HomeMy WebLinkAboutAtqasuk Coal Project Report 1988NORTH SLOPE BOROUGH
Atqasuk Coal Project
Planning & Community Services
CEP shawabel
PO BOxOo
Barrow, Alaska 99723
ee ATQASUK COAL PROJECT
PROJECT REPORT
ene DECEMBER, 1988
PREPARED BY
ARCTIC SLOPE CONSULTING GROUP
Engineers ¢ Scientists ¢ Surveyors
6700 Arctic Spur Road Anchorage, Alaska 99518-1550
Telephone: (907) 349-5148 Fax: (907) 349-4213
North Slope Borough
Atqasuk Coal Mine Project
RELI Project # 13-127
Project Report
NSB Contract NO. 87-1903
December 1988
Submitted To:
North Slope Borough
P.O.Box 69
Barrow, Alaska 99723
Submitted By:
Arctic Slope Consulting Group
P.O. Box 650
Barrow, Alaska 993723
aS ARCTIC SLOPE CONSULTING GROUP
| Engineers °* Scientists * Surveyors
June 12, 1989
North Slope Borough
P.O. Box 69
Barrow, Alaska 99723
Attn: Dave Fauske, Deputy Director, Planning, CIP/Teleconference
Subject: NSB Atqasuk Coal Mine Project
RELI # 13-127, Project Report
Dear Mr. Fauske:
Arctic Slope Consulting Group is pleased to submit herein our project report on the Atqasuk Coal Mine Project- Project Installation Photographs and Checklists.
The NSB coal project has successfully demonstrated: 1) the Atqasuk labor force is capable and the Corporation willing to support a local coal industry on the North Slope; 2) residents of Atqasuk find the use of coal to be an acceptable alternative to oil; 3) and that modern coal fired technology is safe, burns the subbituminous coal cleanly, and is appropriate for the application investigated. There are many steps to be taken concerning the development of the local coal resource, however, this demonstration
has been instrumental in determining local interest and technical
feasibility of the project.
It was a pleasure to work with you and other NSB representatives.
Especially helpful were the people and organizations of Atqasuk. Their cooperation and enthusiasm made this challenging project
possible.
Sin oS e Ge)
Kent M. Grinage
North Slope Regional Manager
KMG/jec
Enclosures
P.O. Box 650, Barrow, AK 99723 . PH (907) 852-4556 . FAX (907) 852-5733
BARROW . ANCHORAGE . FAIRBANK S
Section
TABLE OF CONTENTS
Cover Letter.
List of Table
List of Figures
1 @ INTRODUCTION.
1.1 Background .
1.2 Project Objectives
1.3 Scope of Work. 7
1.4 Project Organization
MINING PROGRAM. .. .
2.1 Project Schedule
2.2 Mobilization. .
2.3 Stripping and Backfilling.
2.4 Coal Mining and Delivery
2.5 Geology and Coal Quality
NSTALLATION.
General. |
Production Schedule.
Equipment Purchase and Transport
Equipment Installation
x
3
3.
3
3
3 Safety and Maintenance OPWNR OAL UTILIZATION.
General. :
Observation.
Coal Use Analysis. mer Bad WNPr PY PROJECT COST.
ls || een mm LILIT Ibis
5.2 Cost Breakdown
PROJECT WORK FORCE.
6.1 General...
6.2 Work Force Profile
6.3 Labor Cost
CONCLUSIONS AND RECOMMENDATIONS
7.1 Conclusions. .
7.1.1 General
7.1.2 Mining Productivity and Costs
7.1.3 Installation.
ii PRP RPE 1 WNRRR N INNNNN mm trutie rPOUNRE WWWWWwW ' NBPWNR KR bP Pb tot NRPRR maou ' PRP i) ' WrRrRr AaADND ' 1 NANA 1 OrPRRP Re
7.2 Recommendations. . 7-6 7.2.1 Coal Mining 7-6 7.2.2 Installation. 7-8
LIST OF TABLES
Number Page
2-1 Summary of Coal Analysis 2-13 5-1 Project Cost Breakdown 5-2 6-1 Project Personnel Employment List. 6-2 6-2 Project Labor Cost : 6-3 7-1 Direct Mining Cost Estimate. 7-3 7-2 Subtask Cost Breakdown... 7-4 71-3 Installation Cost Breakdown. 7-5 7-4 Increased Production Cost Estimate 7-7
LIST OF FIGURES
Number Page
2-1 Project Location Map 2-4 2-2 Plan View of Mine Site - 2-6 2-3 Excavation Plan and Section. .. 2-8 2-4 Coal Stockpile Plan and Section. 2-10 2-5 Geologic Cross Sections. 2-12
iii
1.0 INTRODUCTION
1.1 Background
The high cost of fuel oil on the North Slope has created many hardships amongst
its residents and has suppressed economic development throughout the region.
This problem has further been compounded by substantial decreases in state and
local expenditures in capital projects which have provided cash income opportunities
to many residents. Both the high cost of fuel oil and lack of cash income are the key
factors that make up the energy problems prevalent through rural Alaska.
Aware of this problem, the North Slope Borough (NSB) Mayor and Assembly granted
funds in 1986 to Arctic Slope Consulting Group (ASCG) to perform the NSB Western
Arctic Coal Demonstration Program under the Mayor’s Resident Living Improvements
Program (RELI). The purpose of this project was to extract 100 tons of coal, install
coal burning units in Pt. Lay, Pt. Hope, and Wainwright, distribute the coal to the
participants and monitor its use.
This project was of great interest to the people of Atqasuk since coal was mined
approximately 1.5 miles from their village at the old Meade River Coal Mine.
Due to the high cost of fuel oil for home heating in Atqasuk, any local fuel source
has the potential for reducing heating costs. The Meade River coal mine is a logical
source for an alternate heating fuel. In June of 1987, in response to the villages
request, the NSB Assembly approved funds for the NSB RELI project 13-127, Atqasuk
Coal Mine Project.
1.2 Project Objectives
This project is the first step towards development of a cost effective method for
mining coal at Atqasuk. The purpose of the project is to maximize on the use of the
Atqasuk labor force and to mine and deliver to the village a minimum of 100 tons of
coal for use in a pilot program to test the use of coal for residential heating. The
project yielded information on costs and operating requirements which will assist in
the analysis of mining methods best suited to recovery of the Meade River coal and
the benefits which can be derived from its use. Other tasks of the project included
installation of coal stoves and monitoring of coal use in several residences.
1.3 Scope of Work
The major project tasks undertaken by ASCG are presented below:
1) Mobilization
Planning of the mining operation and procurement of the supplies
and equipment required for performance of the mining. Obtain
all appropriate permits.
2) Mining
Using local labor and NSB heavy equipment excavate 100 tons of
coal and stockpile at the gravel stockpile area adjacent to the
village.
3) Installation
Using local labor install ten (10) coal-fired residential heating
units in selected participating homes under the supervision of
a qualified technician.
4) Coal Utilization
Devise a method for delivery of the coal to the residents which
provides for a continuous supply and a method for measurement
of coal used at each installation.
1.4 Project Organization
Funding for this project was provided by the NSB. ASCG were the recipients of
the NSB grant and were therefore responsible for the management of the overall
project, installation equipment procurement, installation supervision, and final
report preparation. Denton Civil and Mineral was retained by ASCG as a
subconsultant responsible for mining planning and supervision.
Local hiring, project coordination within the village, and selection of demonstration
participants were performed in the village by a Project Coordinator residing in the
village.
2.8 MINING PROGRAM
2.1 Project Schedule
Commencement of the project the beginning of November provided for the use of
overland transport and stockpiling of coal. Mining during the summer or early fall
would have required bagging of coal and transport by all-terrain vehicles or boat,
which would have resulted in a much higher cost per ton. Mining and delivery of
the coal in the later fashion would have provided data which would show inflated
costs above that which is realistic for long term supply of coal to the village of
Atqasuk. Performing the entire project by use of efficient earthmoving equipment
while surface travel over frozen tundra was possible gives a better picture of the
potential cost benefits that can be anticipated from mining of the Meade River coal.
If, in the future, an all season road is constructed to the mine, the data obtained
from this project can easily be extrapolated to predict mining costs under summer
conditions.
Following is an abbreviated summary of the project :
Oct 26 to Oct 29 Planning and procurement in Anchorage.
Research existing information on the mine site,
develop preliminary mining plan, develop material
lists, and line up material suppliers for items not
available on the North Slope.
Nov 1 to Nov 2 Planning and procurement in Barrow
Nov 3 to Nov 4 Project setup in Atqasuk. Hiring, training, liaison
and local procurement.
Nov 5 to Nov 6 Mobilization, construct bridge, mine access and
support facilities.
Nov 7 to Nov 8 Stripping overburden.
Nov 9 No work. Bad blizzard and dozer down.
Nov 1@ to Nov 14 Finished stripping overburden.
Nov 15 Clean hanging wall and haul 4 loads of coal.
Nov 17 to Nov 18 Finish hauling coal, 14 more loads.
Nov 19 to Nov 20 Backfilling pit and demobilization.
Nov 18 to Nov 21 Construct coal cribs and begin delivery to
residences.
Nov 22 to Nov 23 Finish demobilization and return excess materials
and equipment to Barrow for storage.
2.2 Mobilization
Mobilization for this project entailed the procurement of materials and equipment
not available in Atgasuk and air shipment to Atqasuk. When available, materials
and rental equipment were obtained from companies located in Barrow. Primary
items procured outside of the NSB were overburden drills, explosives (which were
not used) and safety equipment. An unoccupied house in Atqasuk was used for
housing for the supervisor and for storage of most of the materials and small
equipment. Explosives were left in storage in Anchorage with the supplier.
Stripping, mining and transportation equipment were rented from the NSB fleet
stationed in Atqasuk.
Access to the site was via a winter road over the tundra which followed a route
previously used for access to the old Meade River CoalMine. A small unnamed creek
had to be crossed about one half mile from the mine site. This creek is used
by local residents as a source of unchlorinated drinking water and it was therefore
important to minimize impacts to the creek. A temporary bridge over the creek was
constructed from scrap glu-lam beams stored at the NSB yard near Ikmakrak Lake
and water from the creek was used to construct ice approaches. At the completion
of mining, the bridge was removed and the beams returned to the storage yard.
Figure 2-1 shows the project location and the access and coal haul route.
A small (about 6 foot by 8 foot) skid mounted warm-up shack was borrowed from
James Aiken, of Atqasuk, and moved to the mine site for shelter. This warm-up
shack was heated with a small kerosene space heater, which maintained the interior
at near room temperature and kept a pot of water hot for instant coffee and tea.
A 50@ gallon fuel tank was moved to the site and filled twice from the NSB "Ardco"
all terrain fuel truck. This was the primary source of fuel for the equipment and
filling was performed by gravity feed using a fork equipped loader to lift the tank.
Demobilization from the site included removal of the temporary bridge, clean-up,
and removal of all materials and facilities located at the mine site. Materials and
equipment which would not be needed for the remainder of the project were
inventoried and returned to Barrow for storage. Mining equipment and facilities
were returned to the location from where they were originally stored at Atqasuk.
TK MAKRAK
Lake
PROJECT LOCATION MAP
ATQASUK COAL MINE PROJECT |
Drawn 1/8/88 by. SWD Scale 1"=1000! FIGURE 2-1
2.3 Stripping and Backfilling
The site selected for the mining operation was at the north edge of the depression
left from previous hydraulic mining. The selected area was believed to be outside
of the limits of underground workings and having been already distributed would
result in minimal new environmental impact fromthe new mining. The general mining
plan was to remove overburden from the coal and stockpile it south and east and
immediately adjacent to the excavation to facilitate easy backfilling after coal
removal. Figure 2-2 shows a general layout of the mine area.
It was originally assumed that blasting would be required to break the frozen sand
which was the anticipated overburden on the coal. It was therefore assumed that
step excavation slopes of approximately one-half horizontal to one vertical could be
achieved. The original pit was laid out with the goal of exposing enough coal surface
to extract 15@ tons and provide a 20 percent ramp to the pit floor. The pit layout
was also based on the assumption of 25 feet of overburden depth and 6 feet of
recoverable coal. From these assumptions a coal area of 2@ feet by 32 feet was
targeted for mining with the pit dimensions required at the top of the excavation of
5@ feet by 200 feet.
Following is a list of the main pieces of mining equipment which were rented from
the NSB, Atqasuk and used in the stripping and mining operations:
lea. Caterpillar D7 Dozer equipped with single shank ripper.
1 ea. Caterpillar 966 Loader with Balderson hitch allowing rapid change
between bucket and fork attachments.
lea. Caterpillar D25 articulated dump truck with rock box.
Epge of
DEPRESSION /
Oro LINDERGROUND
Warn-UiP Sack
‘ ge ee TANK
Drcess
Tap of BuuFF
B® Oco Worst HEaneRame
PLAN VIEW OF MINE SITE
ATQASUK COAL MINE PROJECT
Drawn 1/8/88 by SWD
Scale 1"=100! FIGURE 2-2
After removing the first few feet of thawed overburden by dozer the ability of the
dozer to rip the underlying frozen material was tested and found to be acceptable.
Blizzard conditions prevailed during much of the project and ripping of the
overburden was selected as the preferred method since drilling productivity would
have been extremely low for persons using hand drills in the mustered pit. After
coal was reached, it was found that the top several feet were unacceptable for
shipment due to the high amount of clay and bone layers. At the time that coal was
encountered, the width of the pit bottom was the minimum acceptable for operating
clearance due to the shallower slopes that resulted from ripping as a means of
breaking the overburden. Also, upon reaching the coal hanging wall, the north end
of the pit floor and the loss of focal to the underground necessitated the expansion
of the pit about 34@ feet east and 3@ feet north to enable recovery of the required
amount of coal. Figure 2-3 shows the final plan and section of the pit just prior to
coal removal.
From the cross section survey taken after completion of overburden, it is calculated
that 2,550 bank cubic yards of overburden were removed. Approximately one-half
of the stripping was done by dozer only. The remainder of the overburden was
removed by the dozer ripping and pushing spoilto the edge of the pit, where it was
tramped by the loader to the overburden stockpile. Both the dozer and the loader
were used to backfill the pit, with the final regrading performed by the dozer. Due
to the overburden swell, there was more spoil available than required to backfill the
pit to original contour. The excess spoil was spread and graded in preexistent
depression south of the pit and the final regraded surface closely resembles the
pre-mining condition.
Ter of Excavation
LO ORIGINAL GRouAD
Fo ee
Excavation LMirs
Hawt@in@ WALL CoAL
20°
Secriony A-A
LEGEND
4 34% spot Elevation
RX Underground Workings
Notes: 1) Elevation Datum = 50.0 feet at top of bluff above Meade River
2) Drawing based on cross sections surve ake 8
EXCAVATION PLAN & SECTION
ATQASUK COAL MINE PROJECT
Drawn 1/8/88 by SWD
Scale 1"=20' HeV FIGURE 2-3
2.4 Coal Mining and Delivery
About three feet of alternating layers of coal, bone and clay was removed after first
encountering coal in the excavation. Then, a layer of light colored clay was
encountered immediately above coal which was visibly of higher quality than that
previously encountered. The top of the coal seam was hand and machine cleaned
of foreign material and the sides of the excavation were cleaned of loose material to
reduce contamination of the coal to be mined.
Prior to excavation of coal by the loader, it was lightly ripped by the dozer. The
loader tried digging the coal, without ripping it first, and was unable to do so
without generating large amounts of fines. The area of coal removed is shaded in
Figure 2-3. The boundaries of the coal removed were measured after coal removal
and the depth was found to be between 4 and 4.5 feet. The total volume of coal
mined, assuming an average of 4 feet recovered, is approximately 3,300 cubic feet,
which yields a total of 132 tons, assuming a coal density of 25 cubic feet per ton. At
least 1 foot of coal remained on the bottom of the pit, which was not recoverable due
to space restrictions on the pit floor.
Coal was hauled from the mine to the stockpile located in the gravel stockpile area
east of the village. The stockpile location is shown on Figure 2-1. A total of 18
loads of coal were hauled, 17 tothe stockpile and one to Mrs. Burnell’s house. A long
slender shape for the stockpile was chosen to facilitate covering it with tarp thereby
reducing potential for snow contamination and wind scattering of coal fines.
The stockpile shape also minimizes the amount of stockpile surface which must be
exposed while loading for delivery to the consumers. A plan and section of the coal
stockpile is shown in Figure 2-4.
In order to provide ameans of convenient use for the consumers and for monitoring
of coal consumption the following distribution and monitoring plan was
FoLY PROPYLENE TARP
Tarr Tied To
10 X10 Tim BERS
SEcTIonN A-A
Scare 1* =4'
COAL STOCKPILE PLAN & SECTION ATQASUK COAL MINE PROJECT
Drawn 1/8/88 by SWD
Scale as shown FIGURE 2-4
developed. Covered coal cribs (boxes) were constructed, for each residence using
the coal, and placed at a convenient location adjacent to the house. Each coal crib
has a capacity of about 170@ pounds of coal. A plywood box was constructed for the
bed of a pick-up that would hold 21.5 cubic feet or about 1700 pounds of coal. A
plywood box was constructed for the bed of a pick-up that would hold 21.5 cubic feet
or about 1000 pounds assuming a loose coal density of 45 to 50 pounds per cubic
foot. A crew of two persons will be responsible for maintaining coal in the cribs and
the consumption of each residence can be monitored by the number of loads
delivered.
2.5 Geology and Coal Quality
A geologic section of the formations encountered in the excavation is shown in Figure
2-5. with the exception of the gray sand deposits the overburden and coal were
highly frost fractured with moderate ice content above the clay bed between 1 and
2 seam and low ice content below. The sand deposits were moist upon thawing but
exhibited little thawed strength and no excess water. Samples of number 1 seam
decomposed to about 1/4 inch minus upon thawing and contained enough excess
water to yield a thin muddy consistency. Samples of number 2 seam decomposed to
about 1 inch minus upon thawing with enough excess water to generously coat all
particles of coal. A total of seven samples were taken and sent to the Mineral
Industry Research Laboratory for analysis, the results of which are summarized in
Table 2-1.
2-11
Base of ; ; Fine sand and surface debris (coal & organics)
Seasonal Thaw ee with frozen cap. Rust to gray color.
YZ
Fine sand grading to silty sand.
Gray color
Gray clay with coal inclusions.
Clay, boney coal and coal bands with
occasional sand lenses.
Number 1 Seam. Sample #87-2
Dark gray clay. Sample #87-7
Clean shiny coal, frost fractured.
Number 2 Seam (upper). Sample #87-3
Silty clay parting. Sample #'s 87-4 & 87-6
Clean shiny coal, frost fractured.
Number 2 Seam (lower). Sample #87-5
Notes: 1) Sample #87-1 taken from the side of underground workings
above and below parting.
2) Coal seam designation inferred from MIRL report titled
Charactization and Washability of Alaskan Coals, Phase II
October 1980.
GEOLOGIC CROSS SECTION
ATQASUK COAL MINE PROJECT
Drawn 1/8/88 by SWD
No Scale FIGURE 2-5
TABLE 2-1
Summary of Coal Analysis
Sample Thkn Type Description Moist. Ash Heating # ft. % % BTU/Ib
87-1 3.0 Channel 2 seam old wkgs 20.02 2.51 10,353
87-2 3.7 Channel 1 seam 17.68 21.10 7,848
87-3 2.5 Channel 2 seam (upper) 20.68 5.16 9,848
87-4 @.1 Channel Parting 2 seam 12.99 40.32 5,466
87-5 1.8 Channel 2 seam (lower) 19.08 1.89 10,640
87-6 N/A Grab 2 ptg pit floor 17.61 68.55 1,081
87-7 .8 Channel Clay FW 1 seam 18.09 67.20 1,104
Note: Analysis reported on an as-received basis.
The sample from number 2 seam taken from the old underground workings (87-1) did not
have any visible surface moisture and had as-received moisture value comparable to those
This would tend to indicate that the
surface moisture observed upon thawing of the average of samples 87-3 through 87-6 gives
for the samples of 2 seam taken form the pit walls.
an anticipated average analysis for the stockpiles coal as follows:
Moisture
Ash
Heating Value
19.90 percent
4.94 percent
10,049 BTU per pound
2-13
3.0 INSTALLATION
3.1 General
All installations have been done in accordance with NFPA 211.
It was necessary to select units that were suitable for the participants. A large
percent of this task had been done previously by Pat Gillen in Phase I of the
Western Arctic Coal Project, eliminating many units that were not designed to
burn bituminous coal. After testing units selected in Phase I of the project, and
interviewing participants, the stoves to be installed were narrowed toa selection
of four. With each stove having features of its’ own making it unique for
particular installations.
A couple new stoves were considered but later disqualified after further review
of the product. The four stoves chosen for participants to select from were, the
Sovoy Mod. #53 for its ability to have fuel oil combination, the Ashley CW 85 for
its double wall construction making the outer walls of the stoves cooler and less
likely to burn small children, also reducing clearances tocombustibles. The third
stove selected was the Harman MK III for its blower design, large flat cooling
surface and superior construction. The Riteway Omni was the fourth chosen.
The Riteway design is tall and slender making it attractive to those who have
little space.
All the stoves selected have affectivity ratings between 55% - 65% with the
Harman MK III and Riteway Omni at 65%.
The next step was travel to Atqasuk to meet with the selected participants and
with them decide which of the stoves best met their needs and where to locate
them in the home for maximum space usage and heat distribution. Due to the
floor plan of most of the homes this choice was limited to one location and
occasionally two. At this point an Installation Materials List was assembled.
3.2 Production Schedule
8/5/87
8/6-7/87
8/8-26/87
8/28/87
9/29/87
10/5/87
10/6-8/87
10/9/87
10/10-26/87
10/20/87
12/1-3/87
1/6/88
Travel and Preliminary stove selection.
Travel to Atqasuk - participant housing survey.
Material list and bid preparation.
Material bids awarded.
Material begins arriving at the freight consolidator
in Fairbanks for shipment to Barrow.
First shipment of materials arrives in Barrow.
Consolidate materials for first shipment to Atqasuk.
First of two shipments of materials to Atqasuk.
Orientate employees to installation practices.
Installation of coal stoves and chimneys.
Second shipment of materials arrives.
Travel to Atqasuk - Check on construction of coal
bins and inspect installation of 3 non-participants
stoves to verify proper installation.
Travel to Atqasuk with Kent Grinage and Fenton
Rexford for installation follow-up survey.
1/7/88 Make necessary modifications and return to Barrow.
1/18-29/88 Project Report.
3.3 Equipment Purchase and Transport
Due to the similarities of the NSB Atqasuk Coal Project and the NSB WAC Project
the Material Bid List were combined and materials consolidated in Fairbanks for
volume shipment to Barrow at which time the materials were divided into
respective projects.
Because of the wide variety of materials needed the bid list was divided into
seven sections. With prospective bidders encouraged to bid on all or any of the
individual sections. Each of the seven sections received a minimum of two
competitive bids and were awarded to the low bidder with the exception of
Section 7 (Misc. Installation Materials). In which case there were four bids none
of which were complete. Thus, materials for this section were made at the
discretion of the installation supervisor using portions of the respective bids
where applicable.
To standardize bids and simplify logistics all bids were F.0.B. Fairbanks. Quotes
were received from three air carriers to transport installation materials from
Fairbanks to Barrow. These carriers and their respective quotes are: Northern
Air Cargo ($31.97 per 100); Mark Air ($34.85 per 100); and Northern Air Freight
($35.64 per 100) with the obvious low quote - Northern Air Cargo. The materials
for the Atqasuk Coal Project and the Western Arctic Coal Project were
consolidated in Fairbanks for economical bulk freight rates. The total shipping
of materials was approximately 16,000 pounds with the Atqasuk portion being 6500
pounds.
Once in Barrow a local laborer was hired to divide materials into respective
villages and then the materials were secured in storage at Cape Smythe Air until
needed in the villages.
Cape Smythe Air, Barrow Air, and Northstar Air Cargo were all considered for
transporting the installation materials to the villages. Due to the compatibility
of load sizes with the Twin Otter, the availability of secure warehouse space (at
no charge), and the ideal staging area Cape Smythe Air was chosen. Barrow Air
lacked aircraft with sufficient load capacity. Barrow Air and Northstar Air Cargo
lacked sufficient warehouse space.
3.4 Equipment Installation
Selection of participants was done by the village coordinator. Notification of the
project was done in writing and posted in prominent locations two weeks prior
to selection of participants.
Participants were selected on their 1) desire 2) economic need and 3) anticipated
participation. A list of selected participants and the stove selected for
installation follows:
1. Daniel Stalker, Jr. Riteway Omni
2. Joe A. Akpik Ashley CW85
3. David Simmonds Ashley CW85
4. Ronald Kipp, Sr. Ashley CW85
5. Pheobe Kippi Riteway Omni
6. Daisy Shugluk Harman Mark III
7. Margaret Ahngasuk Ashley CW85
8. Herman Kignak, Sr. Harman Mark III
9. Thomas Brower, Jr. Riteway Omni
10. Peter Kippi, Sr. Ashley CW85
In most cases it was decided that stoves should be installed in locations that
wood heaters were previously installed, thus having chimneys and in some cases
full installations to contend with. This proved to be a detriment rather than
advantage. Prior to April of 1987 NFPA regulations allowed coal heating
appliances to be installed on Class A chimneys. Coal heating appliances installed
after this date ar required to have higher rating of U.L. Standards - 103-HT,
thus making it necessary to remove existing chimneys to install chimneys with the
U.L. 103-HT rating. This increased installation time two-four man hours. ALL
OF THE SIX CHIMNEYS REMOVED HAD BEEN INSTALLED WITHOUT REGARD TO
MANUFACTURES RECOMMENDATIONS OR NFPA 211 REQUIREMENTS, AND WERE
DEFINITELY FIRE HAZARDS, HAVING MELTED INSULATION AND CHARRED RAFTERS.
ITIS THE OPINION OF THE INSTALLATION SUPERVISOR THAT THE ONLY REASON
SOME OF THESE HAD NOT PREVIOUSLY CAUGHT FIRE WAS THE INABILITY TO
OBTAIN OXYGEN FOR COMBUSTION. BECAUSE THE CHIMNEYS WERE INSTALLED
ZERO CLEARANCE TO INSULATION, RAFTERS AND ROOFING MATERIALS, RATHER
THAN WITH 2" AIR CLEARANCE AS SPECIFIED BY MANUFACTURERS
RECOMMENDATION AND NFPA REGULATIONS.
All chimneys installed were Security brand model ASHT having U.L. 103-HT
approval and were installed with the required minimum 2" air space. This 2"
air space is an area of definite heat loss. But necessary! To minimize heat loss
all ceiling trim collars were sealed with silicone in a manner to maintain a vapor
barrier, therefore eliminating filtration heat loss.
Chimneys were installed so that they terminated a minimum of two feet above the
peak of the roof to minimize the possibility of down drafts. Chimneys that
penetrated the roof line more than six feet were secured with a chimney brace.
To connect the stoves to the chimneys - Security double wall connector pipe was
used. Securities double walled pipe far surpasses NFPA’s required standard 24
gage single wall stove pipe ,minimums and has many features that make it
outstanding for the application:
1) Inner liner is stainless steel all but eliminating the need for
replacement;
2) Outer wall is aesthetically pleasing black finish and vented to
allow cooling and heat distribution through convection;
3) Available in a selection of lengths and slip sections eliminating
the need for cutting;
4) Reduced clearances to combustibles 6" rather than 18" for single
wall;
5) Unique twist lock for tight joints. (Although not required for
twist lock pipe - three screws were placed in each joint); and
6) Cool exteriors minimize the possibilities of burns to small children.
Wall protection. NFPA standards state that the stove clearance to combustibles
may be reduced by 2/3 (from 36" without protection to 12” with) by installing a
noncombustible material with one inch of air space behind it, provided that
noncombustible spacers are used. All installation utilized this practice in order
to minimize the loss of living space. In many cases, installation would not have
been possible without this practice. 24 gage galvanized sheet metal with edges
hemmed was used as the noncombustible material with 1" conduit spacers secured
with screws.
Floor protection was fabricated from 5/8’’ Homasote (a commercial grade
noncombustible material that meets NFPA requirement for floor protection)
covered with 24 gage sheet metal. This floor protection was custom sized to allow
proper clearances to all sides of the stove including the 16" ,minimum in front of
the firebox opening.
Heat distribution throughout the house has been a concern. To maximize heat
distribution where forced air oil furnaces are the primary heat sources the
furnace blowers were wired with separate thermostats so they can be operated
independently from the furnaces, and distribute the air heated by the coal stoves
through the existing duct work. Where forced air heat was not available small air
distribution fans were mounted in the hallways to move warm air to the back
rooms.
3.5 Safety and Maintenance
Safety was of the highest priority. Al participants were given a through
explanation of the proper and safe use of their coal heating appliance with an
explanation of the benefits and detriments of proper and improper use and
maintenance of their stove.
Additionally each participant received the necessary accessory items needed for
safe operation of the stove. These items included a coal hod for stoking the fire,
ash bucket w/lid, three piece tool set (shovel, broom and poker), five pound ABC
fire extinguisher, and a smoke detector.
Each village coordinator was supplied with chimney cleaning equipment with
understanding of the participants that the use of this equipment is there upon
request, and should be done when creosote and soot accumulates more than 1/8
of an inch, once a year, whichever is sooner.
4.@ COAL UTILIZATION
4.1 General
This portion of the project involved the usage of coal by the selected demonstration
participants. As part of the monitoring effort during this phase of the project, a
fuel use monitoring report prepared by ASCG for the Western Arctic Coal
Demonstration Project was utilized. These report were used by the Village Project
Coordinator to track the performance of the stoves, amount of coal/oil consumed and
comments of the participants.
In order to provide a means of convenient use for the consumers and for monitoring
of coal consumption, the following distribution and monitoring plan was developed.
on November 18, covered coal cribs (boxes) were constructed, for each residence
using the coal, and placed at a convenient location adjacent to the house. Each coal
crib has a capacity of about 1700 pounds of coal. A plywood box was constructed for
the bed of a pick-up that would hold 21.5 cubic feet or about 10@@ pounds assuming
a loose coal density of 45 to 50 pounds per cubic foot. A crew of two persons will be
responsible for maintaining coal in the cribs and the consumption of each residence
can be monitored by the number of loads delivered. Coal deliveries began on
November 21.
4.2 Observations
The following observations have been recorded:
1) All coal-burning units selected for the demonstration performed well.
2) The primary use of coal has been as a supplemental heating source to
fuel oil, especially in the newer type NSB housing. In the newer
homes stand alone convection type coal stoves can only heat the
immediate surrounding area leaving the backrooms without sufficient
heat.
3) Due to the inconsistent use of the monitoring reports by the
coordinators and at times lack of a coordinator, the data gathered is
spotty. Attempts were made however to evaluate the data and utilize
an end of project participant survey. Results of which are presented
in the next subsection.
4.3 Coal Use Analysis
On April 26, 1987 a survey was conducted of each coal demonstration participant
including two residents who had coal stoves installed prior to this program. This
made for twelve (12) survey respondents.
The survey asked questions pertaining to satisfaction with coal stove installation
and coal use, how often they used the coal and would they participate in future coal
programs. Of the twelve (12) participants, four (4) rated their coal stove
installations as excellent, seven (7) rated them good, and one rated their installation
poor. Concerning the coal as an a fuel, six (6) rated coal as an excellent fuel, five
(5) as good, and one (1) fair.
When asked how long and when do they utilize coal, three (3) said all day, five (5)
stated they use coal during the daytime, others used it when it got too cold or ran
out of fuel. Eight (8) participants said they used coal about 8 months out of the
year, September to April/May.
All eleven (11) participants that responded to the question whether they would
participate in future coal programs responded by saying yes.
In all cases coal was used as a supplemental fuel to oil. This was due to the area
heating limitations of the stand alone convection coal stoves used on this project
and the style of housing which utilizes forced air or hydronic heating systems in
order to reach all of the walled in rooms in the house.
From the fuel use monitoring reports the following examples give a representative
picture of coal and oil use during the demonstration period. During the month of
January, Thomas Itta Sr. burned approximately 2500 pounds of coal and 12@ gallons
of fuel oil. Coal provided 61% of the heating demand for Mr. Itta’s home. From
December to February, Mr. Peter Kippi burned 6520 pounds of coal and consumed 247
gallons of oil. Mr. Kippi met 68% of his heating demand with coal during this period.
Overall coal use provided from 8% to 68% of the heating demand of nine (9)
participants who responded to the surveys. The mean being 36%. For the nine (9)
participants coal displaced approximately 1800 gallons of fuel from November 24 to
January 21. The average reduction in fuel oil consumption per month per participant
was about 100 gallons. This is substantial considering the limitations of the heating
units.
5.@ PROJECT COST
5.1 General
The Atqasuk Coal mine Project, as part of the overall energy resource development
project, has provided much technical and social data required to, develop
appropriate mining methods, demonstrate the applicability of modern coal stove
technology and assess the social acceptance, desires, and capabilities of coal mining
and end use by NSB residents.
5.2 Cost Breakdown
The NSB demonstration project represents the second mining effort at the old Meade
Rive Coal Mine. The project costs presented include the cost of stove installation,
mining, coal distribution and project management.
Total project costs were $209,656. This is 53% of the original project budget of
$395,000.00 and reflects the ease of mining which was not anticipated and mine
planning that located and produced the coal efficiently for a first time effort. The
test mining effort was by far the largest cost category of the project representing
44% of the total project budget. Table 5-1 presents the project cost breakdown.
It should be noted the cost associated with all phases of the project except for the
installation of stoves are not representative of cost conditions that would prevail
under normal operating conditions. The project economics of scale to provide valid
economic data to determine mining feasibility. Further, the initial field effort was
a test mining one that contained non-productive and/or non-recurring costs that
were necessary to get the initial field program up and running. Those activities
will not be necessary or can be reduced in scope for future project development
activities.
TABLE 5-1
Project Cost Breakdown
Project Management.
Administration
Project Coordinator
Mining Operation
Mine Planning and Reconnaissance
Field Supervisor
Supervisor Subsistence/Travel
Material
Freight
Rental
Labor (429.0 Hrs.)
Coal Distribution
Materials/Freight
Labor (206.5 Hrs. )
Installation.
(216.5 Hrs.)
Installation Supervisor
Supervisor Subsistence/Travel
Materials/Freight
Labor (163.@ Hrs.
Coal Crib Construction.
Materials/Freight
Labor (106.@ Hrs.)
$ 37,983.
7,824.
19,767.
12,237.
4,058.
4,122.
3,187.
33,586.
15,504.
837.
6,794.
21,741.
7,285.
20,587.
5,890.
3,749.
4,499.
25
31
@O
50
14
710
6@
eo
@6
16
32
9
15
58
82
35
43
TOTAL
-$ 45,807.56
-$ 92,463.00
-$ 7,631.48
-$ 55,505.45
-$ 8,248.78
$209,656.27
6.0 PROJECT WORK FORCE
6.1 General
All labor requirements, except for field and installation supervision were obtained
through hiring North Slope residents from the village of Atqasuk. The Project
Village Coordinator (PVC) maintained an employment list for the community. The
PVC was responsible for selection of the workers when notified by the field
supervisors that an employee was needed or a job became vacant.
6.2 Work Force Profile
The NSB Atqasuk Coal Mine RELI Project employed 11 Atqasuk residents from July
31, 1987 to May 13, 1988. This project provided 1121 hours of work for the Atqasuk
work force. The total hours are substantially below the original proposed crew hour
estimate of 3000 hours. This is due to the relative ease of mining the coal which was
not anticipated and correlates with the project expenditures being only 53% of the
original budget.
The largest employment sector was in mining, with 5 workers, (45% of total). In
addition to mining, there were employed 4 equipment installers, (36 % of total), and
2 project coordinators (18% of total).
Personnel and job classifications are presented in Table 6-1.
TABLE 6-1
Project Personnel Employment List
Village Project Coordinator
Ron Kippi, Sr.
Leroy Gunderson
Coal Mining Employees
4% Simeon Akpik, Jr.
Larry Itta
Mike Shugluk
x David Simmonds
Alvin Lieb
Village Installers
Joseph Kippi
Thomas Itta, Jr.
Amos Kippi
Joe Akpik
A total of approximately 535 hours of labor, excluding supervision, were used to
perform the mining tasks, which can be broken down as follows:
Mob/Demob 105 Hours 2@ Percent
Stripping 207 Hours 39 Percent
Mining & Hauling 88 Hours 16 Percent
Backfilling 29 Hours 5 Percent
Coal Crib Construction 106 Hours 2@ Percent
A total of 163 hours of labor, excluding supervision, were used to perform the
installation task.
6.3 Labor Cost
Labor costs for the entire project amounted to 19% of the overall project cost.
Labor cost are presented in Table 6-2. Labor cost associated with mining make up
38% of the total labor cost and 17% of the mining costs.
TABLE 6-2
Project Labor Cost
Percent
Major Cost Categories Task Cost Project Cost
Management Fees and
Administration Cost $ 45,800 22
Planning, Mining and Stockpiling 92,500 44
132 tons of coal
Coal Distribution 7,600 @4
Stove Purchase and Installation 55,500 26
Coal Crib Construction 8,200 @4
TOTAL $ 209,600 100
Local Labor Cost
S$ 7,800
15,500
6,800
5,980
S$ 4,500
$42,500
7.0 CONCLUSIONS AND RECOMMENDATIONS
7.1 Conclusions
7.1.1 General
The NSB Atqasuk Coal Demonstration Project has demonstrated that it is
possible to mine 10@ tons of coal and burn coal adequately in today’s modern
coal burning units. All demonstration participants view coal as an acceptable
home heating fuel. Residents of Atqasuk are capable and willing to support
a coal mining effort in their community. Even though the coal mining was
conducted during severe weather conditions, the work crews performed
exceedingly well. In addition there were no work related injuries. This
demonstrates this type of work can be performed in a safe manner even
during harsh winter conditions.
7.1.2 Mining Productivity and Costs
From the cross section survey performed of the pit prior to coal rem,oval it
was estimated that approximately 2,55@ bank cubic yards (BCY) of overburden
was removed to yield 132 tons of coal. This gives a gross stripping ratio of
19.32 BCY per ton. Ofthe 94 hours of dozer time used, approximately 63 hours
were used in the stripping operation, yielding a gross productivity of 40.5
activity for about 7 1/2 days at 1@ hours per day, which yields a net
productivity of 34 BCY per man-hour. Only one truck was available for coal
hauling and about 15 hours were required for coal haul, which yields a hauling
productivity of 8.8 tons per hour. Round trip time for each load was about 50
minutes with less than 10 minutes required for loading. Therefore, addition
of more haul trucks would increase the overall productivity of the coal mining
activity in direct proportion to the number of trucks hauling fleets up to 5
trucks.
Table 7-1 is an estimate of the overall direct mining costs for the project.
Costs for construction of the coal cribs and coal distribution are excluded
from this estimate. Also, it should be noted that, as stated, Table 7-2 is only
an estimate of costs,since actual invoice costs for all items were not in hand
during preparation of this report. Table 7-2 is a breakdown of the direct
mining costs by subtask and the unit cost for each subtask.
It should be noted that the cost for coal loading and hauling (mining) is
significantly higher than need be due to the poor utilization of the equipment
fleet. Only one serviceable truck was available for hauling and the loading
crew therefore spent most of its time waiting forthe truck to return. Addition
of more trucks to the mining operation would only add the cost of the truck
and driver while other costs would remain the same. Each truck added to the
hauling fleet would increase costs by about $2,090.00 and add about 132 tons
to the total production during the same time period. Addition of trucks to the
hauling fleet would therefore have the following effect on the coal mining
costs:
# Trucks Total Tons Cost Per
Cost Mined Ton
1 12,501 132 $ 94.70
2 14,591 264 $ 55.27
3 16,681 396 $ 42.12
TABLE 7-1
Direct Mining Cost Estimate
UNIT TOTAL
UNITS QUANTITY
D7 dozer rental hrs 94 $ 179 $ 16826
966 loader rental hrs 96 118 11328
DJB truck rental hrs 16 81 1296
14@ grader rental hrs 1 96 96
Generator rental days 21 30 630
Drill rental days 6 120 720
Drill tool rental month 2 300 600
Crew cab rental days 25 8 2200
Sno-go rental days 3 30 90
Fuel gal. 1170 2.75 3217.5
Gasoline gal. 25 3 75
Kerosene gal. 10 4 40
Blazo gal 1 10 10
Antifreeze gal. 75 10 75
Sub-zero oil gal. 12 20 240
Ripper teeth each 3 200 600
Grease & Misc. ls 1 200 200
Labor hrs 429 35 15015
Supervision hrs 222.5 55 12237.5
Supervision subsistence days 30 30 900
Misc. supplies lis 1 2000 2000
Freight & Transportation l.s 1 3000 3000
Phone & Utilities ls 1 1000 1000
TOTAL $ 72196
TONS MINED 132
DIRECT MINING COST/TON 546.94
Description
D7 Dozer
966 Loader
DJB Truck
14@ Grader
Generator
Drill & Tools
Crew Cab Pick-up
Sno-go
Fuel and Lube
Ripper Teeth
Labor
Supervision
Super. Subsistence
Supplies
Freight & Transport
Phone & Utilities
UNIT COST $/ton
$/BCY
TABLE 7-2
Subtask Cost Breakdown
Mob/Demob Stripping
1,611 11,277
1,888 5,664
81 1,215
96
454
946
260 1,080
90
5@2 2,983
600
3,675 7,245
5,205 4,482
369 333
260 1,080
3,000
130 540
16,967 35,784
132 ton 2550 BCY
128.54 271.09
14.03
Mining
1,432
2,478
176
374
420
810
3,980
1,760
126
Backfill
2,506
1,298
240
255@ BCY
52.61
7.1.3 Installation
All units installed were of the free standing, radiant type
heaters. The simplicity of this type of installation kept
cost to a minimum (approx. $2400 per installation), maximizing
the number of participants. The material cost of this type
of installation could be $200 less or $60@ more depending on
units selected. If in future projects of this type more
elaborate central heating systems are installed in tandem with
existing oil central heat the cost could be expected to be two
or three times ($5000 - $8000) that of the free standing
stove. Table 7-3 shows the breakdown in installation costs.
TABLE 7-3
Installation Cost Breakdown
Item Cost
Labor - 163 man hours 5892.82
Stoves - 10 each (from $842 - $1245 each) 9265.00
Chimney and Connector Pipe 3353.72
Stove Boards and Wall Protectors 1576.26
Misc. Installation Mat. 1115.02
Freight to Barrow (6500 lbs. at 31.97/12) 2078.05
Freight to Atqasuk (2 trips w/Twin Otter at $920) 1980.00
Total Cost (Ten Installations) $ 25,258.85
Average Cost Per Installation 2311.70
Note: The above costs do not include preliminary research, installation
supervision or management support.
7.2 Recommendations
7.2.1 Coal Mining
The NSB heavy duty equipment was found to be adequate for the task.
Further work in reducing the cost of mining and increasing geologic data are
needed.
There are many ways to reduce the overall mining cost of $546.94 per ton that
is estimated for this project. The potential for cost reduction through use of
additional haul trucks is discussed in the previous section. The greatest
potential for cost reduction would come if alarger tonnage of coal were mined.
This would spread the fixed costs such as mobilization over a greater tonnage
and result ina net reduction in the stripping ratio. Fromthe geologic section
in Figure 2-5, the total depth of overburden is 21.5 feet to yield 4.4 feet of
recoverable coal. This yields a vertical (net) stripping ratio of 4.52 BCY per
ton. Therefore, of the 2550 BCY of overburden excavated, approximately 2000
BCY were excavated to provide side slopes and a ramp into the pit. This
nonproductive excavation would not increase for larger tonnages of coal
mined.
Assuming that a larger pit would provide adequate working room, such that
a total of 5.4 feet of coal could be recovered, then net stripping ratio for the
area mined is 3.7 BCY per ton. The following shows the effect on the overall
stripping ratio for larger production levels:
Tons Net Net Non-Prod Gross Gross
Produced Ratio BCY BCY BCY Ratio
132 4.52 596 1,954 2,550 19.32
200 3.7 740 2,000 2,740 13.70
500 3.7 1,850 2,000 3,850 7.70
1,000 3.7 3,700 2,000 5,700 5.70
2,000 3.7 7,400 2,000 9,400 4.70
There are basically two ways that the above reductions in gross stripping
ratio can be realized. Either by mining the entire tonnage in one year and
stockpiling the coal for future consumption or by leaving the pit open from
year to year so that the non productive stripping would not have to be
repeated each year. Stockpiling of the coal would require compaction and
shaping of the coal stockpile to reduce the potential for spontaneous
combustion, which could be done at little or no additional cost. Leaving the
pit open from year to year would require provisions for drainage control and
treatment which would increase costs, therefore, the stockpile option seems
to be the preferred option. Table 7-4 gives a summary analysis of the
anticipated mining costs for the production levels listed above. Unit costs
are obtained from Table 7-2 and it is assumed that total mobilization cost
would remain constant for the higher production levels. It is also assumed
in Table 7-4 that 3 trucks are used for the coal hauling operation.
TABLE 7-4
Increased Production Cost Estimate
Prod. Gross Mob Strip. Mining Backfill Total
Rate Ratio $/ton S/ton $/ton $/ton $/ton
132 19.32 128.54 271.09 42.12 52.61 494.36
200 13.70 84.84 108.03 42.12 20.94 205.02
1000 5.70 33.93 719.97 42.12 15.50 154.56
2000 4.70 8.48 65.94 42.12 12.78 129.32
Notes 1 Mobe cost assumed constant at $16,967.90.
2 Stripping cost computed at $14.@3/BCY.
)
)
3) Mining cost based on use of 3 haul trucks.
) Backfill cost computed at $2.72/BCY.
The analysis presented in Table 7-4 would seem to indicate that for
production levels greater than 1000 tons, the mining costs can be reduced
to less than $200.00 dollars per ton. This would require only a 23 percent
increase in productivity for the 2@00@ ton scenario, above that which as
achieved by this test program. This increase in productivity would seem
to be a reasonable expectation.
7.2.2 Installation
The general acceptance of the installation portion of the project was positive
with the few recommendations for change being directed to the coal.
Recommendations from the participants were to have the coal screened for
sizing and stored in a manner that would keep snow from mixing with the
coal.
ASCG installation recommendations are:
1. Consider installing coal central heating units in tandem with
existing oil systems for future projects.
2. Closer screening of participant selection to assure more
involvement of participants.
3. Screening all coal to minimum 1/2" size.
4. Consider pelletizing the coal to improve upon dust suppression,
coal combustion and hauling characteristics.
5. Mail a follow-up letter to all participants reminding them of the
importance of keeping combustibles away from the stoves, and
the importance of proper maintenance.
6. For the construction of new North Slope Borough facilities design
for coal heating appliances or for future installation.
7. The use of coal bins is less labor intensive than the bagging
method use in the Western Arctic Coal Project, buta slightly less
desireable method of coal storage. Develop measures to improve
upon the coal bins.
The North Slope Borough run a separate project to correct the
improperly installed chimneys intended for the use of wood heaters in Borough housing. This could be done with minimal
new materials and cutting back framing to the proper 2"
clearances.