wouter niehaus - peabody energy
DESCRIPTION
Longwall 2014TRANSCRIPT
27-28 October
North Goonyella Coal 2 PART PUMPING – A VISION IN APPLICATION
Longwall Conference
Wouter Niehaus
Underground Mine Manager
About Peabody Energy
● The world’s largest private-sector coal company
– 251.7 million tons sold in 2013 from operations, trading and brokerage
– $7 billion in revenues
– 8.3 billion tons of proven and probable reserves
● Customers on six continents
● 27 mines across U.S. and Australia
– 20 surface mines
– Seven underground mines
● Listed on New York Stock Exchange under symbol “BTU”
● “Fortune 500” and
“S&P 500” ranking
2 Wilpinjong Mine
Peabody: World’s Largest Private-Sector Coal Company
Metallurgical and Thermal Coal Customers in 25+ Countries
Essen
Beijing
Ulaanbaatar
Urumqi
Jakarta Balikpapan
New Delhi
Brisbane, QLD
Newcastle, NSW
London
(From U.S.)
St .Louis, MO
Singapore
Mining Operations and Trading
Sales Reserves
SPRB 135 3.4
Midwest 26 3.2
Southwest 16 0.5
Colorado 7 0.2
Australia 35 0.9
Trading 32 -
Total Tons 252 8.3
Million Billion
Reported 2013 sales volumes. Reserves based on 2013 10-K filing. Total sales and reserves variances are based on rounding calculations. Green shading
indicates countries served by Peabody.
(to Europe)
Operating Regions
Customers Served
Corporate Office
Regional Offices
Trading/Business
Development Offices
Coal Flows
3
Metropolitan
Dalrymple Bay
Abbot Point
Port Kembla
Queensland
New South Wales
Brisbane
Wilpinjong Wambo Underground
Wambo Open Cut
NCIG
PWCS
Gladstone
BTU Met
BTU Thermal
Port
PEA PCI Mine
PEA PCI Project
Burton North Goonyella
Millennium Eaglefield
Moorvale
Middlemount
Coppabella
● Peabody’s Australia platform has
grown rapidly since 2002
– Volumes doubled every 3 years,
contributing to a 400%+ increase in
EBITDA
● Acquired Macarthur, largest
purchase in 131-year history
– World’s largest producer of low-vol
PCI coal
– Pro forma combined position in 2011:
Reserves = 1.4 BT (attributable)
Resources = >6 BT (attributable)
● Diverse mix of met/thermal coal
● Ideally located to meet Asian
demand
● More than 2500 employees plus
approximately 500 contractors
Peabody Expands Australian Export Platform Via Joint Ventures, Acquisitions
4
About North Goonyella Coal
● 2 hours south-west of Mackay (Peak
Downs Highway)
● North Goonyella Coal ships to
Japan, Korea, China and India
● Commenced operations in 1994,
Peabody acquired in April 2004
● Produces premium-quality, medium-
volatile, high-strength coking coal.
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Pumpable Crib
● A longwall tailgate is a hazardous environment
– Machine access is restricted by high gas levels and roadway impediments
– Interaction between people and machines
● Costs and logistics challenges:
– Moving equipment long distances from the surface
– Limited capacity of transports
– Impact on roadways
– Timing for installation and limited access (maintenance days)
– General maintenance – nuisance water and irritant dust
● Broad planning was required to manage issues
The Challenge
Pumpable Crib
● Met with RGN (representatives from Heintzmann
Australia) in early 2012
– Pumpable Crib: Used in United States and southern mining
districts of Australia
– Reviewed established processes with focus on innovation
– Developed enhanced system with range of benefits
Developing A Solution
Set Up
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• Crib Bag Installation
Footnotes are Arial 9 and align with the page number on the master
Pumpable Crib
● Long pumping distance – to 5km
● Improved safety
● Reduced:
– Manual handling
– Down time
– Vehicle requirements
– Roadway impact
● We’d developed a safe and cost-effective method of
keeping tailgate open…on paper
Benefits of Enhanced System
Pumpable Crib
● 2-part pumping system set up in a remote location
● Specialist cements proprietary but relevant SDs
provided
● 4-bowls - 2 for each part - so one can be mixing whilst
the other is pumping to avoid stopping and starting
● Mixed at the delivery end (single mixing line) before
branching back out into two fill lines
● Result is rapid-setting cement that is able to be used to
fill a textile crib bag in stages
The System
Set Up
11
• Underground Pumping Unit
Footnotes are Arial 9 and align with the page number on the master
Set Up
12
• Underground installation
Footnotes are Arial 9 and align with the page number on the master
Pumpable Crib
● 2012 employees from Heintzmann and RGN began trial
● Tailgate access impacted by gas levels
1. Options were shut the wall down and manage the gas
2. Push ahead with the trial
● Benefits were evident early – immediate set-time of
cement gave 85% of final strength in 24 hours
– No delays waiting for product to set
– Average 10 pumpable cribs for every 4 hours of pumping time
● The trial continued…
The Trial
Underground
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• Crib Bags available in 762mm, 914mm, 1066mm & Custom Diamaters
Footnotes are Arial 9 and align with the page number on the master
Pumpable Crib
● The trial continued and performance exceeded
expectations
– Adapted to backfill gas drainage stubs on longwall retreat
● Eliminated need to transport 95% of supplies
underground for tailgate support
● Able to pump entire longwall from single site
– Option to pump multiple longwalls
● Benefits to both production and safety
The Results
Surface Installation
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Surface Installation
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