reduced Iron (DRI) Material Handling Facility, Port Lisas, Trinidad ...... 08-4 Crown Asphalt Ridge Company, Oil Sands Extraction Plant Improvements, Vernal, Utah ...... 06-24 Direct Reduction Facility III (DR3), Point Lisas Trinidad & Tobago ...... 06-20 Crusher Project, Lucerne Valley, California ...... 07-21 Dolnoslaskie Surowce Skalne (DSS), Crushing Plant, Deadwood, South Dakota ...... 06-9 Pilawa Quarry Processing Plant, Pilawa, Poland ...... 07-1 Crystal River Station (Units 4 & 5), Dominion Virginia Power, Chesterfi eld Crystal River, Florida ...... 04-3 Power Station, Chester, Virginia ...... 04-5 CS Energy, Kogan Creek Power Station, Doverspike Plant, Dora, Pennsylvania ...... 05-56 Surat Basin, Australia ...... 02-36 Dravo Lime Company, Black River Processing Culley Station, Newburg, Indiana ...... 04-23, 08-24 Plant, Butler, Kentucky ...... 07-17 Curragh Mine, Bowen Basin, Australia ...... 05-28 Drummond Company, Inc., Cynergy Services, Miami Fort Station, Shoal Creek Mine, Shoal Creek, Alabama ...... 05-31 North Bend, Ohio ...... 08-25 Dry Fork Station & Mine, Gillette, Wyoming ...... 02-10 Cyprus Coal Company, Stoney Fork, Kentucky ...... 05-44 DTE Utah Synfuels, Material Handling Cyprus North Shore Mining, System Upgrade, Price, Utah ...... 09-2 Hearth Layer Plant, Silver Bay Processing Duck Creek Power Station, Canton, Illinois ...... 02-19 Facility, Silver Bay, Minnesota ...... 09-13 Duke Energy, Cayuga Generating Station, Cyprus North Shore Mining, Silver Bay Cayuga, Indiana ...... 04-10 Processing Facility, Silver Bay, Minnesota ...... 06-22 Duke Energy, Cliffside Station, Dampier, WA ...... 08-29 Cliffside, North Carolina ...... 02-24 Dandong Generating Station, Dangdong, China ...... 02-26 Duke Energy, Edwardsport Power Station, Danskammer Generating Station, Edwardsport, Indiana ...... 02-6 Coal Handling System, Marlboro, New York ...... 08-8 Dynegy Midwest Generation, Danskammer Generating Station, Baldwin Power Station, Baldwin, Illinois ...... 02-22 Newburgh, New York ...... 02-48 Eagle Butte Mine, Gillette, Wyoming ...... 05-35
Index 5 INDEX
Eagle Roofi ng Tile Plant, Rialto, California ...... 07-25 Galatia Mine, Galatia, Illinois ...... 05-36 Eastern Associated Coal Group, General Dynamics Corp., Keystone Plant, Keystone, West Virginia ...... 05-55 Grinding Mill Plant, Buffi ngton, Indiana ...... 07-19 Edgewater Generating Station, Geneva Steel, Orem, Utah ...... 06-15 Sheboygan, Wisconsin ...... 02-38 Geneva Steel, Provo, Utah ...... 06-18 Edwards Power Station, Bartonville, Illinois ...... 02-19 Georgia Power Company Plant, Edwardsport Power Station, Edwardsport, Indiana ...... 02-6 Milledgeville, Georgia ...... 02-25 Eighty-Four Mining, Eighty-Four, Pennsylvania ...... 05-43 Georgia Power Company, Scherer Plant, Juliette, Georgia ...... 04-15 El Segundo Refi nery, El Segundo, California ...... 03-2 Geovic, Nickel – Cobalt Project, Electric Power Research Institute, Nkamouna, Cameroon ...... 06-1 Homer City Station, Homer City, Pennsylvania ...... 02-49 Gibson Generating Station, Owensville, Indiana ...... 04-11 Electricite de France (EDF) Coal Tailings Reprocessing Facility, Rybnik, Poland ...... 05-11 Glennies Creek Colliery, Hunters Creek, Australia ...... 05-28 Elkol Preparation Plant, Kemmerer, Wyoming ...... 05-40 Golden Eagle Refi nery, Martinez, California...... 03-3 Elkol Tipple Upgrade, Kemmerer, Wyoming ...... 05-14 Grand Badger #1 Plant, Sago, West Virginia ...... 05-55 Elm Road Station, Oak Creek, Wisconsin ...... 02-3 Granit, Strzegom Quarry, Poland ...... 07-4 European Bank of Reconstruction & Development, Granite Rock Company, Logan Quarry Aggregate Muruntau Gold Project ...... 06-12 Plant Renovation, Aromas, California ...... 07-5 Ferteco Mineracao S.A., Sepetiba Bay, Brazil ...... 08-1 Granite Rock Company, Watsonville, California ...... 07-8 Fertilizer Conveying System Support Steel, Great Salt Lake Minerals Corporation, Odessa, Ukraine ...... 09-7 Multi-Site Plant Upgrades, Ogden, Utah ...... 06-27 First Energy, Bay Shore Station Green Hills Plant Elkford, Repowering Project, Oregon, Ohio ...... 04-19 British Columbia, Canada ...... 05-48, 05-52 First Energy, W.H. Sammis Plant, Stratton, Ohio ...... 02-13 Grinding Mill Plant, Buffi ngton, Indiana ...... 07-19 Fisk Station, Waukegan Station and Gund Plant, Pike County, Joliet No. 9 Station ...... 02-41 Turkey Creek, Kentucky ...... 05-55 Flash Chlorination Project ...... 06-5 Haile Gold Mine Feasibility Study ...... 06-4 Florida Canyon Mine, Imlay, Nevada ...... 06-17 Halemba Mine, Poland ...... 05-18 Florida Rock Industries, Interlachen, Florida ...... 07-28 Hamersley Iron Pty., Iron Ore Terminal, Port Dampier, Western Australia ...... 08-26 FMC Corporation, Green River, Wyoming ...... 06-33 Hanna Nickel Mining Company, Fossil Plant, Gallatin, Tennessee ...... 02-48, 08-24 Riddle, Oregon ...... 03-14, 06-16 Freeman United Coal Company, Harding Street Station, Indianapolis, Indiana ...... 04-9 Virdon, Illinois ...... 05-45 Hardy Sand, Tuscaloosa, Alabama ...... 07-29 Freeman United Coal Company, Waltonville, Il linois ...... 05-45 Hawthorn Mine, Sandborn, Indiana ...... 05-51 Fresh Water Pumping Project ...... 06-5 Hazleton Gasifi cation Project, Hazleton, Pennsylvania ...... 02-47, 03-11 Fru-Con Construction Company, North Branch Power Project, Bayard, West Virginia ..... 02-46, 07-23 Heap Leach Crushing Project, Carlin, Nevada ...... 06-5
6 Index INDEX
Hearth Layer Plant, Silver Bay Processing Island Creek Coal Co., Upshur Plant, Facility, Silver Bay, Minnesota ...... 09-13 Tallmansville, West Virginia ...... 05-54 Hecla Mining Company, Coeur D’Alene, Idaho ...... 06-17 Island Creek Coal Company, Gund Plant, Pike County, Turkey Creek, Kentucky ...... 05-55 Hematite Flotation Concentrator, Humboldt, Michigan ...... 06-8 Island Creek Coal Company, Pond Fork Plant, Bob White, West Virginia ...... 05-54 Hexcel, Carbon Manufacturing Lines, Salt Lake City, Utah ...... 09-1 Isover S.A., Mineral Wool Plant, Gliwice, Poland ...... 07-24 High Capacity Stacker, New Madrid, Missouri ...... 02-43 J.A. Jones Construction Company, Cogeneration Facility, Fort Drum, New York ...... 02-32 Hindustan Steel Limited, Bihar, India ...... 05-47 J.H. Miller Steam Plant, West Jefferson, Alabama ...... 02-44 Hindustan Steel Limited, Patherdihi Central Coal Washery, Bihar, India ...... 06-19 J.R. Simplot Company, Plant Retrofi t, Vernal, Utah ...... 06-32 Homer City Station, Homer City, Pennsylvania ...... 02-49 J.R. Simplot Company, Pocatello, Idaho ...... 06-34 Hopewell Pagbilao, Conveyor System, J.R. Simplot, Systems Engineering...... 09-11 Quezon Province, Philippines ...... 02-36 J.W. Cornett Preparation Plant, Hot Briquetted Iron Plant Puerto Ordaz, Venezuela ...... 06-23 Leatherwood, Kentucky ...... 05-25 Huaneng Power International, Dandong James Gores & Associates, Riverton, Wyoming ...... 09-14 Generating Station, Dangdong, China ...... 02-26 James River Power Station, Springfi eld, Missouri ...... 02-31 Ideal Basic Industries ...... 09-8 JEA, Northside Generating Station, Ideal Cement Plant, Jefferson County, Colorado ...... 07-7 Jacksonville, Florida ...... 04-24 Illinois Central Rail Marine Terminal, Jewel Coal & Coke Company, St. James Parish, Louisiana ...... 06-21, 08-6 Jewel Smokeless Plant, Vansant, Virginia ...... 05-53 Indianapolis Power & Light, Harding Street Jim Walter Resources, #4 Mine, Station, Indianapolis, Indiana ...... 04-9 Brookwood, Alabama ...... 05-51 Industrial Minera Mexico, Pasta De Conchos Jim Walter Resources, Brookwood, Alabama ...... 05-44 Mine, Mexico ...... 05-33 John W. Turk Power Plant, Fulton, Arkansas ...... 02-21 Industrial Mineral Mexico, Jones & Laughlin Corporation, Nueva Rosita, Mexico ...... 05-49, 09-9 Harper’s Ferry, Virginia...... 07-23 Inland Steel Company, McLeansboro, Illinois ...... 05-46 Jones & Laughlin Steel Company, Inspiration Mines, Austin, Nevada ...... 06-13 California, Pennsylvania ...... 06-18 Integra Coal, Camberwell Mine, Kaiser Aluminum & Chemical Corporation, Hunter Valley, Australia ...... 05-16 Wendover, Utah ...... 06-35 Integra Coal/Vale, Glennies Creek Colliery, Kaiser Cement Corporation, Hunters Creek, Australia ...... 05-28 Permanente Aggregate, Cupertino, California ...... 07-8 Inter-Rock Minerals, Min-Ad Dolomite Facility, Kaiser Resources, Sparwood, British Columbia ...... 05-45 Humboldt County, Nevada ...... 06-28 Kaltim Prima Coal Facility, Sangatta, Iron Ore Shiploading Terminal, Port Hedland, East Kalimantan, Indonesia...... 05-7 Western Australia ...... 08-25 Kansas City Power and Light Company, Iron Ore Terminal, Port Dampier, Fuel Yard Modifi cations, LaCygne, Kansas ...... 02-46 Western Australia ...... 08-26
Index 7 INDEX
Kansas City Power and Light, Landfi ll, Remediation and Closure, New York ...... 09-8 Specialized Belt Feeders, La Cygne, Missouri ...... 02-34 Laurel Run Mine, Mt. Storm, West Virginia ...... 05-34 Katowice Coal Holding S.A., Katowice, Poland ...... 05-48 Lehigh Cement Company, Cement Facility, Katowice Coal Holding S.A., Staszic Mine, Poland ...... 05-27 Union Bridge, Maryland ...... 07-9 Kennecott Utah Copper Corporation, Liberty Power Company, Tallahassee, Florida ...... 03-14 Bingham Canyon, Utah ...... 06-10 Lihue Plantation Company, Kennecott Utah Copper Corporation, Lihue Kauai, Hawaii ...... 03-14, 09-9 Salt Lake City, Utah ...... 06-10 Limestone Handling Facility, Kentucky Criterion Coal Company, Maysville, Kentucky ...... 07-18 Deane, Kentucky ...... 05-23 Lisbon Valley Copper, Moab, Utah ...... 06-2 Kerr-McGee Coal Corporation, Galatia Mine, Logan Quarry Aggregate Plant Renovation, Galatia, Illinois ...... 05-36 Aromas, California ...... 07-5 Kerr-McGee Coal Corporation, Gillette, Wyoming ...... 05-38 Lonoke Ammunition Manufacturing Kerr-McGee Corporation, Galatia, Illinois ...... 05-44 Plant, Arkansas ...... 09-12 Keystone Plant, Keystone, West Virginia ...... 05-55 Loveridge Plant, Fairview, Wes Virginia ...... 05-52 Killen Generating Station, Manchester, Ohio ...... 04-7 Loy Yang Victoria ...... 08-29 Kings Mountain Mica Company, LTV Steel Corporation, East Chicago, Indiana ...... 06-18 Kings Mountain, North Carolina ...... 07-28 Lubelski Wegiel S.A., Bogdanka Mine, Poland ...... 05-27 Kingston Fossil Plant, Kingston, Tennessee ...... 02-9 Luminant (Sandow Development Company), Knurow Mine, Poland ...... 05-18 TXU-Sandow (Unit 5), Rockdale, Texas ...... 02-14 Kogan Creek Power Station, Surat Basin, Australia ...... 02-36 Luminant Power, Oak Grove Power Station, Franklin, Texas ...... 02-1 Kombinat Koksowniczy W Zabrzu, Coke Production Plant, Dembiensko, Poland ...... 09-3 Luminant, Kosse Mine, Kosse, Texas ...... 05-1 Kombinat Koksowniczy W Zabrzu, Luminant, Oak Grove Power Station, Coke Production Plant, Radlin, Poland ...... 09-3 Franklin, Texas ...... 04-4 Kompania Weglowa (KWK), Halemba Mine, Poland ...... 05-18 Lyman-Richey Sand & Gravel Company, Valley, Nebraska ...... 07-29 Kompania Weglowa (KWK), Knurow Mine, Poland...... 05-18 MacLellan Mine, Lynn Lake, Manitoba ...... 06-13 Kompania Weglowa (KWK), Murcki Mine, Poland ...... 05-19 MAPCO Coal Company, Pontiki Mine, Kompania Weglowa (KWK), Ziemowit Mine, Poland ...... 05-19 Lovely, Kentucky ...... 05-24 Kooragang Coal Terminal Newcastle, NSW ...... 08-22 MAPCO, Pontiki Plant, Martin County, Kosse Mine, Kosse, Texas ...... 05-1 Inze, Kentucky ...... 05-56 Krupinite Corporation, Modular Production Plant ...... 06-30 Marblehead Lime, Buffi ngton Plant, KWB Belchatow, Aggregate & Sand Plant, Buffi ngton, Indiana ...... 07-22 Szczercow, Poland ...... 07-2 Marblehead Lime, Chicago, Illinois ...... 07-23 Lafarge, Sugar Creek Facility, Marblehead Lime, Gary, Indiana ...... 07-23 Sugar Creek, Missouri ...... 07-14 Marblehead Lime, Pleasant Gap, Pennsylvania ...... 07-23 Lamberts Point Coal Loadout Facility, Marine Terminal, St. James Parish, Louisiana ...... 06-21 Norfolk, Virginia ...... 05-31 Marion Generation Station, Marion, Illinois ...... 02-35
8 Index INDEX
Maritime Services Board of NSW, MT Newman Mining Co., Iron Ore Shiploading Kooragang Coal Terminal Newcastle ...... 08-22 Terminal, Port Hedland, Western Australia ...... 08-25 Maritime Services Board of NSW & Combined Mt. Poso Cogeneration Project Fluidized Bed Boiler ...... 02-45 Colliery Operators, Coal Terminal, Botany Bay ...... 08-27 Multi-Site Plant Upgrades, Ogden, Utah ...... 06-27 Maruwai Mine, Central Kalimantan, Indonesia ...... 05-15 Municipal Solid Waste Facility, Riverside, Michigan...... 09-13 Material Handling System Upgrade, Price, Utah ...... 09-2 Murcki Mine, Poland ...... 05-19 McClure #1 Plant, McClure, Virginia ...... 05-54 Muruntau Gold Project ...... 06-12 Meadow Creek Plant, Meadow Creek, Nadwislanskia Spolka Weglowa (NSW) West V irginia ...... 05-54 S.A. Piast Mine, Bierun, Poland ...... 05-10 Mentmore Mine, Gallup, New Mexico ...... 05-40 National Cement Company of California, Metallurgimport, Moscow, Russia ...... 07-29 Plant 2 Modernization, Lebec, California ...... 07-10 Miami Fort Station, North Bend, Ohio ...... 04-11, 08-25 Naughton Station, Kemmerer, Wyoming ...... 02-39 Middle East Oil Refi nery (MIDOR), Neil Simpson Station, Gillette, Wyoming ...... 02-34 Alexandria, Egypt ...... 03-7 Nevada Gold Mining, Inc., Sleeper Project, Millwood Sand Company, Millwood, Ohio ...... 07-28 Winnemucca, Nevada...... 06-14 Min-Ad Dolomite Facility, New Elk Mine, Weston, Colorado ...... 05-38 Humboldt County, Nevada ...... 06-28 New Hope Corporation, Port Of Brisbane ...... 08-9 Mingo Logan, Black Bear Preparation Plant, New Madrid Plant, New Madrid, Missouri ...... 02-50 Mountaineer Mine, Gilbert, West Virginia ...... 05-22 New River Company, Beckley Lick Run Plant, Mirant Mid Atlantic, Chalk Point, Dickerson, Mount Hope, West Virginia ...... 05-56 Morgantown Stations, Maryland ...... 04-16 New River Company, Meadow Creek Plant, Mitchell Plant, Cresap, West Virginia ...... 04-2, 08-23 Meadow Creek, West Virginia ...... 05-54 Mobil Mining and Minerals Company, New South Wales Dept. of Public Works, South Fort Meade Mine Benefi ciation Plant, Offshore Coal Terminal, Coalcliff ...... 08-27 Nichols, Florida ...... 06-31 New South Wales Dept. of Public Works, Modular Asphaltene Recovery Plant, Port Kembla Coal Terminal Port Kembla ...... 08-21 Fort McMurray, Alberta, Canada ...... 06-26 Newcastle, NSW ...... 08-29 Modular Gold Recovery ADR Plant, Ghana, Africa ...... 06-3 Newmont Gold Company, Heap Leach Modular Production Plant ...... 06-30 Crushing Project, Carlin, Nevada ...... 06-5 Monsanto Company, Soda Springs, Idaho ...... 06-35 Newmont Mining, Carbon Regeneration Monterey Coal Company, and Handling Project ...... 06-5 Wayne County, West Virginia ...... 05-46 Newmont Mining, Flash Chlorination Project ...... 06-5 Monterey Sand Company, Monterey, California ...... 07-30 Newmont Mining, Fresh Water Pumping Project ...... 06-5 Morgantown Energy Project, Newmont Mining, Trash Screen Modifi cation Project ...... 06-5 Morgantown, West Virginia ...... 02-29 Newmont Mining, Truck Maintenance Moss III Plant, South Clinchfi eld, Virginia ...... 05-53 & Wash Facility, Carlin, Nevada ...... 09-5 Motiva Enterprises, Motiva Refi nery, Nickel – Cobalt Project, Nkamouna, Cameroon ...... 06-1 Port Arthur, Texas ...... 03-1 Nonoc Island, Philippines ...... 08-28 Mt Arthur North Mine, Hunter Valley, Australia ...... 05-13
Index 9 INDEX
Norfolk & Western Railway Company, Coal Ground Omya California, Crusher Project, Storage Facility, Isle of Wight County, Virginia ...... 05-32 Lucerne Valley, California ...... 07-21 Norfolk & Western Railway Company, Lamberts Omya California, Optical Sorter Improvements, Point Coal Loadout Facility, Norfolk, Virginia ...... 05-31 Lucerne Valley, California ...... 07-20 Norfolk Southern Harris Mine, Optical Sorter Improvements, Kopperston, West Virginia ...... 05-30 Lucerne Valley, California ...... 07-20 North American Coal Company, Orlando Utilities, Fuel Supply System, Powhatan Point, Ohio ...... 05-36 Orlando, Florida ...... 02-50 North Branch Power Project, Ottawa Silica, Ottawa, Illinois ...... 07-28 Bayard, West Virginia ...... 02-46, 07-23 Owens Illinois, Ione, California ...... 07-28 North Carolina State Ports Authority, Oxbow Carbon, Port of Los Angeles (LAXT), Morehead, North Carolina...... 08-10 Los Angeles, California ...... 03-4 North Omaha Station, Omaha, Nebraska ...... 02-16 Oxbow Corporation, Pet Coke Loading Facility, North Rochelle Mine, Gillette, Wyoming ...... 05-6 Port of Texas City, Texas ...... 08-16 Northern Indiana Public Service Co., R.M. Schahfer Pacifi c Corp, Salt Lake City, Utah ...... 06-35 Generating Station, Wheatfi eld, Indiana ...... 02-46 Pacifi corp, Dave Johnston Power Station, Northern Indiana Public Service Co./Pure Air, Glenrock, Wyoming ...... 02-40 Bailey Generating Station, Chesterton, Indiana ...... 04-25 Paradise Fossil Plant, Paradise, Kentucky ...... 04-20 Northern States Power Company, Black Dog, Paradise Plant, Drakesboro, Kentucky...... 02-15 Riverside and Highbridge Generating Stations, Minneapolis, Minnesota ...... 02-38 Parker Point, Dampier, WA ...... 08-28 Northside Generating Station, Jacksonville, Florida ...... 04-24 Pasta de Conchos Mine, Mexico ...... 05-33 Nova Scotia Sand & Gravel, Patherdihi Central Coal Washery, Shubenacadie, Nova Scotia ...... 07-28 Bihar, India ...... 05-47, 06-19 Noyes Bros., Pty., Offshore Clinker and PBS Coals, Inc., Cambria Prep Plant, Cement Terminal, Gladstone, Queensland ...... 08-26 Somerset County, Pennsylvania ...... 05-51 Oak Grove Power Station, Franklin, Texas ...... 02-1, 04-4 PCC Rail, Sand & Gravel Plant, Jaworzno, Poland ...... 07-24 Oakey Creek Mine, Bowen Basin, Australia ...... 05-2 Peabody Coal Company, Hawthorn Mine, Sandborn, Indiana ...... 05-51 Offshore Clinker and Cement Terminal, Gladstone, Queensland ...... 08-26 Peabody Coal Company, Morganfi eld, Kentucky ...... 05-46 Offshore Coal Terminal, Port Kembla...... 08-27 Pegasus Gold Corporation, Florida Canyon Mine, Imlay, Nevada ...... 06-17 Offshore Iron Ore Terminal, Northwest WA ...... 08-26 PEMEX Refi nery Petroleum Coke Handling Project ...... 03-8 Oil Sands Extraction Plant Improvements, Vernal, Utah ...... 06-24 Penn West Fuels, Doverspike Plant, Dora, Pennsylvania ...... 05-56 Oil Sands Extraction Plant, Fort McMurray, Alberta, Canada ...... 06-25 Pennsylvania Electric Company, Homer City Station, Homer City, Pennsylvania ...... 02-49 Old Ben Coal Company, Pike County, Indiana ...... 05-41 Pennsylvania Glass & Sand Corporation, Omaha Public Power District, Berkeley Springs, West Virginia ...... 07-26, 07-27 North Omaha Station, Omaha, Nebraska ...... 02-16 Omg Apex, Tungsten Recycle Project, St George, Utah .....06-7
10 Index INDEX
Pennsylvania Glass & Sand Corporation, Port of Amamapare (Papua), Indonesia ...... 08-15 Brady, Texas ...... 07-29 Port Of Brisbane ...... 08-9 Pennsylvania Glass & Sand Corporation, Port of Los Angeles (LAXT), Los Angeles, California ...... 03-4 Mapleton Depot, Pennsylvania ...... 07-26, 07-27 Port of Lyttelton, Christchurch, New Zealand ...... 08-12 Pennsylvania Glass & Sand Corporation, Mill Creek, Oklahoma ...... 07-26 Posven, Hot Briquetted Iron Plant Puerto Ordaz, Venezuela ...... 06-23 Pennsylvania Glass & Sand Corporation, Pacifi c, M issouri ...... 07-26 Potomac Electric Power Company, Chalk Point Generating Station, Eagle Harbor, Maryland ...... 02-40 Pentair Paper (Sargent & Lundy), St. Paul, Minnesota ...... 09-15 Potomac Electric Power Company, Chalk Point Power Generation Station, Washington, D.C...... 02-38 Peoples Republic of China, Xinglongzhaung Plant, Xinglongzhaung Shangdong Province, Beijing, China ....05-53 Potomac Electric Power Company, Potomac River Station, Washington, D.C...... 02-40 Permanente Aggregate, Cupertino, California ...... 07-8 Potomac River Station, Washington, D.C...... 02-40 Pet Coke Loading Facility, Port of Texas City, Texas ...... 08-16 Process Plant Expansion, Deadwood, South Dakota ...... 06-9 Petrola Ameriven, Coke and Sulfur Handling Systems, Jose, Venezuela ...... 03-6 Produvisa Servicidos, S.A., Garacas, Venezuela ...... 07-28 Petroleos de Venezuela S.A. (PDVSA) Maraven, Progress Energy Carolinas, Cardon Refi nery Project, Cardon, Venezuela ...... 03-5 Roxboro Power Station, Roxboro, North Carolina...... 02-35 Piast Mine, Bierun, Poland ...... 05-10 Progress Energy, Crystal River Station (Units 4 & 5), Crystal River, Florida ...... 04-3 Pier IX and Shipyard River Coal Terminal, Newport News, Virginia ...... 05-42 Protexa Construction Company, PEMEX Refi nery Petroleum Coke Handling Project ...... 03-8 Pilawa Quarry Processing Plant, Pilawa, Poland ...... 07-1 PSI Energy, Wabash River Generating Station, Pinson Mining Company, Winnemucca, Nevada ...... 06-17 West Terre Haute, Indiana ...... 02-41 Pittsburgh & Midway Coal Mining Company, PT Freeport, Irian Jaya, Indonesia ...... 02-37 Elkol Preparation Plant, Kemmerer, Wyoming ...... 05-40 PT Freeport, Port of Amamapare (Papua), Indonesia .....08-15 Pittston Coal Company, McClure, West Virginia ...... 05-46 PT Kaltim Prima Coal Facility, Plexus Resources, Salt Lake City, Utah ...... 06-35 Sangatta, East Kalimantan, Indonesia ...... 05-7 Plum Point Power Partners, Plum Point Station, PT Newmont Nusa Tangarra, Sumbawa, Indonesia...... 08-2 Osceola, Arkansas ...... 02-5 PT Newmont, Batu Hijau Mining Project, Poludniowy Koncern Energetyczny (PKE), Sumbawa, Indonesia ...... 02-48 Sobieski Mine, Jaworzno, Poland ...... 05-17 Quarry Crushing System, Tehachapi, California ...... 07-11 Pond Fork Plant, Bob White, West Virginia ...... 05-54 Quintette Plant, British Columbia, Canada ...... 05-52 Pontiki Mine, Lovely, Kentucky ...... 05-24 Quintette Plant, Tumbler Ridge, Pontiki Plant, Martin County, Inze, Kentucky...... 05-56 British Columbia, Canada ...... 05-49 Port Dickson, Malaysia ...... 08-28 R.M. Schahfer Generating Station, Port Kelang, Malaysia ...... 08-28 Wheatfi eld, Indiana ...... 02-46 Port Kembla Coal Terminal Port Kembla, Ranger Fuel Company, Beckley #2 Plant, New South Wales ...... 08-21 Sabine, West Virginia ...... 05-55 Port Latta Open Sea Ore Terminal Tasmania...... 08-19
Index 11 INDEX
Red Hills Generation Facility, Scrubgrass Power Generating Company, Choctaw County, Mississippi ...... 02-11 Scrubgrass Power Plant, Ventigo County, Pennsylvania ...... 04-22 Reliant Energy, Seward Station, New Florence, Pennsylvania ...... 03-9, 04-24 Scrubgrass Power Plant, Ventigo County, Pennsylvania ...... 04-22 Remington Arms Company, Lonoke Ammunition Manufacturing Plant, Arkansas ...... 09-12 SEI, Birchwood Station, King George County, Virginia ...... 02-44 Republic Steel Corporation, Philippi, West Virginia ...... 06-18 Sepetiba Bay, Brazil ...... 08-1 Ridgeway Coal Company, Meta, Kentucky ...... 05-44 Serco Sodexo Defence Systems ...... 08-3 Rio Tinto, Spring Creek Mine, Decker Montana ...... 05-29 Seward Station, New Florence, Pennsylvania ...... 03-9, 04-24 Riverwood International Paper Mill, Macon, Georgia .....09-15 SGS Canada, Oil Sands Extraction Plant, Roberta Cement and Lime Plant, Calera, Alabama ...... 07-15 Fort McMurray, Alberta, Canada ...... 06-25 Robinson Run Mine, Mannington, West Virginia ...... 05-4 Shawnee Steam Plant, Paducah, Kentucky ...... 02-49 Rochelle Coal Company, Rochelle Mine, Shell Deer Park, Pet Coke Handling, Gillette, Wyoming ...... 05-35 Deer Park, Texas ...... 03-7 Rock Creek Gold Facility, Nome, Alaska ...... 06-6 Shell Mining Company, Standard Hill Project, Rocky Mountain Bank Note, Salt Lake City, Utah ...... 09-13 Kern County, California ...... 06-14 Roc-San Gravel Company, Aggregate Plant, Shell Oil Company, Limera, Ohio...... 05-46 Lodi, California ...... 07-6 Sherrgold Inc., MacLellan Mine, Romarco Minerals, Haile Gold Mine Feasibility Study .....06-4 Lynn Lake, Manitoba ...... 06-13 Roxboro Power Station, Roxboro, North Carolina...... 02-35 Shoal Creek Mine, Shoal Creek, Alabama ...... 05-31 Salt River Project, Springerville Generating Silica Products Company, Guion, Arkansas ...... 07-26, 07-30 Station (Unit 4), Apache County, Arizona ...... 02-4 Silver Bay Processing Facility, San Jose Power Station, Guatemala City, Guatemala.....02-37 Silver Bay, Minnesota ...... 06-22 San Juan Station, New Mexico ...... 05-39 Sleeper Project, Winnemucca, Nevada ...... 06-14 Sandow Development Company (Luminant), SNC Service Ltd., Algeria ...... 07-30 TXU-Sandow (Unit 5), Rockdale, Texas ...... 02-14 Sobieski Mine, Jaworzno, Poland ...... 05-17 Sandy Creek Power Partners, Sandy Creek Sobin Chemical Company (Div. IMC), Energy Station, Riesel, Texas ...... 02-20 Spruce Pine, North Carolina ...... 07-29 Santee Cooper, Cross Station, Cross, South Carolina...... 04-17 South Fort Meade Mine Benefi ciation Plant, Santee Cooper, Winyah Station, Nichols, Florida ...... 06-31 Georgetown, South Carolina ...... 04-18 South Mississippi Electric Power Association, Satellite Goldfi elds, Modular Gold Recovery Coal Handling, Gardner, Kentucky...... 02-50 ADR Plant, Ghana, Africa ...... 06-3 Southdown California Cement, Savage River Mines Limited, Port Latta Open Cement Loadout Facility, Victorville, California ...... 07-13 Sea Ore Terminal Tasmania ...... 08-19 Southern Company Services, Georgia Power Scherer Plant, Juliette, Georgia ...... 04-15 Company Plant, Milledgeville, Georgia ...... 02-25 Scrubgrass Facility, Kennerdell, Pennsylvania ....02-28, 03-10 Southern Electric International, Birchwood Project, King George County, Virginia ...... 02-38
12 Index INDEX
Southern Illinois Power Cooperative, Tennessee Valley Authority, Paradise Plant, Marion Generation Station, Marion, Illinois ...... 02-35 Drakesboro, Kentucky ...... 02-15 Southern Indiana Gas & Electric, Tennessee Valley Authority, Culley Station, Newburg, Indiana ...... 04-23, 08-24 Shawnee Steam Plant, Paducah, Kentucky ...... 02-49 Southern Ohio Coal Company, Langsville, Ohio ...... 05-44 Tennessee Valley Authority, Widows Creek Fossil Plant, Stevenson, Alabama ...... 02-23 Southwestern Electric Power Company, Welsh Power Plant, Cason, Texas ...... 02-49 Tesoro Refi ning, Golden Eagle Refi nery, Martinez, California...... 03-3 Specialized Belt Feeders, La Cygne, Missouri ...... 02-34 Texas Gulf Sulphur Company, Spring Creek Mine, Decker Montana ...... 05-29 Offshore Iron Ore Terminal, Northwest WA ...... 08-26 Springerville Generating Station (Unit 4), Thiokol Corporation, Brigham City, Utah ...... 09-14 Apache County, Arizona ...... 02-4 Thunder Basin Coal Company, Stabilization Facility, Grassy Mountain, Black Thunder Mine, Wright, Wyoming ...... 05-20 USPCI, Western Utah ...... 09-7 Thyssen Krupp Fordertechnik, Standard Hill Project, Kern County, California ...... 06-14 Fertilizer Conveying System Support Steel, Strzegom Quarry, Poland...... 07-4 Odessa, Ukraine ...... 09-7 Stuart Generating Station, Aberdeen, Ohio ...... 04-6, 08-24 Total Energy Plant, Sugar Creek Facility, Sugar Creek, Missouri ...... 07-14 Guayama, Puerto Rico ...... 02-8, 04-8, 08-7 Sukunka Coal Project Plant ...... 05-53 Tractebel Power – Choctaw Generation, Red Hills Generation Facility, Sukunka Coal Project Plant, Choctaw County, Mississippi ...... 02-11 Chetwynd, British Columbia, Canada ...... 05-48 Trash Screen Modifi cation Project ...... 06-5 Tahmoor Mine, New South Wales, Australia ...... 05-12 Tri County Asphalt Corporation, Taipei M arina ...... 08-29 Lake Hopatcong, New Jersey ...... 07-8 Taiwan Power, Coal Yard, Kaonsiung, Taiwan ...... 02-50 Triton Coal Company, North Rochelle Mine, Taiwan Power, Lincou Station ...... 05-50 Gillette, Wyoming ...... 05-6 Taiwan Power, Talin Coal Terminal ...... 05-50 Truck Maintenance & Wash Facility, Tarmac UK, Wisniowka Quarry, Wisniowka, Poland ...... 07-3 Boron, California ...... 09-6 Teberebie Goldfi elds, Process Plant, Truck Maintenance & Wash Facility, Ghana, West Africa ...... 06-11 Carlin, Nevada ...... 09-5 Teck Corporation, Bullmoose Plant, Tungsten Recycle Project, St George, Utah ...... 06-7 Tumbler Ridge, British Columbia, Canada ...... 05-52 Turkish Coal Enterprise, Amasra, Turkey ...... 05-47 Tennessee Valley Authority, Allen Fossil Plant, Turkish Coal Enterprise, Catalagzi, Turkey ...... 05-47 Memphis, Tennessee ...... 02-15 Turkish Coal Enterprise, Tuncbilek, Turkey ...... 05-48 Tennessee Valley Authority, Turkish Coal Enterprise, Zonguldak, Turkey ...... 05-47 Colbert Steam Plant, Tuscumbia, Alabama ...... 02-50 TVA Gallatin, Fossil Plant, Tennessee Valley Authority, Drakesboro, Kentucky ...... 05-45 Gallatin, Tennessee ...... 02-48, 08-24 Tennessee Valley Authority, TXU-Sandow (Unit 5), Rockdale, Texas ...... 02-14 Kingston Fossil Plant, Kingston, Tennessee ...... 02-9 U.S. Borax, Truck Maintenance Tennessee Valley Authority, & Wash Facility, Boron, California ...... 09-6 Paradise Fossil Plant, Paradise, Kentucky ...... 04-20
Index 13 RobeR ts & s chaefeR c ompany
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H o W THe WorlD proC e SSe S i TS reS o U r C e S INDEX
U.S. Generating Company, Western Aggregate Minerals Company, Scrubgrass Facility, Carlsbad, New Mexico ...... 06-35 Kennerdell, Pennsylvania ...... 02-28, 03-10 Western Aggregate, Ideal Cement Plant, U.S. Steel Corporation, Jefferson County, Colorado ...... 07-7 Greene County, Pennsylvania ...... 06-18 Western Canadian Coal Company, U.S. Steel Corporation, Hueytown, Alabama ...... 05-37 Wolverine Mine, Tumbler Ridge, Canada ...... 05-5 U.S. Steel Corporation, Jefferson, Alabama ...... 06-18 Western Coal Company, San Juan Station, New Mexico ...... 05-39 United Engineers & Constructors, Clive Incineration Facility, Western Utah ...... 09-7 Western Energy Company, Chartam Project ...... 06-14 Upshur Plant, Tallmansville, West Virginia ...... 05-54 Western Kentucky Energy, Coleman Station, Hawesville, Kentucky ...... 02-12, 04-13 Utah Power & Light Company, Coal Handling and Processing, Chaco, Utah ...... 02-50 Western Oil Sands, Modular Asphaltene Recovery Plant, Utah Power & Light Company, Fort McMurray, Alberta, Canada ...... 06-26 Cottonwood Mine, Orangeville, Utah ...... 05-43 Western States Minerals Corp., Utah Power & Light Company, Wheatridge, Colorado ...... 06-17 Naughton Station, Kemmerer, Wyoming ...... 02-39 Westfarmers, Curragh Mine, Utah Power & Light Company, Bowen Basin, Australia ...... 05-28 Salt Lake City, Utah ...... 09-14 Weston Station, Rothschild, Wisconsin ...... 02-17 Utah Salt Company, Wendover, Utah ...... 06-35 Westvaco, Cogen South Plant, Victoria, Australia ...... 08-28 Charleston, South Carolina ...... 02-41, 03-13 Virgina Electric Power Company, Wharf Resources, Crushing Plant, Bremo Station, Richmond, Virginia ...... 02-49 Deadwood, South Dakota ...... 06-9 W.H. Sammis Plant, Stratton, Ohio ...... 02-13 Wharf Resources, Process Plant Expansion, Wabash Mine, Keensburg, Illinois ...... 05-21 Deadwood, South Dakota ...... 06-9 Wabash River Generating Station, White Mining (Felix Resources) Ashton Mine, West Terre Haute, Indiana ...... 02-41 Hunter Valley, Australia ...... 05-9 Wallarah Coal Company, Whitehead Bros. Company, Lugoff, South Carolina ...... 07-30 Catherine Hill Bay Coal Loader, NSW ...... 08-25 Widows Creek Fossil Plant, Stevenson, Alabama ...... 02-23 Ward Iron Works (Holmes Foundry), Willamette Industries, Hawesville, Kentucky...... 09-15 Welland, Ontario, Canada ...... 07-29 Willamette Industries, Portland, Washington ...... 09-15 Warrior Run Power Station, Cumberland, Maryland ...... 02-42 William R. Barnes Company, Watertown, Ontario, Canada ...... 07-28 Wedron Silica Company, Byron, California ...... 07-29 Willow and Pleasants Island, Parkersburg, Wedron Silica Company, Emmett, Idaho ...... 07-29 West Virginia ...... 02-49 Wedron Silica Company, Lugoff, South Carolina ...... 07-29 Winyah Station, Georgetown, South Carolina ...... 04-18 Wedron Silica Corporation, Wedron, Illinois ...... 07-28 Wisconsin Energy, Elm Road Station, Wedron Silica, Prairie State Silica Plant, Oak Creek, Wisconsin ...... 02-3 Troy Grove, Illinois ...... 07-26, 07-30 Wisconsin Power & Light, Edgewater Welsh Power Plant, Cason, Texas ...... 02-49 Generating Station, Sheboygan, Wisconsin ...... 02-38
14 Index INDEX
Wisconsin Power & Light, Coal Yard Storage and Reclaim, Portage, Wisconsin ...... 02-49 Wisconsin Public Service Corp., Weston Station, Rothschild, Wisconsin ...... 02-17 Wisniowka Quarry, Wisniowka, Poland ...... 07-3 Wolverine Mine, Tumbler Ridge, Canada ...... 05-5 Wyoming Fuel Company, New Elk Mine, Weston, Colorado ...... 05-38 XCEL Energy Services, Comanche Station (Unit 3), Pueblo, Colorado ...... 02-2 Xinglongzhaung Plant, Xinglongzhaung Shangdong Province, Beijing, China ...... 05-53 Xstrata Coal Company, Oakey Creek Mine, Bowen Basin, Australia ...... 05-2 Zaklady Koksownicze Victoria, Coke Production Plant, Walbrzych, Poland ...... 09-4 Zeigler Coal Company, Murdock, Illinois ...... 05-45 Zeigler Coal Holdings Company, Pier IX and Shipyard River Coal Terminal, Newport News, Virginia ...... 05-42 Ziemowit Mine, Poland ...... 05-19 Zimmer Plant, Moscow, Ohio ...... 04-12, 04-25, 08-13
Index 15