IM COVER MARCH 2016_proof 23/02/2016 15:13 Page 1 www.im-mining.com MARCH 2016 Informed and in-depth editorial on the world mining industry BAUMA PREVIEW COMMINUTION & FRAGMENTATION GERMAN TECHNOLOGY WATER MANAGEMENT PERU COPPER MINING II OPERATION FOCUS: Kaltim Prima Coal OPERATION FOCUS- INDONESIA_proof 24/02/2016 07:33 Page 1 OPERATION FOCUS Indonesia’s premier coal mine Paul Moore visited the Kaltim Prima Coal mining complex in East Kalimantan, Indonesia, in late 2015, to see how such a large operation manages its huge fleet of machines over an extensive area altim Prima Coal (KPC) is the world’s KPC operated pits include East and South One of KPC’s record fleet of 20 R996 excavators largest single producer and exporter of Pinang Pits, Bendili and Bendili Prima (visited by loading a Hitachi EH5000, which along with three R9800s and a number of other machines Kthermal coal, as well as largest single coal IM) and the new Inul region (Inul K, Inul East, make up Liebherr’s largest global fleet mining complex in Asia. The name “Sangatta”, Inul Middle) pits in the northern part of the often used to refer to the mine, more refers to complex, where future mining will be focused. A around six different grades, either mined as is or the fact that the KPC operations are located major pit known as Pit J has now closed and is through blending. Qualities range from the high around the town of Sangatta, the capital of the currently being backfilled. CV Prima to the low CV/low Ash Melawan. East Kutai Regency of the East Kalimantan Future mining will take place in the Pedayak The Sangatta coal preparation plant has a Province, Indonesia. The town is on the Sangatta (also known as Komodo) region and the Inul/Inul clean coal crushing capacity of around 7,000 t/h River, 50 km north of the equator on the east Lignite region. and wash plant feed (dirty coal) crusher capacity coast of Kalimantan Island (Borneo), 180 km The March 2014 Resources are around 7.671 of 300 t/h. The nominal top size of product coal north of the provincial capital Samarinda and 310 billion tonnes, of which around 866 Mt are of is 50 mm. The majority of ROM coal is low ash km north of the major population centre and Marketable Reserves. clean coal and can be crushed for direct shipping industrial capital of Balikpapan. KPC operates two 12 hour shifts and actual with no further preparation necessary. Only The ownership structure of KPC is complex but coal production in 2015 was around 56.5 Mt. The around 1.4 Mt/y of “dirty coal” from the roof and currently PT Bumi Resources Tbk (BUMI) controls contractors account for about two thirds of floor of seams is processed through the dense 51%, while Tata Power holds 30% KPC and China production and KPC itself about one third. From medium cyclone preparation plant for a recovery Investment Corporation (CIC) owns 19%. the Melawan mining area there is an additional of approximately 70%. The mining complex has operations mined by crushing facility and 10 km conveyor that meets Mechanical sampling systems, metal KPC itself (Mining Operation Division) but also a the CHPP, avoiding additional coal trucking detectors, belt scales and temperature sensors number mined by contractors, with the movements. At the CHPP there are six roll are located on belt conveyors across the coal contracted operations managed separately (by crushers while the Melawan crushing complex chain to monitor product quality and quantity the Contract Mining Division) but based on KPC’s has an additional two roll crushers. There is a continuously as well as to prevent scrap metal mine planning. In terms of the contractors, PT fixed 13 km twin covered overland conveyor contamination. Darma Henwa (PTDH) currently mines Bengalon (OLC) with a capacity of 2 x 32 Mt/y or 64 Mt/y The majority of the coal is shipped to Pit A, Bengalon Pit B (sometimes known as BC) in all connecting the main ROM stockpile and customers through the TBCT, whose stockpiles and Elang pits; PT Pamapersada Nusantara Coal Handling and Preparation Plant (CHPP) to have a live capacity of 1 x 1.5 Mt and 1 x 0.75Mt. (PAMA) mines the Pelikan and Kaguru pits and the Tanjung Bara Coal Terminal (TBCT) port. the equipment there has a stacking capacity of 2 Thiess mines the Melawan region pits, currently In the northern region ROM coal from the x 4,200 t/h and reclaimer capacity of 1 x 4,700 consisting of a number of separate pits including Bengalon pits is hauled to the Lubuk Tutung coal t/h. Coal is delivered to the shiploading conveyor the Mustahil and Peri pits. There are no artisanal handling facility where it is crushed and direct or by a combination of reclaimer and direct and small scale mining contractors in the region stockpiled at a 2,500 t/h facility. All coal from bypass from the OLC. The ship loading conveyor and so KPC does not have to cooperate with any. Bengalon is barged from loading facility of 3,500 spans 2 km to a trestle jetty in a deepwater berth KPC has almost 5,000 employees of which nearly t/h capacity (for transhipment or direct domestic with available draft of 17.2 m that is able to 4,000 were recruited locally from the Sangatta market). support 220,000 DWT vessels. Coal is shipped and Bengalon areas. In terms of actual product, the mine produces (mainly for export) from a twin quadrant 12 International Mining | MARCH 2016 OPERATION FOCUS- INDONESIA_proof 24/02/2016 07:33 Page 2 OPERATION FOCUS shiploader and bargeloading facility (for pits/dumping into water, detailed SOPs are in Through Seam Blasting to stop having to transhipment or direct domestic market). place, and trucks dump material some distance separately remove the under and interburden but KPC Tanjung Bara terminal has around a 48-50 from the tip head and this material is then is yet to use this throughout the operation. Mt/y shipping capacity with direct pushed by crawler dozers. The overall mining Draglines have been reviewed but are not used barging/transshipping operations barge loading complex operational safety record is very good at KPC or by its contractors due to the multiple facilities at both Tanjung Bara and Lubuk Tutung, for Indonesia, with an LTIFR for 2015 of 0.16. seams and weak material. In addition, due to with a total average capacity of 18-20 Mt/y Shane Bennett, GM Mine Development, told multiple seams and very deep pits, most pits are loaded at 2-3,000 t/h. IM that waste where possible is backfilled into more akin to a metalliferous operation rather older pits but as many of the pits have multiple than a typical coal strip mining situation. Mining operations overview seams with some of the higher quality seams in KPC and its contractors are supplied with Geologically there is a dome structure (the the bottom of the pits, backfilling is not possible explosives from both Orica and AEL; with both Pinang dome) in the centre of the property. until they have been exhausted. During the visit, companies having storage facilities and delivery Overburden is mainly sandstone, siltstone and IM saw Pit J, where backfilling has been underway MMUs deployed across the mining complex. The mudstone. Early mining focused on the edges of since 2014. It will ultimately accommodate some mine uses around 400 t of explosives per day, the dome and virtually all coal seams dip away 350 Mm3 of waste if completely filled. typically with five or six daily blasts. from this region. This coal is also higher in rank He added that the company has trialled KPC says it continues to look for ways to have due to heat/pressure from the dome. The other limb of a major synclinal structure emerges at the Melawan/Pelikan/Kanguru area where the coal is of lower rank, despite being the same seams. There is a possible further source of higher rank coal in the east of the region, much of which has yet to be drilled due to access limitations, however, it is likely to be steeply dipping and heavily faulted. The mine Strip Ratio (SR) averages 8-10:1 (BCM - Bank Cubic Metres per tonne of coal) or 20-24:1 on a straight waste to ore (tonne to tonne) basis. Production is typically 1.4 Mbcm of overburden per day for 150,000 t of coal. For example, total overburden removal achieved by KPC in the full year 2015 was around 535 Mbcm for a full year production of coal of 56.5 Mt, generating an SR of around 10:1. These are total figures including both KPC owned fleets as well as contractors. The bench heights on average are 10 m. Most of the coal seams are 2-6 m in thickness and anything over 0.5 m is classified as recoverable. The seam dip depends on which side of the syncline the pit is on. Many of the pits dip to the east at about 15 to 20 degrees, with the Pelikan and Kanguru operations dipping slightly more steeper to the east. Trimming of benches is conducted to access more coal and widen roads. There was a highwall miner onsite which has been used successfully but has not continued. Highwall mining is challenging due to the soft ground and the development and mining rates. Pits are monitored for movement, with the danger more from slumps and landslides of soft material rather than rockfalls, as the mine is on the edge of a floodplain.