Cordero Coal Mine

Automation and low maintenance were key factors in the design of the Cordero Mine and its load-out facilities in Gillette, Wyoming.

The project by Fluor began with a feasibility study of the 6,540-acre federal lease. It proceeded through engineering, procurement, and construction management for the entire coal mine, handling, preparation, and shipping facilities. The processing and loading facilities were designed to handle 12 million tons per year (TPY) with provision for later expansion to the present 24 million tons.

Fluor successfully completed the Cordero Mine project ahead of schedule and under budget.

Client's Challenge

Initial evaluation revealed a coal seam 60 feet thick beneath 170 feet of overburden. The feasibility study indicated that an open-pit mine was viable, and Fluor developed a mine plan for 12 million TPY, with provision for later expansion to the present 24 million tons.

Fluor's Solution

Fluor provided the Client with a complete life cycle solution from initial feasibility study, through engineering, procurement, and construction management of the for the entire coal mine, handling, preparation, and shipping facilities.

Stripping of overburden was accomplished by 22-cubic yard shovels to provide greater flexibility than draglines. The receiving hopper was designed to handle coal from rear or bottom dump trucks, and a two-stage crushing process was used.

Each of the three conveyor systems is 160 feet long and 15 feet in diameter. The conveyor system carrier primary / secondary crushed coal to the storage silos. A total of 48,000 tons of coal can be stored in the four 200 feet high silos, which are arranged in pairs over two sets of parallel railroad tracks to permit simultaneous loading of two trains. Two 10,000-ton unit trains can be fully loaded in one hour.

Storage for an additional 100,000 tons of coal is provided in a barn that employs reinforced earth construction. The 55 degree sloped face of the barn is supported by precast concrete panels, with galvanized steel straps extended into the earth mass.

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Conclusion

Fluor provided the Client with a complete life cycle solution from initial feasibility study, through engineering, procurement, and construction management of the coal mine and processing facilities.

The Cordero Mine project was completed ahead of schedule and under budget. It began operations in 1977.

Today, the facilities can crush, convey, sample, store and load out up to 24 million tons of coal per year.