duncan buchanan, pt bayan resources - improving efficiency in bayan mining operations
DESCRIPTION
Duncan Buchanan, General Manager - Operations and Technical, PT Bayan Resources delivered this presentation at Kalimantan Coal 2014 in Balikpapan Indonesia. This event brings together 120+ senior executives, and decision makers from government, mining, infrastructure, shipping and supply sectors to discuss new policies and strategies for tackling the current and emerging issues within the burgeoning Kalimantan coal sector. Visit the website to find out more: http://bit.ly/KalimantanCoal2014TRANSCRIPT
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PT BAYAN RESOURCES Tbk.
Focusing on Efficiency
Duncan Buchanan
Kalimantan Coal Conference - September 2014
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www.bayan.com.sg
Bayan Overview
PT. Bayan Resources Tbk listed on Indonesian stock
exchange in August 2008
22 mining concessions covering approximately 145,000
hectares in East and South Kalimantan
13.3 million tonnes of production in 2013. Targeting 13 to 14
million tonnes this year.
Some of the highest calorific value coal in Indonesia
3 independent port facilities including the Balikpapan Coal
Terminal
Leading mining contractors include Thiess, Petrosea,
Leightons and Bukit Makmur
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Operation Locations
www.bayan.com.sg
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Why the concern and
need to focus on efficiencies?
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The concerns
70 Persen Tambang Tutup
Tribun Kaltim, 29 Aug 2014
70% of Mines Closed
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The concerns
Since 2011, over 35% drop in coal price due to oversupply in
market.
Significant reduction in overburden removal in Indonesia in
2013 means there is approx. 500mBCM of fleet capacity just
sitting around, meaning if there is any increase in coal price
this will be counteracted with an increase in production => this
and other factors means that current prices are here to stay.
Coal price declines over the long term need to be offset by
efficiency improvements.
Year on year inflation of mining costs ranging between 5 – 10%
(labour, spare parts, tyres).
No more easy coal in Indonesia, logistically it’s becoming
tougher.
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The concerns
• Change in relationship between revenue / cost drivers
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Mining Costs and Efficiencies
Realistic assessment of mining costs
and efficiencies
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Mining Costs and Efficiencies
Efficiency is all too often referred to in
operational terms only.
Cost and efficiency go hand-in-hand,
cannot look at one without the other.
Doing something efficiently doesn’t
necessarily mean low cost.
Need to balance practical efficiency with
cost. We can make any activity extremely
efficient with enough resources but need
to keep a handle on the real cost benefit.
What is ‘efficient’ for any mine will
depend upon where it is in it’s mine life
cycle and it’s eventual production target,
i.e. what is efficient for one mine may not
be efficient for another.
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Assessing Mining Costs
Need to look at all-in mining costs, i.e.
loaded onto customers vessel.
Compare to industry standards (within
Indonesia and the rest of world) but
make sure comparing like for like.
When looking at specific efficiencies,
need to capture and record costs at the
activity level.
Start by looking for the ‘low-hanging
fruit’.
Use independent consultants to assess
current activities and advise where
appropriate.
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Logistics
Logistics costs – Improving efficiency
throughout the supply chain.
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Logistics
• Logistics is the key to success in the coal mining industry.
Coal mining is a logistics based
business. Mining is the ‘easy’ part.
If you can’t move the coal to your
customers ship, you can’t sell it.
Identifying logistics options and
constraints should form a key part of
due diligence during concession
acquisition and development.
Logistics routes need to consider all permitting requirements, e.g. crossing
other concessions (mining, timber and agriculture), pinjam pakai, etc., and
land compensation.
When planning the logistics chain, a holistic approach is needed so that
capacities align. Design now for future expansion.
In Indonesia, minimise trucking distance and maximise barging distance.
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Logistics
Transportation
The majority of significant
coal deposits in coastal
regions of Indonesia are
either being exploited or
being developed.
This means companies are
forced to turn to coal
resources further inland. For example Wahau, Central Kalimantan and
South Sumatra.
As the coal mines move inland, the cost of transportation takes over
as the dominant cost, i.e. ahead of the mining costs.
We are seeing the same in Australia also: the above applies to the
planned development of the Surat and Galilee Basins.
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Efficiencies
Large efficiency gains can be achieved through capital
expenditure, yielding moves down the cost curve.
Smaller efficiency gains can be achieved through evaluating
and modifying existing processes:
Time and motion studies;
Fuel consumption;
Wasteful expenditure;
Theft and leakages;
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Efficiencies
Truck size and road quality impact hauling costs.
US$0.20/tonne/km> Operating costs <US$0.08/tonne/km
20 tonne 30 tonne 85 tonne 150 tonne
US$50,000/km > Capital expenditure >US$1,000,000/km
10% < Road Gradients < 4%
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Efficiencies
Transport methodology
US$0.20/tonne/km Operating costs US$0.02/tonne/km
- Capital expenditure +
+ Flexibility -
Coal trucking Overland conveyor Rail
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Efficiencies
Other bulk transport methodologies
Railveyor – Narrow gauge light
railway is construct upon which
coal-cars are propelled using
rollers that are stationary
alongside the track
Coal Slurry Pipeline – previously
used in US on commercial scale.
Large volumes of water required
Coal Log Pipeline – Large
experimental
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Efficiencies
Other ‘transport’ alternatives
Generally require the coal to be
modified from its original form:
Coal upgrading => reduces
moisture thereby improving the
energy content of coal transported
Coal bed methane => transports gas
instead of coal
Coal to oil conversion => transport oil instead of coal
Mine mouth power station => transport electricity, would benefit
from a national / international power grid
All require large capital expenditure and by implication, large coal
reserve
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Efficiencies
Barge Loading
US$10/tonne Cash Operating costs US$1.50/tonne
- Capital expenditure +
+ Flexibility -
Manual direct loading Simple Integrated (complex)
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Efficiencies
Barge Size & Capacity
US$0.05/tonne/km Operating costs US$0.01/tonne/km
- Capital expenditure +
+ Flexibility -
180’ 230’ 300’ 300’ self-propelled
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Efficiencies
New generation, purpose-built tugs and barges starting to appear
Self-propelled
Self discharging barges
Pusher tug / barge configurations
Barges designed with low-draft
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Efficiencies
Vessel Loading
+ Operating costs -
- Capital expenditure +
+ Flexibility -
Geared vessel Floating cranes Floating Terminal Shore based
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Efficiencies implemented by
PT Bayan Resources Tbk
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Mine Planning
One of the single largest cost drivers we
have is the waste haulage distance.
This is dependent on mining sequence and
in-pit and ex-pit OB dumping strategies.
Optimisation of pits and long-term
sequencing is essential to determine the
optimum hauling distance.
We have invested in Minex optimiser and
XPAC scheduling software and training.
We have reduced our group’s overall waste
haulage distance by approximately 500
metres since late 2012.
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Geotechnical review & slope monitoring
Slope stability analysis of
active and in-active pits
leading to steeper high-walls
in some cases.
Continuous slope monitoring
using Groundprobe SXRS
radar units (used at 4 sites).
Implementation has facilitated
coal mining from areas
otherwise deemed un-safe.
Return on investment
measured in months, not
years.
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Re-tendering Fuel Supply
Bayan group uses between 250-300
million litres per annum, expected to
increase in coming years.
Historically, Bayan and its contractors
purchased fuel independently and
from a number of sources.
In 2013, we conducted a tender to
amalgamate and award supply to one
company, hence improving our
purchasing power and reducing cost.
Stage I supply has already commenced using each sites existing
infrastructure and includes “Vendor Managed Inventory”.
Stage II will include construction of a fuel terminal adjacent to our
Balikpapan Coal Terminal, reducing costs further in years to come.
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Fuel Consumption Reduction Strategy
Engaged a consulting team to
assess and assist developing and
implementing a fuel management
control system at one of our
largest mine sites.
Joint taskforce formed with Bayan
and consulting personnel, full
time onsite.
9 month program included all our
contractors.
All aspects were targeted from mining, coal hauling, coal handling,
barging and infrastructure.
This initiative resulted in sustainable reductions and is now being rolled
out across other sites.
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Reduced Number of Employees
Reviewed all national and expatriate
staffing and re-aligned to current
requirements but with provision for
near future.
Selective relocation / transfer of staff
or retrenchment as a last option.
15 - 20% reduction of total employees
during 2013, with a further 5% in 2014.
Predominantly non-staff.
Not just about salaries and wages -
also has a flow on effect reducing
employee related overheads
(insurance, catering & camp costs,
travel expenses, office expenses etc.)
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Improved Barge Loading Efficiency
A review of barge loading cycle
times identified inefficiencies,
particularly excessive queuing
times.
Upgraded barge loader capacities
at most sites and installed
additional breasting dolphins
upstream.
Coal Transfer Station on the
Mahakam river to be replaced.
New high-speed, high capacity
transshipping facility ordered for
delivery in late 2014.
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Barging Efficiency Programme
Conducted a detailed barging
review of selected barging
routes.
The results suggest larger
barges than those we currently
use would be possible. Selected
trials have commenced.
Self-propelled barges identified
as optimal for certain barging
routes.
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Bulk Dozer Push
Implemented dozer push at 2
sites in 2013, and at a 3rd this
year.
Overburden removal cost per
BCM is approximately 50% of
traditional traditional truck
and excavator.
Will only replace a proportion
of production.
Limited to certain deposits /
seam geometry and mine
designs.
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Floating Transfer Stations / Terminals
KFT-2 commissioned in 2013,
designed specifically for our
Tabang / Pakar project.
Will be positioned off the
Mahakam delta reducing barging
cycle times.
Design incorporates belt metal
detectors, magnetic separators
and automatic samplers
ensuring quality control during
loading (traditional floating
cranes do not have this
capability).
Twin ship loaders (3,000 tph each) facilitate complete vessel loading
with minimal shifting.
Can load any vessel up to Capesize.
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Other strategies
Increase third party use of
our coal terminals.
Sheeting coal haul roads to
permit safe operations in all
weather conditions.
Cast / throw blasting.
Wash plant scoping studies.
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These strategies and improvements are
reflected in Bayan’s continued success.
However:
Our greatest challenge lies ahead…..
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……….Thank you
Sustaining the improvements
achieved to date as coal prices
improve and production rates
increase…..