coal preparation and handling experience

Transcription

R O B E R T S
&
S C H A E F E R
C O M P A N Y
COMPANY PROFILE
H O W
T H E
W O R L D
P R O C E S S E S
I T S
R E S O U R C E S
RO BERTS & SCHAEFER COMPANY
PRESENTATION OF
GENERAL QUALIFICATIONS
TO PERFORM PROFESSIONAL
www.r- s.c om
ENGINEERING AND
CONSTRUCTION SERVICES
Chicago
Salt Lake City
Australia
Indonesia
Poland
India
222 South Riverside Plaza
10150 South Centennial
Level 5, 35 Boundary Street
Sequis Center; 7th Floor
UI. Bojkowska
20 White House, C G Road
South Brisbane, Australia 4101
Jl. Jenderal Sudirman Kav. 71
44-100 Gliwice, Poland
Ahmedabad - 380 006, India
Chicago, IL 60606-3986
Parkway, Suite 400
TEL: 312-236-7292
Sandy, Utah 84070
O: +61 (0) 7-3234-9555
Jakarta, Indonesia 12190
O: +48-32-461-2722
TEL: +91 79 40328000
FAX: 312-726-2872
TEL: 801-984-0900
F: +61 (0) 7-3234-9595
TEL: +62-21-252 4177
F: +48-32-461-2720
FAX: +91 79 40328001
[email protected]
FAX: 801-984-0909
[email protected]
FAX: +62-21-252 4138
[email protected]
[email protected]
[email protected]
H O W
T H E
W O R L D
[email protected]
P R O C E S S E S
I T S
R E S O U R C E S
RO BERTS & SCHAEFER COMPANY
www.r- s.c om
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
H O W
T H E
W O R L D
P R O C E S S E S
I T S
R E S O U R C E S
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
Project Lifecycle
• Process Design Engineering
• P & ID Development
Study/Planning
With specialties in:
• Process Flowsheet Development
Engineering & Design
• Feasibility Studies and Project Evaluation
• 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.
• Coal fired electric utilities including fuel handling, limestone and gypsum
handling for flue gas desulfurization.
Construction
Testing/Commissioning
• Petroleum Coke handling at refineries and power stations
• The aggregate, cement and sand industry, with its broad spectrum
of individual operations ranging from portable plants to sophisticated
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.
• Proprietary equipment supply including specialized stackers, reclaimers,
ship loaders and unloaders, belt feeders, curved conveyors, gates and
specialized products unique to coal and mineral beneficiation
Operations & Maintenance
The measures of a company providing
specialized engineering, procurement and
construction services are the professional
quality of its staff personnel and the
history of its project experience.
INTRODUCTION
A
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 beneficiation 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
different approaches to present industry practices. We understand the processes;
we understand the steps to organize all aspects of a project; and we understand
the best technology for the applications.
Our engineering capabilities, technical expertise, and ability to execute
projects on a turnkey basis provide a significant value proposition to both
A&E firms and end customers, such as electric utilities, coal producers,
and other mining companies.
INTRODUCTION
2
Section 01
For over 100 years, 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.
OUR PROJECT EXPERTISE
In the projects experience section of this qualification manual you will find
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 retrofit projects
FLUE GAS DESULFURIZATION (“FGD”)
FGD is the technology used for removing sulfur dioxide from the exhaust flue
gases in coal-fired power plants. Environmental protection legislation mandates
that utilities install FGD systems to curb their emissions profile 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
flue 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
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 refinery, utilized as a fuel source, and its
applications to the cement industry. This assures careful analysis, correct criteria
and equipment selection, and efficient facility configuration 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, flotation,
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
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 beneficiation 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 five operating offices 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 specific 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 flexibility that
allows its total resources of engineering design, procurement and
construction management services to be accessible for a specific 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
efficient and effective performance. This qualification 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
techniques based on Project Management Institute guidelines (PMBOK).
From material handling systems to advanced process engineering, all disciplines
are coordinated with a single point of responsibility. The Project Execution section
of this qualification manual fully describes our approach to projects.
We continually reinvest in our people and technology to maintain the highest
professional standards of capability, efficiency 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
Our reputation and financial stability
is exemplified in our ability to provide
bonding for projects in excess of
$100,000,000. Roberts & Schaefer is
insured for errors and omissions insurance
in the amount of $20,000,000.
A TEAM OF EXPERTISE
Roberts & Schaefer Company is comprised of nearly 250 highly qualified engineers,
designers, draftsmen, project managers, construction managers and administrative
personnel in our five offices. 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 five 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 filters 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.
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
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.
being transferred on dual conveyors to the plant transfer tower.
or wet dust suppression.
Ancillary systems include sump pumps and service air.
2
Section 02
The six plant silos are arranged in
a single row and feed by a conveyor
with a traveling tripper.
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 fill system for the
Oak Creek units. A second set of dual conveyors transfer the coal to the silo fill
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
collection with pneumatic return to the plant coal silos or fog type suppression.
An as-received and as-fired, for both Elm Road and Oak Creek (future) sampling
systems are provided. Ancillary systems include washdown, conveyor creep
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.
The coal handling system provides
bituminous coal to the new Elm Road
Units 1 & 2 and PRB coal to the existing
Oak Creek Units 5 & 6.
Section 02
3
SALT RIVER PROJECT
SPRINGERVILLE GENERATING STATION (UNIT 4),
APACHE COUNTY, ARIZONA
Engineering, procurement, expediting, and field 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-fired coal sampling system is
located in the Unit 4 crusher tower.
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 first 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 five silos in a single row.
Both as-received and as-fired sampling
systems are provided.
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 gasification 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.
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 modifications include new
drive, pulleys, idlers, to increase capacity to 425 TPH.
The modified 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 modifications. 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
Unit to minimize overall downtime.
A dozer trap and temporary reclaim conveyor are provided to bypass the existing
breaker house during construction.
R&S has extensive experience in fuel
switching to Powder River Basin coal
and its distinct handling requirements.
Ancillary systems include wet dust collection, wash down and vacuum cleaning
piping for the new transfer tower, crusher tower, and connecting conveyors.
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 fly 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).
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 fixed 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
modified with new drives and increased belt speed for the increased capacity.
The ancillary systems included fire 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.
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.
The coal is discharged from these two silos by multi-directional mass flow gates
to a variable speed reversible conveyor. The conveyor capacity is 4,000 TPH to
the existing system and 1,200 TPH to the first transfer house in the new system.
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 five silos in a single row with traveling tripper. The transfer
house has provisions for feeding coal to future Unit 2.
with processed dust return or fog type dust suppression.
10
Section 02
Truck coal can also be delivered to the
power station and unloaded at a truck
hopper with provisions for a second
future truck hopper.
TRACTEBEL POWER – CHOCTAW GENERATION
RED HILLS GENERATION FACILITY,
CHOCTAW COU NTY, 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 fluidized 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 fire detection systems.
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.
12
Section 02
FIRST ENERGY
W.H. SAMMIS PLANT, STRATTON, OH IO
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.
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-fired sampling system, emergency
reclaim hopper, belt scales and upgraded control system.
14
Section 02
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 modifications 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
two 1200TPH conveyors into a 150T crusher surge bin. On the surge bin outlet
are two posimetric feeders which feed two 600TPH hammermill crushers.
Paradise Plant, Drakesboro, Kentucky
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 modified 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
modified control system.
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.
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 first of the new conveyors provided by R&S, Conveyor CVY-11.
Conveyor CVY-11 is a fixed 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 modified 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 fixed tripper conveyor CVY-18 located in the tripper
bay of the new unit 4 generating building. Conveyor CVY-18 feeds the coal into
the five (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.
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.
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 flow and reduced spillage.
DUCK CREEK POWER STATION, CANTON, ILLINOIS
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 modified 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 modifications included conveyor chutework and skirtboards, and conveyor/
building structural steel and foundations.
The stacker-reclaimer boom conveyor was modified with a new drive, chutework,
and structural steel for the increased capacity
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 first 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.
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.
Both as-received and as-fired sampling systems are provided.
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.
At the central transfer tower, the coal is transferred to the first lowering well or
to the crusher tower. At the first lowering well, the coal is discharged to form a
20,000-ton capacity storage pile or transferred to the second lowering well to form
an additional 20,000-ton capacity storage pile. The unloading and stockout
capacity is 3,000 TPH.
There are provisions for a future
emergency reclaim system with
a drag feeder and a separate reclaim
conveyor to the crusher tower.
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 fill, and Unit 2 silo fill.
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 retrofitted with new idlers, belt plows,
skirtboards, control devices, drives and motors, etc.
Since the power station was in constant operation, the modifications were
coordinated with the station to maintain a constant coal supply to the bunkers.
New items also included magnetic
separators and belt scales.
22
Section 02
WIDOWS CREEK FOSSIL PLANT, STEVENSON, ALABAMA
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 fixed 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.
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 finally 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 first conveyor includes a modular sampling system.
The new pedestal mounted circular stacker boom is cable supported with luffing
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.
24
Section 02
SOUTHERN COMPANY SERVICES
GEORGIA POW ER 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
flow gate that is used to discharge the synfuel onto an existing conveyor system
that feeds the Georgia Power Company fuel silos.
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.
The traveling hopper is equipped with on board PLC and dust
suppression systems.
26
Section 02
R&S has significant international project
experience and is an expert in specialty
material handling equipment.
BALTIMORE GAS & ELECTRIC COMPANY
BRANDON SHORES, UNITS 1 AND 2,
ANNE ARUNDE L 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 floating 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 fitted 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 fitted with a trailing
tripper and stacking slewing boom.
4,400 TPH of coal handling capability.
The storage yard itself has a concrete
reclaim tunnel traversing the length of
the coal yard. This tunnel provides live
storage for a major portion of the coal
yard. The reclaim tunnel is fitted with
five 12' diameter dischargers feeding
vibrating feeders. These feeders in
turn, feed the main reclaim belt. The
reclaimed coal is then loaded on a
transfer belt. This transfer belt joins
with the yard belt in a combination
transfer sampling building ahead of
the main power block. In this building,
coal is crushed to a 2" x 0 product and is
conveyed to reversible shuttle conveyors
that feed the coal bunkers. The coal
reclaim rate feeding the bunkers is
850 TPH.
This project had unique construction
challenges due to the seasonal
availability of the river access and
interface restrictions with the power
block general contractor. The entire
project took approximately 26 months
from award to operation of Units
No. 1 and No. 2.
The reversible shuttle belt conveyor
system feeding the power block provide
flexibility in plant loading requirements.
This system is fully automated with
individual remote stations, each of
which is capable of operating the
equipment from barge to bunker.
An additional coal handling system
serves Unit No. 2 of the Brandon Shores
Power Plant. This system begins atop
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 distributed by traveling shuttle conveyors.
The coal conveying rate is 850 TPH.
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
fine reclaim hopper. The coarse gob is reclaimed on a 48" variable speed belt feeder.
The fine gob is reclaimed by a special designed variable speed rotary plow feeder,
integral with the fines hopper. Both the coarse and the fine material are collected
on a 36" reclaim tripper belt. This belt terminates in a 6,000 ton capacity storage
barn. The belt is fitted 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 fitted 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 filling.
A control system is provided, which interfaces with the owner-supplied distributed
control system. The project was completed in approximately 12 months.
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 flexible belt wall.
This unique conveyor is a special design and is fitted 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 fitted 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 fitted
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.
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 fitted with a variable speed trip feeder for reclaiming at a
rate of 1 to 270 TPH. The reclaim feeder is fitted 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 fills 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 fired" 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.
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 modified 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 fire
protection, wash-down and pumping systems.
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 fired 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 fitted with
12" x 12" grizzly and the full area coal valves. At a rate of 150 TPH, twin vibrating
feeders reclaim the coal to a 36" crusher feed conveyor. This conveyor is fitted with
a belt scale and magnetic separator for tramp iron removal.
The reclaimed coal passes over an "as received" 2-stage sampling system and is
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 first 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 filters, 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.
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Section 02
The scope of supply included the complete
electrical supply and installation, including
instrumentation and control systems.
Interfaces with the boiler block control
system were also included.
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.
Section 02
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MORE EXPERIENCE
KANSAS CITY POWER AND LIGHT, SP ECIALIZED BELT
FEE DERS, LA CYGNE, MISSOURI
R&S added a blending system at their existing La Cygne facility.
This addition/retrofit 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
speed drive, allowing belt speeds of 5 - 50 FPM and a downturn to 60 TPH
Above: Kansas City Power and Light, Specialized Belt Feeders,
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
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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 fill conveyor system was upgraded to 300 TPH with increased belt
speeds, new drives, and conveyor components as required.
A new silo fill 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 filter dust collectors were furnished for the silo fill 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 floor 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 modified
transfer tower. The conveyor from the transfer tower to the radial stacker and
the radial stacker boom conveyor were modified 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 modified too for the new conveyor to the transfer tower.
Progress Energy Carolinas, Roxboro Power
Station, Roxboro, North Carolina
Section 02
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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,
QUEZON PROVINCE, PHILIPPINES
Engineering, procurement and operation and maintenance technical assistance
of a conveyor system. The system transfers coal from the stockpile to the bunkers
of a 700 MW power plant.
The conveyor system runs from the ship unloader to the stockout/reclaim, then to
the coal crushers and finally 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.
36
Section 02
Top: CS Energy, Kogan Creek Power Station,
Surat Basin, Australia
Below: Hopewell Pagbilao, Conveyor System,
Quezon Province, Philippines
MORE EXPERIENCE
CENTRAL GENERADORA ELECTRICA, SAN JOSE POWER
STATION, GUATEMALA CITY, GUATEM ALA
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
filling 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 filling 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 fill the silos.
PT FREEPORT, IRIAN JAYA, INDONESIA
Above: Central Generadora Electrica, San Jose Power Station,
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
Section 02
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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 final 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 field
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 modifications 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 final report followed, addressing those preliminary
recommendations selected by Northern States, providing conceptual drawings
and capital cost estimates.
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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
capacity highway truck-trailers delivering coal or sorbent to a receiving pocket
fitted 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 fitted with reclaim screw feeders
which deliver on demand coal and sorbent to a fluid bed combustor. High temperature bed ash (600°F) and fly 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 flight
type water cooled screw conveyors for ash temperature control prior to storage
and loadout. Telescoping loadout chutes deliver bedash and flyash 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.
We can customize our service to include
just the assistance you need, from
complete design and construction to
performing conceptual and feasibility
studies, or furnishing only equipment.
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, refitted 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.
Section 02
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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 first phase of the project initiated
with a detailed inspection and evaluation of the facility. This phase provided a
written report recommending resolution of the identified 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 field 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, D AVE 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 modifications to existing conveyors to increase their capacity
from 900 TPH to 1,200 TPH.
Top & Above: PacifiCorp, Dave Johnston Power Station,
Glenrock, Wyoming
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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 H AUTE, INDIANA
Engineering, procurement and construction of the coal handling system for
the Wabash River Generating Station’s Coal Gasification Repowering Project.
The system takes the coal from the existing conveyors at the crushing house
and transports it to the new coal gasification plant. The coal gasification plant
transforms the solid coal into gas allowing PSI to use it in a boiler that was
originally designed for gas. The coal gasification plant also removes the sulfur
and particulate matter from the coal before burning, helping PSI meet
environmental regulations.
The scope of the project included all conveyors, drives, structural steel,
foundations, fire protection, electrical and controls. The system is rated
at a capacity of 1,600 TPH.
Top: ComEd, Fisk Station, Waukegan Station
and Joliet No. 9 Station
Bottom: Westvaco-Cogen South Project,
Charleston, South Carolina
Section 02
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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 finished 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 fill
the four coal silos. The new system also included dust suppression, dust collections
and new as-fired coal sampling systems.
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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 luffing 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, modified 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, fire protection and
washdown collection pumping.
Fuel switch to Powder River Basin coal.
Section 02
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MORE EXPERIENCE
ALABAMA POWER COMPANY, J. H. M ILLER 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:
• Dual belt wiper
• Belt plow
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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 fired
cogeneration power plant. Work included the design of a truck dump to receive
27-ton capacity, highway trucks with tandem trailers.
The dump is fitted 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 fill 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 fitted 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
fill 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 flop 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 fitted 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.
Section 02
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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:
• Dual belt wiper
• Belt plow
• Skirtboard
KANSAS CITY POWER & LIGHT COMPANY,
LACYGNE, KANSAS
Engineering, procurement and construction for fuel yard modifications.
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.
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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 gasification. Roberts & Schaefer was commissioned
to build a facility to reclaim anthracite culm from the existing indigenous banks
to beneficiate the material to specific thermal quality and size characteristics.
Scope of supply started with a hillside truck dump fitted 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 beneficiation. A water clarification 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 gasification process.
This project offered many design challenges, since it was the first 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.
Section 02
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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 modified 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.
48
Section 02
Top: TVA Gallatin
Middle: Danskammer Generating Station
Bottom: Batu Hijau Mining Project
MORE EXPERIENCE
ALLEGHENY POWER SERVICE CORPORATION, WILLOW AND
PLE ASANTS 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,
RIC HMOND, 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 POW ER 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 ELECTR IC GENERATING STATION, NEW JERSEY
Engineering, procurement and construction of a coal handling system for
Units 3 and 4 of the Danskammer Station
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 modification
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.
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 refinery 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:
The use of coker drum technology in an oil refinery improves the yield of the higher
value gasoline and diesel products; as a result most new refiners include a coker in
their design and many existing refineries are converting to add cokers. The residue
from the coker, petroleum coke, is a solid carbon similar in many ways to coal and
is typical used as a fuel to generate power or steam, often being blended with coal.
Pet coke handling includes crushing, storage, reclaim, blending, loading/unloading,
and transportation, both at the refinery and at the end use location.
Our experience in designing and
building these systems, assures that we
will find the optimum solution to suit
your needs. It will be a solution that is
economical, reliable, safety conscious
and environmentally sound.
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
refinery 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 final 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.
2
Section 03
TESORO REFINING
GOLDEN EAGLE REFINERY, MARTINEZ, CALIFORNIA
Engineering and procurement for the coke handling system.
Tesoro Refining and Marketing Company (Tesoro) has implemented major
modifications to their coking facility at the Golden Eagle Refinery 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.
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 specification 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.
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 Refinery 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
luffing 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. Luffing 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 first 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.
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 Refinery
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 five (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.
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 Refining 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 Refinery (MIDOR) for
a pet coke stockpiling and truck loading facility at the MIDOR refinery 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 fill 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 Refinery (MIDOR),
Alexandria, Egypt
Section 03
7
MORE EXPERIENCE
PROTEXA CONSTRUCTION COMPANY,
PEMEX REFINE RY PETROLEUM COKE HANDLING PROJECT
Contract to handle petroleum coke was received from Protexa Construction
Company for Pemex Refinery. The scope includes engineering, material
procurement, shipment and field 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.
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.
PETROLEUM COKE
ALTERNATIVE
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
fine reclaim hopper. The coarse gob is reclaimed on a 48" variable speed belt feeder.
The fine gob is reclaimed by a special designed variable speed rotary plow feeder,
integral with the fines hopper. Both the coarse and the fine material are collected
on a 36" reclaim tripper belt. This belt terminates in a 6,000 ton capacity
storage barn. The belt is fitted 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 above ground dump hopper. The reclaim conveyor is fitted 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 filling.
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
We can provide you with complete
stockpiling, reclaiming, blending,
unloading and loading facilities.
Whether it’s 50 TPH or 10,000 TPH
of gob, wood chips, or biomass, we
can design the system to handle it.
CONTINENTAL ENERGY ASSOCIATES
HAZLETON GASIFICATION PROJECT,
HAZLETON, PE NNSYLVANIA
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 gasification.
R&S was commissioned to build a facility to reclaim anthracite culm from
the existing indigenous banks to beneficiate the material to specific thermal
quality and size characteristics.
Scope of supply started with a hillside truck dump fitted with protective
grizzly and reclaim vibratory feeder.
This project offered many design
challenges, since it was the first
plant built for reprocessing anthracite
culm. The entire project was completed
in 14 months.
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 beneficiation. A water clarification 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 gasification process.
The quality characteristic of the culm being extremely abrasive required
unusual wear resistant materials.
PETROLEUM COKE
ALTERNATIVE
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 fired 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.
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.
PETROLEUM COKE
ALTERNATIVE
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 flume 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 flume superstructure
resulting in considerable cost and time savings.
While not used for fuel in this case, the project demonstrates our ability
to handle general Biomass.
14
Section 03
Lihue Plantation Company, Ltd., Lihue Kauai, Hawaii
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.
The gypsum handling system is designed to receive gypsum from the process
filters and convey it at 400 TPH to the gypsum storage dome with a radial stacker.
The dome capacity is 10,000 tons.
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.
R&S performed installation of the coal
handling systems at the Brandon
Shores Power Plant during its original
construction in 1981.
The limestone and gypsum handling systems share several transfer towers.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE
Section 04
1
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.
filters 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.
At the storage building the gypsum is discharged through a traveling tripper.
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
plow feeder located at the dock. 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. 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.
2
Section 04
R&S has unmatched experience in the
loading and unloading of river barges
and designing the marine infrastructure
to support it.
PROGRESS E NERGY
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 certifiable 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.
filters 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 certifiable 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.
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.
filters 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.
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
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.
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 five silos
per row are each feed by a reversing shuttle conveyor.
or wet dust suppression and the distribution conveyor has wash down.
Ancillary systems for the coal, limestone, and gypsum include service water.
4
Section 04
DO MINION VIRGINIA POWER
CHESTERFIELD POWER STATION, CHESTER, VIRGINIA
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.
filters 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.
Section 04
5
DAYTON POWER & LIGHT
STUART GENERATING STATION, ABERDEEN, OHIO
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.
filters 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.
6
Section 04
DAYTON POWER & LIGHT
KILLEN GENER ATING STATION, MANCHESTER, OHIO
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.
filters 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.
Section 04
7
AES – PUERTO RICO
limestone and aggregate material handling systems; the contract was awarded
by Duke/Fluor Daniel.
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.
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 fly 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.
8
Section 04
INDIANAPOLIS POWER & LIGHT
HARDING STREET STATION, INDIANAPOLIS, INDIANA
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 filters
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.
Section 04
9
DUKE ENERGY
CAYUGA GENERATING STATION, CAYUGA, INDIANA
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 filters
and transfers the product onto Gypsum fixed stockout conveyor GH-2B in Transfer
Tower 1B. Conveyor GH-2B is a fixed 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.
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.
Limestone is reclaimed with hoppers and belt feeders to three day
bins in the limestone preparation building.
Above: Miami Fort Station, North Bend, Ohio
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.
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 fill covered barges through open hatches,
which requires that the chute/spout be able to move laterally and extend
and retract.
A certified 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.
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.
Section 04
13
CARDINAL PLANT, BRILLIANT, OHIO
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 filters 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 filters 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.
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.
Section 04
15
MIRANT MID ATLANTIC
CHALK POINT, DICKERSON,
MORGANTOWN STATIONS, MARYLAND
Engineering, procurement, and construction assistance of limestone handling
for flue 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.
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 first 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.
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.
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 fills 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.
Section 04
19
PARADISE FOSSIL PLANT, PARADISE, KENTUCKY
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 filters were provided for the silo and also for each surge bin.
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 final
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.
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 fitted 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 fitted 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 fitted 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.
22
Section 04
SOUTHERN INDIANA GAS & ELE CTRIC
CULLEY STATION, NEWBURG, 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 floating barge.
The barge is fitted with drainage pump
and is anchored to two 20' diameter
concrete capped river cells.
Material is reclaimed from the receiving
hopper via an apron feeder. A riverside
dust collection system is included on the
floating dock.
Material reclaimed from the receiving
hopper is conveyed by a belt conveyor
to a combination loadout and storage
facility. Since this facility is also capable
of unloading coal at the same time, a fire
protection system is provided on a belt on
the floating dock at the loading/transfer
station. A bifurcated chute and flop gate
are provided at the discharge of the
unloading conveyor to transport the coal
or limestone to a loadout bin or to the
limestone transfer conveyor. Sampling
is also included.
The limestone transfer conveyor
discharges into an enclosed limestone
storage shed, which consists of a
concrete lowering tube as the center
of a circular (segmented) structure.
The storage structure houses
approximately 750 tons of limestone.
An open section in the wall is provided
to allow the owner’s front end loaders
to build additional storage or work on
the enclosed storage pile. An above
grade reclaim hopper with a ramp
suitable for an unloader is provided
for limestone reclaiming. This hopper is
fitted with an especially designed feeder
break unit which regulates the feed
while minimizing oversize material.
A fifth transfer conveyor delivers the
product to a new limestone silo. Each
transfer station is equipped with an
independent dust collecting system.
Additionally, our scope of supply
included gypsum handling, storage
and reclaim.
The reclaimed and crushed material
is conveyed by a belt conveyor to a new
transfer station where tramp iron is
removed with a magnetic separator. At
the transfer point the material is delivered to another transfer conveyor which
delivers the material to an existing belt
line feeding the existing power block.
The limestone is then conveyed on
an additional length of the conveying
system to an elevated transfer tower
adjacent to the new FGD installation.
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
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 flights 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 fixtures, 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 OWEN SBORO, KENTUCKY
Gypsum handling conveyors.
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
to the batch weigh dual hopper loadout system where the railcars are loaded.
Ancillary systems include wet dust suppression, wash down, service air, and
closed circuit TV.
The storage building is designed for a
future clean coal conveyor with traveling
tripper and segregated piles.
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 fines circuit of the Main Plant to achieve a whole plant average of 1,350 TPH.
The fines 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 efficiency.
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 fines plant:
• All major fines circuit pump capacities including clarified water;
• Jameson Cell capacity Clean coal and desliming cyclone capacities;
• Spiral product dewatering capacity;
• All major fines circuit pipeline sizes.
• Modification 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 fines plant. This was achieved through
the following key changes:
• Upgrade of 4AM Conveyor
• Additional 2 desliming cyclones and 3 spiral product cyclones;
• Installation of a new bank of 8 triple start spirals;
• Installation of 2 fine 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
2
Section 05
The main plant consists of 3 separate
coarse coal processing circuits, separate
and common fine coal and reject
processing circuits and common water
treatment and reticulation circuits.
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.
The train loadout consists of two 18,500-ton capacity silos each including
an under-silo batch loading system.
A three-stage sample station is included to sample the crushed coal to
ASTM standards.
It is significant to note that a number
of the concepts developed by Roberts
& Schaefer in the 1988 project were
included in the 2006 project including:
the passive dust control system, overland
conveyor support system, non-enclosed
and at-grade drive systems. It is also
significant 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.
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 first 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.
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 fluidized 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
provides a maximum degree of safety.
A fail-safe PLC control system with
automatic and manual emergency sprays
provides a maximum degree of safety.
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,
and sump pumps.
6
Section 05
All areas of the coal handling system are
provided with bag house dust collectors.
PT KALTIM PRIMA COAL (KPC)
KALTIM PRIMA COAL FACILITY, SANGATTA,
EAST KALIMANTAN, INDONESIA
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 five 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
meeting KPC & Australian standards.
The reclaim conveyor discharges into a surge bin. Additionally, coal from the
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.
A tramp iron magnet and a metal
detector are included on the sizer
station feed conveyor.
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 fire detection and protection, wash down hose stations, and
tunnel ventilation.
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 – fines dewatering
Coal is delivered by a variety of haul trucks (belly dumps, rear dumps or 8 triple
side dumps) to either of 3 X 600-tonne ROM hoppers. Coal is fed from the ROM
hoppers, via apron feeder through three stages of crushing where it is reduced
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.
8
Section 05
This is now one ne of the largest
coal handling/prep plants in the area
with a fully automated train load
out system (TLO).
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 financed
under a Build, Own, and Operate, Transfer
(BOOT) partnership with White Mining,
R&S, and Itochu.
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 fine 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 office. 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
• Jeffrey vibrating feeders
Facility features:
• 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
10
Section 05
This is a green-field fine coal
preparation facility processing
19mm-0mm raw coal from existing
coarse coal preparation plant.
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
efficiently re-deposit the final tailings back at the site including the re-planting
of vegetation to meet local ordinances.
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 fines circuit.
The Tank Cell acts as a rougher to reduce the load on the existing conventional
flotation circuit. Filtration capacity was increased by the addition of a 3rd
Drum Filter.
The crushing and sizing circuit was modified by the installation of a Primary
and Secondary sizer and new Coal Screen.
The project also included extensive modification to the feed conveyor to both
align with the new ROM sizing module and increase capacity.
The installation for this brownfield
upgrade was constructed during
a limited period during which the
plant production was shutdown.
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)
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.
A series of conveyors and transfer stations can direct the coal to storage and
reclaim in one of three different storage stockpiles (domestic thermal
coal = 150,000 tons, preparation plant feed = 120,000 tons, and export product
coal = 500,000 tons).
The facility also includes a Bypass System
to deliver product to Macquire Generation
for domestic power consumption.
Coal from the product coal storage stockpile is delivered to a rail loadout station.
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 flow 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 flop gate
• Transfer conveyor to truck loadout silos
• Modification at roof of existing loadout silos to receive new transfer conveyor
• New shuttle conveyor at roof of existing loadout silos
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 floating
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, Office, and Admin Complex
• Man Camp Facilities
• On-site power generation, utilities, infrastructure
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 first stage involved upgrading one of the two DMC circuits to include a new
wing tank, 1100mm DMC, and large gravel pumps and modified dense medium
recovery circuit.
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 field upgrades allowing minimal production downtime
for construction installation.
16
Section 05
The projects were completed in 2004
and 2005, respectively.
POLUDNIOWY KONCERN ENERGETYCZNY (PKE)
SOBIESKI MINE, JAWORZNO, POLAND
Engineering, procurement for upgrades to the coarse coal and fine 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 fine slurry circuit pumping
system and dewatering equipment.
The power plant storage yard was also redesigned with a new stockpile
configuration to enable the creation of a clean coal blending station.
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
efficiency and flexibility.
In 2007 and 2008 additional
modifications engineered by R&S
were carried out at the Sobieski
facility, dealing with refuse handling
and plant automation.
Elgin’s Equipment Group supplied CMI fine coal dewatering centrifuges
for the plant and provides maintenance services for that equipment.
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 flotation circuit, introduction of high
speed fine coal dryers and associated equipment – vibratory screens, belt scales,
PLC controls, flocculation system, pumps and process piping.
New equipment required partial demolition of the reinforced concrete building
floors, 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 modifications to the Halemba Mine existing coal washery in the
coarse coal and fine coal circuits.
The project required engineering the construction workflow 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.
18
Section 05
KOMPANIA WEGLOWA (KWK)
MURCKI MINE, POLAND
Design for a modification to the KWK Murcki coal mine existing coal washery
in the coarse coal and fine coal circuits, as well as closing the water slurry circuit
due to environmental concerns.
The project required engineering the construction work flow 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.
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
semi-mobile, near-pit crushing units, each arranged with 500-ton capacity dump
hoppers and fitted with passive dust control systems. Drag chain type feeders
are fitted to the dump hoppers and reclaim the coal. Each feeds a crusher unit
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) modifications 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.
20
Section 05
The near pit crushing and conveying
project received the outstanding project
of the year award, presented by the
Wyoming Engineering Society.
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
fine 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.
This plant design is unique in that screen bowl centrifuges are used to dewater
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 fine magnetite.
The overall project was completed
in approximately 14 months.
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-flight 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. Overflow 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 classified at approximately 65 mesh with the
overflow reporting to a spiral circuit and the underflow reporting to single stage
froth flotation. 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 clarification 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 fire
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
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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 classified at 100 mesh with the
underflow reporting to conventional spiral circuit. The -100 mesh reports to the
water clarification circuit. Conventional vertical centrifuges are used for product
dewatering. Medium density control is accomplished by the use of a conventional
overdense control circuit. The raw 100 mesh x 0 is combined with the 48 mesh x 0
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
and conveyed to a remote refuse loading bin by an overland conveyor belt system.
This project was done in phases with
the raw coal addition operable in
approximately seven months, and the
plant completion approximately six
months later. The plant is presently
operating at capacities in excess
of 950 TPH.
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 modifications to the existing screening facilities.
Also included was a complete control system incorporating both the existing
and new facilities.
The existing water clarification 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.
24
Section 05
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.
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 flow 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 overflow from the superscalping circuit is screened in high refuse capacity double deck Deister tables.
The 28 mesh x raw coal is classified at approximately 100 mesh; the classifying
cyclone underflow reports to a spiral circuit. The cyclone overflow is delivered to
the water clarification 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-flow circuit clean coal screens.
The primary rejects from the low-flow 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
flexibility 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 floor to a neighboring
bench at a substantially higher elevation.
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.
The installation consists of a second stream raw coal handling system with
scalping screens and rotary breaker. Breaker rejects are gravity fed to the
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 overflow classified
at 100 mesh. Froth flotation 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 filters. 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.
26
Section 05
Roberts & Schaefer completed the facility
so that it was operating at full capacity in
11 months from date of award.
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 field 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 efficient and reliable system.
KATOWICE COAL HOLDING S.A., STASZIC MINE, POLAND
Engineering, procurement and construction of an addition to the existing
coal washery.
The project included a 4000 MT storage silo and load-out, including coal blending
utilizing state of the art equipment and automation.
Above: Lubelski Wegiel S.A., Bogdanka Mine, Poland
Below: Katowice Coal Holding S.A., Staszic Mine, Poland
Project involved the installation of high efficiency 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 “floating” concrete mat, due to poor soil conditions
and subsidence.
Modernized plant started production on budget and ahead of schedule.
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 modification 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 floating
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
mine operation at Curragh.
The studies initially considered a brown field expansion of the existing facility
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 flotation circuit
(0.5 mm x 0mm)
• Spiral circuit – retreat for
flotation tails
• Belt filter dewatering
• Coking and Thermal Products
28
Section 05
Above: Integra Coal/Vale, Glennies Creek Colliery,
Hunters Creek, Australia
Below: Westfarmers, Curragh Mine, Bowen Basin, Australia
MORE EXPERIENCE
BOWIE RESOURCES, NO. 2 MINE EXPANSION,
PAONIA, COLO RADO
Engineering, procurement, and construction for the mine expansion.
The Bowie No. 2 Mine, located high on a mountain side, was operating in a very
confined 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 five (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
MCC was also part of this scope, along with a new compressor installation.
Top: Bowie Resources, No. 2 Mine Expansion, Paonia, Colorado
Bottom: Rio Tinto Energy, Spring Creek Mine, Decker Montana
Section 05
29
MORE EXPERIENCE
NORFOLK SOU THERN 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.
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
management services are being provided for the addition of coal surge silos and
modifications 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
car dumpers and a duel conveyor system to two shiploaders. The new surge bins
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 modification 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 fitted with variable speed reclaim belt feeders to transfer
the coal back onto modified 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.
Norfolk & Western Railway Company, Lamberts Point Coal
Loadout Facility, Norfolk, Virginia
Section 05
31
MORE EXPERIENCE
NORFOLK & WESTERN RAILWAY COMPANY COAL GROUND
STORAGE FACILITY ISLE OF WIGHT C OUNTY, 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 final 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 fitted 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.
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
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 fitted with a feederbreaker 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
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 Carter Mining Company, Gillette, Wyoming
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.
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 final 2"x 0 product, sampled and conveyed to two 12,000-ton
storage silos, each configured to flood 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 first major, high capacity coal facility constructed in the Power
River Basin of Wyoming.
LAUREL RUN MINING COMPANY, MT. STORM,
WEST VIRGINIA
construction were provided under a turnkey contract to construct an overland
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.
34
Section 05
Laurel Run Mining Company, Mt. Storm, West Virginia
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, fitted 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 samplingtransfer 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
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,
fitted 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 efficiently preheats
incoming outside air required for the heating system.
Rochelle Coal Company, Rochelle Mine, Gillette, Wyoming
Section 05
35
MORE EXPERIENCE
KERR MCGEE COAL CORPORATION, GALATIA, ILLINOIS
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
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.
36
Section 05
MORE EXPERIENCE
ARCO COAL COMPANY, BEAVER CREEK MINE,
PRICE, UTAH
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,
HUEYTOWN, ALABAMA
ARCO Coal Company, Beaver Creek Mine, Price, Utah
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 first 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 fill areas.
Section 05
37
MORE EXPERIENCE
KERR-MCGEE COAL CORPORATION, GILLETTE, WYOMING
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 flood-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 flow.
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 configuration to fit the existing terrain
and also tie into the existing facilities. The 400 TPH preparation plant layout was
based on a flowsheet 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 flowsheets and detailed process piping,
and utility piping. Response to the project schedule required the utmost in
coordination and control.
38
Section 05
Kerr-McGee Coal Corporation, Gillette, Wyoming
MORE EXPERIENCE
BETHLEHEM MINES CORPORATION,
EBENSBURG, PENNSYLVANIA
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
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, fire 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.
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 modified to add ASTM sampling system to the station, and a certified belt
scale. The addition was accomplished through major modifications to the
existing chute work, adding two belt conveyors and extensive changes to the
structure. The final system allows P&M to meet their customer’s requirements
of weight and quality verification.
CARBON COAL COMPANY, GALLUP, NEW MEXICO
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,
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 fitted with a manual operated loading system rated at 3,000 TPH. Ancillary
facilities included a water supply and distribution system, a fire protection system
and truck service facilities with change and warehouse area.
40
Section 05
Carbon Coal Company, Gallup, New Mexico
MORE EXPERIENCE
OLD BEN COAL COMPANY, PIKE COUNTY, INDIANA
Complete project management, detailed engineering, procurement and construction 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 five 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 P REPARATION 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.
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
five 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 fit around the existing one.
The project scope included upgrading conveyors, modifying screens, installing new
sieve bends, cyclones, centrifuges, sumps, pumps, spirals and flotation cells. Also
included process, air, floor drain and washdown piping, chutes, hoppers and sluices.
42
Section 05
MORE EXPERIENCE
EIG HTY-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
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
certified 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,
and sufficient area for the coal handling system. Water collection and diversion
to meet all O.S.M. regulations was also included with the project.
Above: Eighty-Four Mining, Eighty-Four, Pennsylvania
Below: Utah Power & Light Company, Cottonwood Mine,
Orangeville, Utah
Section 05
43
MORE EXPERIENCE
JIM WALTER RESOURCES, BROOKWOOD, ALABAMA
Engineering, procurement and construction of a fine 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 fine 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.
44
Section 05
MORE EXPERIENCE
CONSOLIDATION COAL COMPANY,
BLACKSVILLE, WEST VIRGINIA
Engineering, procurement and construction of a 400 TPH fine 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 clarification 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.
KAI SER 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.
Section 05
45
MORE EXPERIENCE
ARMCO STEEL CORPORATION, SUNDIAL, WEST VIRGINIA
Engineering, procurement and construction of a 550 TPH heavy medium and
froth flotation cleaning facility with extensive rough terrain conveying systems.
PEABODY COAL COMPANY, MORGANFIELD, KENTUCKY
cleaning plant and coal handling facility.
PITTSTON COA L 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
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
vessel, heavy medium cyclone and froth flotation preparation plant and
coal handling facility.
INLAND STEEL COMPANY, MCLEANSBORO, ILLINOIS
Engineering, procurement and construction of a 1,320 TPH heavy medium/froth
flotation, 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.
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 clarification and slurry filtering.
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
TURKISH COAL ENTERPRISE, ZONGULDAK, TURKEY
Section 05
47
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
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).
48
Section 05
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 flotation plant with complete coal handling
including thermal drying.
DENISON MINES, LTD., QUINTETTE PLANT,
TUMBLER RIDGE, BRITISH COLUMBIA, CANADA
dryer size #12.5 (38 TPH water evaporation).
TUMBLER RIDGE, BRITISH COLUMBIA, CANADA
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).
Section 05
49
TAIWAN POWER, TALIN COAL TERMINAL
Engineering and procurement for conveyors for power plant.
TAIWAN POWER, LINCOU STATION
Engineering and procurement for material handling.
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
PEABODY COAL COMPANY, HAWTHORN MINE,
SANDBORN, INDIANA
• 18 TPH water Evaporation Rate
BETH ENERGY MINES, CAMBRIA MINE 133,
EBENSBURG,PENNSYLVANIA
• Two 800 TPH Coal Thermal Dryers Size #12.5
JIM WALTER RESOURCES, #4 MINE,
BROOKWOOD, ALABAMA
• 600 TPH Coal Thermal Dryer Size # 12.5
Section 05
51
CONSOLIDATION COAL COMPANY, LOVERIDGE PLANT,
FAIRVIEW, WES VIRGINIA
CONSOLIDATION COAL COMPANY, BUCHANAN PLANT,
BUCHANAN COUNTY, VIRGINIA
TECK CORPORATION, BULLMOOSE PLANT, TUMBLER RIDGE,
BRITISH COLUMBIA, CANADA
BRITISH COLUMBIA, CANADA
• 468 TPH Thermal Coal Dryer Size #12.5
DENNISON MINES, LTD., QUINTETTE PLANT,
TUMBLER RIDGE, BRITISH COLUMBIA CANADA
BRITISH COLUMBIA COALS, LTD., GREEN HILLS PLANT,
ELKFORD BRIT ISH COLUMBIA, CANADA
52
Section 05
JEWEL COAL & COKE COMPANY, JEWEL SMOKELESS PLANT,
VANSANT, VIRGINIA
PEOPLES REPUBLIC OF CHINA, XINGLONGZHAUNG PLANT,
XINGLONGZHAUNG SHANGDONG PROVINCE,
BEI JING, CHINA
CONSOLIDATION COAL COMPANY, DENTS RUN PLANT,
MANNINGTON, WEST VIRGINIA
CLINCHFIELD COAL CO., DIVISION OF PITTSTON COAL GROUP,
MOSS III PLANT, SOUTH CLINCHFIELD, VIRGINIA
CLINCHFIELD COAL CO., DIVISION OF PITTSTON COAL GROUP,
MOSS III PLANT, SOUTH CLINCHFIELD, VIRGINIA
BP CANADA, LTD., SUKUNKA COAL PROJECT PLANT
• 265 Coal Thermal Dryer Size #7.5
Section 05
53
CARDINAL RIVER COALS, LTD., DIVISION OF LUSCAR
CONSOLIDATION COAL CO., CARDINAL RIVER PLANT,
LUSCAR ALBERTA, CANADA
• 16 TPH water evaporation rate
ISLAND CREEK COAL CO., UPSHUR P LANT,
TALLMANSVILLE, WEST VIRGINIA
CLINCHFIELD COAL COMPANY, DIVISION OF PITTSTON
COAL GROUP, MCCLURE #1 PLANT, MCCLURE, VIRGINIA
ISLAND CREEK COAL COMPANY, POND FORK PLANT,
BOB WHITE, WEST VIRGINIA
THE NEW RIVE R COMPANY, MEADOW CREEK PLANT,
MEADOW CREEK, WEST VIRGINIA
54
Section 05
BADGER COAL COMPANY, DIVISION OF PITTSTON COAL GROUP,
GRAND BADGER #1 PLANT, SAGO, WEST VIRGINIA
RANGER FUEL COMPANY,DIVISION OF PITTSTON COAL GROUP,
BECKLEY #2 PLANT, SABINE, WEST VIRGINIA
CONSOLIDATION COAL COMPANY, AMONATE PLANT,
MCDOWELL COUNTY, TAZEWELL, WEST VIRGINIA
EASTERN ASSOCIATED COAL GROUP, KEYSTONE PLANT,
KEYSTONE, WEST VIRGINIA
ISLAND CREEK COAL COMPANY, GUND PLANT,
PIK E COUNTY, TURKEY CREEK, KENTUCKY
Section 05
55
THE NEW RIVE R COMPANY, BECKLEY LICK RUN PLANT,
MOUNT HOPE, WEST VIRGINIA
• 345 TPH Coal Thermal Dryer Size #l2.5
PENN WEST FUELS, DOVERSPIKE PLANT,
DORA, PENNSYLVANIA
MAPCO, PONTIKI PLANT, MARTIN COUNTY,
INZE, KENTUCKY
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 first 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 first of seven potential cobalt-nickel-manganese
deposits to be developed and it is estimated to contain 53 million tons of proven
and probable ore reserves at average grades of 0.24% cobalt, 0.72% nickel and
1.22% manganese.
The ore is concentrated by simple sizing and upgraded to 0.7% cobalt, 1.0% nickel
and 3.5% manganese prior to processing. The project includes a shallow open pit
mine, ore concentration facilities and a 2,000 metric ton per day process plant.
Roberts & Schaefer has provided the
complete engineering, procurement and
construction management services in
all phases of precious and base metal
processing facilities and crushing plants.
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 Goldfields
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 refining.
The facility modules were designed to fit in shipping containers for delivery to the
site with minimal field 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 field 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
RO MARCO 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 significant 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 first cost
and operating costs of a new gold processing plant based upon the results of the
new and extensive core sampling that had taken place. This work was coordinated
with other consultants that were more specifically focused on the mining and
metallurgical aspects of the project.
The R&S scope of work included:
• Development of the process flow sheets
• Development of the process flow 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 specifications
• Identification of critical path and lead times
for major equipment procurement
• Capital cost estimate
• Operating cost estimate
Engineering design was completed in sufficient 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, flotation,
thickening, cyanidation, and gold recovery facilities.
• Process plant support facilities
• Cyanide recovery and destruction
• Truck shop, warehouse, lab, powder magazine,
and Admin & Engineering offices
• Fuel/lube supply, storage and facilities
• Water supply, storage and distribution facilities
• Electrical supply and distribution
• Waste water treatment
METALS EXPERIENCE
4
Section 06
The study was completed within
the client’s required time frame
and within budget.
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
for the addition of three flash chlorination vessels and associated platforms and
equipment at Newmont Gold’s No. 1 Mill. The flash 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
for modification to the cyclone overflow trash screens at Newmont Gold’s Gold
Quarry Mill. The project required conceptual layout and final 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 final 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, fitted 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 fine 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 underflow returns to the ball mill for further grinding, and cyclone
overflow is processed in gravity concentrators and in a flash flotation cell.
Gravity concentrate, containing relatively clean gold, is refined into doré
bars on site.
Gravity tailings feed the flash flotation cell and flotation tailings feed
a high density tailings thickener.
Tailings thickener underflow is pumped to a tailings disposal area and
thickener overflow 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 fluxes 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 modifications
• Reactor modification
• 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 fine tuning they were able to increase the slurry feed which
required additional process equipment to convert to final product.
In order to properly dry the scrap material R&S designed a feed conveyor to a
dryer vessel modified 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 flow required a third crystallizer which was tied into
crystallizers 1 and 2. A filter Feed Tank, Belt Filter, concentrate tank, agitator,
centrifuge, and product silo were added to finalize 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 flotation 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 fine 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 flotation,
a cyanide leach circuit, static thickeners and drum and disk vacuum filters.
The leachate was clarified in a pressure leaf filter 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 flow sheets, P&ID and equipment specifications
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 efficient
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 flowsheet 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 specification for reactor,
converter and fugitive gas collection and control at the Kennecott Garfield 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 specification and construction
specification for the repair and gas flow improvement to four copper converter
gas flues.
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 CAN YON, UTAH
Copper ore and concentrate handling systems.
METALS EXPERIENCE
10
Section 06
MORE EXPERIENCE
AMAX GOLD, I NC., 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 flowsheets, 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 flow, 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 refinery 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 field installation. Field duties consist of supervision in
erecting, testing and commissioning the facility.
Teberebie Goldfields, 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:
• defined capital cost
• operating cost
• engineering
• construction, schedule,
• finalizing 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 final 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 five interested financial institutions in London.
In additional to completing the final 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 flotation 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 overflow is directed to a flotation circuit, reporting to rougher cells
and two stages of cleaners. Thickened concentrates are dewatered for shipment.
Thickened rougher flotation 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 offices, changehouse, laboratory, warehouse and shop area, parking and fencing. All electrical power and control design
was provided, including finalizing of process flow sheets, P&ID’s, specification,
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 flow 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 field assembly. The skids included carbon
adsorption, atmospheric strip, acid washing, thermal carbon regeneration,
electrowinning, melting and associated accessories. Electrowinning and melting
were housed in modified shipping containers. All skids were set in the field
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 field 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 fitted 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 final 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 five
stages of carbon-in-column adsorption, pressure stripping, regeneration, electrowinning 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 refined 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, fire 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 flux 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 fluxes 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 modifications 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, WINNEM UCCA, 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.
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 beneficiation 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 COR PORATION, WESTON, COLORADO
Turnkey project for a coal storage facility.
METALS EXPERIENCE
Section 06
19
CARIBBEAN ISPAT LTD
DIRECT REDUC TION 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 fines 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 fines 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.
METALS REDUCED
DIRECT
EXPERIENCE
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 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 first green pellet elevating conveyor.
The first 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 fitted 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 field 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 fines (-6.35 mm) are conveyed
to two ore/pellets fines 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 fines
to the reactor reduction system and briquetter machines. The briquettes are then
conveyed along product cooling conveyors to two screens. The screened HBI fines
are then transported by conveyor to an HBI fines 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.
METALS REDUCED
DIRECT
EXPERIENCE
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. Modification 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 modifications 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 clarifier.
The following describes the engineering deliverables for the project:
• Site Investigation
• General Arrangement Drawings
• Piping Routing Drawings
• Electrical Modifications and Design
• Control System Design
• Structural Drawings
• Concrete Design
• Cost Estimates
Project substantial completion is expected in the first 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 first 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, floatation columns, thickeners
and instrumentation.
Upon successfully delivering the first job, R&S was sole sourced to reconfigure
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.
METALS EXPERIENCE
INDUSTRIAL
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
fit prior to shipment to the final 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 final processing site on a concrete containment slab.
Field work included structural assembly, interconnecting piping, and making
final electrical connections from the motor control center to the power and control
panels on the skids.
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 sufficient enough to develop the
funding CAR. Once funding was approved, the work included developing final
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 modifications
• 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.
• Specification 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.
METALS EXPERIENCE
INDUSTRIAL
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, flow 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 modifications 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 fines grades).
• Installing a truck loadout system (2-400 ton silos) separate
from the railcar loadout system.
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 finishing at existing crushing
station and stockpile.
METALS EXPERIENCE
INDUSTRIAL
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 refine 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 hydrofluoric 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 fluoride and a solid waste containing
fluorides and residual hydrofluoric 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 hydrofluoric 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 fluoride instead of hydrofluoric 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.
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 Beneficiation 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 flotation. This will produce four
sizes of phosphate concentrate for direct application as fertilizer, or the production
of phosphoric acid. Also included in the beneficiation 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 fine
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 beneficiation plant, the project includes complete site
development, distribution of utilities, storage of reagents, warehouse,
shop and maintenance facilities, offices, parking and roads, reservoirs
for plant water and drainage and all site drainage.
Roberts & Schaefer has provided a variety
of facilities with sound basic engineering
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,
beneficiation and refining.
METALS EXPERIENCE
INDUSTRIAL
Section 06
31
MORE EXPERIENCE
J.R. SIMPLOT COMPANY, PLANT RETROFIT, VERNAL, UTAH
Mineral: Phosphate
Engineering Only for a retrofit of a nearly fifty-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 Definition services, Process Criteria
documents, process flow diagrams, calculations, and both preliminary and detailed
engineering drawings to allow the customer to replace the existing eight flotation
cells with new and larger capacity cells.
The R&S project team was tasked with developing an engineering plan that
enabled the plant to remain operational throughout construction.
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 sufficient to allow
the customer to proceed with equipment procurement and construction.
32
Section 06
The project was completed on
schedule and under budget largely
due to Roberts & Schaefer’s use
of rigorous earned value project
control techniques (metrics).
MORE EXPERIENCE
ASARCO, INC., OMAHA, NEBRASKA
Mineral: Antimony Oxide
The design engineering and equipment specifications for an oxide fuming plant to
produce antimony oxide as a by-product in the refining of lead. The work included
designs for the collection of high temperature dust and fumes, the conveying
of fine 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 specifications 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 fired 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 fine 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
METALS EXPERIENCE
INDUSTRIAL
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 fifth 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, (fired 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 confined 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 fired. Work included site visits to determine
the best way to install the new equipment, field measuring and evaluations.
Prepared all general arrangement and detailed drawings to complete the work.
34
Section 06
MORE EXPERIENCE
KAI SER ALUMINUM & CHEMICAL CORPORATION,
WENDOVER, UTAH
Mineral: Potassium Chloride
Three design studies and the subsequent construction of additions and modernization at a potassium chloride processing plant in Western Utah. The studies included 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 flotation 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 fired rotary dryer, size classification
with screens, dust collection with cyclones, bagging and product storage.
Ancillary facilities included a shop-office-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.
PLE XUS RESOURCES, SALT LAKE CITY, UTAH
Bornite project services.
MONSANTO COMPANY, SODA SPRINGS, IDAHO
Phosphate ore handling services-Enoch Valley Tipple.
METALS EXPERIENCE
INDUSTRIAL
Section 06
35
DO LNOSLASKIE SUROWCE SKALNE (DSS)
PILAWA QUARRY PROCESSING PLANT, PILAWA, POLAND
Engineering and procurement for a 1,000 MTPH capacity, green-field 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 efficient 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 efficient plants of its
type in Europe.
AG GREGATE 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
• Underflow sump/pump system
• (2) 400mm classifying hydrocyclones
• 3 x 4 sieve bends
• Rotary bucket dewaterizer
• 17' dia. conical thickener
Aggregate production line for 3 grades of product:
• (2) 6x18 dual deck vibratory screen, (1) 5 x 12 dual deck screen
• Vacuum filter dewaterizer
• PH balance system
• Slurry sump/pumps
• 17' dia. conical thickener
• (2) 7TPH Belt filter 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
2
Section 07
Sand and Aggregate stockpiles designed
for a 15 production day capacity. The
plants are controlled by two independent
PLC systems. The process water circuit is
a closed type with make-up water from
local streams and PH balancing .
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.
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
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 classification, 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 fill specification products.
Material entering the plant is screened into fine 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 underflow is classified to produce specification 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 specification 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 filled upon demand with the various products. Truck scales running
the length of the loadout lanes allow accurate loading to a targeted weight.
Section 07
5
RO C-SAN GRAVEL COMPANY
AGGREGATE PLANT, LODI, CALIFORNIA
Detailed engineering services, procurement assistance and field 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 fine 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.
6
Section 07
WESTERN AGGREGATE
IDE AL 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 benefits
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 profile is given. Plant reports are generated and
historical trends are plotted on demand.
Scope items worthy of note include:
• System architecture design
• Specification 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-fit
• Implemented micro-processor based distributed PID controllers
• Special programming for high-dynamic applications.
Section 07
7
MORE EXPERIENCE
KAI SER 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 specification
products, concrete sand, base rock and asphalt rock. Washed and rinsed
aggregate products reclaimed from storage are automatically weighed and
loaded into customer trucks.
Significant 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.
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 final 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.
AG GREGATE
CEMENT
EXPERIENCE
EXPERIENCE
Section 07
9
NATIONAL CEMENT COMPANY OF CALIFORNIA
PLANT 2 MODERNIZATION, LEBEC, C ALIFORNIA
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 specifically 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 final product is transferred to the
existing overland conveyor via a transfer station. The transfer station includes
an emergency flop gate to direct material to the ground in case there is a
disruption on the overland conveyor.
AG GREGATE
CEMENT
EXPERIENCE
EXPERIENCE
Section 07
11
ASHGROVE CEMENT COMPANY
CEMENT PROCESSING FACILITY, MOAPA, NEVADA
Engineering, Costing and Specifications with Cement Performance International
(CPI) for the preliminary engineering, facility general arrangements, EPC
schedule, mechanical and construction specifications, 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,
finish 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 final 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 Specifications.
• 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 specifications 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/modified 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.
AG GREGATE
CEMENT
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 configuration
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.
Primary crushed limestone rock is conveyed from the pit to a location adjacent
to the cement and lime production circuits. The limestone rock is further crushed
in a secondary crusher before reporting to a primary screening station for sizing.
Based upon the grade of limestone being processed, oversize material reports to
a tertiary crusher arranged in closed circuit and after crushing, is recombined
with the primary screen station feed.
The facility also provides means to
handle clay/shale and dirty rock materials
directly to the cement production plant.
The facility incorporates the most modern
of process technology.
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 finished products to separate storage
stations. All materials are reclaimed from storage, reporting to each
production plant.
AG GREGATE
CEMENT
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 filter 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 five 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 classifier 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).
Section 07
17
CAREMUSE L IME 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.
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 fine storage tank for the
processed 1/4" x 0 fines. The material was reclaimed by use of a fixed rate screw
feeder ahead of an elevator rated at 25 TPH. Material was then transported
by two 14" diameter screw conveyors to a 24" fines transfer belt. This belt also
received 1/4" x 0 material from the existing facilities.
The 24" fines transfer belt delivers the 1/4" x 0 material to a 490-ton storage
tank. Material from the storage tank has the options of being directly loaded
onto railroad cars or conveyed via a 20" diameter screw conveyor to a new mill
surge bin.
This system is electrically interlocked and
controlled from the existing plant control
system. This installation was completed
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 final 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.
AG GREGATE HANDLING
LIMESTONE
EXPERIENCEEXPERIENCE
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
specifications for the items listed below.
• Site Plan
• General Arrangements
• Piping
• Structural
• Plate work
• Concrete
• Civil
• Electrical and Instrumentation
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 finalize the flowsheet for the project, and prepare
preliminary site plans and general arrangement drawings in sufficient 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
modifications 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 flowsheet for the project.
• Develop of the final 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 specifications for borings, testing requirements,
and required recommendations
• Capital Cost Estimate
• Final Report
AG GREGATE HANDLING
LIMESTONE
Section 07
21
MARBLEHEAD LIME CO.
BUFFINGTON PLANT, BUFFINGTON, INDIANA
Engineering, procurement and construction of rotary kiln installation at the
existing Buffington Plant.
The existing facility at Buffington, 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
1,600-ton capacity. The limestone is reclaimed by variable speed weigh feeders
from the new silo, and via a splitter gate and a variable speed feeder from the
existing limestone storage silo. Two new kiln feed belts were provided to feed
kiln No. 4 and kiln No. 5.
The coal is also stored in two silos, one new and one existing. Each coal silo has
a 750-ton capacity. The coal is reclaimed from the new coal storage silo by belt
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, fire protection and heat tracing.
The processed material is collected on the existing product conveying system,
modified to handle the increased capacity. In addition to the kiln installation,
modifications were done in the existing facility including the addition of a 24"
reversible fines belt, a fines recycling system consisting of bucket elevators,
screw conveyors and transfer belt conveyors for recycling of kiln or process fines.
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.
22
Section 07
This project proved challenging in that
a major portion of the equipment
used in the project had been previously
used, and on-site refurbishing and
testing was required. The entire
project took approximately 16 months
to become operational.
MORE EXPERIENCE
MARBLEHEAD LIME, PLEASANT GAP, PENNSYLVANIA
Limestone handling facility.
FRU-CON CONSTRUCTION, NORTH BRANCH PROJECT,
BAYARD, WEST VIRGINIA
Engineering and procurement of a limestone handling system.
MARBLEHEAD LIME, GARY, INDIANA
Roberts & Schaefer’s broad engineering
capabilities give it the distinct advantage
of being more responsive to customers.
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.
AG GREGATE HANDLING
LIMESTONE
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 fine 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 Roofing tile plant near in Rialto, California. The system included
an approximately 2,000-ton, above-ground storage bin to contain damp sand,
and 24"-wide belt conveyors to convey the sand from the existing drive-over
storage bins to the new above ground bin. Additional belt conveyors were
included to reclaim sand from the new bin for transport to existing conveyors
that fed two existing roofing tile manufacturing plants. Three new conveyors
and the extension or modification of two existing conveyor were required.
Roberts & Schaefer Company’s
commitment to the sand industry
includes complete engineering design
and construction services for handling
and processing of sand.
AG GREGATE
SAND
HANDLING
EXPERIENCE
EXPERIENCE
Section 07
25
MORE EXPERIENCE
PENNSYLVANIA GLASS & SAND CORPORATION
BERKELEY SPR INGS, 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.
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.
Engineering layouts—boiler house bottom ash removal.
MAPLETON DEPOT, PENNSYLVANIA
Engineering layouts—dust collection at micron bagging station.
MILL CREEK, OKLAHOMA
Engineering layouts and design for two mill silica flour grinding system
including bulk storage, rail and truck loading.
SAND HANDLING EXPERIENCE
26
Section 07
MORE EXPERIENCE
Engineering layouts and sand loadout system—furnished structural,
mechanical and fabricated items.
MAPLETON DEPOT, PENNSYLVANIA ENGINEERING
Engineering layouts—dust collection at old screen tower.
Engineering layouts, design and construction rod mill installation—
wet reduction of silica sand.
Layouts and design, and installation slurry pumping system.
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 clarification.
AG GREGATE
SAND
HANDLING
EXPERIENCE
EXPERIENCE
Section 07
27
MORE EXPERIENCE
COLORADO LEIN
LAPORTE, COLORADO
WILLIAM R. BARNES COMPANY
WATERTOWN, ONTARIO, CANADA
30 TPH Sand Dryer
10 TPH Sand Heater-Cooler
COLUMBIANA FOUNDRY
COLUMBIANA, OHIO
MILLWOOD SAND COMPANY
MILLWOOD, OHIO
10 TPH Sand Dryer-Cooler
65 TPH Sand Dryer
KINGS MOUNTAIN
MICA COMPANY
KINGS MOUNTAIN,
NORTH CAROLINA
FLORIDA ROCK INDUSTRIES
INTERLACHEN, FLORIDA
20 TPH Dryer
PRODUVISA SERVICIDOS, S.A.
GARACAS, VENEZUELA
45 TPH Sand Dryer
OTTAWA SILICA
OTTAWA, ILLINOIS
55 TPH Sand Dryer
NOVA SCOTIA SAND & GRAVEL
SHUBENACADIE, NOVA SCOTIA
CAROLINA SILICA, INC.
MARSTON, NORTH CAROLINA
90 TPH Sand Dryer
OWENS ILLINOIS
IONE, CALIFORNIA
WEDRON SILICA CORPORATION
WEDRON, ILLINOIS
60 TPH Sand Cooler
FLUID BED SAND DRYERS/COOLERS EXPERIENCE
28
Section 07
MORE EXPERIENCE
METALLURGIMPORT
MOSCOW, RUSSIA
100 MTPH Sand Dryer
WARD IRON WORKS
(HOLMES FOUNDRY)
WELLAND, ONTARIO, CANADA
PENNSYLVANIA GLASS
& SAND CORPORATION
BRADY, TEXAS
115 TPH Sand Dryer
60 TPH Sand Dryer
LYMAN-RICHEY SAND
& GRAVEL COMPANY
VALLEY, NEBRASKA
SOBIN CHEMICAL
COMPANY (DIV. IMC)
SPRUCE PINE, NORTH CAROLINA
6 TPH Sand Dryer
METALLURGIMPORT
MOSCOW, RUSSIA
WEDRON SILICA COMPANY
BYRON, CALIFORNIA
30 MTPH Sand Dryer-Cooler
60 TPH Sand Dryer
METALLURGIMPORT
MOSCOW, RUSSIA
HARDY SAND
TUSCALOOSA, ALABAMA
65 TPH Sand Dryer and Separate
65 TPH Sand Cooler
EMMETT, IDAHO
60 TPH Sand Dryer
CAROLINA SILICA, INC.
MARSTON, NORTH CAROLINA
LUGOFF, SOUTH CAROLINA
60 TPG Sand Dryer
AG GREGATE
FLUID
BED SAND
EXPERIENCE
DRYERS/COOLERS EXPERIENCE
Section 07
29
MORE EXPERIENCE
WHITEHEAD BROS. COMPANY
LUGOFF, SOUT H CAROLINA
75 TPH Sand Dryer
SNC SERVICE LTD.
ALGERIA
COLUMBINE MINERALS
WHEATRIDGE, COLORADO
25 TPH Sand Dryer
ACME RESIN COMPANY
OREGON, ILLINOIS
ENGINEERING ONLY
MONTEREY SAND COMPANY
MONTEREY, CALIFORNIA
50 TPH Sand Dryer
SILICA PRODUCTS COMPANY
GUION, ARKANSAS
WEDRON SILICA PRAIRIE
STATE SILICA PLANT
TROY GROVE, 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 identified
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 floating 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.
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 five 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
Section 08
3
CARIBBEAN ISPAT LIMITED
DIRECT REDUC ED 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 five-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.
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 modification for the inclusion of a dust
collector system, and field supervision for this addition. The design work provided included strengthening the existing boom structure, supporting shuttle frame.
Leveraging this previous experience with the Alcoa operation and specifically 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.
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.
6
Section 08
AES – PUERTO RICO
limestone and aggregate material handling systems included ship loading and
unloading; the contract was awarded by Duke/Fluor Daniel.
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.
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 fly 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.
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 modified 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.
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 modifications) 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 justification 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 fit 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.
Section 08
9
NO RTH 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’ final 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 benefit 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 flooring;
• Corrosion due to product build-up in conveyor A-frames;
• Thickness testing for tanks;
• Deficient 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.
10
Section 08
BALTIMORE GAS & ELECTRIC COMPANY
BRANDON SHORES, UNITS 1 AND 2,
ANNE ARUNDE L COUNTY, MARYLAND
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 floating 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 fitted 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 fitted with a trailing tripper and stacking slewing boom.
4,400 TPH of coal handling capability.
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 identified. 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
identified and implemented.
The initial study work completed by Soros looked at various options for the
upgrade and the respective equipment. An opportunity was identified 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 specifications to procure replacement/new equipment and provided the
consulting support during the procurement, fabrication and construction phases
of the project. Detailed shiploader modeling identified 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 definition phase
• Prefeasibility which required conceptual design and ±30% capital estimates; and
• Feasibility which required preliminary design with ±20% capital estimates.
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 fill covered barges through open hatches, which
requires that the chute/spout be able to move laterally and extend and retract.
A certified 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.
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 classified
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’ findings were discussed with the CMDI, who then engaged Soros
and its Chilean partners to provide further assistance by way of:
• Defining 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.
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.
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 field measured material thickness recalculated
the member strength to determine its suitability for
the imposed load/ stress;
• Prepared structural modification drawings for all
over stressed members;
• Prepared reinforcement / replacement joint detail drawings;
• Prepared field structural installation instruction;
• Expected useful life with and without repairs;
• Estimated cost for structural repairs;
• Estimated outage period to carry out structural
modifications; and
• Cost of new replacement and including a temporary
system to continue their loading operation.
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 findings report results and this report findings;
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 findings report including suggested
improvements that will reduce cost and improve the operation;
Review draft findings report with project manager and record his comment; and
Furnish a final report which outlines the findings 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 reconfirmed 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],
confirmed that direct shipment of coal in barges was a viable alternative.
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 traffic resulting from implementation
of the project. With the increased traffic 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 modifications
to the shed and conveyor systems.
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 floating 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.
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 efficiency 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 first fully enclosed bulk loading facility
in Australia, an environmental ‘first’ at the time and the shiploader design was
later recognized with an award reflecting this advancement.
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.
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 affiliate 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.
22
Section 08
MORE EXPERIENCE
CONSTELLATION ENERGY, BRANDON SHORES POWER
STATION, BALTIMORE, MARYLAND
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).
AMERICAN ELECTRIC POWER, MITCHELL PLANT,
CRESAP, WEST VIRGINIA
Engineering, procurement, construction, startup and commissioning
by E & C Group, Inc.
Above: Constellation Energy, Brandon Shores Power Station,
Baltimore, Maryland
Below: American Electric, Power, Mitchell Plant,
Cresap, West Virginia
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.
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 floating barge. The barge is fitted with drainage pump and
is anchored to two 20’ diameter concrete capped river cells.
TVA GALLATIN, FOSSIL PLANT, GALLATIN, TN
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
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.
24
Section 08
Southern Indiana Gas & Electric, Culley Station,
Newburgh, Indiana
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 B AY, 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, PO RT HEDLAND, WESTERN AUSTRALIA
Soros conducted a study to identify existing bottlenecks at the terminal,
recommend solutions for product quality improvement, loading larger cargoes,
improved shiploading rate and expanded stockyard. Significant 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.
Wallarah Coal Company, Catherine Hill Bay Coal Loader, NSW
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.
Section 08
25
MORE EXPERIENCE
AMERICAN ELECTRIC POWER, CARDINAL PLANT,
BRILLIANT, OHIO
by Black & Veatch
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,
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 modifications
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.
26
Section 08
American Electric Power, Cardinal Plant, Brilliant, Ohio
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 flexibility to act as a grab crane for
bulk materials such as gypsum. Erection supervision of the crane structure
was also provided.
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 specifications 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 refinery.
PORT DICKSON, MALAYSIA
Port planning, engineering economics and preliminary design
of a multi-purpose dry cargo facility.
VIC TORIA
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.
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 modifications to tendering system for a salt
loading installation.
NEWCASTLE, N SW
Feasibility study and cost estimate for 250,000 DWT offshore
coal loading facility.
NEWCASTLE, N SW
Feasibility study and cost evaluation of dredging Newcastle
harbor to permit vessels of up to 250,000 DWT.
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
Shekou, China, for P&O Ports.
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.
30
Section 08
Above: Port of Gangavaram, India
Below: Container terminal in Shekou, China
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
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.
Evaluation of new wharf and coal shiploader options at Lyttelton,
New Zealand, for Lyttelton Port Company.
Design specification, in support of tender bid, for an alumina ship loader
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.
32
Section 08
Above: Feasibility study of wharf facilities, Punta Cana in the
Dominican Republic to San Juan, Puerto Rico
Below: Study of coal supply system from mine to power station,
Indonesia, for Credit Lyonnais Bank
HEXCEL
CARBON MANUFACTURING LINES, SALT LAKE CITY, UTAH
R&S was awarded a time and materials contract from Hexcel to engineer a new
carbon fiber manufacturing line #10 to be attached to the existing carbon fiber
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 fiber enhancement equipment
• Integration of vendor supplied equipment for a complete operating fiber line
• Fabrication and construction engineering support
• Integration of controls and automation with the other fiber 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
flexible to the type of fiber that can be produced. The building was located and
utilities designed to accommodate the future carbon fiber lines.
Our work on this project included:
Roberts & Schaefer knows how to apply
its skills and experience to any type of
processing or resource handling project,
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 fiber
enhancement equipment
• Integration of vendor supplied equipment for a complete operating fiber line
• Fabrication and construction engineering support
• Integration of controls and automation with the other fiber 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 final 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.
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 first phase involved modernization 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 final phase involved engineering a complex fire 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
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.
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 exacting requirements for a new haul truck maintenance facility and was ultimately
awarded the turnkey contract to engineer, procure and construct the facility.
The final 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 difficult
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
• 18-inch thick repair bay concrete floors with centerline drain trench
• 36' x 30' rubber break-away overhead doors
• Two 40-ton bridge cranes with 10-ton auxiliary hoists (64' 8" span)
Roberts & Schaefer can engineer ancillary
facilities for utility, mining and industrial
operations to meet a variety of needs and
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
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 fleet 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 offices, one supervisors office, a lunchroom,
bathrooms and showers. The existing offices 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 final solution the new building mirrored the largest existing
building. The existing sectional doors were removed resulting in a 10 bay shop.
Modifications were made to the existing buildings to improve the working
environment and to meet fire codes. The fire code issue was especially difficult
due to the enormous size and height of the building. Numerous meetings were
held with Kern county to resolve the fire 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 floor 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
difficult. Approximately 30% of the water is replaced automatically during use.
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, flexwall, 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 finalization of process flowsheets, piping
and instrument diagrams, overall facility layout, facility plot plans. Further, the
preparation of equipment and material specifications, construction packages,
overall schedule for engineering, procurement, deliveries and construction.
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 landfill 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.
IDE AL 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.
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
fitted 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 fitted with reclaim screw feeders
which deliver on demand coal and sorbent to a fluid bed combustor. High temperature bed ash (600°F) and fly 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 flight
type water cooled screw conveyors for ash temperature control prior to storage
and loadout. Telescoping loadout chutes deliver bedash and flyash 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 flume 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 flume superstructure
resulting in considerable cost and time savings.
Section 09
9
MORE EXPERIENCE
ARCO, DENVER, COLORADO
Total engineering for a refit of a pollution control system for a coal mine.
The project consisted of field measuring to determine the best way to fit
the new hardware into existing facility, and the writing of specifications
for procurement of equipment.
ASARCO INC., OMAHA, NEBRASKA
Provided design engineering and equipment specifications for an oxide fuming
plant to produce antimony oxide as a by-product in the refining of lead. The
work included designs for the collection of high temperature dust and fumes,
the conveying of fine 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 instrumentation and the preparation of specifications 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 fired 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 fine products and storage bins. It provided the electrical designs and complete
furnace instrumentation and control.
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 fifth 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, (fired 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 confined 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 firing.
Work included site visits to determine the best way to install the new equipment,
field measuring and evaluations. Prepared all general arrangement and detailed
drawings to complete the work.
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 Rimfire
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 field 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 modifications
were included during this relocation to improve production and plant efficiency.
Foundations for the relocated equipment were completed using field measurements, 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.
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 first green pellet elevating conveyor.
The first 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 fitted 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 field 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.
Section 09
13
MORE EXPERIENCE
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, field 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.
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
Design, engineering, procurement, delivery and commissioning of material
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.
Through the years Roberts & Schaefer
has completed a myriad of projects
relating to the pulp and paper industry.
RIVERWOOD INTERNATIONAL PAPER MILL,
MACON, GEORGIA
The project consists of the modifications 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 modification and digester feed system for Riverwood
International. The modifications 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 modifications 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, MIN NESOTA
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, refining, digesters, drying and bagging.
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 specific engineering disciplines according to
your requirements. Our design, scheduling, cost control and project management
capabilities provide you with efficient 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 offices 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 Profile was
helpful in bringing to light who we are. Thank you for taking the time to find 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 specifically assist you, or for a
quotation on your project, please contact your nearest Roberts & Schaefer office.
DEDICATED TO QUALITY ENGINEERING SINCE 1903
Section 10
1
ANOTHER LOOK
Chicago
TEL: 312-236-7292
FAX: 312-726-2872
Email: [email protected]
Salt Lake City
10150 South Centennial Parkway
Suite 400
Sandy, Utah 84070
TEL: 801-984-0900
FAX: 801-984-0909
Australia
TEL: +61 (0) 7-3234-9555
FAX: +61 (0) 7-3234-9595
Indonesia
TEL: +62-21-252 4177
FAX: +62-21-252 4138
Poland
UI. Bojkowska
TEL: +48-32-461-2722
FAX: +48-32-461-2720
DEDICATED TO QUALITY ENGINEERING SINCE 1903
2
Section 10
RO BERTS & 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 specifications, as well as for those items not specifically 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 efficient 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 Profit & 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
Management
H O W
Estimating
T H E
Sales and
Marketing
W O R L D
Engineering
Procurement
P R O C E S S E S
I T S
Construction
Admin
R E S O U R C E S
Section 10
3
3
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 Office 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 staffing. 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 specific 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 certification.
H O W
4
Section 10
T H E
W O R L D
P R O C E S S E S
I T S
R E S O U R C E S
Other management positions exist for specific 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 &
Planning
H O W
Engineering
& Design
T H E
W O R L D
Procurement
Construction
P R O C E S S E S
Commissioning
I T S
Operations &
Maintenance
R E S O U R C E S
Section 10
5
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-specific technical requirements. The Sales and
Estimating group’s key functions are:
• Identification 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 flow of engineering development is as follows:
• Layouts: establish the overall process and general area configuration that
will meet the needs of the project in the most efficient 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.
H O W
6
Section 10
T H E
W O R L D
P R O C E S S E S
I T S
R E S O U R C E S
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 field. The mobilization effort requires interface with overall
client project management on-site to coordinate activities. Our CMs typically have
an office 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 specific 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 efficiency.
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 certification 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 reflects the heritage and reputation of Roberts &
Schaefer—a reputation that is precious to us as we continually seek ways to
uphold and improve it.
H O W
T H E
W O R L D
P R O C E S S E S
I T S
R E S O U R C E S
Section 10
7
INDEX
A.B.B. Taiwan ....................................................................04-25
Acme Resin Company, Oregon, Illinois .............................07-30
Advanced Transformer, Monroe, Wisconsin .....................09-14
AES – Barbers Point, Cogeneration Plant,
Barbers Point, Hawaii .......................................................04-21
American Electric Power,
John W. Turk Power Plant, Fulton, Arkansas ..................02-21
American Electric Power, Mitchell Plant,
Cresap, West Virginia .............................................. 04-2, 08-23
American Electric Power, Zimmer Coal Plant,
Moscow, Ohio ......................................................................04-25
AES – Barbers Point, Oahu, Hawaii.................................02-30
American Steel Foundries, Alliance, Ohio ........................07-26
AES - Puerto Rico, Total Energy Plant,
Guayama, Puerto Rico ............................................... 02-8, 08-7
AES, Warrior Run Power Station,
Cumberland, Maryland .....................................................02-42
Aggregate & Sand Plant, Szczercow, Poland ......................07-2
Aggregate Plant, Lodi, California .......................................07-6
Alabama Power Company, J.H. Miller Steam Plant,
West Jefferson, Alabama ...................................................02-44
Alaska Gold Company (Novagold),
Rock Creek Gold Facility, Nome, Alaska ............................06-6
Alcan South Pacific, Bauxite Loading Facility,
Cape York, Queensland ......................................................08-28
Alcoa, Bunbury Alumina Loader Western Australia .......08-20
American Steel Foundries, Granite City, Illinois .............07-27
Amonate Plant, McDowell County,
Tazewell, West Virginia .....................................................05-55
Amos Plant, Winfield, West Virginia ................................04-14
Apex Plant, Apex Nevada ..................................................07-16
Aptus Environmental Services,
Salt Lake City, Utah ..........................................................09-14
Arch Coal Company, Black Thunder Mine,
Wright, Wyoming .................................................................05-3
Arch Minerals, Cave Branch Prep Plant,
Lynch, Kentucky ................................................................05-42
Arch of Illinois, Captain Mine Preparation Plant,
Percy, Illinois ......................................................................05-41
Alcoa, Condition Assessment of Radial Shiploader ............08-5
Allegheny Power Service Corporation, Willow and
Pleasants Island, Parkersburg, West Virginia .................02-49
Arco Coal Company, Beaver Creek Mine,
Price, Utah .........................................................................05-37
Arco, Denver, Colorado ......................................................09-10
Allen Fossil Plant, Memphis, Tennessee ..........................02-15
Amax Coal Company, Belle Ayr Mine,
Gillette, Wyoming ..............................................................05-34
Argyle Diamonds, Underground Expansion Project,
Western Australia ..............................................................06-29
Armco Steel Corporation, Edwight, West Virginia ..........06-18
Amax Coal Company, Eagle Butte Mine,
Amax Gold, Golden, Colorado ...........................................06-11
Amax, Wabash Mine, Keensburg, Illinois.........................05-21
Ameren Energy, Coffeen Generation Station,
Coffeen, Illinois ..................................................................02-18
Ameren Energy, Duck Creek Power Station,
Canton, Illinois ...................................................................02-19
Ameren Energy, Edwards Power Station,
Bartonville, Illinois ............................................................02-19
Armco Steel Corporation, Sundial, West Virginia............05-46
Asamera Minerals, Wenatchee, Washington ....................06-17
ASARCO, Hillsboro, Illinois .................................. 06-33, 09-10
ASARCO, Omaha, Nebraska ................................. 06-33, 09-10
ASARCO, Salt Lake City, Utah .........................................06-17
Ash Grove Cement West, Lehi, Utah ..................................07-8
Ashgrove Cement Company,
Cement Processing Facility, Moapa, Nevada ...................07-12
Ashton Mine, Hunter Valley, Australia...............................05-9
American Electric Power, Amos Plant,
Winfield, West Virginia ......................................................04-14
Associated Electric Cooperative,
High Capacity Stacker, New Madrid, Missouri ................02-43
American Electric Power, Cardinal Plant,
Brilliant, Ohio ............................................. 02-33, 04-14, 08-26
Associated Electric Cooperative, Moberly, Missouri ........05-44
Index
1
INDEX
Associated Electric Cooperative, New Madrid Plant,
New Madrid, Missouri .......................................................02-50
Associated Southern Engineering Co., California
Biogen Power Facility, San Bernardino County ...............02-39
Atlantic City Electric, Coal Yard Addition and
Upgrade, Beasley’s Point, New Jersey ..............................02-47
Atlantic Energy, B.L. England Generating Station,
New Jersey .........................................................................03-12
Austral Coal (Xstrata) Tahmoor Mine,
New South Wales, Australia ..............................................05-12
Belle Ayr Mine, Gillette, Wyoming ....................................05-34
Beth Energy Mines, Cambria Mine 133,
Ebensburg, Pennsylvania ..................................................05-51
Bethlehem Mines Corporation,
Ebensburg, Pennsylvania ..................................................05-39
Bethlehem Steel Corporation,
Drennan, West Virginia .....................................................05-44
Lackawanna, New York ......................................... 06-18, 09-14
B.L. England Generating Station, New Jersey ................03-12
Van, West Virginia .............................................................06-18
Badger Coal Company, Grand Badger #1 Plant,
Sago, West Virginia ............................................................05-55
BHP Billiton, Maruwai Mine,
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,
Anne Arundel County, Maryland ...........................02-27, 08-11
Black Bear Preparation Plant,
Mountaineer Mine, Gilbert, West Virginia .......................05-22
Baltimore Gas & Electric, C.P. Crane Station,
Baltimore, Maryland..........................................................02-42
Black Dog, Riverside and Highbridge
Generating Stations, Minneapolis, Minnesota .................02-38
Barbers Point, Oahu, Hawaii ............................................02-30
Black Hills Corporation, Coal Yard Upgrade,
Barr Murphy Industries, Caribou, Maine ........................09-15
Basin Electric Power Cooperative,
Dry Fork Station & Mine, Gillette, Wyoming...................02-10
Batu Hijau Mining Project, PT Newmont
Nusa Tangarra, Sumbawa, Indonesia .................... 02-48, 08-2
Bauxite Loading Facility,
Cape York, Queensland ......................................................08-28
Bay Shore Station Repowering Project,
Oregon, Ohio ......................................................................04-19
Black Hills Power and Light,
Neil Simpson Station, Gillette, Wyoming .........................02-34
Black River Processing Plant, Butler, Kentucky..............07-17
Black Thunder Mine, Wright, Wyoming ................. 05-3, 05-20
Blackwater Mine, Bowen Basin, Australia .........................05-8
Blue Circle, Inc., Roberta Cement and
Lime Plant, Calera, Alabama ............................................07-15
Beaver Creek Mine, Price, Utah .......................................05-37
Blue Resources, Inc., J.W. Cornett
Preparation Plant, Leatherwood, Kentucky .....................05-25
Bechtel Construction Company,
Mt. Poso Cogeneration Project Fluidized Bed Boiler .......02-45
Bowie Resources, No. 2 Mine Expansion,
Paonia, Colorado ................................................................05-29
Bechtel Power Corp., Morgantown Energy
Project, Morgantown, West Virginia .................................02-29
BP Canada, LTD., Sukunka Coal Project Plant ...............05-53
Beckley #2 Plant, Sabine, West Virginia ..........................05-55
Beckley Lick Run Plant, Mount Hope, West Virginia ......05-56
2
Index
BP Canada, Ltd., Sukunka Coal Project Plant,
Chetwynd, British Columbia, Canada ..............................05-48
INDEX
BP Minerals America Fallon,
Rawhide Mine, Nevada ......................................................06-16
Carbon Manufacturing Lines,
Salt Lake City, Utah ............................................................09-1
Brandon Shores Power Station,
Baltimore, Maryland................................................ 04-1, 08-23
Carbon Regeneration and
Handling Project ..................................................................06-5
Brandon Shores, Units 1 and 2,
Anne Arundel County, Maryland ...........................02-27, 08-11
Cardinal Plant, Brilliant, Ohio .................. 02-33, 04-14, 08-26
Brazilian National Steel Company,
Capivari Mine, Brazil ............................................ 05-49, 06-19
Cardinal River Coals,
Cardinal River Plant,
Luscar, Alberta Canada ........................................ 05-49, 05-54
Bremo Station, Richmond, Virginia ..................................02-49
Cardon Refinery Project, Cardon, Venezuela .....................03-5
British Columbia Coals, Ltd.,
Green Hills Plant Elkford,
British Columbia, Canada ..................................... 05-48, 05-52
Caremuse Lime Company,
Limestone Handling Facility,
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,
Port Lisas, Trinidad .............................................................08-4
Buchanan Plant, Buchanan County, Virginia ..................05-52
Buffington Plant, Buffington, Indiana ..............................07-22
Bullmoose Plant, Tumbler Ridge,
British Columbia, Canada .................................................05-52
Caribbean Ispat Ltd., Direct Reduction
Facility III (DR3), Point Lisas Trinidad & Tobago ...........06-20
Carlota Copper, Miami, Arizona........................................06-15
Bunbury Alumina Loader Western Australia...................08-20
C.E. Basic Industries, Gabbs, Nevada ..............................09-11
Carolina Silica, Inc.,
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,
Quarry Crushing System, Tehachapi, California .............07-11
Cayuga Generating Station, Cayuga, Indiana .................04-10
Cement Facility, Union Bridge, Maryland..........................07-9
California Biogen Power Facility,
San Bernardino County .....................................................02-39
Callahan Mining Corp., Hematite Flotation
Concentrator, Humboldt, Michigan ....................................06-8
Camberwell Mine, Hunter Valley, Australia ....................05-16
Cambria Mine 133, Ebensburg, Pennsylvania .................05-51
Cambria Prep Plant,
Somerset County, Pennsylvania ........................................05-51
Cement Loadout Facility, Victorville, California ..............07-13
Cement Processing Facility, Moapa, Nevada ...................07-12
Centex Cement Enterprises, Dallas, Texas ........................07-8
Central Generadora Electrica, San Jose
Power Station, Guatemala City, Guatemala ....................02-37
Central Hudson Gas & Electric, Danskammer
Generating Station, Newburgh, New York .......................02-48
Caper Cuvier, WA ...............................................................08-29
Central Hudson Gas & Electric,
Danskammer Point Steam Electric
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
Cape Lambert, WA .............................................................08-29
Carbon Coal Company, Mentmore Mine,
Gallup, New Mexico ...........................................................05-40
Index
3
INDEX
Chalk Point Generating Station,
Eagle Harbor, Maryland ....................................................02-40
Coal Tailings Reprocessing Facility,
Rybnik, Poland ...................................................................05-11
Chalk Point Power Generation Station,
Washington, D.C. ...............................................................02-38
Coal Transshipment Terminal,
Balls Head Bay, Sydney .....................................................08-25
Chalk Point, Dickerson, Morgantown Stations,
Maryland ............................................................................04-16
Coffeen Generation Station, Coffeen, Illinois ...................02-18
Chartam Project .................................................................06-14
Cogen South Plant,
Charleston, South Carolina ................................... 02-41, 03-13
Chemical Lime, Apex Plant, Apex Nevada .......................07-16
Cogeneration Facility, Fort Drum, New York ...................02-32
Chesterfield Power Station, Chester, Virginia ...................04-5
Cogeneration Plant, Barbers Point, Hawaii .....................04-21
Chevron Mining, Elkol Tipple Upgrade,
Kemmerer, Wyoming..........................................................05-14
Coke and Sulfur Handling Systems,
Jose, Venezuela ....................................................................03-6
Chevron, El Segundo Refinery,
El Segundo, California .........................................................03-2
Coke Production Plant, Dembiensko, Poland .....................09-3
China National Technical, Xinglongzuang,
Shandong Province, P.R.C. ................................................05-49
Coke Production Plant, Walbrzych, Poland ........................09-4
Coke Production Plant, Radlin, Poland ..............................09-3
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,
North Bend, Ohio ...............................................................04-11
Colorado Lein, Laporte, Colorado .....................................07-28
Cinergy Services, Zimmer Plant,
Moscow, Ohio .......................................................... 04-12, 08-13
Columbine Minerals, Wheatridge, Colorado ....................07-30
Citizen’s Gas & Coke Utility,
Indianapolis, Indiana.........................................................09-14
City of Owensboro, Kentucky ............................................04-25
City Utilities, James River Power Station,
Springfield, Missouri..........................................................02-31
Columbiana Foundry, Columbiana, Ohio .........................07-28
Comanche Station (Unit 3), Pueblo, Colorado ....................02-2
ComEd, Fisk Station, Waukegan Station
and Joliet No. 9 Station .....................................................02-41
Companhia Minera Doña Ines de Collahuasi,
Puerto Patache, Chile ........................................................08-14
Cliffside Station, Cliffside, North Carolina ......................02-24
CONSOL Energy, Robinson Run Mine,
Mannington, West Virginia .................................................05-4
Clinchfield Coal Company, Moss III Plant,
South Clinchfield, Virginia ................................................05-53
CONSOL Pennsylvania Coal Company,
Bailey Mine, Green County, Pennsylvania .......................05-51
Clinchfield Coal Company, McClure #1 Plant,
McClure, Virginia ...............................................................05-54
CONSOL, Bailey Mine Coal Preparation Plant,
Enon, Pennsylvania ...........................................................05-26
Clive Incineration Facility, Western Utah ..........................09-7
Consolidation Coal Company, Amonate Plant,
McDowell County, Tazewell, West Virginia ......................05-55
Clive Tank Farm, USPCI, Western Utah .........................09-12
Clutha Developments, Maritime Services
Board & Combined Colliery Operators,
Coal Terminal, Botany Bay ...............................................08-27
Coal & Allied Limited, Coal Transshipment
Terminal, Balls Head Bay, Sydney ....................................08-25
Coal Ground Storage Facility,
Isle of Wight County, Virginia ...........................................05-32
4
Index
Consolidation Coal Company,
Blacksville, West Virginia..................................................05-45
Consolidation Coal Company, Buchanan Plant,
Buchanan County, Virginia ...............................................05-52
Consolidation Coal Company, Dents Run Plant,
Mannington, West Virginia ...............................................05-53
Consolidation Coal Company, Enon, Pennsylvania .........05-46
INDEX
Consolidation Coal Company, Loveridge Plant,
Fairview, Wes Virginia .......................................................05-52
Danskammer Point Steam Electric
Generating Station, New Jersey .......................................02-49
Constellation Copper, Lisbon Valley Copper,
Moab, Utah ...........................................................................06-2
Darwin Port Authority, Container Crane,
Port of Darwin, Northern Territory ..................................08-27
Constellation Energy, Brandon Shores
Power Station, Baltimore, Maryland ...................... 04-1, 08-23
Dave Johnston Power Station, Glenrock, Wyoming .........02-40
Constellation Energy, C.P. Crane Station,
Baltimore, Maryland............................................................02-7
Continental Energy Associates, Hazleton
Gasification Project, Hazleton, Pennsylvania .......02-47, 03-11
Cortez Gold Mines, Cortez, Nevada ..................................06-17
Cottonwood Mine, Orangeville, Utah ...............................05-43
Credit Lyonnais Singapore,
Kalimantan and Java, Indonesia ......................................08-17
Cross Station, Cross, South Carolina ...............................04-17
Crown Asphalt Ridge Company, Oil Sands
Extraction Plant Improvements, Vernal, Utah ................06-24
Crusher Project, Lucerne Valley, California .....................07-21
Crushing Plant, Deadwood, South Dakota .........................06-9
Crystal River Station (Units 4 & 5),
Crystal River, Florida ..........................................................04-3
Dayton Power & Light, Killen
Generating Station, Manchester, Ohio ...............................04-7
Dayton Power & Light, Stuart Generating
Station, Aberdeen, Ohio ........................................... 04-6, 08-24
Denison Mines, Ltd., Quintette Plant,
Denison Mines, Ltd., Quintette Plant,
Tumbler Ridge, British Columbia, Canada ......................05-49
Dents Run Plant, Mannington, West Virginia .................05-53
Direct Reduced Iron (DRI) Material
Handling Facility, Port Lisas, Trinidad ..............................08-4
Direct Reduction Facility III (DR3),
Point Lisas Trinidad & Tobago ..........................................06-20
Dolnoslaskie Surowce Skalne (DSS),
Pilawa Quarry Processing Plant, Pilawa, Poland ..............07-1
Dominion Virginia Power, Chesterfield
Power Station, Chester, Virginia.........................................04-5
CS Energy, Kogan Creek Power Station,
Surat Basin, Australia .......................................................02-36
Doverspike Plant, Dora, Pennsylvania .............................05-56
Culley Station, Newburg, Indiana ........................ 04-23, 08-24
Dravo Lime Company, Black River Processing
Plant, Butler, Kentucky .....................................................07-17
Curragh Mine, Bowen Basin, Australia............................05-28
Cynergy Services, Miami Fort Station,
North Bend, Ohio ...............................................................08-25
Drummond Company, Inc.,
Shoal Creek Mine, Shoal Creek, Alabama........................05-31
Dry Fork Station & Mine, Gillette, Wyoming...................02-10
Cyprus Coal Company, Stoney Fork, Kentucky ...............05-44
Cyprus North Shore Mining,
Hearth Layer Plant, Silver Bay Processing
Facility, Silver Bay, Minnesota..........................................09-13
Cyprus North Shore Mining, Silver Bay
Processing Facility, Silver Bay, Minnesota .......................06-22
Dampier, WA.......................................................................08-29
DTE Utah Synfuels, Material Handling
System Upgrade, Price, Utah ..............................................09-2
Duck Creek Power Station, Canton, Illinois ....................02-19
Duke Energy, Cayuga Generating Station,
Cayuga, Indiana .................................................................04-10
Duke Energy, Cliffside Station,
Cliffside, North Carolina ...................................................02-24
Dandong Generating Station, Dangdong, China .............02-26
Danskammer Generating Station,
Coal Handling System, Marlboro, New York ......................08-8
Danskammer Generating Station,
Newburgh, New York .........................................................02-48
Duke Energy, Edwardsport Power Station,
Edwardsport, Indiana ..........................................................02-6
Dynegy Midwest Generation,
Baldwin Power Station, Baldwin, Illinois .......................02-22
Eagle Butte Mine, Gillette, Wyoming ...............................05-35
Index
5
INDEX
Eagle Roofing Tile Plant, Rialto, California .....................07-25
Galatia Mine, Galatia, Illinois ..........................................05-36
Eastern Associated Coal Group,
Keystone Plant, Keystone, West Virginia .........................05-55
General Dynamics Corp.,
Grinding Mill Plant, Buffington, Indiana .........................07-19
Edgewater Generating Station,
Sheboygan, Wisconsin........................................................02-38
Geneva Steel, Orem, Utah .................................................06-15
Edwards Power Station, Bartonville, Illinois ...................02-19
Georgia Power Company Plant,
Milledgeville, Georgia ........................................................02-25
Edwardsport Power Station, Edwardsport, Indiana..........02-6
Eighty-Four Mining, Eighty-Four, Pennsylvania ............05-43
El Segundo Refinery, El Segundo, California .....................03-2
Electric Power Research Institute,
Homer City Station, Homer City, Pennsylvania ..............02-49
Electricite de France (EDF) Coal Tailings
Reprocessing Facility, Rybnik, Poland ..............................05-11
Geneva Steel, Provo, Utah.................................................06-18
Georgia Power Company, Scherer Plant,
Juliette, Georgia.................................................................04-15
Geovic, Nickel – Cobalt Project,
Nkamouna, Cameroon .........................................................06-1
Gibson Generating Station, Owensville, Indiana ............04-11
Glennies Creek Colliery, Hunters Creek, Australia .........05-28
Elkol Preparation Plant, Kemmerer, Wyoming ................05-40
Golden Eagle Refinery, 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,
Muruntau Gold Project ......................................................06-12
Granite Rock Company, Logan Quarry Aggregate
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,
Odessa, Ukraine ...................................................................09-7
Great Salt Lake Minerals Corporation,
Multi-Site Plant Upgrades, Ogden, Utah .........................06-27
First Energy, Bay Shore Station
Repowering Project, Oregon, Ohio ....................................04-19
Green Hills Plant Elkford,
British Columbia, Canada ..................................... 05-48, 05-52
First Energy, W.H. Sammis Plant, Stratton, Ohio ...........02-13
Grinding Mill Plant, Buffington, Indiana .........................07-19
Fisk Station, Waukegan Station and
Joliet No. 9 Station ............................................................02-41
Gund Plant, Pike County,
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
Fossil Plant, Gallatin, Tennessee .......................... 02-48, 08-24
Hanna Nickel Mining Company,
Riddle, Oregon........................................................ 03-14, 06-16
Freeman United Coal Company,
Virdon, Illinois ....................................................................05-45
Harding Street Station, Indianapolis, Indiana ..................04-9
Freeman United Coal Company,
Waltonville, Illinois ............................................................05-45
Fresh Water Pumping Project .............................................06-5
Fru-Con Construction Company, North
Branch Power Project, Bayard, West Virginia ..... 02-46, 07-23
6
Index
Hardy Sand, Tuscaloosa, Alabama ....................................07-29
Hawthorn Mine, Sandborn, Indiana .................................05-51
Hazleton Gasification Project,
Hazleton, Pennsylvania ..........................................02-47, 03-11
Heap Leach Crushing Project, Carlin, Nevada ..................06-5
INDEX
Hearth Layer Plant, Silver Bay Processing
Facility, Silver Bay, Minnesota..........................................09-13
Island Creek Coal Co., Upshur Plant,
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
Hexcel, Carbon Manufacturing Lines,
Salt Lake City, Utah ............................................................09-1
High Capacity Stacker, New Madrid, Missouri ................02-43
Hindustan Steel Limited, Bihar, India .............................05-47
Hindustan Steel Limited, Patherdihi Central
Coal Washery, Bihar, India ................................................06-19
Island Creek Coal Company, Pond Fork Plant,
Bob White, West Virginia ..................................................05-54
Isover S.A., Mineral Wool Plant, Gliwice, Poland ............07-24
J.A. Jones Construction Company,
Cogeneration Facility, Fort Drum, New York ...................02-32
J.H. Miller Steam Plant, West Jefferson, Alabama .........02-44
J.R. Simplot Company, Plant Retrofit, Vernal, Utah .......06-32
J.R. Simplot Company, Pocatello, Idaho ...........................06-34
Hopewell Pagbilao, Conveyor System,
Quezon Province, Philippines............................................02-36
J.R. Simplot, Systems Engineering...................................09-11
Hot Briquetted Iron Plant Puerto Ordaz, Venezuela .......06-23
J.W. Cornett Preparation Plant,
Leatherwood, Kentucky .....................................................05-25
Huaneng Power International, Dandong
Generating Station, Dangdong, China .............................02-26
James Gores & Associates, Riverton, Wyoming ...............09-14
Ideal Basic Industries ..........................................................09-8
Ideal Cement Plant, Jefferson County, Colorado ...............07-7
JEA, Northside Generating Station,
Jacksonville, Florida ..........................................................04-24
Illinois Central Rail Marine Terminal,
St. James Parish, Louisiana .................................... 06-21, 08-6
Jewel Coal & Coke Company,
Jewel Smokeless Plant, Vansant, Virginia .......................05-53
Indianapolis Power & Light, Harding Street
Station, Indianapolis, Indiana ............................................04-9
Jim Walter Resources, #4 Mine,
Brookwood, Alabama .........................................................05-51
Industrial Minera Mexico, Pasta De Conchos
Mine, Mexico ......................................................................05-33
Jim Walter Resources, Brookwood, Alabama ...................05-44
Industrial Mineral Mexico,
Nueva Rosita, Mexico .............................................. 05-49, 09-9
Jones & Laughlin Corporation,
Harper’s Ferry, Virginia.....................................................07-23
Inland Steel Company, McLeansboro, Illinois ..................05-46
Inspiration Mines, Austin, Nevada ...................................06-13
Jones & Laughlin Steel Company,
California, Pennsylvania ...................................................06-18
Integra Coal, Camberwell Mine,
Hunter Valley, Australia ....................................................05-16
Kaiser Aluminum & Chemical Corporation,
Wendover, Utah ..................................................................06-35
Integra Coal/Vale, Glennies Creek Colliery,
Hunters Creek, Australia ..................................................05-28
Kaiser Cement Corporation,
Permanente Aggregate, Cupertino, California ...................07-8
Inter-Rock Minerals, Min-Ad Dolomite Facility,
Humboldt County, Nevada ................................................06-28
Kaiser Resources, Sparwood, British Columbia ...............05-45
Iron Ore Shiploading Terminal, Port Hedland,
Iron Ore Terminal, Port Dampier,
James River Power Station, Springfield, Missouri ..........02-31
John W. Turk Power Plant, Fulton, Arkansas ..................02-21
Kaltim Prima Coal Facility, Sangatta,
East Kalimantan, Indonesia................................................05-7
Kansas City Power and Light Company,
Fuel Yard Modifications, LaCygne, Kansas .....................02-46
Index
7
INDEX
Kansas City Power and Light,
Specialized Belt Feeders, La Cygne, Missouri .................02-34
Landfill, Remediation and Closure, New York ...................09-8
Katowice Coal Holding S.A., Katowice, Poland ................05-48
Lehigh Cement Company, Cement Facility,
Union Bridge, Maryland ......................................................07-9
Katowice Coal Holding S.A., Staszic Mine, Poland ..........05-27
Kennecott Utah Copper Corporation,
Bingham Canyon, Utah .....................................................06-10
Kennecott Utah Copper Corporation,
Kentucky Criterion Coal Company,
Deane, Kentucky ................................................................05-23
Laurel Run Mine, Mt. Storm, West Virginia ....................05-34
Liberty Power Company, Tallahassee, Florida .................03-14
Lihue Plantation Company,
Lihue Kauai, Hawaii................................................ 03-14, 09-9
Limestone Handling Facility,
Maysville, Kentucky ..........................................................07-18
Lisbon Valley Copper, Moab, Utah ......................................06-2
Kerr-McGee Coal Corporation, Galatia Mine,
Galatia, Illinois ..................................................................05-36
Logan Quarry Aggregate Plant Renovation,
Aromas, California ...............................................................07-5
Kerr-McGee Coal Corporation, Gillette, Wyoming ...........05-38
Kerr-McGee Corporation, Galatia, Illinois .......................05-44
Lonoke Ammunition Manufacturing
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,
Kings Mountain, North Carolina ......................................07-28
LTV Steel Corporation, East Chicago, Indiana ................06-18
Kingston Fossil Plant, Kingston, Tennessee ......................02-9
Luminant (Sandow Development Company),
TXU-Sandow (Unit 5), Rockdale, Texas ............................02-14
Knurow Mine, Poland ........................................................05-18
Kogan Creek Power Station, Surat Basin, Australia .......02-36
Kombinat Koksowniczy W Zabrzu,
Coke Production Plant, Dembiensko, Poland .....................09-3
Lubelski Wegiel S.A., Bogdanka Mine, Poland ................05-27
Luminant Power, Oak Grove Power Station,
Franklin, Texas ....................................................................02-1
Luminant, Kosse Mine, Kosse, Texas .................................05-1
Kombinat Koksowniczy W Zabrzu,
Coke Production Plant, Radlin, Poland ..............................09-3
Luminant, Oak Grove Power Station,
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
Kompania Weglowa (KWK), Murcki Mine, Poland ..........05-19
Kompania Weglowa (KWK), Ziemowit Mine, Poland ......05-19
MacLellan Mine, Lynn Lake, Manitoba............................06-13
MAPCO Coal Company, Pontiki Mine,
Lovely, Kentucky ................................................................05-24
Kooragang Coal Terminal Newcastle, NSW .....................08-22
Kosse Mine, Kosse, Texas ....................................................05-1
Krupinite Corporation, Modular Production Plant ..........06-30
KWB Belchatow, Aggregate & Sand Plant,
Szczercow, Poland ................................................................07-2
Lafarge, Sugar Creek Facility,
Sugar Creek, Missouri .......................................................07-14
MAPCO, Pontiki Plant, Martin County,
Inze, Kentucky ...................................................................05-56
Marblehead Lime, Buffington Plant,
Buffington, Indiana ............................................................07-22
Marblehead Lime, Chicago, Illinois ..................................07-23
Marblehead Lime, Gary, Indiana ......................................07-23
Marblehead Lime, Pleasant Gap, Pennsylvania ..............07-23
Lamberts Point Coal Loadout Facility,
Norfolk, Virginia ................................................................05-31
Marine Terminal, St. James Parish, Louisiana ...............06-21
Marion Generation Station, Marion, Illinois ....................02-35
8
Index
INDEX
Maritime Services Board of NSW,
Kooragang Coal Terminal Newcastle ................................08-22
MT Newman Mining Co., Iron Ore Shiploading
Terminal, Port Hedland, Western Australia .....................08-25
Maritime Services Board of NSW & Combined
Colliery Operators, Coal Terminal, Botany Bay...............08-27
Mt. Poso Cogeneration Project Fluidized Bed Boiler .......02-45
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,
West Virginia ......................................................................05-54
Nadwislanskia Spolka Weglowa (NSW)
S.A. Piast Mine, Bierun, Poland .......................................05-10
Mentmore Mine, Gallup, New Mexico ..............................05-40
Metallurgimport, Moscow, Russia .....................................07-29
National Cement Company of California,
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 Refinery (MIDOR),
Alexandria, Egypt ................................................................03-7
Neil Simpson Station, Gillette, Wyoming .........................02-34
Millwood Sand Company, Millwood, Ohio ........................07-28
Multi-Site Plant Upgrades, Ogden, Utah .........................06-27
Nevada Gold Mining, Inc., Sleeper Project,
Winnemucca, Nevada.........................................................06-14
Min-Ad Dolomite Facility,
Humboldt County, Nevada ................................................06-28
New Elk Mine, Weston, Colorado......................................05-38
Mingo Logan, Black Bear Preparation Plant,
Mountaineer Mine, Gilbert, West Virginia .......................05-22
New Madrid Plant, New Madrid, Missouri ......................02-50
Mirant Mid Atlantic, Chalk Point, Dickerson,
Morgantown Stations, Maryland ......................................04-16
New Hope Corporation, Port Of Brisbane ..........................08-9
New River Company, Beckley Lick Run Plant,
Mount Hope, West Virginia ...............................................05-56
Mitchell Plant, Cresap, West Virginia .................... 04-2, 08-23
New River Company, Meadow Creek Plant,
Meadow Creek, West Virginia ...........................................05-54
Mobil Mining and Minerals Company,
South Fort Meade Mine Beneficiation Plant,
Nichols, Florida ..................................................................06-31
New South Wales Dept. of Public Works,
Offshore Coal Terminal, Coalcliff ......................................08-27
Modular Asphaltene Recovery Plant,
Fort McMurray, Alberta, Canada ......................................06-26
New South Wales Dept. of Public Works,
Port Kembla Coal Terminal Port Kembla.........................08-21
Newcastle, NSW .................................................................08-29
Modular Gold Recovery ADR Plant, Ghana, Africa ...........06-3
Modular Production Plant .................................................06-30
Monsanto Company, Soda Springs, Idaho ........................06-35
Monterey Coal Company,
Wayne County, West Virginia ............................................05-46
Newmont Gold Company, Heap Leach
Crushing Project, Carlin, Nevada .......................................06-5
Newmont Mining, Carbon Regeneration
and Handling Project ...........................................................06-5
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,
Morgantown, West Virginia ...............................................02-29
Newmont Mining, Trash Screen Modification Project .......06-5
Moss III Plant, South Clinchfield, Virginia ......................05-53
Newmont Mining, Truck Maintenance
& Wash Facility, Carlin, Nevada .........................................09-5
Motiva Enterprises, Motiva Refinery,
Port Arthur, Texas ................................................................03-1
Nickel – Cobalt Project, Nkamouna, Cameroon .................06-1
Nonoc Island, Philippines ..................................................08-28
Mt Arthur North Mine, Hunter Valley, Australia ............05-13
Index
9
INDEX
Norfolk & Western Railway Company, Coal Ground
Storage Facility, Isle of Wight County, Virginia ...............05-32
Omya California, Crusher Project,
Lucerne Valley, California .................................................07-21
Norfolk & Western Railway Company, Lamberts
Point Coal Loadout Facility, Norfolk, Virginia .................05-31
Omya California, Optical Sorter Improvements,
Norfolk Southern Harris Mine,
Kopperston, West Virginia.................................................05-30
Optical Sorter Improvements,
North American Coal Company,
Powhatan Point, Ohio ........................................................05-36
Orlando Utilities, Fuel Supply System,
Orlando, Florida .................................................................02-50
North Branch Power Project,
Bayard, West Virginia............................................ 02-46, 07-23
Ottawa Silica, Ottawa, Illinois ..........................................07-28
North Carolina State Ports Authority,
Morehead, North Carolina.................................................08-10
Oxbow Carbon, Port of Los Angeles (LAXT),
Los Angeles, California ........................................................03-4
North Omaha Station, Omaha, Nebraska ........................02-16
Oxbow Corporation, Pet Coke Loading Facility,
Port of Texas City, Texas ....................................................08-16
North Rochelle Mine, Gillette, Wyoming ............................05-6
Northern Indiana Public Service Co., R.M. Schahfer
Generating Station, Wheatfield, Indiana .........................02-46
Northern Indiana Public Service Co./Pure Air,
Bailey Generating Station, Chesterton, Indiana .............04-25
Owens Illinois, Ione, California.........................................07-28
Pacific Corp, Salt Lake City, Utah ....................................06-35
Pacificorp, Dave Johnston Power Station,
Glenrock, Wyoming ............................................................02-40
Paradise Fossil Plant, Paradise, Kentucky ......................04-20
Northern States Power Company, Black Dog,
Riverside and Highbridge Generating Stations,
Minneapolis, Minnesota ....................................................02-38
Paradise Plant, Drakesboro, Kentucky.............................02-15
Northside Generating Station, Jacksonville, Florida ......04-24
Pasta de Conchos Mine, Mexico ........................................05-33
Nova Scotia Sand & Gravel,
Shubenacadie, Nova Scotia ...............................................07-28
Patherdihi Central Coal Washery,
Bihar, India ............................................................ 05-47, 06-19
Noyes Bros., Pty., Offshore Clinker and
Cement Terminal, Gladstone, Queensland .......................08-26
PBS Coals, Inc., Cambria Prep Plant,
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, Morganfield, Kentucky .............05-46
Offshore Coal Terminal, Port Kembla...............................08-27
Pegasus Gold Corporation, Florida Canyon Mine,
Imlay, Nevada ....................................................................06-17
Parker Point, Dampier, WA ...............................................08-28
Offshore Iron Ore Terminal, Northwest WA.....................08-26
PEMEX Refinery Petroleum Coke Handling Project .........03-8
Oil Sands Extraction Plant Improvements,
Vernal, Utah .......................................................................06-24
Oil Sands Extraction Plant, Fort McMurray,
Alberta, Canada .................................................................06-25
Penn West Fuels, Doverspike Plant,
Dora, Pennsylvania ............................................................05-56
Pennsylvania Electric Company,
Old Ben Coal Company, Pike County, Indiana .................05-41
Omaha Public Power District,
North Omaha Station, Omaha, Nebraska ........................02-16
Omg Apex, Tungsten Recycle Project, St George, Utah .....06-7
10
Index
Pennsylvania Glass & Sand Corporation,
Berkeley Springs, West Virginia ........................... 07-26, 07-27
INDEX
Brady, Texas .......................................................................07-29
Port of Amamapare (Papua), Indonesia ............................08-15
Mapleton Depot, Pennsylvania ............................. 07-26, 07-27
Port of Los Angeles (LAXT), Los Angeles, California .........03-4
Port Of Brisbane ..................................................................08-9
Port of Lyttelton, Christchurch, New Zealand .................08-12
Mill Creek, Oklahoma........................................................07-26
Pacific, Missouri .................................................................07-26
Pentair Paper (Sargent & Lundy),
St. Paul, Minnesota............................................................09-15
Peoples Republic of China, Xinglongzhaung Plant,
Xinglongzhaung Shangdong Province, Beijing, China ....05-53
Posven, Hot Briquetted Iron Plant
Puerto Ordaz, Venezuela ...................................................06-23
Potomac Electric Power Company, Chalk Point
Generating Station, Eagle Harbor, Maryland ..................02-40
Potomac Electric Power Company, Chalk Point
Power Generation Station, Washington, D.C. ..................02-38
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,
Cardon Refinery Project, Cardon, Venezuela .....................03-5
Progress Energy Carolinas,
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 Refinery Petroleum Coke Handling Project .........03-8
Pilawa Quarry Processing Plant, Pilawa, Poland ..............07-1
Pinson Mining Company, Winnemucca, Nevada ..............06-17
PSI Energy, Wabash River Generating Station,
West Terre Haute, Indiana ................................................02-41
Pittsburgh & Midway Coal Mining Company,
Elkol Preparation Plant, Kemmerer, Wyoming ................05-40
PT Freeport, Irian Jaya, Indonesia...................................02-37
PT Freeport, Port of Amamapare (Papua), Indonesia .....08-15
Pittston Coal Company, McClure, West Virginia .............05-46
Plexus Resources, Salt Lake City, Utah ...........................06-35
PT Kaltim Prima Coal Facility,
Sangatta, East Kalimantan, Indonesia ..............................05-7
Plum Point Power Partners, Plum Point Station,
Osceola, Arkansas ................................................................02-5
PT Newmont Nusa Tangarra, Sumbawa, Indonesia..........08-2
Poludniowy Koncern Energetyczny (PKE),
Sobieski Mine, Jaworzno, Poland......................................05-17
PT Newmont, Batu Hijau Mining Project,
Sumbawa, Indonesia ..........................................................02-48
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
Pontiki Plant, Martin County, Inze, Kentucky.................05-56
Port Dickson, Malaysia ......................................................08-28
Quintette Plant, Tumbler Ridge,
Port Kelang, Malaysia ......................................................08-28
R.M. Schahfer Generating Station,
Wheatfield, Indiana ...........................................................02-46
Port Kembla Coal Terminal Port Kembla,
New South Wales ...............................................................08-21
Ranger Fuel Company, Beckley #2 Plant,
Sabine, West Virginia ........................................................05-55
Port Latta Open Sea Ore Terminal Tasmania..................08-19
Index
11
INDEX
Red Hills Generation Facility,
Choctaw County, Mississippi .............................................02-11
Reliant Energy, Seward Station,
New Florence, Pennsylvania ................................... 03-9, 04-24
Remington Arms Company, Lonoke
Ammunition Manufacturing Plant, Arkansas ..................09-12
Republic Steel Corporation, Philippi, West Virginia........06-18
Ridgeway Coal Company, Meta, Kentucky .......................05-44
Rio Tinto, Spring Creek Mine, Decker Montana ..............05-29
Riverwood International Paper Mill, Macon, Georgia .....09-15
Roberta Cement and Lime Plant, Calera, Alabama.........07-15
Scrubgrass Power Generating Company,
Scrubgrass Power Plant,
Ventigo County, Pennsylvania ...........................................04-22
Scrubgrass Power Plant,
Ventigo County, Pennsylvania ...........................................04-22
SEI, Birchwood Station,
King George County, Virginia ...........................................02-44
Sepetiba Bay, Brazil .............................................................08-1
Serco Sodexo Defence Systems ............................................08-3
Seward Station, New Florence, Pennsylvania ....... 03-9, 04-24
SGS Canada, Oil Sands Extraction Plant,
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,
Deer Park, Texas ..................................................................03-7
Rock Creek Gold Facility, Nome, Alaska ............................06-6
Rocky Mountain Bank Note, Salt Lake City, Utah ..........09-13
Shell Mining Company, Standard Hill Project,
Kern County, California.....................................................06-14
Roc-San Gravel Company, Aggregate Plant,
Lodi, California ....................................................................07-6
Shell Oil Company, Limera, Ohio......................................05-46
Romarco Minerals, Haile Gold Mine Feasibility Study .....06-4
Sherrgold Inc., MacLellan Mine,
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
Station (Unit 4), Apache County, Arizona ...........................02-4
Silica Products Company, Guion, Arkansas ......... 07-26, 07-30
San Jose Power Station, Guatemala City, Guatemala.....02-37
Silver Bay Processing Facility,
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
Sobieski Mine, Jaworzno, Poland......................................05-17
Sandy Creek Power Partners, Sandy Creek
Energy Station, Riesel, Texas ............................................02-20
Sobin Chemical Company (Div. IMC),
Spruce Pine, North Carolina .............................................07-29
Santee Cooper, Cross Station, Cross, South Carolina......04-17
Santee Cooper, Winyah Station,
Georgetown, South Carolina .............................................04-18
Satellite Goldfields, Modular Gold Recovery
ADR Plant, Ghana, Africa ...................................................06-3
Savage River Mines Limited, Port Latta Open
Sea Ore Terminal Tasmania ..............................................08-19
Scherer Plant, Juliette, Georgia........................................04-15
Scrubgrass Facility, Kennerdell, Pennsylvania.... 02-28, 03-10
12
Index
South Fort Meade Mine Beneficiation Plant,
Nichols, Florida ..................................................................06-31
South Mississippi Electric Power Association,
Coal Handling, Gardner, Kentucky...................................02-50
Southdown California Cement,
Cement Loadout Facility, Victorville, California ..............07-13
Southern Company Services, Georgia Power
Company Plant, Milledgeville, Georgia ............................02-25
Southern Electric International,
Birchwood Project, King George County, Virginia ...........02-38
INDEX
Southern Illinois Power Cooperative,
Marion Generation Station, Marion, Illinois ....................02-35
Tennessee Valley Authority, Paradise Plant,
Drakesboro, Kentucky .......................................................02-15
Southern Indiana Gas & Electric,
Culley Station, Newburg, Indiana ........................ 04-23, 08-24
Tennessee Valley Authority,
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
Specialized Belt Feeders, La Cygne, Missouri .................02-34
Tesoro Refining, Golden Eagle Refinery,
Martinez, California.............................................................03-3
Spring Creek Mine, Decker Montana ...............................05-29
Texas Gulf Sulphur Company,
Offshore Iron Ore Terminal, Northwest WA.....................08-26
Springerville Generating Station (Unit 4),
Apache County, Arizona .......................................................02-4
Thiokol Corporation, Brigham City, Utah ........................09-14
Stabilization Facility, Grassy Mountain,
USPCI, Western Utah..........................................................09-7
Standard Hill Project, Kern County, California ...............06-14
Strzegom Quarry, Poland.....................................................07-4
Stuart Generating Station, Aberdeen, Ohio ........... 04-6, 08-24
Sugar Creek Facility, Sugar Creek, Missouri ...................07-14
Sukunka Coal Project Plant ..............................................05-53
Sukunka Coal Project Plant,
Chetwynd, British Columbia, Canada ..............................05-48
Tahmoor Mine, New South Wales, Australia ...................05-12
Taipei Marina .....................................................................08-29
Taiwan Power, Coal Yard, Kaonsiung, Taiwan .................02-50
Taiwan Power, Lincou Station...........................................05-50
Taiwan Power, Talin Coal Terminal ..................................05-50
Thunder Basin Coal Company,
Black Thunder Mine, Wright, Wyoming ...........................05-20
Thyssen Krupp Fordertechnik,
Fertilizer Conveying System Support Steel,
Odessa, Ukraine ...................................................................09-7
Total Energy Plant,
Guayama, Puerto Rico ...................................... 02-8, 04-8, 08-7
Tractebel Power – Choctaw Generation,
Red Hills Generation Facility,
Choctaw County, Mississippi .............................................02-11
Trash Screen Modification Project ......................................06-5
Tri County Asphalt Corporation,
Lake Hopatcong, New Jersey ..............................................07-8
Triton Coal Company, North Rochelle Mine,
Gillette, Wyoming ................................................................05-6
Tarmac UK, Wisniowka Quarry, Wisniowka, Poland ........07-3
Truck Maintenance & Wash Facility,
Boron, California ..................................................................09-6
Teberebie Goldfields, Process Plant,
Ghana, West Africa ............................................................06-11
Truck Maintenance & Wash Facility,
Carlin, Nevada .....................................................................09-5
Teck Corporation, Bullmoose Plant,
Tumbler Ridge, British Columbia, Canada ......................05-52
Tungsten Recycle Project, St George, Utah ........................06-7
Tennessee Valley Authority, Allen Fossil Plant,
Memphis, Tennessee ..........................................................02-15
Turkish Coal Enterprise, Catalagzi, Turkey ....................05-47
Colbert Steam Plant, Tuscumbia, Alabama......................02-50
Turkish Coal Enterprise, Zonguldak, Turkey...................05-47
Tennessee Valley Authority, Drakesboro, Kentucky ........05-45
TVA Gallatin, Fossil Plant,
Gallatin, Tennessee ................................................ 02-48, 08-24
Kingston Fossil Plant, Kingston, Tennessee ......................02-9
Paradise Fossil Plant, Paradise, Kentucky ......................04-20
Turkish Coal Enterprise, Amasra, Turkey .......................05-47
Turkish Coal Enterprise, Tuncbilek, Turkey ....................05-48
U.S. Borax, Truck Maintenance
& Wash Facility, Boron, California .....................................09-6
Index
13
INDEX
U.S. Generating Company,
Scrubgrass Facility,
Kennerdell, Pennsylvania ..................................... 02-28, 03-10
U.S. Steel Corporation,
Greene County, Pennsylvania ...........................................06-18
U.S. Steel Corporation, Hueytown, Alabama ...................05-37
U.S. Steel Corporation, Jefferson, Alabama .....................06-18
United Engineers & Constructors,
Clive Incineration Facility, Western Utah ..........................09-7
Upshur Plant, Tallmansville, West Virginia ....................05-54
Utah Power & Light Company,
Coal Handling and Processing, Chaco, Utah....................02-50
Cottonwood Mine, Orangeville, Utah ...............................05-43
Naughton Station, Kemmerer, Wyoming ..........................02-39
Utah Salt Company, Wendover, Utah ...............................06-35
Victoria, Australia ..............................................................08-28
Virgina Electric Power Company,
Bremo Station, Richmond, Virginia ..................................02-49
Western Aggregate Minerals Company,
Carlsbad, New Mexico .......................................................06-35
Western Aggregate, Ideal Cement Plant,
Jefferson County, Colorado ..................................................07-7
Western Canadian Coal Company,
Wolverine Mine, Tumbler Ridge, Canada ...........................05-5
Western Coal Company,
San Juan Station, New Mexico .........................................05-39
Western Energy Company, Chartam Project ....................06-14
Western Kentucky Energy,
Coleman Station, Hawesville, Kentucky .............. 02-12, 04-13
Western Oil Sands,
Modular Asphaltene Recovery Plant,
Western States Minerals Corp.,
Wheatridge, Colorado ........................................................06-17
Westfarmers, Curragh Mine,
Bowen Basin, Australia .....................................................05-28
Weston Station, Rothschild, Wisconsin.............................02-17
Westvaco, Cogen South Plant,
Charleston, South Carolina ................................... 02-41, 03-13
Wharf Resources, Crushing Plant,
Deadwood, South Dakota ....................................................06-9
W.H. Sammis Plant, Stratton, Ohio ..................................02-13
Wabash Mine, Keensburg, Illinois ....................................05-21
Wharf Resources, Process Plant Expansion,
Deadwood, South Dakota ....................................................06-9
Wabash River Generating Station,
West Terre Haute, Indiana ................................................02-41
White Mining (Felix Resources) Ashton Mine,
Hunter Valley, Australia ......................................................05-9
Wallarah Coal Company,
Catherine Hill Bay Coal Loader, NSW .............................08-25
Whitehead Bros. Company, Lugoff, South Carolina ........07-30
Widows Creek Fossil Plant, Stevenson, Alabama ............02-23
Ward Iron Works (Holmes Foundry),
Welland, Ontario, Canada .................................................07-29
Warrior Run Power Station,
Cumberland, Maryland .....................................................02-42
Wedron Silica Company, Byron, California ......................07-29
Wedron Silica Company, Emmett, Idaho ..........................07-29
Willamette Industries, Hawesville, Kentucky..................09-15
Willamette Industries, Portland, Washington..................09-15
William R. Barnes Company, Watertown,
Ontario, Canada .................................................................07-28
Willow and Pleasants Island, Parkersburg,
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
Wedron Silica, Prairie State Silica Plant,
Troy Grove, Illinois ................................................ 07-26, 07-30
Welsh Power Plant, Cason, Texas .....................................02-49
14
Index
Wisconsin Energy, Elm Road Station,
Oak Creek, Wisconsin ..........................................................02-3
Wisconsin Power & Light, Edgewater
Generating Station, Sheboygan, Wisconsin......................02-38
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
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