market. Since then, Mibrag has unCLl!IpIl1e

extensive restructwing process _.ng.J*,~

completely modified organisa ture marked by streamlined maJ-'_l\t.

The new owners focus activities on the core business and outsource redundant support facilities and systems. At the same time, new systems and structures have been introduced. The process affected all organisational units, including teclmical, financial, commercial and legal operations.

A long-term capital investment programme worth € 600 million was initiated for the remaining company units and new subsidiaries. Existing heavy equipment was refurbished or replaced. Major capital projects included the construc­tion of two coal blending stockyards and a fluiclised bed power plant, as weil as the installation of flue gas desulphurisation plants at existiflg power stations to improve environmental controls.

Since 2001, Washington Group and NRG Energy Inc. have each held 50% of the shares in Mibrag. By the end of last year capital inveshnents totalled approximately € 798 million.

At present raw brown coal is mined

chain excavators. The coal is transported on conveyor belts to the coal blending stock­yard. Loading shovels and wheelloaders are used to recover the remaining coallocated in synclines and basins.

The qualities of the raw coal mined at Profen are shown in Table 1. Between 32 and 35 million m3 of overburden are removed to recover approximately 9 to 10 million tpa. The amount of water pumped equals 45 million m3. Since 1998, the water has been transported via a pipeline to the area south of Leipzig to ensure fast flooding of end holes. Currently operations in a new mine fjeld (Schwerzau) are being prepared.

The United Schleenhain mine comprises three mine fields: Schleenhain, Peres and Groitzscher Dreieck. The mine has four different coal seams. The thickness and position of the seams are significantly influenced by underground leaching forms.

Between 1995 and 1999 the mine was

temporarily shut down for modernisation and refurbishment. The scope of activities (worth € 225 million) included the construction of a new coal blending stockyard, the construction and installation of a new belt conveyor system, including distribution stations and energy supply systems, and the installation of a central monitoring system.

Currently the mine produces between 9 and 12 million tpa and 30 million m3 of overburden/year. The qualities of the raw coal mined at United Schleenhainare shown in Table 2.

Mining activities take place in seven coal cuts and two dump benches with continuous mining equipment (bucket wheel, bucket chain excavators and spreader). In basins and thinner coal seams or where little coal is left, mobile equipment is used (shovels, trucks, loaders).

The coal is shipped on conveyor belts to the coal blending stockyard, which has 400,000 t of storage capacity. From there it goes directly to the sole customer, the Lippendorf power plant.

In accordance with the coal supply between and theagreement Mibrag

from two large surface mines, Profen Lippendorf power plant, the brown coal and United Schleenhain. Approximately company accepts the residuals from the 19 mjJJjon tpa of raw coal and power plant (gypsum and water from the approximately 60 million m3/year of flue gas desulphurisation plant as weil as overburden are recovered. Most of the ash). Mitteldeutsche Umwelt-und coal is shipped on belt conveyors or by Entsorgung GmbH (MUEG), an affiliate train to large power plants located near of MIBRAG, was assigned by the the mines. Mibrag's main customers are company to take care of the treahnent the Lippendorf power plant (1860 MW) process. and the Schkopau power plant (900 MW). Emission proteetIon

The new owners have installed Buckel wheel excavator SRs 1300 al Schleenhain mine. The company is required by law to imple­state-of-the-art Mincon mine planning ment emission protection, including the software and processes. planting of vegetation, the The mine plans, includ­ installation and operation ing equipment deploy­ of special spraying sys­ment, are prepared for tems and the housing of each mine every two belt conveyors to avoid years. Permits are dust emissions. obtained from relevant authorities. The plans are Reclamation and based on the stipulations redevelopment

Following the require­and the Federal Regional of the Federal Mining Act

ments of the German Planning Act. Federal Mining Act,

Mibrag employs three forms of redevelopment: land reclamation for agricultural use, reforesta­

The Profen mine fjeld has tion and flooding of end two coal seams that are lakes. Mibrag prepares the continuously mined with planning and a subsidiary, bucket wheel and bucket Hydraulic buckel wheel excavalor SRs 703 al Schleenhain mine. Gala-Mi brag-Service

Reprinted from World Goal' Oetober 2005

Table 1. Profen MIne eoal qualltles

Calorific value 9.5 - 10.5 MJ/kg

1..5 - 2.0% Sulphur (as received)

Ash (as received) 7.0 - 9.0%

Table 2. Unlted Sehleenhaln mIne eoal qualltles

Calorltic value 9.7 ·ll.l MJ/kg

Sulptlur (as recelved) 1.5 - 2.0%

Ash (as recelved) 5.3·8.5%

•

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Bucket wheel excavator SRs 1200 at Pro/en mine.

GmbH, is in charge of the irnplementation. By last year approxirnately 3600 ha. of land had been redeveloped.

Beneficatlon In addition to surface mines, Mibrag operates three industrial power plants and a dust grinding plant to supply the cement industry with pulverised fuel dust. The power plants operate with a combined heat

and power process. The energy generated is mainly used for internal demand. Surplus capacities are fed into the 110 kV grid of the regional power supplier. The heat is delivered to neighbouring towns and villages.

Occupational safety Mibrag is five to six times safer than other German mining companies and is the safest industrial business in Germany today. To increase occupational safety and accident prevention standards, regular training is conducted by the Occupational SafetyIFire Brigade departrnent. The experience that the company has gained in occupational safety has been transferred to other national and international brown coal producing companies.•

Human resources The company is one of the largest employers and training providers in central Germany. At the end of last

year, 2083 people were employed at Mibrag, of wruch 132 were trainees. Since 1995 more than 330 young people have completed their training as skilled workers in the Deuben training centre. The training rate is 6.3%, wruch is rugher than average for the industry. There have been no redundancies for operational reasons since 2001. A human resource development programme was launched.

International business actMtles Apart from its core business, Mibrag has become increasingly active in international fields. Since 1997, the company has performed consulting on international projects in Europe, Africa and the the South Pacific. In 1999 a subsidiary was formed to co-ordinate and execute international business activities. Montan Bildungs-und Entwicklungsgesellschaft mbH (MBEG) renders consulting and engineering services for international mining and environrnental projects. Its scope of services includes training and preparation of further training programmes in the field of mining, business management, environment and benefication.

Importance to the regional economy Mibrag is a reliable company and stabilising factor in the economic life of central Germany. In addition to the purchasing power of the employees and tax revenues, Mibrag purchased products and services worth € 144 million from 1800 contractors in the region last year. Large contracts have been awarded to regional enterprises for mining and power plant projects. •

The author would like to thank Heike Hildesheim of Mibrag/Mbeg for assistance in preparing this article.

MINING BUSINESS UNlT HEADQlJARTERS

7800 E. UNION AVENUE, SUITE 100 DENVER, CO, 80237 USA

TEL: 1 303-843-3113 . FAX: 1 303-843-2324 . URL: WWW.WGINT.COM

Reprinted trom World Goal· Oetober 2005

I

Tbe talent, innovation, and proven performance to deliver integrated solutions for engineering, constmction, and management nceds worldwide.

Recently awarded projects include APEX San Cristobal, Glamis Millennium, TransAlta Centralia, Agrium Kapuskasing Mine, and Agrium Dry Valley Mine and pond constmctiol1.

We continue long-term management of major coal mines in Venezuela and Germany and contract mining projects in Montana and the Powder River Basin.

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7800 E. Union Ave., Suite 100, Denver, Colorado 80237. 303-843-3113

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Denver, CO, 80237, USA Tel: 303-843-3113