09.02.2012 modern coking coal technology, peter long
TRANSCRIPT
SEDGMAN
Recognised for leading
innovative solutions for the
resource industry
1. COMPANY OVERVIEW
2. LOCATIONS AND PERSONNEL
3. ADVANCED TECHNOLOGY FOR COKING COALS
4. PROCESS DESIGN
5. UGH DESIGN FOR CHPP
6. DESIGNING FOR EXTREME WEATHER VARIANCES
7. OVERCOMING OPERATIONAL CHALLENGES IN REMOTE LOCATIONS
8. UHG CHPP CONSTRUCTION
13 February 20122
AGENDA
• Global leader in the design, construction and
operation of coal handling and processing
plants (CHPPs)
• Established in 1979 in Australia
• Publicly listed, ASX 300 company
• Focused on technology leadership and
reputation built on delivering simple, certain
quality
• Over 1,000 employees worldwide
• Conceptual Design through to Operations
• Contract experience from EPCM to full EPC risk
• Currently undertaking coal projects in four
continents – Asia, Australia, Africa and
South America
• Delivered over $1.7 billion of CHPPs in the past
6 years
• Processing capacity of more than 30 Mt/a of
coal
13 February 20123
1. COMPANY OVERVIEW
13 February 20124
2. LOCATIONS AND PERSONNEL
Currently Executing 15 projects and 12 operations contracts world wide
South America 80 StaffOffice Santiago
Projects Bocamina CHP
South Africa 79 staffOffices Johannesburg
Projects Atcom (Sth Africa), Benga, Zambeze (Mozambique),
Boseto (Botswana)
Mongolia / China 95 staffOffices Ulaanbaatar Beijing, Shanghai
Projects UHG Stage 1, UHG Stage 2, UHG Stage 3, Phu Kam
Operations UHG Management
Australia 805 StaffOffices Brisbane (head office), Townsville, Mackay & Perth
Projects Bengalla Upgrade, Caval Ridge, Lake Vermont 2, Maules Creek, Middlemount Upgrade,
Narrabri, Red Mountain Upgrade, South Walker Creek
Operations Agnew, Blair Athol, Cannington, Coppabella, Ernest Henry, McArthur River, Moorvale,
Middlemount, Mt Isa, Red Mountain, Sonoma
Coking coal is a high value product
Currently > US$300/t
Expected long term > US$150/t
Maximum recovery is major driver for project return
Design Elements for Maximising Recovery
Analysis of resource
- Best practice techniques for bore core analysis
and interpretation
- Simulations for accurate prediction of yield for
plant
design purposes
- Coking coals can be very different
Selection of most appropriate plant circuit and
equipment for the range of coal seams to be treated
- Computer models of alternative circuits using
models based on a large in-house database of
actual operating plant data
Detailed Coal Handling and Plant design using 3D
CAD to optimise layout for operating and
maintenance
13 February 20125
3. ADVANCED DESIGN FOR COKING COALS
• Dense Medium Cyclones for coarse coal with circuits designed for optimum efficiency High medium : coal ratios to maximise efficiency
Large diameter cyclones with high spigot capacity for low yielding feed types
• High rank coking coals have a high percentage of recoverable coal in the fine circuits Fine circuit selection critical for maximum recovery
Latest Reflux Classifier technology for fine coal to balance operation of coarse and fine circuits
Latest pneumatic / column flotation for ultrafines
• Hard coking coal is intrinsically fine, so high product moisture is inevitable if high recovery of fine coal Free moisture can be a problem, especially in
Mongolia
- Poor handleability for subsequent transport
- Can freeze in winter
Use of proven, large scale centrifuge technology for all plant streams to minimise final product moisture
13 February 20127
4. PROCESS TECHNOLOGY
CPP Module design feed rate 900 t/h (as); Coking coal products 8.5% to 9.0% ash,
<10%TM.
Phase 1 – 5 Mt/a one CPP module 60 t ROM Dump Hopper with Feeder Breaker
Roller Screen & Secondary Sizer station
1000 t Plant Feed Surge Bin
Radial Stacker for Coking Product
Radial Stacker for Thermal Product
Radial Stacker for Rejects and Tailings Dam
Phase 2 – 10 Mt/a two CPP modules Additional 350 t ROM Hopper with Feeder
Breaker
Roller Screen, Secondary & Tertiary Sizer station
Reject Bin & Tailings Dam
Phase 3 – 15 Mt/a three CPP modules
13 February 20128
5. UHG DESIGN FOR CHPP
Nominal throughput 900 t/h (ar)
Two stage DMC 1300mm and 1000mm
diameter cyclones
-50mm +1.2mm (ww)
Spirals -1.2mm (ww) +0.250mm
Flotation Jameson Cells (B6000/20)
-0.250mm
Centrifuges Coarse Coal
Fine Coal
Screen bowl
13 February 20129
5. UHG DESIGN FOR CHPP
Extreme temperatures -40 to +40oC
Structural
Euro Code 3 provisions
Chinese low temp steel (D & C Grade) in impact areas
Reduced design stress
Notch tough welds
CPP, bins & transfers contained in fully insulated sheds
Significant heating system
2.6MW installed heating capacity for Phase 1
Civil
Cast in heating
Building foundations below frost line
Climate controlled concrete pours
Winter crash drainage
13 February 201210
6. DESIGNING FOR EXTREME WEATHER VARIANCES
Electrical and Controls Buried and heated cable racks
Double insulated cabinets
Enclosed MCC and HV systems
Instrument selection driven by temperature variance
Winter setting which fundamentally changes the trip and shutdown sequencing
Process Assumes shed >0˚C
Flotation dewatering selection
Thickeners are covered, sheeted and heated
Pipes between buildings are insulated, heat traced, have Δ50˚C rubber expansion joint
Automated plant shutdown and drain should heating system fail
Tailings Pipes insulated with 10mm rigid polyurethane
foam (cyano-polyester based) and protective shell
Operate at above critical freezing velocity
Mechanically drained by diesel pump
13 February 201211
6. DESIGNING FOR EXTREME WEATHER VARIANCES
13 February 201212
7. OVERCOMING OPERATIONAL CHALLENGES IN REMOTE LOCATIONS
Issues to be considered
Logistics
Systems and procedures
Training requirements
Maintenance
Logistics Spare holdings on site
Delivery time of materials
Vendors
Quality control
Systems and procedures Developed well in advance
Remote links to monitor facility off site
Technical support
Training Mongolian supervisors/key managers trained in
Australia
Sedgman managers and trainers
Ongoing development on site
Maintenance Majority of activities performed by site personnel
Specialty maintenance tasks
- OEM’s
- Source from external providers
- Train on site resources and procure appropriate tools/equipment
13 February 201213
7. OVERCOMING OPERATIONAL CHALLENGES IN REMOTE LOCATIONS