Bear Run Coal Preparation Facility


Peabody Energy


Indiana, USA


1,600 tph



Contract Type:



Coal Plant and Infrastructure

Peabody’s Bear Run mine site is the largest surface mine in the eastern United States. DRA Global provided the turnkey design, engineering, procurement, erection, and commissioning of the new coal handling and washing facility just 13 months after the contract was awarded.

The surface-mined run-of-mine (ROM) coal from Bear Run mine is delivered by off-road truck to a 270-tonne hopper. Reclaimed at 1 800 tph, the ROM coal is conveyed to a crushing and screening building for reduction to 5 inch top size and then transported to one of the two 50 000 tonne raw coal stockpiles. The raw coal is reclaimed at the rate of 1 360 tph and transported to the preparation plant.

The coal preparation plant is designed to process 1 450 tph of raw coal in two parallel circuits with future expansion to 1,800 tph allowed for in the design, equipment sizing and floor space allowance. Heavy medium cyclones wash the +1 mm coarse material. Water-only cyclones and spirals wash the -1 mm fines.

Vibrating centrifuges provide final dewatering of the coarse coal, while stack sizers followed by screenbowl centrifuges dewater the fine coal. The plant employs a 145-foot diameter thickener for fine refuse recovery and water clarification. The design also incorporates a PLC control system to operate at maximum efficiency with minimum manpower requirements. Dual overhead cranes with access to all plant equipment simplify maintenance and reduce unscheduled downtime.