Featured Project
Warrior Met Coal – Maximizing Ultrafine Coal Recovery & Sustainable Tailings Management
Warrior is an environmentally, and socially minded supplier to the global steel industry. They are dedicated entirely to mining non-thermal metallurgical coal used as a critical component of steel production by metal manufacturers in Europe, South America, and Asia.
Key Outcomes
By integrating these advanced recovery and dewatering solutions, Warrior Met Coal is setting the industry standard for both operational efficiency and ESG responsibility.
- 1.4 million tons of additional high quality metallurgical coal recovered since 2020;
- Approximately $251 million in additional revenue generated;
- Improved product yield, recovering premium met coal that was previously discarded;
- Lower environmental impact by eliminating material sent to impoundments and removing the need for further tailings dam disposal;
- Up to 99.95% of solids recovered from slurry tailings; and
- Up to 900 GPM of water recycled back to the plant, reducing freshwater demand.
The Problem
Historically, coal preparation plants were not designed to capture sub-325 mesh (-44 µm) ultrafine coal, resulting in significant losses of valuable product and increased reliance on coal mine tailings impoundments. This led to missed revenue opportunities and greater long-term environmental challenges associated with coal tailings.
The Solution
Recognizing the potential to recover more of its high-quality reserves while reducing waste, Warrior Met Coal partnered with Somerset International to implement a two-phase strategy:
Phase I
Fine Coal Recovery System (FCRS)
- Recovering ultrafine coal previously discarded to tailings.
- Total Units Installed: 12 FCRS currently installed
Phase II
Tailings Dewatering System (TDS)
- Capturing solids and recycling process water to remove the need for tailings dam disposal for the dewatered material.
- Total Units Installed: 5 TDS units currently installed
Results
By integrating these advanced recovery and dewatering solutions, Warrior Met Coal is setting the industry standard for both operational efficiency and ESG responsibility in coal mining.
A Long-Term Partnership Focused on Innovation & Results
Somerset International is proud to be a trusted technology partner to Warrior Met Coal, working together since 2020 to improve resource recovery, environmental sustainability, and operational efficiency. Warrior and Somerset continue to work together to explore additional opportunities. Somerset is now also installing FCRS and TDS systems at Warrior’s Blue Creek plant which is under construction and due to commence operations in 2025.
Blue Creek Preparation Plant:
- 8 TDS units with ability to scale to 10 as needed.
- 1 FCRS to be installed and ability to scale up to 3 as needed.
The successful implementation of FCRS and TDS demonstrates Warrior’s leadership in adopting advanced coal processing technology and its commitment to sustainability across its operations.