Bogatyr Coal

The Development Prospects

For the period of 2010-2020 Bogatyr Coal, LLP set itself the following GOALS:

► Provision of growing needs of the power sector of the Republic of Kazakhstan in Ekibastuz coal for account of technical development of operations according to the Development Concept of Coal Industry of the Republic of Kazakhstan for the Period till 2020 approved by the RoK Government;

► Observance of state interests in issues of guaranteed development of power generation and mining capacities;

► Preservation and improvement of the social situation in Ekibastuz region.

THE TASKS facing Bogatyr Coal, LLP:

► Maintenance and increase of the enterprise production capacity;

► Improvement of coal products quality in the interests of power engineers;

► Reduction of operating costs.

► Increase in labor productivity;

► Replacement of physically worn-out equipment;

► Reduction of environmental hazards.

The projects and investments

Beginning from 2005 Bogatyr Coal, LLP has been implementing a planned conversion to the truck and conveyor technology of coal transportation to the surface with its blending and continuous loading into railcars at Bogatyr and Severny mines.

The introduction of the truck and conveyor technology will allow not only preserving the current capacity of the enterprise, but also increasing the coal production to provide the forecasted growth of coal demand from power engineers of Kazakhstan and Russia. The technology will allow:

► minimizing the negative impact of mining works deepening;

► upgrading the acting operations with replacement of equipment and technologies with new ones;

► streamlining the order of reserves mining within the boundaries of the mining allotment;

► reducing the time of rolling stock turnover by 2,5 time and introducing the processes of accurate loading of railcars without train fragmentation.

To fulfill the set goals for conversion to the truck and conveyor technology of coal transportation to the surface with its blending and continuous loading into railcars:

At Bogatyr mine:

► In 2006 the company jointly with the German firm called Willibald – Strek and the design institute Karagandagiproshakht i K, LLP developed the Feasibility Study on Conversion to the Truck and Conveyor Technology with Blending Coal at Bogatyr Mine with Stage-by-Stage Increase of its Capacity up to 40,0 mm t per year;

► From 2005 to 2008 at the company mines the truck and railway technology was introduced with the use of shovel excavators, large dump-trucks, and also conveyor and railway technology on coal blending, what is an intermediary stage of conversion to the cycle and continuous technology of coal mining, blending and loading. The coal is mined by shovel excavators, then it gets loaded into large dump-trucks (90-130 t capacity), which, in their turn, transport coal to the points of formation of stockpiles with blended coal. The loading of blended coal from the stockpiles into railcars is made by bucket-wheel excavators;

► During the period of 2008-2010 the investment project was implemented to the amount of 2,880 mm tenge on reconstruction of the transportation scheme for preparation of the works front for construction of the cycle and continuous technology objects of Bogatyr mine, mining blocks 5, 6, 9, and 10. The implementation of the project allowed:

- preparing the sites for construction of the cycle and continuous technology objects;

- reducing the average coal transportation distance from 16,2 km in 2006 down to 12,9 km in 2010;

- reducing the length of rail tracks of the coal complex by 19,4 km and 128 rail switches;

► The preparation of mining works front is carried out to form a permanent in-pit waste dump on the stationary slope of mining block 5;

► By 2020 the final stage of the full conversion of Bogatyr mine will be completed to the truck and conveyor technology of coal transportation to the surface with its blending and continuous loading into railcars, with stage-by-stage increase of its production capacity up to 40,0 mm t per year. The use of this technology envisages the use of modern high-performance equipment: shovel excavators, large dump-trucks; construction of crushing and transshipment points; systems of main and lifting conveyors; blending and loading complex, in the composition of which there are receiving and shipping conveyors, stackers, loading machines, loading points with coal batch-weighing loading into rail trains without train fragmentation by a loop circuit.

At Severny mine:

► In 2005 the truck and railway technology was introduced, where coal mining is made by shovel excavators with coal loading into large dump-trucks (90 t cargo capacity), which, in their turn, transport coal to the point of formation of blended coal stockpiles. The loading of blended coal from the stockpiles into rail semi-cars is made by bucket-wheel excavators.

► During the period from 2010 to 2020 the capacity of Severny mine will be preserved on the level of 10,0 mm t per year. The final stage of the full conversion of Severny mine to the truck and railway technology of coal transportation with its blending will be completed, and the reconstruction of the transportation scheme will be fulfilled with disassembly of the existing and the construction of the new rail stations, with preparation of mining works front to form a permanent in-pit waste dump on the stationary slope of mining block 1. The use of this technology envisages the use of modern high-performance equipment: shovel excavators, large dump-trucks.

► After 2020 it is envisaged to convert to the new technology of coal transportation to the surface with its blending and continuous loading into semi-cars with stage-by-stage increase of the mine production capacity and formation of a permanent in-pit waste dump in mining block 1.