Roberts and Schaefer Company

R o b e R t s
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s c h a e f e R Company profile
c o m p a n y
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p r o C e S S e S
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r e S o U r C e S
RO BERTS & SCHAEFER COMPAN Y
PRESENTATION OF GENERAL QUALIFICATIONS TO PERFORM PROFESSIONAL ENGINEERING AND CONSTRUCTION SERVICES

www.r- s.c om
Chicago 222 South Riverside Plaza Chicago, IL 60606-3986 TEL: 312-236-7292 FAX: 312-726-2872 Email: info@kbr.com
Pittsburgh 4412 Route 66 Apollo, Pennsylvania 15613 TEL: 801-984-0900 FAX: 801-984-0909 Email: info@kbr.com
Indonesia Sequis Center; 7th Floor JL Jenderal Duirman KAV 71 Jakarta, Indonesia 12190 TEL: +62 (0) 21-252-4177 FAX: +62 (0) 21-252-4138 Email: info@kbr.com
Poland ul. Bojkowska 37 Gliwice, Poland 44-100 TEL: +48-32-461-2722 FAX: +48-32-461-2720 Email: info@kbr.com
Salt Lake City 10150 South Centennial Parkway Sandy, Utah 84070 TEL: 801-984-0900 FAX: 801-984-0909 Email: info@kbr.com
Australia Level 11, 199 Grey Street, South Bank Qld 4101 Australia TEL: +617 3234 9555 FAX: +617 3234 9595 Email: info@kbr.com India 20, White House, C.G.Road Ahmedabad, India 380006 TEL: 079-40328000 FAX: 079-40328001 Email: info@kbr.com
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R E S O U R C E S
RO BERTS & SCHAEFER COMPAN Y
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
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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 & Schaefers full service includes the engineering disciplines of: Layout & Plant Design Engineering Mechanical & Piping Design Engineering Civil, Foundation and Structural Design Engineering Process Design Engineering P & ID Development With specialties in: Process Flowsheet Development Feasibility Studies and Project Evaluation Cost Analysis and Estimation
Project Lifecycle Study/Planning Engineering & Design 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 red electric utilities including fuel handling, limestone and gypsum handling for ue gas desulfurization. Petroleum Coke handling at reneries 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 beneciation
Construction Testing/Commissioning 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.
A FULL SERVICE INTRODUCTION 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 beneciation 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 signicant value proposition to both A&E rms and end customers, such as electric utilities, coal producers, and other mining companies.
For over 100 years, Roberts & Schaefer has engineered solutions to process and handle the worlds resourceswith a spirit of innovation, a dedication to quality and a skill for management.
INTRODUCTION
2 Section 01
OUR PROJECT EXPERTISE
In the projects experience section of this qualication manual you will nd 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 retrot projects FLUE GAS DESULFURIZATION (FGD) FGD is the technology used for removing sulfur dioxide from the exhaust ue gases in coal-red power plants. Environmental protection legislation mandates that utilities install FGD systems to curb their emissions prole 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 plants ue 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 Companys 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 renery, utilized as a fuel source, and its applications to the cement industry. This assures careful analysis, correct criteria and equipment selection, and efcient facility conguration 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, otation, 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 worlds 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 beneciation 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 ve operating ofces 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 specic 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 exibility that allows its total resources of engineering design, procurement and construction management services to be accessible for a specic 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 efcient and effective performance. This qualication 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 qualication manual fully describes our approach to projects. We continually reinvest in our people and technology to maintain the highest professional standards of capability, efciency 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.
Our reputation and nancial stability is exemplied 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.
INTRODUCTION
6 Section 01
A TEAM OF EXPERTISE
Roberts & Schaefer Company is comprised of nearly 250 highly qualied engineers, designers, draftsmen, project managers, construction managers and administrative personnel in our ve ofces. This section highlights the company leadership and provides the resumes for our technical staff. Presidents David CarterPresident, Global Resources Jeff RodabaughPresident, Power Division Brian PetersenPresident, Mining Division Senior Management Personnel (Power Division) Ravji PatelSenior Vice President Robert WilliamsVice President of Sales and Marketing Alan BontjesVice President of Project Management David FongVice President of Construction Management Ramesh AminVice President of Estimating David WaltersdorfVice President of Engineering Senior Management Personnel (Mining Division) Bruce HaleSenior Vice President of Business Development Daniel SchilatyVice President of Project Management Michael HarrisVice President of Estimating Rainer StephensonVice President of Engineering W. Albert NiedzinskiVice President & General Manager, Poland Steve McCoyGeneral 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 ve 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 lters 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 Colorados Comanche Station. The coal handling system is designed to receive coal from trains at the rapid 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 and stockout rate is 4,000 TPH. 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. 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. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression. Ancillary systems include sump pumps and service air.
The six plant silos are arranged in a single row and feed by a conveyor with a traveling tripper.

2 Section 02
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 ll system for the Oak Creek units. A second set of dual conveyors transfer the coal to the silo ll 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-red, 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 eld 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 -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-red 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 rst 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 ve silos in a single row. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression.
Both as-received and as-red 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 gasication 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 modications include new drive, pulleys, idlers, to increase capacity to 425 TPH. The modied 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 modications. 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. Ancillary systems include wet dust collection, wash down and vacuum cleaning piping for the new transfer tower, crusher tower, and connecting conveyors.
R&S has extensive experience in fuel switching to Powder River Basin coal and its distinct handling requirements.

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 y 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 xed 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 modied with new drives and increased belt speed for the increased capacity. The ancillary systems included re 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 COOPE RATIVE 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 ow gates to a variable speed reversible conveyor. The conveyor capacity is 4,000 TPH to the existing system and 1,200 TPH to the rst 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 ve silos in a single row with traveling tripper. The transfer house has provisions for feeding coal to future Unit 2. All areas of the coal handling system are provided with bag house dust collection with processed dust return or fog type dust suppression.
Truck coal can also be delivered to the power station and unloaded at a truck hopper with provisions for a second future truck hopper.

10 Section 02
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 uidized 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 re 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

Engineering, procurement, construction, start-up and commissioning of the coal 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-red sampling system, emergency reclaim hopper, belt scales and upgraded control system.

14 Section 02
TENNESSEE VALLEY AUTHORITY
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 modications 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. 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 modied 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 modied control system. Paradise Plant, Drakesboro, Kentucky

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 rst of the new conveyors provided by R&S, Conveyor CVY-11. Conveyor CVY-11 is a xed 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 modied 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 xed tripper conveyor CVY-18 located in the tripper bay of the new unit 4 generating building. Conveyor CVY-18 feeds the coal into the ve (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 2s 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 ow and reduced spillage.
DUCK CREEK POWER STATION, CANTON, ILLINOIS

Engineering, procurement, construction, start-up and commissioning of the coal 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 modied 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 modications included conveyor chutework and skirtboards, and conveyor/ building structural steel and foundations. The stacker-reclaimer boom conveyor was modied 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 rst 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. The coal is reclaimed from the two storage piles by two variable rate rotary plow 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. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression. Both as-received and as-red 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 rst lowering well or to the crusher tower. At the rst 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. The coal is reclaimed from the two storage piles by two variable rate rotary plow 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 ll, and Unit 2 silo ll. All areas of the coal handling system are provided with bag house dust collection or wet dust suppression.
There are provisions for a future emergency reclaim system with a drag feeder and a separate reclaim conveyor to the crusher tower.

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 retrotted with new idlers, belt plows, skirtboards, control devices, drives and motors, etc. Since the power station was in constant operation, the modications 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
TENNESSEE VALLEY AUTHORITY WIDOWS CREEK FOSSIL PLANT, STEVENSON, ALABAMA

Engineering, procurement, construction, start-up and commissioning of the coal 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 xed 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 nally 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 rst conveyor includes a modular sampling system. The new pedestal mounted circular stacker boom is cable supported with lufng 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 ow 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.
R&S has signicant international project experience and is an expert in specialty material handling equipment.

26 Section 02
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 oating 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 tted 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 tted 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 tted with ve 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. The reversible shuttle belt conveyor system feeding the power block provide exibility 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.
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.

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 ne reclaim hopper. The coarse gob is reclaimed on a 48" variable speed belt feeder. The ne gob is reclaimed by a special designed variable speed rotary plow feeder, integral with the nes hopper. Both the coarse and the ne material are collected on a 36" reclaim tripper belt. This belt terminates in a 6,000 ton capacity storage barn. The belt is tted 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 tted 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 lling. 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 exible belt wall. This unique conveyor is a special design and is tted 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 tted 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 tted 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 owners harbor loadout conveyor. This conveyor discharges atop one of two concrete lowering walls provided by Roberts & Schaefer. The material delivered from the owners 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 tted with a variable speed trip feeder for reclaiming at a rate of 1 to 270 TPH. The reclaim feeder is tted 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 lls the owners four coal silos. A complete control and instrumentation package is included complete with interface to Owners control system. A complete "as red" 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 modied 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 re 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 red 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 tted 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 tted 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 rst 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 lters, 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.
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.

32 Section 02
AMERICAN ELECTRIC POWER 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 33
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/retrot 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 Each of these units is complete with abrasion resistant steel lined loading skirts with adjustable seal rubber.
Above: Kansas City Power and Light, Specialized Belt Feeders, La Cygne, Missouri
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

34 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 ll conveyor system was upgraded to 300 TPH with increased belt speeds, new drives, and conveyor components as required. A new silo ll 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 lter dust collectors were furnished for the silo ll 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 oor 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 modied transfer tower. The conveyor from the transfer tower to the radial stacker and the radial stacker boom conveyor were modied 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 modied too for the new conveyor to the transfer tower. Progress Energy Carolinas, Roxboro Power Station, Roxboro, North Carolina

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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 nally 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.
Top: CS Energy, Kogan Creek Power Station, Surat Basin, Australia Below: Hopewell Pagbilao, Conveyor System, Quezon Province, Philippines

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CENTRAL GENERADORA ELECTRICA, SAN JOSE POWER STATION, GUATEMALA CITY, GUATEMALA
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 lling 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 lling 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 ll the silos.
PT FREEPORT, IRIAN JAYA, INDONESIA

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.
Above: Central Generadora Electrica, San Jose Power Station, Guatemala City, Guatemala
Left: PT Freeport, Irian Jaya, Indonesia

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SOUTHERN ELECTRIC INTERNATIONAL, BIRCHWOOD PROJECT, KING GEORGE COUNTY, VIRGINIA

Design, engineering and procurement of a coal handling system for Southern Electric Internationals 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 plants 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 nal 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 eld 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 modications 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 nal report followed, addressing those preliminary recommendations selected by Northern States, providing conceptual drawings and capital cost estimates.

38 Section 02
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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 tted 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 tted with reclaim screw feeders which deliver on demand coal and sorbent to a uid bed combustor. High temperature bed ash (600F) and y ash (380F) 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 ight type water cooled screw conveyors for ash temperature control prior to storage and loadout. Telescoping loadout chutes deliver bedash and yash 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&Ls 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, retted 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.

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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 rst phase of the project initiated with a detailed inspection and evaluation of the facility. This phase provided a written report recommending resolution of the identied 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 eld 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 modications to existing conveyors to increase their capacity from 900 TPH to 1,200 TPH.
Top & Above: PaciCorp, Dave Johnston Power Station, Glenrock, Wyoming

40 Section 02
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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 TPHa 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 pileshortening 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 Stations Coal Gasication Repowering Project. The system takes the coal from the existing conveyors at the crushing house and transports it to the new coal gasication plant. The coal gasication plant transforms the solid coal into gas allowing PSI to use it in a boiler that was originally designed for gas. The coal gasication 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, re 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

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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 nished 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 ll the four coal silos. The new system also included dust suppression, dust collections and new as-red coal sampling systems.

42 Section 02
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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 lufng 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, modied 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. Ancillary systems include dust collection, vacuum cleaning, re protection and washdown collection pumping.
Associated Electric Co., High Capacity Stacker, New Madrid, Missouri
Fuel switch to Powder River Basin coal.

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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: Rack & pinion type regulating gate Head pulley alignment device Dual belt wiper Belt plow

44 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 red cogeneration power plant. Work included the design of a truck dump to receive 27-ton capacity, highway trucks with tandem trailers. The dump is tted 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 ll 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 tted 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 ll 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 op 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 tted 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.

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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: Rack & pinion type regulating gate Head pulley alignment device Dual belt wiper Belt plow Skirtboard
KANSAS CITY POWER & LIGHT COMPANY, LACYGNE, KANSAS

Engineering, procurement and construction for fuel yard modications.
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.

46 Section 02
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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 gasication. Roberts & Schaefer was commissioned to build a facility to reclaim anthracite culm from the existing indigenous banks to beneciate the material to specic thermal quality and size characteristics. Scope of supply started with a hillside truck dump tted 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 beneciation. A water clarication 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 gasication process. This project offered many design challenges, since it was the rst 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, BEASLEYS POINT, NEW JERSEY

Engineering, procurement and construction for coal yard addition and up-grade.

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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 modied 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 operators cab is provided on-board the shiploader with a radio control unit that permits remote operation.
Top: TVA Gallatin Middle: Danskammer Generating Station Bottom: Batu Hijau Mining Project

48 Section 02
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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

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ASSOCIATED ELECTRIC COOPERATIVE, INC. (REA PROJECT) NEW MADRID PLANT, NEW MADRID, MISSOURI
Engineering, design and material procurement for a coal handling modication 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 LLCs renery 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 renery improves the yield of the higher value gasoline and diesel products; as a result most new reners include a coker in their design and many existing reneries 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 renery and at the end use location.
Our experience in designing and building these systems, assures that we will nd 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 renery 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 nal 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 Rening and Marketing Company (Tesoro) has implemented major modications to their coking facility at the Golden Eagle Renery 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 specication 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
PETRLEOS 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 Renery 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 lufng 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. Lufng 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 operators 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 rst 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 operators 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 Renery 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 ve (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 Rening 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 Renery (MIDOR) for a pet coke stockpiling and truck loading facility at the MIDOR renery 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 ll 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 Renery (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 Renery. The scope includes engineering, material procurement, shipment and eld 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.
ALTERNATIVE FUEL HANDLING EXPERIENCE PETROLEUM COKE HANDLING 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 ne reclaim hopper. The coarse gob is reclaimed on a 48" variable speed belt feeder. The ne gob is reclaimed by a special designed variable speed rotary plow feeder, integral with the nes hopper. Both the coarse and the ne material are collected on a 36" reclaim tripper belt. This belt terminates in a 6,000 ton capacity storage barn. The belt is tted 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 tted 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 lling. A control system is provided, which interfaces with the owner-supplied distributed control system. The project was completed in approximately 12 months.
We can provide you with complete stockpiling, reclaiming, blending, unloading and loading facilities. Whether its 50 TPH or 10,000 TPH of gob, wood chips, or biomass, we can design the system to handle it.
ALTERNATIVE FUEL HANDLING EXPERIENCE

10 Section 03
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 gasication. R&S was commissioned to build a facility to reclaim anthracite culm from the existing indigenous banks to beneciate the material to specic thermal quality and size characteristics. Scope of supply started with a hillside truck dump tted with protective grizzly and reclaim vibratory feeder. 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 beneciation. A water clarication 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 gasication process. The quality characteristic of the culm being extremely abrasive required unusual wear resistant materials.
This project offered many design challenges, since it was the rst plant built for reprocessing anthracite culm. The entire project was completed in 14 months.

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 red 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.

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 ume 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 ume 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. Lihue Plantation Company, Ltd., Lihue Kauai, Hawaii

14 Section 03
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 lters 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. The limestone and gypsum handling systems share several transfer towers.
R&S performed installation of the coal handling systems at the Brandon Shores Power Plant during its original construction in 1981.
LIMESTONE & GYPSUM (FGD) HANDLING EXPERIENCE

Section 04 1
AMERICAN ELECTRIC POWER 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. The gypsum handling system is designed to receive gypsum from the process lters 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.
R&S has unmatched experience in the loading and unloading of river barges and designing the marine infrastructure to support it.

2 Section 04
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 certiable 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. The gypsum handling system is designed to receive gypsum from the process lters 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 certiable 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. The gypsum handling system is designed to receive gypsum from the process lters 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. 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 ve 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. Ancillary systems for the coal, limestone, and gypsum include service water.

4 Section 04
DO MINION VIRGINIA POWER CHESTERFIELD POWER STATION, CHESTER, VIRGINIA

Engineering, procurement, construction, start-up and commissioning 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. The gypsum handling system is designed to receive gypsum from the process lters 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

Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems. 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. The gypsum handling system is designed to receive gypsum from the process lters 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
Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems. The limestone handling system is designed to receive limestone from barges 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. The gypsum handling system is designed to receive gypsum from the process lters 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

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 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 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 bottom and y 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

Engineering, procurement, construction, start-up and commissioning of the 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 lters 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

Engineering, procurement, construction, start-up and commissioning 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 lters and transfers the product onto Gypsum xed stockout conveyor GH-2B in Transfer Tower 1B. Conveyor GH-2B is a xed 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. The gypsum facility accepts gypsum from the dewatering buildings 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.
Above: Miami Fort Station, North Bend, Ohio Below: Gibson Generating Station, Owensville, Indiana

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 ll covered barges through open hatches, which requires that the chute/spout be able to move laterally and extend and retract. A certied 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
AMERICAN ELECTRIC POWER
CARDINAL PLANT, BRILLIANT, OHIO

Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; the contract was awarded 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 lters 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 lters 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 ue 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 rst 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 owners 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 lls 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
TENNESSEE VALLEY AUTHORITY PARADISE FOSSIL PLANT, PARADISE, KENTUCKY

Engineering, procurement, construction, start-up and commissioning of the 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 TVAs 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 lters 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 nal 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 tted 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 tted 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 tted 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 owners supplied DCS system.

22 Section 04
SOUTHERN INDIANA GAS & ELECTRIC 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 oating barge. The barge is tted 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 oating 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 re protection system is provided on a belt on the oating dock at the loading/transfer station. A bifurcated chute and op 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 owners 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 tted with an especially designed feeder break unit which regulates the feed while minimizing oversize material. 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. A fth 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.

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 ights 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 xtures, 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 nes circuit of the Main Plant to achieve a whole plant average of 1,350 TPH. The nes 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 efciency. 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 nes plant: All major nes circuit pump capacities including claried water; Jameson Cell capacity Clean coal and desliming cyclone capacities; Spiral product dewatering capacity; All major nes circuit pipeline sizes. Modication 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 nes 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 ne 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
The main plant consists of 3 separate coarse coal processing circuits, separate and common ne coal and reject processing circuits and common water treatment and reticulation circuits.

2 Section 05
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 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 signicant 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 signicant 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 rst 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 uidized 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.
All areas of the coal handling system are provided with bag house dust collectors.

6 Section 05
PT KALTIM PRIMA COAL (KPC) KALTIM PRIMA COAL FACILITY, SANGATTA, EAST KALIMANTAN, INDONESIA
Engineering, procurement, construction, start-up and commissioning of the 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 ve 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. 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 re detection and protection, wash down hose stations, and tunnel ventilation.
A tramp iron magnet and a metal detector are included on the sizer station feed conveyor.

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 ORourke) was awarded the Engineering, Procurement, and Construction (EPC) contract by BMA for the coal handing and coal preparation for the Blackwater Mine in Australias 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 nes 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.
This is now one ne of the largest coal handling/prep plants in the area with a fully automated train load out system (TLO).

8 Section 05
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 nanced 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 ne 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 ofce. 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
This is a green-eld ne coal preparation facility processing 19mm-0mm raw coal from existing coarse coal preparation plant.

10 Section 05
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 CFBs. 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 efciently re-deposit the nal 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 nes circuit. The Tank Cell acts as a rougher to reduce the load on the existing conventional otation circuit. Filtration capacity was increased by the addition of a 3rd Drum Filter. The crushing and sizing circuit was modied by the installation of a Primary and Secondary sizer and new Coal Screen. The project also included extensive modication to the feed conveyor to both align with the new ROM sizing module and increase capacity.
The installation for this browneld 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 Australias 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) Spiral circuit (0.5mm x 0.125mm) Spiral circuit (0.5mm x 0.125mm) 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). Coal from the product coal storage stockpile is delivered to a rail loadout station.
The facility also includes a Bypass System to deliver product to Macquire Generation for domestic power consumption.

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 Minings Elkol Tipple near Kemmerer, Wyoming. Design throughput is 750 TPH. Major components of the work included the following, listed in ow 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 op gate Transfer conveyor to truck loadout silos Modication 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 oating 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, Ofce, 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 rst stage involved upgrading one of the two DMC circuits to include a new wing tank, 1100mm DMC, and large gravel pumps and modied 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 eld upgrades allowing minimal production downtime for construction installation.
The projects were completed in 2004 and 2005, respectively.

16 Section 05
POLUDNIOWY KONCERN ENERGETYCZNY (PKE) SOBIESKI MINE, JAWORZNO, POLAND

Engineering, procurement for upgrades to the coarse coal and ne 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 ne slurry circuit pumping system and dewatering equipment. The power plant storage yard was also redesigned with a new stockpile conguration 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 efciency and exibility. Elgins Equipment Group supplied CMI ne coal dewatering centrifuges for the plant and provides maintenance services for that equipment.
In 2007 and 2008 additional modications engineered by R&S were carried out at the Sobieski facility, dealing with refuse handling and plant automation.

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 otation circuit, introduction of high speed ne coal dryers and associated equipment vibratory screens, belt scales, PLC controls, occulation system, pumps and process piping. New equipment required partial demolition of the reinforced concrete building oors, 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 modications to the Halemba Mine existing coal washery in the coarse coal and ne coal circuits. The project required engineering the construction workow 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 modication to the KWK Murcki coal mine existing coal washery in the coarse coal and ne coal circuits, as well as closing the water slurry circuit due to environmental concerns. The project required engineering the construction work ow 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 tted with passive dust control systems. Drag chain type feeders are tted 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) modications 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.
The near pit crushing and conveying project received the outstanding project of the year award, presented by the Wyoming Engineering Society.

20 Section 05
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 ne 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 ne 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-ight 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. Overow 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 classied at approximately 65 mesh with the overow reporting to a spiral circuit and the underow reporting to single stage froth otation. 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 clarication 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 re 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 in approximately 13 months.

22 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 classied at 100 mesh with the underow reporting to conventional spiral circuit. The -100 mesh reports to the water clarication 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 modications to the existing screening facilities. Also included was a complete control system incorporating both the existing and new facilities. The existing water clarication 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.
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.

24 Section 05
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 ow 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 overow from the superscalping circuit is screened in high refuse capacity double deck Deister tables. The 28 mesh x raw coal is classied at approximately 100 mesh; the classifying cyclone underow reports to a spiral circuit. The cyclone overow is delivered to the water clarication 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-ow circuit clean coal screens. The primary rejects from the low-ow 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 exibility 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 oor 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 overow classied at 100 mesh. Froth otation 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 lters. 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.
Roberts & Schaefer completed the facility so that it was operating at full capacity in 11 months from date of award.

26 Section 05
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 eld 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 efcient 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. Project involved the installation of high efciency 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 oating concrete mat, due to poor soil conditions and subsidence. Modernized plant started production on budget and ahead of schedule. Above: Lubelski Wegiel S.A., Bogdanka Mine, Poland Below: Katowice Coal Holding S.A., Staszic Mine, Poland

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 modication 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 oating 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 eld 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 otation circuit (0.5 mm x 0mm) Spiral circuit retreat for otation tails Belt lter dewatering Coking and Thermal Products Above: Integra Coal/Vale, Glennies Creek Colliery, Hunters Creek, Australia Below: Westfarmers, Curragh Mine, Bowen Basin, Australia

28 Section 05
MORE EXPERIENCE
BOWIE RESOURCES, NO. 2 MINE EXPANSION, PAONIA, COLORADO

Engineering, procurement, and construction for the mine expansion. The Bowie No. 2 Mine, located high on a mountain side, was operating in a very conned 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 ve (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
Complete project management, detailed engineering, procurement and construction management services are being provided for the addition of coal surge silos and modications 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 modication 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 tted with variable speed reclaim belt feeders to transfer the coal back onto modied 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 nal 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 tted 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 Corporations 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

Complete project management, detailed engineering, procurement and construction services were provided under a turnkey lump sum contract for The Carter Mining Companys 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 tted 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 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.
The Carter Mining Company, Gillette, Wyoming

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 nal 2"x 0 product, sampled and conveyed to two 12,000-ton storage silos, each congured to ood 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 rst major, high capacity coal facility constructed in the Power River Basin of Wyoming.
LAUREL RUN MINING COMPANY, MT. STORM, WEST VIRGINIA

Complete project management, detailed engineering, procurement and 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. Laurel Run Mining Company, Mt. Storm, West Virginia

34 Section 05
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, tted 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, tted 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 BTUs in the dust collector exhaust. This efciently 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

Complete project management, detailed engineering, procurement and 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

Complete project management, detailed engineering, procurement and 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

Complete project management, detailed engineering, procurement and 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

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 rst 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 ll areas.
ARCO Coal Company, Beaver Creek Mine, Price, Utah

Section 05 37
MORE EXPERIENCE
KERR-MCGEE COAL CORPORATION, GILLETTE, WYOMING

Complete project management, detailed engineering, procurement and 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 ood-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 ow.
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 Companys initial participation involved preparation of the general arrangement layouts of the total facility. This established the most economical plant conguration to t the existing terrain and also tie into the existing facilities. The 400 TPH preparation plant layout was based on a owsheet 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 owsheets and detailed process piping, and utility piping. Response to the project schedule required the utmost in coordination and control. Kerr-McGee Coal Corporation, Gillette, Wyoming

38 Section 05
MORE EXPERIENCE
BETHLEHEM MINES CORPORATION, EBENSBURG, PENNSYLVANIA

Complete project management, detailed engineering, procurement and 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

Complete project management, detailed engineering, procurement and construction were provided under a turnkey contract for a coal crushing and storage facility at the Public Service Company of New Mexicos 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, re 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&Ms existing Elkol tipple near Kemmerer, Wyoming. Under severe physical and operating conditions the load-out tipple was modied to add ASTM sampling system to the station, and a certied belt scale. The addition was accomplished through major modications to the existing chute work, adding two belt conveyors and extensive changes to the structure. The nal system allows P&M to meet their customers requirements of weight and quality verication.
CARBON COAL COMPANY, GALLUP, NEW MEXICO

Complete project management, detailed engineering, procurement and construction 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 tted with a manual operated loading system rated at 3,000 TPH. Ancillary facilities included a water supply and distribution system, a re protection system and truck service facilities with change and warehouse area.
Carbon Coal Company, Gallup, New Mexico

40 Section 05
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 ve 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 Archs 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 systems 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 Engineers 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 ve 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 t around the existing one. The project scope included upgrading conveyors, modifying screens, installing new sieve bends, cyclones, centrifuges, sumps, pumps, spirals and otation cells. Also included process, air, oor 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

Complete project management, detailed engineering, procurement and construction 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 certied 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 sufcient 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 ne 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 ne 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 ne 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 clarication 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 otation cleaning facility with extensive rough terrain conveying systems.
PEABODY COAL COMPANY, MORGANFIELD, KENTUCKY

Engineering, procurement and construction of a 2,000 TPH heavy medium 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

Engineering, procurement and construction of a 1,000 TPH heavy medium 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

Engineering, procurement and construction of a 1,000 TPH heavy medium vessel, heavy medium cyclone and froth otation preparation plant and coal handling facility.
INLAND STEEL COMPANY, MCLEANSBORO, ILLINOIS

Engineering, procurement and construction of a 1,320 TPH heavy medium/froth otation, 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 EXPERIENCEINTERNATIONAL
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 clarication and slurry ltering.
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
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 otation plant with complete coal handling including thermal drying.
DENISON MINES, LTD., QUINTETTE P LANT, TUMBLER RIDGE, BRITISH COLUMBIA, CANADA
DENISON MINES, LTD., QUINTETTE P LANT, TUMBLER RIDGE, BRITISH COLUMBIA, CANADA
Turnkey, engineering, procurement and construction of a 468 TPH coal thermal 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 16 TPH Water Evaporation Rate Turnkey engineering, procurement and construction
PEABODY COAL COMPANY, HAWTHORN MINE, SANDBORN, INDIANA

246 TPH Coal Thermal Dryer Size #7.5 18 TPH water Evaporation Rate Turnkey engineering, procurement and construction
BETH ENERGY MINES, CAMBRIA MINE 133, EBENSBURG,PENNSYLVANIA

Two 800 TPH Coal Thermal Dryers Size #12.5 53 TPH Water Evaporation Rate Turnkey engineering, procurement and construction
JIM WALTER RESOURCES, #4 MINE, BROOKWOOD, ALABAMA

600 TPH Coal Thermal Dryer Size # 12.5 40 TPH Water Evaporation Rate Turnkey engineering, procurement and construction

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

DENISON MINES, LTD., QUINTETTE P LANT, BRITISH COLUMBIA, CANADA

468 TPH Thermal Coal Dryer Size #12.5 38 TPH Water Evaporation Rate Turnkey engineering, procurement and construction
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 27 TPH Water Evaporation Rate Turnkey engineering, procurement and construction

Section 05 53
CARDINAL RIVER COALS, LTD., DIVISION OF LUSCAR CONSOLIDATION COAL CO., CARDINAL RIVER PLANT, LUSCAR ALBERTA, CANADA
250 TPH Coal Thermal Dryer Size #7.5 16 TPH water evaporation rate Turnkey engineering, procurement and construction
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 33 TPH Water Evaporation Rate Turnkey engineering, procurement and construction
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 rst 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 rst 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. 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.
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.
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 Goldelds 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 rening. The facility modules were designed to t in shipping containers for delivery to the site with minimal eld 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 eld 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 signicant 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 rst 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 specically focused on the mining and metallurgical aspects of the project. The R&S scope of work included: Development of the process ow sheets Development of the process ow 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 specications Identication of critical path and lead times for major equipment procurement Capital cost estimate Operating cost estimate Engineering design was completed in sufcient 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, otation, thickening, cyanidation, and gold recovery facilities. Process plant support facilities Cyanide recovery and destruction Truck shop, warehouse, lab, powder magazine, and Admin & Engineering ofces Fuel/lube supply, storage and facilities Water supply, storage and distribution facilities Electrical supply and distribution Waste water treatment
The study was completed within the clients required time frame and within budget.
METALS EXPERIENCE
4 Section 06
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 Newmonts 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 Golds 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

Engineering, procurement and construction management services were provided for the addition of three ash chlorination vessels and associated platforms and equipment at Newmont Golds No. 1 Mill. The ash 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

Engineering, procurement and construction management services were provided for modication to the cyclone overow trash screens at Newmont Golds Gold Quarry Mill. The project required conceptual layout and nal 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 Companys Gold Quarry Mine near Carlin, Nevada. The nal 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, tted 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 ne 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 underow returns to the ball mill for further grinding, and cyclone overow is processed in gravity concentrators and in a ash otation cell. Gravity concentrate, containing relatively clean gold, is rened into dor bars on site. Gravity tailings feed the ash otation cell and otation tailings feed a high density tailings thickener. Tailings thickener underow is pumped to a tailings disposal area and thickener overow 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 uxes 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 modications Reactor modication 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 ne tuning they were able to increase the slurry feed which required additional process equipment to convert to nal product. In order to properly dry the scrap material R&S designed a feed conveyor to a dryer vessel modied 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 ow required a third crystallizer which was tied into crystallizers 1 and 2. A lter Feed Tank, Belt Filter, concentrate tank, agitator, centrifuge, and product silo were added to nalize 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 otation 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 ne 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 otation, a cyanide leach circuit, static thickeners and drum and disk vacuum lters. The leachate was claried in a pressure leaf lter 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 ow sheets, P&ID and equipment specications 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 efcient 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 owsheet 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 specication for reactor, converter and fugitive gas collection and control at the Kennecott Gareld 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 specication and construction specication for the repair and gas ow improvement to four copper converter gas ues. 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 owsheets, 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 ow, 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 renery 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 eld installation. Field duties consist of supervision in erecting, testing and commissioning the facility.
Teberebie Goldelds, 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 Minings 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: dened capital cost operating cost engineering construction, schedule, nalizing 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 nal 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 ve interested nancial institutions in London. In additional to completing the nal 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 otation 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 overow is directed to a otation circuit, reporting to rougher cells and two stages of cleaners. Thickened concentrates are dewatered for shipment. Thickened rougher otation 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 ofces, changehouse, laboratory, warehouse and shop area, parking and fencing. All electrical power and control design was provided, including nalizing of process ow sheets, P&IDs, specication, 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 ow 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 eld assembly. The skids included carbon adsorption, atmospheric strip, acid washing, thermal carbon regeneration, electrowinning, melting and associated accessories. Electrowinning and melting were housed in modied shipping containers. All skids were set in the eld 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 eld 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 tted 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 nal 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 Energys 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 ve 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 companys 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 rened 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, re 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 ux 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 uxes 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 modications 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&IDs 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.
BETHLEHEM STEEL CORPORATION, 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 beneciation 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 nes 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 nes 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.
DIRECT EXPERIENCE METALS REDUCED IRON & BRIQUETTED IRON HANDLING

Section 06 21
CYPRUS NORTH SHORE MINING HEARTH LAYER PLANT, SILVER BAY P ROCESSING 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 rst green pellet elevating conveyor. The rst 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 tted 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 eld 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 nes (-6.35 mm) are conveyed to two ore/pellets nes 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 nes to the reactor reduction system and briquetter machines. The briquettes are then conveyed along product cooling conveyors to two screens. The screened HBI nes are then transported by conveyor to an HBI nes 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.
DIRECT EXPERIENCE METALS REDUCED 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. Modication 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 modications 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 clarier. The following describes the engineering deliverables for the project: Site Investigation General Arrangement Drawings Piping Routing Drawings Electrical Modications and Design Control System Design Structural Drawings Concrete Design Cost Estimates Project substantial completion is expected in the rst 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 rst 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, oatation columns, thickeners and instrumentation. Upon successfully delivering the rst job, R&S was sole sourced to recongure the extraction process equipment, design and deliver 3 froth treatment skids for SGSs 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.
INDUSTRIAL NON-METAL MINERALS EXPERIENCE METALS 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 t prior to shipment to the nal 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 nal processing site on a concrete containment slab. Field work included structural assembly, interconnecting piping, and making nal 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 sufcient enough to develop the funding CAR. Once funding was approved, the work included developing nal 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 modications 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&IDs, Electrical One Lines and MCCs. Specication 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.

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, ow 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 modications 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 nes 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 ORourke, 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 nishing at existing crushing station and stockpile.

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 rene the new recovery process for commercialization. To date the design engineering has been completed and the construction of the modules is awaiting the owners 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 hydrouoric 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 uoride and a solid waste containing uorides and residual hydrouoric 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 hydrouoric 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 uoride instead of hydrouoric 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 Beneciation 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 otation. This will produce four sizes of phosphate concentrate for direct application as fertilizer, or the production of phosphoric acid. Also included in the beneciation 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 ne 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 & Schaefers Process Control and Automation Group using open distributed control system technology. In addition to the beneciation plant, the project includes complete site development, distribution of utilities, storage of reagents, warehouse, shop and maintenance facilities, ofces, parking and roads, reservoirs for plant water and drainage and all site drainage. Industrial mineral facilities generally require one or more of the major steps in mineral processing, that is: size reduction, liberation, concentration, beneciation and rening.
Roberts & Schaefer has provided a variety of facilities with sound basic engineering expertise to meet overall objectives.

Section 06 31
MORE EXPERIENCE J.R. SIMPLOT COMPANY, PLANT RETROFIT, VERNAL, UTAH

Mineral: Phosphate Engineering Only for a retrot of a nearly fty-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 Denition services, Process Criteria documents, process ow diagrams, calculations, and both preliminary and detailed engineering drawings to allow the customer to replace the existing eight otation 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 sufcient to allow the customer to proceed with equipment procurement and construction.
The project was completed on schedule and under budget largely due to Roberts & Schaefers use of rigorous earned value project control techniques (metrics).

32 Section 06
MORE EXPERIENCE
ASARCO, INC., OMAHA, NEBRASKA

Mineral: Antimony Oxide The design engineering and equipment specications for an oxide fuming plant to produce antimony oxide as a by-product in the rening of lead. The work included designs for the collection of high temperature dust and fumes, the conveying of ne 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 specications 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 red 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 ne 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

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 fth 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, (red 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 conned 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 red. Work included site visits to determine the best way to install the new equipment, eld 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 otation 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 red rotary dryer, size classication with screens, dust collection with cyclones, bagging and product storage. Ancillary facilities included a shop-ofce-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.

Section 06 35
DO LNOSLASKIE SUROWCE SKAL NE (DSS) PILAWA QUARRY PROCESSING PLANT, PILAWA, POLAND
Engineering and procurement for a 1,000 MTPH capacity, green-eld 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 efcient 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 efcient 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 Underow 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 lter dewaterizer PH balance system Slurry sump/pumps 17' dia. conical thickener (2) 7TPH Belt lter 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
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 .
2 Section 07
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 Rocks Logan Quarry. The project consists of dry screening, tertiary crushing, wet screening, sand classication, 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 ll specication products. Material entering the plant is screened into ne 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 underow is classied to produce specication 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 specication 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 lled 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 eld 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 ne 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 benets 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 prole is given. Plant reports are generated and historical trends are plotted on demand. Scope items worthy of note include: System architecture design Specication 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-t 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 specication products, concrete sand, base rock and asphalt rock. Washed and rinsed aggregate products reclaimed from storage are automatically weighed and loaded into customer trucks. Signicant 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 nal 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.
CEMENT EXPERIENCE AG GREGATE 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 specically 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 nal product is transferred to the existing overland conveyor via a transfer station. The transfer station includes an emergency op gate to direct material to the ground in case there is a disruption on the overland conveyor.

Section 07 11
ASHGROVE CEMENT COMPANY CEMENT PROCESSING FACILITY, MOAPA, NEVADA

Engineering, Costing and Specications with Cement Performance International (CPI) for the preliminary engineering, facility general arrangements, EPC schedule, mechanical and construction specications, 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, nish 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 nal 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 Specications. 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 specications 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/modied 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.

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 conguration 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 Plants 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. 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 nished products to separate storage stations. All materials are reclaimed from storage, reporting to each production plant.
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.

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 lter 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 ve 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 classier 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 ne storage tank for the processed 1/4" x 0 nes. The material was reclaimed by use of a xed rate screw feeder ahead of an elevator rated at 25 TPH. Material was then transported by two 14" diameter screw conveyors to a 24" nes transfer belt. This belt also received 1/4" x 0 material from the existing facilities. The 24" nes 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. 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 nal 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.
This system is electrically interlocked and controlled from the existing plant control system. This installation was completed in approximately 13 months.
LIMESTONE EXPERIENCE AG GREGATE HANDLING EXPERIENCE

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 specications 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 nalize the owsheet for the project, and prepare preliminary site plans and general arrangement drawings in sufcient 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 modications 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 owsheet for the project. Develop of the nal 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 specications for borings, testing requirements, and required recommendations Capital Cost Estimate Final Report

Section 07 21
MARBLEHEAD LIME CO. BUFFINGTON PLANT, BUFFINGTON, INDIANA

Engineering, procurement and construction of rotary kiln installation at the existing Bufngton Plant. The existing facility at Bufngton, 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 providedeach 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, re protection and heat tracing. The processed material is collected on the existing product conveying system, modied to handle the increased capacity. In addition to the kiln installation, modications were done in the existing facility including the addition of a 24" reversible nes belt, a nes recycling system consisting of bucket elevators, screw conveyors and transfer belt conveyors for recycling of kiln or process nes. 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.
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.

22 Section 07
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

Kiln renovation.
Roberts & Schaefers broad engineering capabilities give it the distinct advantage of being more responsive to customers.
MARBLEHEAD LIME, CHICAGO, ILLINOIS

Engineering services and bid preparation for a two-kiln line plant.
JONES & LAUGHLIN CORPORATION, HARPERS FERRY, VIRGINIA

Limestone cleaning and crushing plant; engineering, procurement and construction.

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 ne 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 Roong 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 roong tile manufacturing plants. Three new conveyors and the extension or modication of two existing conveyor were required.
Roberts & Schaefer Companys commitment to the sand industry includes complete engineering design and construction services for handling and processing of sand.
SAND HANDLING EXPERIENCE AG GREGATE 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.
PENNSYLVANIA GLASS & SAND CORPORATION PACIFIC, MISSOURI

Engineering layouts and estimate for slurry pumping system.
AMERICAN STEEL FOUNDRIES ALLIANCE, OHIO

Engineering layout and designfoundry sand reclamationwashing, drying and cooling.
SILICA PRODUCTS COMPANY GUION, ARKANSAS

Engineering and estimate studysand screening, storing and handling.
Engineering layoutsboiler house bottom ash removal.
PENNSYLVANIA GLASS & SAND CORPORATION MAPLETON DEPOT, PENNSYLVANIA

Engineering layoutsdust collection at micron bagging station.
PENNSYLVANIA GLASS & SAND CORPORATION MILL CREEK, OKLAHOMA

Engineering layouts and design for two mill silica our grinding system including bulk storage, rail and truck loading.
SAND HANDLING EXPERIENCE

26 Section 07
MORE EXPERIENCE
Engineering layouts and sand loadout systemfurnished structural, mechanical and fabricated items.
PENNSYLVANIA GLASS & SAND CORPORATION MAPLETON DEPOT, PENNSYLVANIA ENGINEERING

Engineering layoutsdust 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 reclamationwashing, drying, cooling, chrome and sand extraction and water clarication.
SAND HANDLING EXPERIENCE AG GREGATE EXPERIENCE

Section 07 27
MORE EXPERIENCE
COLORADO LEIN LAPORTE, COLORADO

30 TPH Sand Dryer
WILLIAM R. BARNES COMPANY WATERTOWN, ONTARIO, CANADA

10 TPH Sand Heater-Cooler
COLUMBIANA FOUNDRY COLUMBIANA, OHIO

10 TPH Sand Dryer-Cooler
MILLWOOD SAND COMPANY MILLWOOD, OHIO

65 TPH Sand Dryer
KINGS MOUNTAIN MICA COMPANY KINGS MOUNTAIN, NORTH CAROLINA

20 TPH Dryer
FLORIDA ROCK INDUSTRIES INTERLACHEN, FLORIDA

55 TPH Sand Dryer
NOVA SCOTIA SAND & GRAVEL SHUBENACADIE, NOVA SCOTIA

PRODUVISA SERVICIDOS, S.A. GARACAS, VENEZUELA

45 TPH Sand Dryer
CAROLINA SILICA, INC. MARSTON, NORTH CAROLINA

90 TPH Sand Dryer
OTTAWA SILICA OTTAWA, ILLINOIS

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
CAROLINA SILICA, INC. MARSTON, NORTH CAROLINA

60 TPH Sand Dryer
LYMAN-RICHEY SAND & GRAVEL COMPANY VALLEY, NEBRASKA

SOBIN CHEMICAL COMPANY (DIV. IMC) SPRUCE PINE, NORTH CAROLINA

6 TPH Sand Dryer

30 MTPH Sand Dryer-Cooler
WEDRON SILICA COMPANY BYRON, CALIFORNIA

60 TPH Sand Dryer

HARDY SAND TUSCALOOSA, ALABAMA

65 TPH Sand Dryer and Separate 65 TPH Sand Cooler
WEDRON SILICA COMPANY EMMETT, IDAHO

60 TPH Sand Dryer
WEDRON SILICA COMPANY LUGOFF, SOUTH CAROLINA

60 TPG Sand Dryer
FLUID BED SAND DRYERS/COOLERS EXPERIENCE AG GREGATE EXPERIENCE

Section 07 29
MORE EXPERIENCE
WHITEHEAD BROS. COMPANY LUGOFF, SOUT H CAROLINA

75 TPH Sand Dryer
ENGINEERING ONLY MONTEREY SAND COMPANY MONTEREY, CALIFORNIA

50 TPH Sand Dryer
SNC SERVICE LTD. ALGERIA

SILICA PRODUCTS COMPANY GUION, ARKANSAS

COLUMBINE MINERALS WHEATRIDGE, COLORADO

25 TPH Sand Dryer
ACME RESIN COMPANY OREGON, ILLINOIS

37 TPH Sand Cooler
WEDRON SILICA PRAIRIE STATE SILICA PLANT TROY GROVE, ILLINOIS

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 identied 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 1970s. 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 operators 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 oating 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 SYSTE MS 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 ve 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 ve-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 Alcoas 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 modication for the inclusion of a dust collector system, and eld 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 specically 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 MARIN E 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

Engineering, procurement, construction, start-up and commissioning of the coal, limestone and aggregate material handling systems included ship loading and unloading; 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 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 y 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 modied 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 modications) 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 justication 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 t 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 nal 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 benet 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 ooring; Corrosion due to product build-up in conveyor A-frames; Thickness testing for tanks; Decient 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
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 oating 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 tted 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 tted 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 identied. 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 identied and implemented. The initial study work completed by Soros looked at various options for the upgrade and the respective equipment. An opportunity was identied 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 specications to procure replacement/new equipment and provided the consulting support during the procurement, fabrication and construction phases of the project. Detailed shiploader modeling identied 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 denition 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 ll covered barges through open hatches, which requires that the chute/spout be able to move laterally and extend and retract. A certied 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 DOA 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 classied 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 ndings were discussed with the CMDI, who then engaged Soros and its Chilean partners to provide further assistance by way of: Dening 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 Freeports 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 eld measured material thickness recalculated the member strength to determine its suitability for the imposed load/ stress; Prepared structural modication drawings for all over stressed members; Prepared reinforcement / replacement joint detail drawings; Prepared eld structural installation instruction; Expected useful life with and without repairs; Estimated cost for structural repairs; Estimated outage period to carry out structural modications; 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 ndings report results and this report ndings; 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 ndings report including suggested improvements that will reduce cost and improve the operation; Review draft ndings report with project manager and record his comment; and Furnish a nal report which outlines the ndings 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 reconrmed 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], conrmed 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 trafc resulting from implementation of the project. With the increased trafc 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 modications 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 oating 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 1970s 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 efciency 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 rst fully enclosed bulk loading facility in Australia, an environmental rst at the time and the shiploader design was later recognized with an award reecting 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 afliate 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 worlds 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

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).
AMERICAN ELECTRIC POWER, 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. 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.
Above: Constellation Energy, Brandon Shores Power Station, Baltimore, Maryland Below: American Electric, Power, Mitchell Plant, Cresap, West Virginia

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 oating barge. The barge is tted 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.
Southern Indiana Gas & Electric, Culley Station, Newburgh, Indiana
DAYTON POWER & LIGHT, STUART GENERATING STATION, ABERDEEN, OHIO

Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems. 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 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
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, PORT 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. Signicant 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

Engineering, procurement, construction, start-up and commissioning of the limestone and gypsum handling systems; the contract was awarded 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. 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 modications and/or additions for least capital and operating costs.
American Electric Power, Cardinal Plant, Brilliant, Ohio
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 & Wrights 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
MORE EXPERIENCE
NEW SOUTH WALES DEPARTMENT OF PUBLIC WORKS & COLLIERY PROPRIETORS ASSOCIATION, OFFSHORE COAL TERMINAL, CO ALCLIFF
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 exibility 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 specications 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 renery.
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 modications 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. Above: Port of Gangavaram, India Below: Container terminal in Shekou, China

30 Section 08
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 specication, in support of tender bid, for an alumina ship loader to be located at Fishermans 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.
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

32 Section 08
HEXCEL CARBON MANUFACTURING LINES, SALT LAKE CITY, UTAH

R&S was awarded a time and materials contract from Hexcel to engineer a new carbon ber manufacturing line #10 to be attached to the existing carbon ber 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 ber enhancement equipment Integration of vendor supplied equipment for a complete operating ber line Fabrication and construction engineering support Integration of controls and automation with the other ber 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 exible to the type of ber that can be produced. The building was located and utilities designed to accommodate the future carbon ber lines. Our work on this project included: 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 ber enhancement equipment Integration of vendor supplied equipment for a complete operating ber line Fabrication and construction engineering support Integration of controls and automation with the other ber lines.
Roberts & Schaefer knows how to apply its skills and experience to any type of processing or resource handling project, regardless of size or scope.
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 nal 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 rst 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 nal phase involved engineering a complex re 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 nal 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 difcult 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 oors 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) 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
Roberts & Schaefer can engineer ancillary facilities for utility, mining and industrial operations to meet a variety of needs and operational requirements.

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 eet 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 ofces, one supervisors ofce, a lunchroom, bathrooms and showers. The existing ofces 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 nal solution the new building mirrored the largest existing building. The existing sectional doors were removed resulting in a 10 bay shop. Modications were made to the existing buildings to improve the working environment and to meet re codes. The re code issue was especially difcult due to the enormous size and height of the building. Numerous meetings were held with Kern county to resolve the re 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 oor 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 difcult. 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 & Schaefers 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, exwall, 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 1,000F. 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 nalization of process owsheets, piping and instrument diagrams, overall facility layout, facility plot plans. Further, the preparation of equipment and material specications, construction packages, overall schedule for engineering, procurement, deliveries and construction.

Section 09 7
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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 landll 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 250F 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
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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 tted 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 tted with reclaim screw feeders which deliver on demand coal and sorbent to a uid bed combustor. High temperature bed ash (600F) and y ash (380F) 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 ight type water cooled screw conveyors for ash temperature control prior to storage and loadout. Telescoping loadout chutes deliver bedash and yash 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 ume 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 ume superstructure resulting in considerable cost and time savings.

Section 09 9
MORE EXPERIENCE
ARCO, DENVER, COLORADO

Total engineering for a ret of a pollution control system for a coal mine. The project consisted of eld measuring to determine the best way to t the new hardware into existing facility, and the writing of specications for procurement of equipment.
ASARCO INC., OMAHA, NEBRASKA

Provided design engineering and equipment specications for an oxide fuming plant to produce antimony oxide as a by-product in the rening of lead. The work included designs for the collection of high temperature dust and fumes, the conveying of ne 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 specications 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 red 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 ne 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 fth 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, (red 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 conned 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 ring. Work included site visits to determine the best way to install the new equipment, eld 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 Rimre 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 eld 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 modications were included during this relocation to improve production and plant efciency. Foundations for the relocated equipment were completed using eld 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 rst green pellet elevating conveyor. The rst 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 tted 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 eld 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
BETHLEHEM STEEL CORPORATION, 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, eld engineering services.
CABLE BELT CONVEYORS, INC., NASHVILLE, TENNESSEE

Overland conveyor system services.
CITIZENS 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 plants 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 modications 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 modication and digester feed system for Riverwood International. The modications 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 modications 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, rening, 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 specic engineering disciplines according to your requirements. Our design, scheduling, cost control and project management capabilities provide you with efcient 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 worlds resourceswith a spirit of innovation, a dedication to quality and a skill for management. With major engineering ofces 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 Prole was helpful in bringing to light who we are. Thank you for taking the time to nd 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 specically assist you, or for a quotation on your project, please contact your nearest Roberts & Schaefer ofce.
DEDICATED TO QUALITY ENGINEERING SINCE 1903

Section 10 1
ANOTHER LOOK
Chicago 222 South Riverside Plaza Chicago, IL 60606-3986 TEL: 312-236-7292 FAX: 312-726-2872 Email: rs@elginindustries.com Salt Lake City 10150 South Centennial Parkway Suite 400 Sandy, Utah 84070 TEL: 801-984-0900 FAX: 801-984-0909 Email: rs@elginindustries.com Australia Level 5, 35 Boundary Street South Brisbane, Australia 4101 TEL: +61 (0) 7-3234-9555 FAX: +61 (0) 7-3234-9595 Email: rs@elginindustries.com
Indonesia Sequis Center; 7th Floor Jl. Jenderal Sudirman Kav. 71 Jakarta, Indonesia 12190 TEL: +62-21-252 4177 FAX: +62-21-252 4138 Email: rs@elginindustries.com Poland UI. Bojkowska 44-100 Gliwice, Poland TEL: +48-32-461-2722 FAX: +48-32-461-2720 Email: rs@elginindustries.com India 20 White House, C G Road Ahmedabad - 380 006, India TEL: +91 79 40328000 FAX: +91 79 40328001 Email: rs@elginindustries.com
DEDICATED TO QUALITY ENGINEERING SINCE 1903

2 Section 10
RO BERTS & SCHAEFER EXECUTION SUMMARY
As an Engineering, Procurement and Construction company, Roberts & Schaefers 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 specications, as well as for those items not specically 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 efcient 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 Prot & 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
Estimating
Sales and Marketing
Engineering
Procurement
Construction
Admin
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 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 Ofce 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 stafng. 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 specic 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 certication.
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Other management positions exist for specic 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 companys 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)
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Engineering & Design
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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-specic technical requirements. The Sales and Estimating groups key functions are: Identication 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 ow of engineering development is as follows: Layouts: establish the overall process and general area conguration that will meet the needs of the project in the most efcient 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.
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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 eld. The mobilization effort requires interface with overall client project management on-site to coordinate activities. Our CMs typically have an ofce 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 specic 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 efciency. 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 certication 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 reects the heritage and reputation of Roberts & Schaefera reputation that is precious to us as we continually seek ways to uphold and improve it.
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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 AES Barbers Point, Oahu, Hawaii.................................02-30 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 Pacic, Bauxite Loading Facility, Cape York, Queen sland ......................................................08-28 Alcoa, Bunbury Alumina Loader Western Australia .......08-20 Alcoa, Condition Assessment of Radial Shiploader ............08-5 Allegheny Power Service Corporation, Willow and Pleasants Island, Parkersburg, West Virginia .................02-49 Allen Fossil Plant, Memphis, Tennessee ..........................02-15 Amax Coal Company, Belle Ayr Mine, Gillette, Wyoming ..............................................................05-34 Amax Coal Company, Eagle Butte Mine, Gillette, Wyoming ..............................................................05-35 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 American Electric Power, Amos Plant, Wineld, West Virginia ......................................................04-14 American Electric Power, Cardinal Plant, Brilliant, Ohio ............................................. 02-33, 04-14, 08-26 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 American Steel Foundries, Alliance, Ohio ........................07-26 American Steel Foundries, Granite City, Illinois .............07-27 Amonate Plant, McDowell County, Tazewell, West Virginia .....................................................05-55 Amos Plant, Wineld, 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 Arco Coal Company, Beaver Creek Mine, Price, Utah .........................................................................05-37 Arco, Denver, Colorado ......................................................09-10 Argyle Diamonds, Underground Expansion Project, Western Australia ..............................................................06-29 Armco Steel Corporation, Edwight, West Virginia ..........06-18 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 Associated Electric Cooperative, High Capacity Stacker, New Madrid, Missouri ................02-43 Associated Electric Cooperative, Moberly, Missouri ........05-44
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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, Beasleys 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 B.L. England Generating Station, New Jersey ................03-12 Badger Coal Company, Grand Badger #1 Plant, Sago, West Virginia ............................................................05-55 Bailey Generating Station, Chesterton, Indiana .............04-25 Bailey Mine Coal Preparation Plant, Enon, Pennsylvania ...........................................................05-26 Bailey Mine, Green County, Pennsylvania .......................05-51 Baldwin Power Station, Baldwin, Illinois ........................02-22 Baltimore Gas & Electric Company, Brandon Shores, Units 1 and 2, Anne Arundel County, Maryland ...........................02-27, 08-11 Baltimore Gas & Electric, C.P. Crane Station, Baltimore, Maryland..........................................................02-42 Barbers Point, Oahu, Hawaii ............................................02-30 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, Queen sland ......................................................08-28 Bay Shore Station Repowering Project, Oregon, Ohio ......................................................................04-19 Beaver Creek Mine, Price, Utah .......................................05-37 Bechtel Construction Company, Mt. Poso Cogeneration Project Fluidized Bed Boiler .......02-45 Bechtel Power Corp., Morgantown Energy Project, Morgantown, West Virginia .................................02-29 Beckley #2 Plant, Sabine, West Virginia ..........................05-55 Beckley Lick Run Plant, Mount Hope, West Virginia ......05-56 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 Bethlehem Steel Corporation, Lackawanna, New York ......................................... 06-18, 09-14 Bethlehem Steel Corporation, Van, West Virginia .............................................................06-18 BHP Billiton, Maruwai Mine, Central Kalimantan, Indonesia ........................................05-15 BHP Billiton, Mt Arthur North Mine, Hunter Valley, Australia ....................................................05-13 BHP Blackwater Mine, Bowen Basin, Australia ................05-8 Biogen Power Facility, Systems Engineering .....................09-9 Birchwood Project, King George County, Virginia ............................... 02-38, 02-44 Black Bear Preparation Plant, Mountaineer Mine, Gilbert, West Virginia .......................05-22 Black Dog, Riverside and Highbridge Generating Stations, Minneapolis, Minnesota .................02-38 Black Hills Corporation, Coal Yard Upgrade, Gillette, Wyoming ..............................................................02-50 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 Blue Resources, Inc., J.W. Cornett Preparation Plant, Leatherwood, Kentucky .....................05-25 Bowie Resources, No. 2 Mine Expansion, Paonia, Colorado ................................................................05-29 BP Canada, LTD., Sukunka Coal Project Plant ...............05-53 BP Canada, Ltd., Sukunka Coal Project Plant, Chetwynd, British Columbia, Canada ..............................05-48
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BP Minerals America Fallon, Rawhide Mine, Nevada ......................................................06-16 Brandon Shores Power Station, Baltimore, Maryland................................................ 04-1, 08-23 Brandon Shores, Units 1 and 2, Anne Arundel County, Maryland ...........................02-27, 08-11 Brazilian National Steel Company, Capivari Mine, Brazil ............................................ 05-49, 06-19 Bremo Station, Richmond, Virginia ..................................02-49 British Columbia Coals, Ltd., Green Hills Plant Elkford, British Columbia, Canada ..................................... 05-48, 05-52 Brown and Root, Maco, Georgia ........................................09-15 Brush Wellman Company, Delta, Utah ............................06-35 Buchanan Plant, Buchanan County, Virginia ..................05-52 Bufngton Plant, Bufngton, Ind iana ..............................07-22 Bullmoose Plant, Tumbler Ridge, British Columbia, Canada .................................................05-52 Bunbury Alumina Loader Western Australia...................08-20 C.E. Basic Industries, Gabbs, Nevada ..............................09-11 C.E. Basic Refractories, Gabbs, Nevada ...........................06-34 C.P. Crane Station, Baltimore, Maryland ............... 02-7, 02-42 Cable Belt Conveyors, Nashville, Tennessee ....................09-14 Calaveras Cement Company, Quarry Crushing System, Tehachapi, California .............07-11 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 Cape Lambert, WA .............................................................08-29 Caper Cuvier, WA ...............................................................08-29 Capivari Mine, Brazil ........................................................06-19 Captain Mine Preparation Plant, Percy, Illinois ..............05-41 Carbon Coal Company, Mentmore Mine, Gallup, New Mexico ...........................................................05-40 Carbon Manufacturing Lines, Salt Lake City, Utah ............................................................09-1 Carbon Regeneration and Handling Project ..................................................................06-5 Cardinal Plant, Brilliant, Ohio .................. 02-33, 04-14, 08-26 Cardinal River Coals, Cardinal River Plant, Luscar, Alberta Canada ........................................ 05-49, 05-54 Cardon Renery Project, Cardon, Venezuela .....................03-5 Caremuse Lime Company, Limestone Handling Facility, Maysville, Kentucky ..........................................................07-18 Cargill Crop Nutrition .......................................................08-18 Caribbean Ispat Limited, Direct Reduced Iron (DRI) Material Handling Facility, Port Lisas, Trinidad .............................................................08-4 Caribbean Ispat Ltd., Direct Reduction Facility III (DR3), Point Lisas Trinidad & Tobago ...........06-20 Carlota Copper, Miami, Arizona........................................06-15 Carolina Silica, Inc., Marston, North Carolina ....................................... 07-28, 07-29 Carter Mining Company, Gillette, Wyoming ....................05-33 Catherine Hill Bay Coal Loader, NSW .............................08-25 Cave Branch Prep Plant, Lynch, Kentucky ......................05-42 Cayuga Generating Station, Cayuga, Indiana .................04-10 Cement Facility, Union Bridge, Maryland..........................07-9 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 Central Hudson Gas & Electric, Danskammer Point Steam Electric Generating Station, New Jersey .......................................02-49 CF&J Steel Corporation, Comstock Mine, Utah ..............06-19 CFI Steel Corporation, Weston, Colorado .........................06-19
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INDEX
Chalk Point Generating Station, Eagle Harbor, Maryland ....................................................02-40 Chalk Point Power Generation Station, Washington, D.C. ...............................................................02-38 Chalk Point, Dickerson, Morgantown Stations, Maryland ............................................................................04-16 Chartam Project .................................................................06-14 Chemical Lime, Apex Plant, Apex Nevada .......................07-16 Chestereld Power Station, Chester, Virginia ...................04-5 Chevron Mining, Elkol Tipple Upgrade, Kemmerer, Wyoming..........................................................05-14 Chevron, El Segundo Renery, El Segundo, California .........................................................03-2 China National Technical, Xinglongzuang, Shandong Province, P.R.C. ................................................05-49 Cinergy Services, Gibson Generating Station, Owensville, Indiana ...........................................................04-11 Cinergy Services, Miami Fort Station, North Bend, Ohio ...............................................................04-11 Cinergy Services, Zimmer Plant, Moscow, Ohio .......................................................... 04-12, 08-13 Citizens Gas & Coke Utility, Indianapolis, Indiana.........................................................09-14 City of Owensboro, Kentucky ............................................04-25 City Utilities, James River Power Station, Springeld, Missouri..........................................................02-31 Cliffside Station, Cliffside, North Carolina ......................02-24 Clincheld Coal Company, Moss III Plant, South Clincheld, Virginia ................................................05-53 Clincheld Coal Company, McClure #1 Plant, McClure, Virginia ...............................................................05-54 Clive Incineration Facility, Western Utah ..........................09-7 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 Coal Tailings Reprocessing Facility, Rybnik, Poland ...................................................................05-11 Coal Transshipment Terminal, Balls Head Bay, Sydney .....................................................08-25 Coffeen Generation Station, Coffeen, Illinois ...................02-18 Cogen South Plant, Charleston, South Carolina ................................... 02-41, 03-13 Cogeneration Facility, Fort Drum, New York ...................02-32 Cogeneration Plant, Barbers Point, Hawaii .....................04-21 Coke and Sulfur Handling Systems, Jose, Venezuela ....................................................................03-6 Coke Production Plant, Dembiensko, Poland .....................09-3 Coke Production Plant, Radlin, Poland ..............................09-3 Coke Production Plant, Walbrzych, Poland ........................09-4 Colbert Steam Plant, Tuscumbia, Alabama......................02-50 Coleman Station, Hawesville, Kentucky .............. 02-12, 04-13 Colorado Lein, Laporte, Colorado .....................................07-28 Columbiana Foundry, Columbiana, Ohio .........................07-28 Columbine Minerals, Wheatridge, Colorado ....................07-30 Comanche Station (Unit 3), Pueblo, Colorado ....................02-2 ComEd, Fisk Station, Waukegan Station and Joliet No. 9 Station .....................................................02-41 Companhia Minera Doa Ines de Collahuasi, Puerto Patache, Chile ........................................................08-14 CONSOL Energy, Robinson Run Mine, Mannington, West Virginia .................................................05-4 CONSOL Pennsylvania Coal Company, Bailey Mine, Green County, Pennsylvania .......................05-51 CONSOL, Bailey Mine Coal Preparation Plant, Enon, Pennsylvania ...........................................................05-26 Consolidation Coal Company, Amonate Plant, McDowell County, Tazewell, West Virginia ......................05-55 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
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INDEX
Consolidation Coal Company, Loveridge Plant, Fairview, Wes Virginia .......................................................05-52 Constellation Copper, Lisbon Valley Copper, Moab, Utah ...........................................................................06-2 Constellation Energy, Brandon Shores Power Station, Baltimore, Maryland ...................... 04-1, 08-23 Constellation Energy, C.P. Crane Station, Baltimore, Maryland............................................................02-7 Continental Energy Associates, Hazleton Gasication 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 CS Energy, Kogan Creek Power Station, Surat Basin, Australia .......................................................02-36 Culley Station, Newburg, Indiana ........................ 04-23, 08-24 Curragh Mine, Bowen Basin, Australia............................05-28 Cynergy Services, Miami Fort Station, North Bend, Ohio ...............................................................08-25 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 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 Danskammer Point Steam Electric Generating Station, New Jersey .......................................02-49 Darwin Port Authority, Container Crane, Port of Darwin, Northern Territory ..................................08-27 Dave Johnston Power Station, Glenrock, Wyoming .........02-40 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, British Columbia, Canada .................................................05-52 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, Chestereld Power Station, Chester, Virginia.........................................04-5 Doverspike Plant, Dora, Pennsylvania .............................05-56 Dravo Lime Company, Black River Processing Plant, Butler, Kentucky .....................................................07-17 Drummond Company, Inc., Shoal Creek Mine, Shoal Creek, Alabama........................05-31 Dry Fork Station & Mine, Gillette, Wyoming...................02-10 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 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
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Eagle Roong Tile Plant, Rialto, California .....................07-25 Eastern Associated Coal Group, Keystone Plant, Keystone, West Virginia .........................05-55 Edgewater Generating Station, Sheboygan, Wisconsin........................................................02-38 Edwards Power Station, Bartonville, Illinois ...................02-19 Edwardsport Power Station, Edwardsport, Indiana..........02-6 Eighty-Four Mining, Eighty-Four, Pennsylvania ............05-43 El Segundo Renery, 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 Elkol Preparation Plant, Kemmerer, Wyoming ................05-40 Elkol Tipple Upgrade, Kemmerer, Wyoming ....................05-14 Elm Road Station, Oak Creek, Wisconsin ..........................02-3 European Bank of Reconstruction & Development, Muruntau Gold Project ......................................................06-12 Ferteco Mineracao S.A., Sepetiba Bay, Brazil ....................08-1 Fertilizer Conveying System Support Steel, Odessa, Ukraine ...................................................................09-7 First Energy, Bay Shore Station Repowering Project, Oregon, Ohio ....................................04-19 First Energy, W.H. Sammis Plant, Stratton, Ohio ...........02-13 Fisk Station, Waukegan Station and Joliet No. 9 Station ............................................................02-41 Flash Chlorination Project ..................................................06-5 Florida Canyon Mine, Imlay, Nevada ...............................06-17 Florida Rock Industries, Interlachen, Florida..................07-28 FMC Corporation, Green River, Wyoming ........................06-33 Fossil Plant, Gallatin, Tennessee .......................... 02-48, 08-24 Freeman United Coal Company, Virdon, Illinois ....................................................................05-45 Freeman United Coal Company, Waltonville, Il linois ............................................................05-45 Fresh Water Pumping Project .............................................06-5 Fru-Con Construction Company, North Branch Power Project, Bayard, West Virginia ..... 02-46, 07-23 Galatia Mine, Galatia, Illinois ..........................................05-36 General Dynamics Corp., Grinding Mill Plant, Bufngton, Indiana .........................07-19 Geneva Steel, Orem, Utah .................................................06-15 Geneva Steel, Provo, Utah.................................................06-18 Georgia Power Company Plant, Milledgeville, Georgia ........................................................02-25 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 Golden Eagle Renery, Martinez, California......................03-3 Grand Badger #1 Plant, Sago, West Virginia ...................05-55 Granit, Strzegom Quarry, Poland .......................................07-4 Granite Rock Company, Logan Quarry Aggregate Plant Renovation, Aromas, California ................................07-5 Granite Rock Company, Watsonville, California ...............07-8 Great Salt Lake Minerals Corporation, Multi-Site Plant Upgrades, Ogden, Utah .........................06-27 Green Hills Plant Elkford, British Columbia, Canada ..................................... 05-48, 05-52 Grinding Mill Plant, Bufngton, Indiana .........................07-19 Gund Plant, Pike County, Turkey Creek, Kentucky ....................................................05-55 Haile Gold Mine Feasibility Study......................................06-4 Halemba Mine, Poland ......................................................05-18 Hamersley Iron Pty., Iron Ore Terminal, Port Dampier, Western Australia ......................................08-26 Hanna Nickel Mining Company, Riddle, Oregon........................................................ 03-14, 06-16 Harding Street Station, Indianapolis, Indiana ..................04-9 Hardy Sand, Tuscaloosa, Alabama ....................................07-29 Hawthorn Mine, Sandborn, Indiana .................................05-51 Hazleton Gasication Project, Hazleton, Pennsylvania ..........................................02-47, 03-11 Heap Leach Crushing Project, Carlin, Nevada ..................06-5
Index
INDEX
Hearth Layer Plant, Silver Bay Processing Facility, Silver Bay, Minnesota..........................................09-13 Hecla Mining Company, Coeur DAlene, Idaho ................06-17 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 Homer City Station, Homer City, Pennsylvania ..............02-49 Hopewell Pagbilao, Conveyor System, Quezon Province, Philippines............................................02-36 Hot Briquetted Iron Plant Puerto Ordaz, Venezuela .......06-23 Huaneng Power International, Dandong Generating Station, Dangdong, China .............................02-26 Ideal Basic Industries ..........................................................09-8 Ideal Cement Plant, Jefferson County, Colorado ...............07-7 Illinois Central Rail Marine Terminal, St. James Parish, Louisiana .................................... 06-21, 08-6 Indianapolis Power & Light, Harding Street Station, Indianapolis, Indiana ............................................04-9 Industrial Minera Mexico, Pasta De Conchos Mine, Mexico ......................................................................05-33 Industrial Mineral Mexico, Nueva Rosita, Mexico .............................................. 05-49, 09-9 Inland Steel Company, McLeansboro, Illinois ..................05-46 Inspiration Mines, Austin, Nevada ...................................06-13 Integra Coal, Camberwell Mine, Hunter Valley, Australia ....................................................05-16 Integra Coal/Vale, Glennies Creek Colliery, Hunters Creek, Australia ..................................................05-28 Inter-Rock Minerals, Min-Ad Dolomite Facility, Humboldt County, Nevada ................................................06-28 Iron Ore Shiploading Terminal, Port Hedland, Western Australia ..............................................................08-25 Iron Ore Terminal, Port Dampier, Western Australia ..............................................................08-26 Island Creek Coal Co., Upshur Plant, Tallmansville, West Virginia .............................................05-54 Island Creek Coal Company, Gund Plant, Pike County, Turkey Creek, Kentucky..............................05-55 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 Retrot, Vernal, Utah .......06-32 J.R. Simplot Company, Pocatello, Idaho ...........................06-34 J.R. Simplot, Systems Engineering...................................09-11 J.W. Cornett Preparation Plant, Leatherwood, Kentucky .....................................................05-25 James Gores & Associates, Riverton, Wyoming ...............09-14 James River Power Station, Springeld, Missouri ..........02-31 JEA, Northside Generating Station, Jacksonville, Florida ..........................................................04-24 Jewel Coal & Coke Company, Jewel Smokeless Plant, Vansant, Virginia .......................05-53 Jim Walter Resources, #4 Mine, Brookwood, Alabama .........................................................05-51 Jim Walter Resources, Brookwood, Alabama ...................05-44 John W. Turk Power Plant, Fulton, Arkansas ..................02-21 Jones & Laughlin Corporation, Harpers Ferry, Virginia.....................................................07-23 Jones & Laughlin Steel Company, California, Pennsylvania ...................................................06-18 Kaiser Aluminum & Chemical Corporation, Wendover, Utah ..................................................................06-35 Kaiser Cement Corporation, Permanente Aggregate, Cupertino, California ...................07-8 Kaiser Resources, Sparwood, British Columbia ...............05-45 Kaltim Prima Coal Facility, Sangatta, East Kalimantan, Indonesia................................................05-7 Kansas City Power and Light Company, Fuel Yard Modications, LaCygne, Kansas .....................02-46
Index
INDEX
Kansas City Power and Light, Specialized Belt Feeders, La Cygne, Missouri .................02-34 Katowice Coal Holding S.A., Katowice, Poland ................05-48 Katowice Coal Holding S.A., Staszic Mine, Poland ..........05-27 Kennecott Utah Copper Corporation, Bingham Canyon, Utah .....................................................06-10 Kennecott Utah Copper Corporation, Salt Lake City, Utah ..........................................................06-10 Kentucky Criterion Coal Company, Deane, Kentucky ................................................................05-23 Kerr-McGee Coal Corporation, Galatia Mine, Galatia, Illinois ..................................................................05-36 Kerr-McGee Coal Corporation, Gillette, Wyoming ...........05-38 Kerr-McGee Corporation, Galatia, Illinois .......................05-44 Keystone Plant, Keystone, West Virginia .........................05-55 Killen Generating Station, Manchester, Ohio ....................04-7 Kings Mountain Mica Company, Kings Mountain, North Carolina ......................................07-28 Kingston Fossil Plant, Kingston, Tennessee ......................02-9 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 Kombinat Koksowniczy W Zabrzu, Coke Production Plant, Radlin, Poland ..............................09-3 Kompania Weglowa (KWK), Halemba Mine, Poland .......05-18 Kompania Weglowa (KWK), Knurow Mine, Poland.........05-18 Kompania Weglowa (KWK), Murcki Mine, Poland ..........05-19 Kompania Weglowa (KWK), Ziemowit Mine, Poland ......05-19 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 Lamberts Point Coal Loadout Facility, Norfolk, Virginia ................................................................05-31 Landll, Remediation and Closure, New York ...................09-8 Laurel Run Mine, Mt. Storm, West Virginia ....................05-34 Lehigh Cement Company, Cement Facility, Union Bridge, Maryland ......................................................07-9 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 Logan Quarry Aggregate Plant Renovation, Aromas, California ...............................................................07-5 Lonoke Ammunition Manufacturing Plant, Arkansas ..................................................................09-12 Loveridge Plant, Fairview, Wes Virginia ..........................05-52 Loy Yang Victoria ...............................................................08-29 LTV Steel Corporation, East Chicago, Indiana ................06-18 Lubelski Wegiel S.A., Bogdanka Mine, Poland ................05-27 Luminant (Sandow Development Company), TXU-Sandow (Unit 5), Rockdale, Texas ............................02-14 Luminant Power, Oak Grove Power Station, Franklin, Texas ....................................................................02-1 Luminant, Kosse Mine, Kosse, Texas .................................05-1 Luminant, Oak Grove Power Station, Franklin, Texas ....................................................................04-4 Lyman-Richey Sand & Gravel Company, Valley, Nebraska.................................................................07-29 MacLellan Mine, Lynn Lake, Manitoba............................06-13 MAPCO Coal Company, Pontiki Mine, Lovely, Kentucky ................................................................05-24 MAPCO, Pontiki Plant, Martin County, Inze, Kentucky ...................................................................05-56 Marblehead Lime, Bufngton Plant, Bufngton, Indiana ............................................................07-22 Marblehead Lime, Chicago, Illinois ..................................07-23 Marblehead Lime, Gary, Indiana ......................................07-23 Marblehead Lime, Pleasant Gap, Pennsylvania ..............07-23 Marine Terminal, St. James Parish, Louisiana ...............06-21 Marion Generation Station, Marion, Illinois ....................02-35
Index
INDEX
Maritime Services Board of NSW, Kooragang Coal Terminal Newcastle ................................08-22 Maritime Services Board of NSW & Combined Colliery Operators, Coal Terminal, Botany Bay...............08-27 Maruwai Mine, Central Kalimantan, Indonesia ..............05-15 Material Handling System Upgrade, Price, Utah ..............09-2 McClure #1 Plant, McClure, Virginia ...............................05-54 Meadow Creek Plant, Meadow Creek, West V irginia ......................................................................05-54 Mentmore Mine, Gallup, New Mexico ..............................05-40 Metallurgimport, Moscow, Russia .....................................07-29 Miami Fort Station, North Bend, Ohio ..................04-11, 08-25 Middle East Oil Renery (MIDOR), Alexandria, Egypt ................................................................03-7 Millwood Sand Company, Millwood, Ohio ........................07-28 Min-Ad Dolomite Facility, Humboldt County, Nevada ................................................06-28 Mingo Logan, Black Bear Preparation Plant, Mountaineer Mine, Gilbert, West Virginia .......................05-22 Mirant Mid Atlantic, Chalk Point, Dickerson, Morgantown Stations, Maryland ......................................04-16 Mitchell Plant, Cresap, West Virginia .................... 04-2, 08-23 Mobil Mining and Minerals Company, South Fort Meade Mine Beneciation Plant, Nichols, Florida ..................................................................06-31 Modular Asphaltene Recovery Plant, Fort McMurray, Alberta, Canada ......................................06-26 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 Monterey Sand Company, Monterey, California ..............07-30 Morgantown Energy Project, Morgantown, West Virginia ...............................................02-29 Moss III Plant, South Clincheld, V irginia ......................05-53 Motiva Enterprises, Motiva Renery, Port Arthur, Texas ................................................................03-1 Mt Arthur North Mine, Hunter Valley, Australia ............05-13 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 Newmont Mining, Fresh Water Pumping Project ..............06-5 Newmont Mining, Trash Screen Modication Project .......06-5 Newmont Mining, Truck Maintenance & Wash Facility, Carlin, Nevada .........................................09-5 Nickel Cobalt Project, Nkamouna, Cameroon .................06-1 Nonoc Island, Philippines ..................................................08-28 MT Newman Mining Co., Iron Ore Shiploading Terminal, Port Hedland, Western Australia .....................08-25 Mt. Poso Cogeneration Project Fluidized Bed Boiler .......02-45 Multi-Site Plant Upgrades, Ogden, Utah .........................06-27 Municipal Solid Waste Facility, Riverside, Michigan.......09-13 Murcki Mine, Poland .........................................................05-19 Muruntau Gold Project ......................................................06-12 Nadwislanskia Spolka Weglowa (NSW) S.A. Piast Mine, Bierun, Poland .......................................05-10 National Cement Company of California, Plant 2 Modernization, Lebec, California .........................07-10 Naughton Station, Kemmerer, Wyoming ..........................02-39 Neil Simpson Station, Gillette, Wyoming .........................02-34 Nevada Gold Mining, Inc., Sleeper Project, Winnemucca, Nevada.........................................................06-14 New Elk Mine, Weston, Colorado......................................05-38 New Hope Corporation, Port Of Brisbane ..........................08-9 New Madrid Plant, New Madrid, Missouri ......................02-50 New River Company, Beckley Lick Run Plant, Mount Hope, West Virginia ...............................................05-56 New River Company, Meadow Creek Plant, Meadow Creek, West Virginia ...........................................05-54 New South Wales Dept. of Public Works, Offshore Coal Terminal, Coalcliff ......................................08-27 New South Wales Dept. of Public Works, Port Kembla Coal Terminal Port Kembla.........................08-21 Newcastle, NSW .................................................................08-29
Index
INDEX
Norfolk & Western Railway Company, Coal Ground Storage Facility, Isle of Wight County, Virginia ...............05-32 Norfolk & Western Railway Company, Lamberts Point Coal Loadout Facility, Norfolk, Virginia .................05-31 Norfolk Southern Harris Mine, Kopperston, West Virginia.................................................05-30 North American Coal Company, Powhatan Point, Ohio ........................................................05-36 North Branch Power Project, Bayard, West Virginia............................................ 02-46, 07-23 North Carolina State Ports Authority, Morehead, North Carolina.................................................08-10 North Omaha Station, Omaha, Nebraska ........................02-16 North Rochelle Mine, Gillette, Wyoming ............................05-6 Northern Indiana Public Service Co., R.M. Schahfer Generating Station, Wheateld, Indiana .........................02-46 Northern Indiana Public Service Co./Pure Air, Bailey Generating Station, Chesterton, Indiana .............04-25 Northern States Power Company, Black Dog, Riverside and Highbridge Generating Stations, Minneapolis, Minnesota ....................................................02-38 Northside Generating Station, Jacksonville, Florida ......04-24 Nova Scotia Sand & Gravel, Shubenacadie, Nova Scotia ...............................................07-28 Noyes Bros., Pty., Offshore Clinker and Cement Terminal, Gladstone, Queensland .......................08-26 Oak Grove Power Station, Franklin, Texas .............. 02-1, 04-4 Oakey Creek Mine, Bowen Basin, Australia ......................05-2 Offshore Clinker and Cement Terminal, Gladstone, Queensland ......................................................08-26 Offshore Coal Terminal, Port Kembla...............................08-27 Offshore Iron Ore Terminal, Northwest WA.....................08-26 PEMEX Renery 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 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 Pennsylvania Glass & Sand Corporation, Berkeley Springs, West Virginia ........................... 07-26, 07-27 Penn West Fuels, Doverspike Plant, Dora, Pennsylvania ............................................................05-56 Pennsylvania Electric Company, Homer City Station, Homer City, Pennsylvania ..............02-49 Omya California, Crusher Project, Lucerne Valley, California .................................................07-21 Omya California, Optical Sorter Improvements, Lucerne Valley, California .................................................07-20 Optical Sorter Improvements, Lucerne Valley, California .................................................07-20 Orlando Utilities, Fuel Supply System, Orlando, Florida .................................................................02-50 Ottawa Silica, Ottawa, Illinois ..........................................07-28 Owens Illinois, Ione, California.........................................07-28 Oxbow Carbon, Port of Los Angeles (LAXT), Los Angeles, California ........................................................03-4 Oxbow Corporation, Pet Coke Loading Facility, Port of Texas City, Texas ....................................................08-16 Pacic Corp, Salt Lake City, Utah ....................................06-35 Pacicorp, Dave Johnston Power Station, Glenrock, Wyoming ............................................................02-40 Paradise Fossil Plant, Paradise, Kentucky ......................04-20 Paradise Plant, Drakesboro, Kentucky.............................02-15 Parker Point, Dampier, WA ...............................................08-28 Pasta de Conchos Mine, Mexico ........................................05-33 Patherdihi Central Coal Washery, Bihar, India ............................................................ 05-47, 06-19 PBS Coals, Inc., Cambria Prep Plant, Somerset County, Pennsylvania ........................................05-51 PCC Rail, Sand & Gravel Plant, Jaworzno, Poland .........07-24 Peabody Coal Company, Hawthorn Mine, Sandborn, Indiana .............................................................05-51 Peabody Coal Company, Morganeld, Kentucky .............05-46 Pegasus Gold Corporation, Florida Canyon Mine, Imlay, Nevada ....................................................................06-17
10
Index
INDEX
Pennsylvania Glass & Sand Corporation, Brady, Texas .......................................................................07-29 Pennsylvania Glass & Sand Corporation, Mapleton Depot, Pennsylvania ............................. 07-26, 07-27 Pennsylvania Glass & Sand Corporation, Mill Creek, Oklahoma........................................................07-26 Pennsylvania Glass & Sand Corporation, Pacic, M issouri .................................................................07-26 Pentair Paper (Sargent & Lundy), St. Paul, Minnesota............................................................09-15 Peoples Republic of China, Xinglongzhaung Plant, Xinglongzhaung Shangdong Province, Beijing, China ....05-53 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 Petroleos de Venezuela S.A. (PDVSA) Maraven, Cardon Renery Project, Cardon, Venezuela .....................03-5 Piast Mine, Bierun, Poland ...............................................05-10 Pier IX and Shipyard River Coal Terminal, Newport News, Virginia ....................................................05-42 Pilawa Quarry Processing Plant, Pilawa, Poland ..............07-1 Pinson Mining Company, Winnemucca, Nevada ..............06-17 Pittsburgh & Midway Coal Mining Company, Elkol Preparation Plant, Kemmerer, Wyoming ................05-40 Pittston Coal Company, McClure, West Virginia .............05-46 Plexus Resources, Salt Lake City, Utah ...........................06-35 Plum Point Power Partners, Plum Point Station, Osceola, Arkansas ................................................................02-5 Poludniowy Koncern Energetyczny (PKE), Sobieski Mine, Jaworzno, Poland......................................05-17 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 Port Kelang, Malaysia ......................................................08-28 Port Kembla Coal Terminal Port Kembla, New South Wales ...............................................................08-21 Port Latta Open Sea Ore Terminal Tasmania..................08-19 Quintette Plant, Tumbler Ridge, British Columbia, Canada .................................................05-49 R.M. Schahfer Generating Station, Wheateld, Indiana ...........................................................02-46 Ranger Fuel Company, Beckley #2 Plant, Sabine, West Virginia ........................................................05-55 PT Kaltim Prima Coal Facility, Sangatta, East Kalimantan, Indonesia ..............................05-7 PT Newmont Nusa Tangarra, Sumbawa, Indonesia..........08-2 PT Newmont, Batu Hijau Mining Project, Sumbawa, Indonesia ..........................................................02-48 Quarry Crushing System, Tehachapi, California .............07-11 PSI Energy, Wabash River Generating Station, West Terre Haute, Indiana ................................................02-41 PT Freeport, Irian Jaya, Indonesia...................................02-37 PT Freeport, Port of Amamapare (Papua), Indonesia .....08-15 Produvisa Servicidos, S.A., Garacas, Venezuela ..............07-28 Progress Energy Carolinas, Roxboro Power Station, Roxboro, North Carolina............02-35 Progress Energy, Crystal River Station (Units 4 & 5), Crystal River, Florida ..........................................................04-3 Protexa Construction Company, PEMEX Renery Petroleum Coke Handling Project .........03-8 Port of Amamapare (Papua), Indonesia ............................08-15 Port Of Brisbane ..................................................................08-9 Port of Los Angeles (LAXT), Los Angeles, California .........03-4 Port of Lyttelton, Christchurch, New Zealand .................08-12 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
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 Robinson Run Mine, Mannington, West Virginia ..............05-4 Rochelle Coal Company, Rochelle Mine, Gillette, Wyoming ..............................................................05-35 Rock Creek Gold Facility, Nome, Alaska ............................06-6 Rocky Mountain Bank Note, Salt Lake City, Utah ..........09-13 Roc-San Gravel Company, Aggregate Plant, Lodi, California ....................................................................07-6 Romarco Minerals, Haile Gold Mine Feasibility Study .....06-4 Roxboro Power Station, Roxboro, North Carolina............02-35 Salt River Project, Springerville Generating Station (Unit 4), Apache County, Arizona ...........................02-4 San Jose Power Station, Guatemala City, Guatemala.....02-37 San Juan Station, New Mexico .........................................05-39 Sandow Development Company (Luminant), TXU-Sandow (Unit 5), Rockdale, Texas ............................02-14 Sandy Creek Power Partners, Sandy Creek Energy Station, Riesel, Texas ............................................02-20 Santee Cooper, Cross Station, Cross, South Carolina......04-17 Santee Cooper, Winyah Station, Georgetown, South Carolina .............................................04-18 Satellite Goldelds, 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 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, Fort McMurray, Alberta, Canada ......................................06-25 Shawnee Steam Plant, Paducah, Kentucky .....................02-49 Shell Deer Park, Pet Coke Handling, Deer Park, Texas ..................................................................03-7 Shell Mining Company, Standard Hill Project, Kern County, California.....................................................06-14 Shell Oil Company, Limera, Ohio......................................05-46 Sherrgold Inc., MacLellan Mine, Lynn Lake, Manitoba .........................................................06-13 Shoal Creek Mine, Shoal Creek, Alabama........................05-31 Silica Products Company, Guion, Arkansas ......... 07-26, 07-30 Silver Bay Processing Facility, Silver Bay, Minnesota ........................................................06-22 Sleeper Project, Winnemucca, Nevada .............................06-14 SNC Service Ltd., Algeria ..................................................07-30 Sobieski Mine, Jaworzno, Poland......................................05-17 Sobin Chemical Company (Div. IMC), Spruce Pine, North Carolina .............................................07-29 South Fort Meade Mine Beneciation 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
12
Index
INDEX
Southern Illinois Power Cooperative, Marion Generation Station, Marion, Illinois ....................02-35 Southern Indiana Gas & Electric, Culley Station, Newburg, Indiana ........................ 04-23, 08-24 Southern Ohio Coal Company, Langsville, Ohio ..............05-44 Southwestern Electric Power Company, Welsh Power Plant, Cason, Texas .....................................02-49 Specialized Belt Feeders, La Cygne, Missouri .................02-34 Spring Creek Mine, Decker Montana ...............................05-29 Springerville Generating Station (Unit 4), Apache County, Arizona .......................................................02-4 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 M arina .....................................................................08-29 Taiwan Power, Coal Yard, Kaonsiung, Taiwan .................02-50 Taiwan Power, Lincou Station...........................................05-50 Taiwan Power, Talin Coal Terminal ..................................05-50 Tarmac UK, Wisniowka Quarry, Wisniowka, Poland ........07-3 Teberebie Goldelds, Process Plant, Ghana, West Africa ............................................................06-11 Teck Corporation, Bullmoose Plant, Tumbler Ridge, British Columbia, Canada ......................05-52 Tennessee Valley Authority, Allen Fossil Plant, Memphis, Tennessee ..........................................................02-15 Tennessee Valley Authority, Colbert Steam Plant, Tuscumbia, Alabama......................02-50 Tennessee Valley Authority, Drakesboro, Kentucky ........05-45 Tennessee Valley Authority, Kingston Fossil Plant, Kingston, Tennessee ......................02-9 Tennessee Valley Authority, Paradise Fossil Plant, Paradise, Kentucky ......................04-20 Tennessee Valley Authority, Paradise Plant, Drakesboro, Kentucky .......................................................02-15 Tennessee Valley Authority, Shawnee Steam Plant, Paducah, Kentucky .....................02-49 Tennessee Valley Authority, Widows Creek Fossil Plant, Stevenson, Alabama .....................................02-23 Tesoro Rening, Golden Eagle Renery, Martinez, California.............................................................03-3 Texas Gulf Sulphur Company, Offshore Iron Ore Terminal, Northwest WA.....................08-26 Thiokol Corporation, Brigham City, Utah ........................09-14 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 Modication Project ......................................06-5 Tri County Asphalt Corporation, Lake Hopatcong, New Jersey ..............................................07-8 Triton Coal Company, North Rochelle Mine, Gillette, Wyoming ................................................................05-6 Truck Maintenance & Wash Facility, Boron, California ..................................................................09-6 Truck Maintenance & Wash Facility, Carlin, Nevada .....................................................................09-5 Tungsten Recycle Project, St George, Utah ........................06-7 Turkish Coal Enterprise, Amasra, Turkey .......................05-47 Turkish Coal Enterprise, Catalagzi, Turkey ....................05-47 Turkish Coal Enterprise, Tuncbilek, Turkey ....................05-48 Turkish Coal Enterprise, Zonguldak, Turkey...................05-47 TVA Gallatin, Fossil Plant, Gallatin, Tennessee ................................................ 02-48, 08-24 TXU-Sandow (Unit 5), Rockdale, Texas ............................02-14 U.S. Borax, Truck Maintenance & Wash Facility, Boron, California .....................................09-6
Index
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c o m p a n y
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r e S o U r C e S
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 Utah Power & Light Company, Cottonwood Mine, Orangeville, Utah ...............................05-43 Utah Power & Light Company, Naughton Station, Kemmerer, Wyoming ..........................02-39 Utah Power & Light Company, Salt Lake City, Utah ..........................................................09-14 Utah Salt Company, Wendover, Utah ...............................06-35 Victoria, Australia ..............................................................08-28 Virgina Electric Power Company, Bremo Station, Richmond, Virginia ..................................02-49 W.H. Sammis Plant, Stratton, Ohio ..................................02-13 Wabash Mine, Keensburg, Illinois ....................................05-21 Wabash River Generating Station, West Terre Haute, Indiana ................................................02-41 Wallarah Coal Company, Catherine Hill Bay Coal Loader, NSW .............................08-25 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 Wedron Silica Company, Lugoff, South Carolina .............07-29 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 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, Fort McMurray, Alberta, Canada ......................................06-26 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 Wharf Resources, Process Plant Expansion, Deadwood, South Dakota ....................................................06-9 White Mining (Felix Resources) Ashton Mine, Hunter Valley, Australia ......................................................05-9 Whitehead Bros. Company, Lugoff, South Carolina ........07-30 Widows Creek Fossil Plant, Stevenson, Alabama ............02-23 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 Winyah Station, Georgetown, South Carolina .................04-18 Wisconsin Energy, Elm Road Station, Oak Creek, Wisconsin ..........................................................02-3 Wisconsin Power & Light, Edgewater Generating Station, Sheboygan, Wisconsin......................02-38
14
Index
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

Roberts and Schaefer Company

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R o b e R t s

RO BERTS & SCHAEFER COMPAN Y

PRESENTATION OF GENERAL QUALIFICATIONS TO PERFORM PROFESSIONAL ENGINEERING AND CONSTRUCTION SERVICES

RO BERTS & SCHAEFER COMPAN Y

Project Lifecycle Study/Planning Engineering & Design Procurement

Construction Testing/Commissioning Operations & Maintenance

A FULL SERVICE INTRODUCTION ORGANIZATION

OUR PROJECT EXPERTISE

OUR PROJECT EXPERTISE

OUR PROJECT EXPERTISE

LUMINANT POWER OAK GROVE POWER STATION, FRANKLIN, TEXAS

COAL FUEL HANDLING EXPERIENCE

XCEL ENERGY SERVICES COMANCHE STATION (UNIT 3), PUEBLO, COLORADO

COAL FUEL HANDLING EXPERIENCE

WISCONSIN ENERGY ELM ROAD STATION, OAK CREEK, WISCONSIN

COAL FUEL HANDLING EXPERIENCE

An as-red coal sampling system is located in the Unit 4 crusher tower.

COAL FUEL HANDLING EXPERIENCE

PLUM POINT POWER PARTNERS PLUM POINT STATION, OSCEOLA, ARKANSAS

Both as-received and as-red sampling systems are provided.

COAL FUEL HANDLING EXPERIENCE

DUKE ENERGY EDWARDSPORT POWER STATION, EDWARDSPORT, INDIANA

COAL FUEL HANDLING EXPERIENCE

CONSTELLATION ENERGY C.P. CRANE STATION, BALTIMORE, MARYLAND

COAL FUEL HANDLING EXPERIENCE

AES PUERTO RICO TOTAL ENERGY PLANT, GUAYAMA, PUERTO RICO

COAL FUEL HANDLING EXPERIENCE

TENNESSEE VALLEY AUTHORITY KINGSTON FOSSIL PLANT, KINGSTON, TENNESSEE

COAL FUEL HANDLING EXPERIENCE

COAL FUEL HANDLING EXPERIENCE

COAL FUEL HANDLING EXPERIENCE

WESTERN KENTUCKY ENERGY COLEMAN STATION, HAWESVILLE, KENTUCKY

COAL FUEL HANDLING EXPERIENCE

FIRST ENERGY W.H. SAMMIS PLANT, STRATTON, OH IO

PRB coal is now also received at the plant.

COAL FUEL HANDLING EXPERIENCE

SANDOW DEVELOPMENT COMPANY (LUMINANT) TXU-SANDOW (UNIT 5), ROCKDALE, TEXAS

COAL FUEL HANDLING EXPERIENCE

TENNESSEE VALLEY AUTHORITY

PARADISE PLANT, DRAKESBORO, KENTUCKY

ALLEN FOSSIL PLANT, MEMPHIS, TENNESSEE

COAL FUEL HANDLING EXPERIENCE

OMAHA PUBLIC POWER DISTRICT NORTH OMAHA STATION, OMAHA, NEBRASKA

COAL FUEL HANDLING EXPERIENCE

WISCONSIN PUBLIC SERVICE CORP WESTON STATION, ROTHSCHILD, WISCONSIN

COAL FUEL HANDLING EXPERIENCE

AMEREN ENERGY COFFEEN GENERATION STATION, COFFEEN, ILLINOIS

COAL FUEL HANDLING EXPERIENCE

EDWARDS POWER STATION, BARTONVILLE, ILLINOIS

DUCK CREEK POWER STATION, CANTON, ILLINOIS

COAL FUEL HANDLING EXPERIENCE

COAL FUEL HANDLING EXPERIENCE

AMERICAN ELECTRIC POWER JOHN W. TURK POWER PLANT, FULTON, ARKANSAS

COAL FUEL HANDLING EXPERIENCE

DYNEGY MIDWEST GENERATION BALDWIN POWER STATION, BALDWIN, ILLINOIS

New items also included magnetic separators and belt scales.

COAL FUEL HANDLING EXPERIENCE

TENNESSEE VALLEY AUTHORITY WIDOWS CREEK FOSSIL PLANT, STEVENSON, ALABAMA

COAL FUEL HANDLING EXPERIENCE

DUKE ENERGY CLIFFSIDE STATION, CLIFFSIDE, NORTH CAROLINA

COAL FUEL HANDLING EXPERIENCE

SOUTHERN COMPANY SERVICES GEORGIA POW ER COMPANY PLANT, MILLEDGEVILLE, GEORGIA

COAL FUEL HANDLING EXPERIENCE