Business
OVERVIEW
We are a leading producer of coal in Northern and Central Appalachia with a
broad range of mid to high Btu, low sulfur steam and metallurgical coal. Our
Appalachian mining complexes, which include 11 of our mining complexes, are
located in West Virginia, Kentucky and Maryland. We also have a complementary
mining complex of mid to high sulfur steam coal strategically located in the
Illinois Basin. We market our coal to a diverse customer base of largely
investment grade electric utilities, as well as domestic and international
industrial customers. The high quality of our coal and the availability of
multiple transportation options, including rail, truck and barge, throughout the
Appalachian region enable us to participate in both the domestic and
international coal markets. Due to the decline in Appalachian coal production in
recent years, these markets are currently characterized by strong demand with
limited supply response and elevated spot and contract prices.
The company was formed by WLR and other investors in May 2004 to acquire and
operate competitive coal mining facilities. As of September 30, 2004, ICG, Inc.
acquired certain key assets of Horizon through a bankruptcy auction. These
assets are high quality reserves strategically located in Appalachia and the
Illinois Basin, are union free, have limited reclamation liabilities and are
substantially free of other legacy liabilities. Due to our initial
capitalization, we were able to complete the acquisition without incurring a
significant level of indebtedness. Consistent with the WLR investor group's
strategy to consolidate profitable coal assets, the Anker and CoalQuest
acquisitions further diversify our reserves. On or about the same time as the
Anker and CoalQuest acquisitions, we will complete a corporate reorganization.
With the proceeds of this offering, we expect to retire substantially all of our
debt, including debt assumed through the Anker and CoalQuest acquisitions, and,
thus, we will be strategically well-positioned.
As of January 1, 2005 (pro forma for the Anker and CoalQuest acquisitions), we
owned or controlled approximately 315 million tons of metallurgical quality coal
reserves and approximately 572 million tons of steam coal reserves. Based on
expected 2005 production rates, our Northern and Central Appalachian reserves
(pro forma for the Anker and CoalQuest acquisitions) could support existing
production levels for approximately 35 years and all of our reserves could
support existing production levels for approximately 49 years. Further, we own
or control approximately 707 million tons of coal resources, pro forma for the
Anker and CoalQuest acquisitions.
Steam coal is primarily consumed by large electric utilities and industrial
customers as fuel for electricity generation. Demand for low sulfur steam coal
has grown significantly since the introduction of certain controls associated
with the Clean Air Act and the decline in coal production in the eastern half of
the United States. Metallurgical coal is primarily used to produce coke, a key
raw material used in the steel making process. Generally, metallurgical coal
sells at a premium to steam coal because of its higher quality and its
importance and value in the steel making process. During 2004 and the first
quarter of 2005, the demand for metallurgical coal increased substantially as
the global demand for steel increased.
For the year ended December 31, 2004 (pro forma for the Anker and CoalQuest
acquisitions), we sold 18.4 million tons of coal, of which 18.2 million tons
were steam coal and 0.2 million tons were metallurgical coal. Our steam coal
sales volume in 2004 consisted of mid to high quality, high Btu (greater than
12,000 Btu/lb.), low sulfur (1.5% or less) coal, which typically sells at a
premium to lower quality, lower Btu, higher sulfur steam coal, pro forma for the
Anker and CoalQuest acquisitions. Our three largest customers for the three
months ended March 31, 2005 were Georgia Power Company, Carolina Power & Light
Company and Duke Power and we derived approximately 49% of our coal revenues
from sales to our five largest customers, pro forma for the Anker and CoalQuest
acquisitions.
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OUR HISTORY
The Horizon acquisition
On February 28, 2002, Horizon (at that time operating as AEI Resources Holdings,
Inc.) filed a voluntary petition for Chapter 11 and its plan of reorganization
became effective on May 8, 2002. However, Horizon's profit margins and cash
flows were negatively impacted in fiscal year 2002 by, among other things, the
falling price of coal and continued increases in certain operating expenses. Due
to capital and permit constraints, Horizon had to mine in areas which produced
coal but at greatly reduced profit margins thus severely reducing cash flow.
As a result of its continuing financial and operational difficulties, Horizon
filed a second voluntary petition for relief under Chapter 11 on November 13,
2002. Horizon obtained a debtor-in-possession financing facility of up to
$350.0 million and was effective in rationalizing its operations, selling
non-core assets, paying down outstanding borrowings and generating substantial
operating profit. With stabilized operations and a significantly improved coal
market, Horizon filed a joint plan of reorganization and a joint plan of
liquidation under Chapter 11.
ICG was formed by WL Ross & Co. LLC and other investors in May 2004. The Horizon
assets were sold to us through a bankruptcy auction on August 17, 2004.
Presented as a combined $290.0 million cash bid with A.T. Massey, ICG, Inc.
agreed to pay $285.0 million in cash plus the assumption of up to $5.0 million
in cure costs to acquire the assets plus ICG, Inc. also contributed a credit bid
of second lien Horizon bonds, and A.T. Massey agreed to pay $5.0 million in cash
to acquire a separate group of assets associated with two Horizon subsidiaries.
The credit bid included the cancellation of $482.0 million of certain Horizon
bonds in return for which those Horizon bondholders received the right to
participate in a rights offering to purchase ICG common stock. Shares issued in
connection with the rights offering are included in our outstanding stock. The
former bondholders of Horizon that purchased shares of ICG, Inc. common stock in
the rights offering were creditors of Horizon and received the shares in
reliance on Section 1145 of the U.S. Bankruptcy Code, which in general provides
for the limited exemption from the registration requirements of the Securities
Act for securities issued in exchange for a claim against the debtor in
bankruptcy. Since ICG's formation, some trading of ICG, Inc.'s common stock has
occurred. See "Price range of ICG, Inc. common stock." ICG has not previously
been a reporting company under the Securities Exchange Act of 1934, as amended.
In addition, Lexington Coal Company, LLC, a newly formed entity, was organized
by the founding ICG, Inc. stockholders to assume certain reclamation liabilities
and assets not otherwise being purchased by A.T. Massey or ICG, Inc. In order to
provide support to Lexington Coal in consideration for assuming these
liabilities, we agreed to provide a $10.0 million letter of credit to support
reclamation obligations and to pay a 0.75% royalty on the gross sales receipts
for coal mined and sold from the assets we acquired from Horizon until the
completion by Lexington Coal of all reclamation liabilities acquired from
Horizon. Other than this support and a limited commonality of ownership of ICG
and Lexington Coal Company, there is no relationship between the entities.
The bankruptcy court confirmed the sale on September 16, 2004 as part of the
completion of the Horizon bankruptcy proceedings. At closing, we increased the
purchase price by $6.25 million, primarily to satisfy increased administrative
expenses, and the sale was completed as of September 30, 2004.
The acquisition was financed through equity investments and borrowings under our
senior secured credit facility, which we entered into at the closing of the
Horizon acquisition. See "Description of indebtedness" for a discussion of our
senior credit facility. We expect to repay a portion of the term loan facility
with the proceeds of this offering.
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The Anker and CoalQuest acquisitions
On March 31, 2005, ICG, Inc. entered into a business combination agreement with
Anker Coal Group, Inc., ICG (then known as ICG Holdco, Inc.), at that time a
wholly owned subsidiary of ICG, Inc., ICG Merger Sub, Inc., an indirect wholly
owned subsidiary of ICG, and Anker Merger Sub, Inc., an indirect wholly owned
subsidiary of ICG. Under the terms of the business combination agreement,
simultaneously with the effective time of the mergers under the CoalQuest
business combination agreement, ICG Merger Sub will merge with and into ICG,
Inc. and Anker Merger Sub will merge with and into Anker, with each of ICG, Inc.
and, Anker surviving their respective mergers as indirect wholly owned
subsidiaries of ICG and ICG will be the new parent holding company. The
agreement was amended May 10, 2005 to allow the exchange ratio formula to be
adjusted if ICG engages in a stock split.
The stockholders of Anker, collectively, are entitled to receive the lesser of
(i) 19,498,581 shares of ICG common stock and (ii) the number of shares of ICG
common stock equal to the quotient of 173,250,000 divided by the price per share
at which our stock is offered in this offering (the "base merger share number"),
subject to the following possible adjustments. If certain events relating to the
commencement of specified coal production and the execution of a coal purchase
contract do not occur prior to the effectiveness of the merger, ICG will only
issue shares equal to the lesser of (i) 18,373,122 shares of ICG common stock
and (ii) the number of shares of ICG common stock equal to the quotient of
163,250,000 divided by the price per share at which our common stock is offered
in this offering (the "adjusted merger share number") at the effective time of
the merger and will reserve but not issue the number of shares equal to the
difference between the adjusted merger share number and base merger share number
(this difference, the "contingent shares"). These contingent shares are only
issuable to the former stockholders of Anker if one of the following events
occurs: (i) the commencement of the production of coal at Anker's Stoney River
mine or (ii) the execution of a contract for the purchase of coal from the
Glady's Fork mine; provided in either case that such event, at the time it
occurs, could reasonably be expected (alone or with the other event) to generate
at least $6.0 million of EBITDA during calendar years of 2005 and 2006.
On March 31, 2005, ICG, Inc. also entered into a business combination agreement
with CoalQuest, ICG and CoalQuest Merger Sub LLC, an indirect wholly owned
subsidiary of ICG, and the members of CoalQuest. Under the terms of the business
combination agreement, simultaneously with the effective time of the mergers
under the Anker business combination agreement, the members of CoalQuest will
contribute their interests in CoalQuest to us in exchange for shares of our
common stock. As a result of this contribution, CoalQuest will become our wholly
owned subsidiary. The agreement was amended May 10, 2005 to allow the exchange
ratio formula to be adjusted if ICG engages in a stock split.
The members of CoalQuest, collectively, will receive the lesser of
(i) 11,451,548 shares of ICG common stock and (ii) the number of shares of
common stock equal to the quotient of 101,750,000 divided by the price per share
at which our common stock is offered in this offering.
The former stockholders of Anker and former members of CoalQuest will be granted
certain piggyback registration rights with respect to the ICG common stock
issued to them. For additional information on registration rights, see
"Description of capital stock-Registration rights."
The completion of both transactions is subject to various conditions, all of
which have been fulfilled other than the approval by the ICG, Inc. stockholders
of the corporate reorganization. In addition, the completion of the transactions
under each business combination agreement is conditioned upon the satisfaction
of the conditions precedent of the transactions under the other business
combination agreement.
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Our reorganization
On or about the same time as the Anker and CoalQuest acquisitions, we will
complete a corporate reorganization. Prior to the reorganization, our current
top-tier parent holding company is ICG, Inc. Upon completion of the
reorganization, ICG will become the new top-tier parent holding company. In the
corporate reorganization, the stockholders of ICG, Inc. are expected to receive
one share of ICG common stock for each share of ICG, Inc. common stock. The
shares of our common stock being issued to the ICG, Inc. stockholders are
expected to be registered pursuant to a separate registration statement to be
filed with the SEC. All stockholders of ICG, Inc., all Anker stockholders and
all CoalQuest members will be stockholders of ICG after the reorganization and
the Anker and CoalQuest acquisitions.
OUR COMPETITIVE STRENGTHS
We believe that the following competitive strengths enhance our prominent market
position in the United States:
Ability to provide variety of high-quality steam and metallurgical coal. Our
customers, which include largely investment grade electric utilities, as well as
domestic and international industrial customers, demand a variety of coal
products. Our variety of coal qualities also allows us to blend coal in order to
meet the exact specifications of our customers. Our access to a comprehensive
range of high Btu steam and metallurgical quality coal allows us to market
differentiated coal products to a variety of customers with different coal
quality demands, which allows us to benefit from particularly strong pricing
dynamics in the current metallurgical coal market.
Concentration in highly valued Central Appalachian region. Our operations are
primarily located in Central Appalachia, a region known for its high quality
coal characterized by low sulfur and high Btu content. Production from Central
Appalachian mines accounted for approximately 73.2% of our 2004 coal sales
volume, pro forma for the Anker and CoalQuest acquisitions. Increased
electricity generation and steel production both domestically and
internationally has lead to a substantial increase in demand and a significantly
improved pricing environment. In addition to general market factors creating a
favorable environment, the Central Appalachian region has experienced production
declines in five out of the last six years, primarily due to difficult mining
conditions, yet demand continues to increase. We believe that generally
favorable market dynamics and trends in Central Appalachian coal supply and
demand, the high quality of Central Appalachian coal and the low transportation
costs that result from the relative proximity of Central Appalachian producers
and customers have created favorable pricing dynamics that provide us with an
advantage over producers from other regions.
Significant reserve base providing internal expansion opportunities. We own
approximately 613 million tons of reserves and control an additional 274 million
tons of reserves through long-term leases, pro forma for the Anker and CoalQuest
acquisitions. We own or control an additional 707 million tons of coal
resources, pro forma for the Anker and CoalQuest acquisitions. We have not yet
developed approximately 73% of these owned and controlled reserves. We believe
these owned and controlled but as yet undeveloped reserves and resources would
allow us to as much as double our existing production levels over the next
several years. Our ownership and control of such a substantial portion of
undeveloped reserves in both Northern and Central Appalachia and the Illinois
Basin provides us with significant internal growth opportunities, this is in
contrast to other U.S. coal producers who must acquire or lease new reserves to
enable their growth. We also have coalbed methane reserves in our owned reserves
in West Virginia, which provides us with additional growth opportunities in this
complementary energy market.
Ability to capitalize on strong coal market dynamics. A significant portion of
our coal supply contracts were renegotiated during the second half of 2004 in
connection with Horizon's bankruptcy
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and were re-priced at that time to then-current (and more favorable) market
prices and terms. On average, our coal supply contracts have a life of
approximately five years, however, the majority of our contracts contain annual
price reopeners. Our marketing effort is focused on maintaining a balance of
longer-term contracts and spot sales. We typically have 50% of our production
contracted by the early part of the previous year with another 35% contracted by
the second half of the year with the remainder of our production used to take
advantage of market dynamics and maximize value in the spot market.
Diversity of reserves, resources and production. Our reserves, resources and
production are located in three of the four major coal regions in the United
States. Our production, reserves and resources in Northern and Central
Appalachia and the Illinois Basin provide important geographical diversity in
terms of markets, transportation and labor. The diversity of our operations and
reserves provides us with a significant competitive advantage, allowing us to
source coal from multiple operations to meet the needs of our customers and
reduce transportation costs.
Minimal level of long-term liabilities. We believe that compared to other
publicly-traded U.S. coal producers we have among the lowest legacy reclamation
liabilities and post-retirement employee obligations. As of March 31, 2005 (pro
forma for the Anker and CoalQuest acquisitions), we had total accrued
reclamation liabilities of only $68.9 million, post-retirement employee
obligations of only $8.4 million, "black lung" liabilities of approximately
$10.6 million and Coal Act liabilities of only $4.7 million. We maintain a
comprehensive mine reclamation plan which we believe ensures that all of our
mining operations are current on reclamation requirements. In addition, our
entire workforce is union free, which minimizes employee-related liabilities
commonly associated with union-represented mines. As of March 31, 2005 (pro
forma for the Anker and CoalQuest acquisitions), our total debt was
$216.7 million and after this offering we expect to retire all of this debt,
excluding $7.1 million of capitalized leases and other debt obligations. We
believe that our financial leverage is among the lowest of the publicly traded
U.S. coal producers. We believe this low leverage will afford significant
financial and operational flexibility.
Highly skilled management team. The members of our senior management team have,
on average, 23 years of industry work experience across a variety of mining
methods, including longwall mining. We have substantial Appalachian mining
experience in increasing productivity, reducing costs, enhancing work safety
practices, and maintaining strong customer relationships. In addition, the
majority of our senior management team has extensive mine development and
expansion experience.
Recognized leadership in safety and environmental stewardship. The injury
incident rates at our mines throughout 2004, according to MSHA, were below
industry averages. We have been recognized by safety and environmental agencies
with several prestigious awards for our safety and environmental record, such as
the "Sentinels of Safety Award" from MSHA, The Department of Interior
"Excellence in Surface Coal Mining and Reclamation Award" and a reclamation
award for innovative methods from the West Virginia Coal Association. Our focus
on safety and environmental performance results in the reduced likelihood of
disruption of production at our mines, which leads to higher productivity and
improved financial performance.
OUR BUSINESS STRATEGY
Our objective is to increase stockholder value through sustained earnings and
cash flow growth. Our key strategies to achieve this objective are described
below:
Maximize profitability through highly efficient and productive mining
operations. We are continuing to evaluate and assess our current operations in
order to maximize operating efficiency and returns on invested capital. We are
focused on maintaining low-cost, highly productive operations by continuing to
invest substantial capital in state-of-the-art equipment and advanced
technologies. We expect to
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internally fund approximately $304 million of capital expenditures in the next
two years. As we take advantage of planned expansion opportunities from 2007
through 2009 principally as a result of the Anker and CoalQuest acquisitions, we
expect to spend approximately $627 million on capital expenditures, which may
require external financing. We have developed and cultivated a
productivity-focused culture through incentive programs that encourage employees
to work efficiently, safely and productively. We intend to further leverage the
scale of our purchasing power to obtain favorable pricing from suppliers of raw
materials in addition to developing reserves and utilizing mining techniques,
such as longwall mining and dragline operation, to enhance and streamline our
operations.
Leverage owned and controlled reserve base to generate substantial internal
growth. We own a large undeveloped reserve in Northern Appalachia containing
approximately 194 million tons of high Btu, low sulfur steam and metallurgical
quality coal, pro forma for the Anker and CoalQuest acquisitions. We currently
expect underground longwall mining operations at this reserve to commence within
the next four years, which will increase our production level by providing
highly valued premium quality coal in an increasingly tight supply market. In
addition, we have two substantial reserves in Central Appalachia (pro forma for
the Anker and CoalQuest acquisitions), which contain 56.5 million tons of
premium metallurgical coal and are expected to be developed in the next three to
six years. Further, the substantial reserve position that we own in the Illinois
Basin is expected to allow us to benefit from the expected increase in demand
for high sulfur coal to generate electricity. We are in the process of
developing and exploiting our coalbed methane reserves (the first such
development and exploration in the region). Finally, we intend to
opportunistically acquire new coal reserves and/or coal companies to expand our
coal market opportunities and increase shareholder value.
Capitalize on favorable industry fundamentals by opportunistically marketing
coal. U.S. coal market fundamentals are among the strongest in the last
20 years. We believe this generally favorable pricing environment will persist
given systemic changes in market dynamics such as long-term supply constraints
and increasing demand, particularly in Central Appalachia and for our
metallurgical coal. Furthermore, because of the high quality of our coal, our
access to a variety of alternative transportation methods, including truck, rail
and barge, and our mix of long-term contract and spot market sales, we will be
able to capitalize on the favorable industry dynamics to maximize our revenues
and profits. We plan to extend the life of our longer-term contract arrangements
and limit price reopeners in order to lock in margins and enhance our financial
stability, while at the same time, we plan to maintain an uncommitted portion of
planned production to allow for additional future pricing upside exposure. As of
May 31, 2005 (pro forma for the Anker and CoalQuest acquisitions), we had
entered into contracts to sell approximately 93% of 2005 planned production,
approximately 69% of 2006 planned production and approximately 48% of 2007
planned production.
Continue to focus on improving workplace safety and environmental compliance. We
have maintained and plan to continue to maintain an excellent safety and
environmental performance record. We continue to implement safety measures and
environmental initiatives that are designed to promote safe operating practices
and improved environmental stewardship among our employees. Our ability to
maintain a good safety and environmental record improves our productivity and
lowers our overall cost structure as well as bolsters employee morale.
COAL MINING METHODS
We produce coal using two mining methods: underground room and pillar mining
using continuous and longwall mining equipment, and surface mining, which are
explained as follows:
Underground mining
Underground mines in the United States are typically operated using one of two
different techniques: room and pillar mining or longwall mining. In 2004,
approximately 36% of our produced and
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processed coal volume came from underground mining operations generally using
the room and pillar method with continuous mining equipment.
Room and pillar mining
In room and pillar mining, rooms are cut into the coalbed leaving a series of
pillars, or columns of coal, to help support the mine roof and control the flow
of air. Continuous mining equipment is used to cut the coal from the mining
face. Generally, openings are driven 20 feet wide and the pillars are generally
rectangular in shape measuring 35-50 feet wide by 35-80 feet long. As mining
advances, a grid-like pattern of entries and pillars is formed. Shuttle cars are
used to transport coal to the conveyor belt for transport to the surface. When
mining advances to the end of a panel, retreat mining may begin. In retreat
mining, as much coal as is feasible is mined from the pillars that were created
in advancing the panel, allowing the roof to cave. When retreat mining is
completed to the mouth of the panel, the mined panel is abandoned. The room and
pillar method is often used to mine smaller coal blocks or thinner seams. It is
also employed whenever subsidence is prohibited. Seam recovery ranges from 35%
to 70%, with higher seam recovery rates applicable where retreat mining is
combined with room and pillar mining. Productivity for continuous room and
pillar mining in the United States averages 3.3 tons per employee per hour,
according to the EIA.
Longwall mining
The other underground mining method commonly used in the United States is the
longwall mining method. ICG does not currently have any longwall mining
operations, but expects to use this mining method in the development for two of
its undeveloped mining properties in West Virginia. In longwall mining, a
rotating drum is trammed mechanically across the face of coal and a hydraulic
system supports the roof of the mine while it advances through the coal. Chain
conveyors then move the loosened coal to an underground mine conveyor system for
delivery to the surface.
Surface mining
Surface mining is used when coal is found close to the surface. In 2004,
approximately 64% of our produced and processed coal volume came from surface
mines. This method involves the removal of overburden (earth and rock covering
the coal) with heavy earth moving equipment and explosives, loading out the
coal, replacing the overburden and topsoil after the coal has been excavated and
reestablishing vegetation and plant life and making other improvements that have
local community and environmental benefit. Overburden is typically removed at
our mines using large, rubber-tired diesel loaders. Seam recovery for surface
mining is typically between 80% and 90%. Productivity depends on equipment,
geological composition and mining ratios and averages 4.2 tons per employee per
hour in eastern regions of the United States, according to the EIA.
We use the following four types of surface mining methods.
Truck-and-shovel/loader mining
Truck-and-shovel/loader mining is a surface mining method that uses large
shovels or loaders to remove overburden which is used to backfill pits after
coal removal. Shovels or loaders load coal into haul trucks for transportation
to a preparation plant or unit train loadout facility. Seam recovery using the
truck-and-shovel/ loader mining method is typically 85% or more.
Dragline mining
Dragline mining is a surface mining method that uses large capacity draglines to
remove overburden to expose the coal seams. Shovels load coal in haul trucks for
transportation to a preparation plant or unit train loadout facility. Seam
recovery using the dragline method is typically 85% or more and productivity
levels are similar to those for truck-and-shovel/loader mining.
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Highwall mining
Highwall mining is a surface mining method generally utilized in conjunction
with truck-and-shovel/ loader surface mining. At the highwall exposed by the
truck-and-shovel/ loader operation a modified continuous miner with an attached
beltline system cuts horizontal passages from the highwall into a seam. These
passages can penetrate to a depth of up to 1,600 feet. This method typically can
recover up to 65% of the reserve block penetrated.
Auger mining
Auger mining is a surface mining method generally utilized in conjunction with
truck-and-shovel/ loader operations. At the highwall exposed by a
truck-and-shovel/ loader operation, a spiral steel auger bit is used to bore a
horizontal hole into the coal seam up to a depth of 400 feet. The auger also
conveys the coal to the highwall. Seam recovery using auger mining is typically
33%.
Coal preparation and blending
Depending on coal quality and customer requirements, raw coal may in some cases
be shipped directly from the mine to the customer. Generally, raw coal from
mountaintop removal, contour and strip mines can be shipped in this manner.
However, the quality of most underground raw coal does not allow it to be
shipped directly to the customer without processing in a preparation plant.
Preparation plants separate impurities from coal. This processing upgrades the
quality and heating value of the coal by removing or reducing sulfur and
ash-producing materials, but entails additional expense and results in some loss
of coal. Coals of various sulfur and ash contents can be mixed or "blended" at a
preparation plant or loading facility to meet the specific combustion and
environmental needs of customers. Coal blending helps increase profitability by
reducing the cost of meeting the quality requirements of specific customer
contracts, thereby optimizing contract revenue.
COAL CHARACTERISTICS
In general, coal of all geological composition is characterized by end use as
either steam coal or metallurgical coal. Heat value and sulfur content are the
most important variables in the profitable marketing and transportation of steam
coal, while ash, sulfur and various coking characteristics are important
variables in the profitable marketing and transportation of metallurgical coal.
We mine, process, market and transport bituminous and sub-bituminous coal,
characteristics of which are described below.
Heat value
The heat value of coal is commonly measured in Btus per pound of coal. A Btu is
the amount of heat needed to raise one pound of water one degree Fahrenheit.
Coal found in the Eastern and Midwestern regions of the United States tends to
have a heat content ranging from 10,000 to 14,000 Btus per pound, as received.
As received Btus per pound includes the weight of moisture in the coal on an as
sold basis. Most coal found in the Western United States ranges from 8,000 to
10,000 Btus per pound, as received.
Lignite coal
Lignite coal is a brownish-black coal with a heat content that generally ranges
from 4,000 to 8,000 Btus per pound. Major lignite operations are located in
Louisiana, Montana, North Dakota and Texas. Lignite is used almost exclusively
in power plants located adjacent to or near these mines because any significant
transportation costs, coupled with mining costs, would render its use
uneconomical.
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Sub-bituminous coal
Sub-bituminous coal is a black coal with a heat content that ranges from 8,300
to 11,500 Btus per pound. Most sub-bituminous reserves are located in Alaska,
Colorado, Montana, New Mexico, Washington and Wyoming. Sub-bituminous coal is
used almost exclusively by electricity generators and some industrial consumers.
Bituminous coal
Bituminous coal is a relatively soft black coal with a heat content that ranges
from 10,000 to 14,000 Btus per pound. This coal is located primarily in
Appalachia, Arizona, Colorado, the Midwest and Utah, and is the type most
commonly used for electricity generation in the United States. Bituminous coal
is also used for industrial steam purposes by utility and industrial customers,
and as metallurgical coal in steel production. Coal used in metallurgical
processes has higher expansion/contraction characteristics than steam coal.
Anthracite coal
Anthracite coal is a hard coal with a heat content that can range from 14,000 to
15,000 Btus per pound. There is a limited number of anthracite deposits
primarily located in the Appalachian region of Pennsylvania. Anthracite is used
primarily for utility, industrial and home heating purposes.
Sulfur content
Sulfur content can vary from seam to seam and sometimes within each seam. When
coal is burned, it produces sulfur dioxide, the amount of which varies depending
on the chemical composition and the concentration of sulfur in the coal.
Compliance coal is coal which, when burned, emits 1.2 pounds or less of sulfur
dioxide per million Btus and complies with the requirements of the Clean Air Act
Acid Rain program. Low sulfur coal is coal which, when burned, emits
approximately 1.6 pounds or less of sulfur dioxide per million Btus.
Sub-bituminous coal typically has a lower sulfur content than bituminous coal,
but some of our bituminous coal in West Virginia also has a low sulfur content.
High sulfur coal can be burned in electric utility plants equipped with
sulfur-reduction technology, such as scrubbers, which can reduce sulfur dioxide
emissions by up to 90%. Plants without scrubbers can burn high sulfur coal by
blending it with lower sulfur coal, or by purchasing emission allowances on the
open market, which credits allow the user to emit a ton of sulfur dioxide. Each
emission allowance permits the user to emit a ton of sulfur dioxide. By 2000,
90,000 megawatts of electric generation capacity utilized scrubbing
technologies. According to the EIA, by 2025, an additional 27,000 megawatts of
electric generation capacity will have installed scrubbers. Additional scrubbing
will provide new market opportunities for our mid sulfur coal. All new
coal-fired electric utility generation plants built in the United States will
use clean coal-burning technology.
Other characteristics
Ash is the inorganic residue remaining after the combustion of coal. As with
sulfur content, ash content varies from coal seam to coal seam. Ash content is
an important characteristic of coal because it increases transportation costs
and electric generating plants must handle and dispose of ash following
combustion.
Moisture content of coal varies by the type of coal, the region where it is
mined and the location of coal within a seam. In general, high moisture content
decreases the heat value per pound of coal, thereby increasing the delivered
cost per Btu. Moisture content in coal, as sold, can range from approximately 5%
to 30% of the coal's weight.
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COAL RESERVES
"Reserves" are defined by SEC Industry Guide 7 as that part of a mineral deposit
which could be economically and legally extracted or produced at the time of the
reserve determination. "Proven (Measured) Reserves" are defined by SEC Industry
Guide 7 as reserves for which (1) quantity is computed from dimensions revealed
in outcrops, trenches, workings or drill holes; grade and/or quality are
computed from the results of detailed sampling and (2) the sites for inspection,
sampling and measurement are spaced so closely and the geologic character is so
well defined that size, shape, depth and mineral content of reserves are
well-established. "Probable reserves" are defined by SEC Industry Guide 7 as
reserves for which quantity and grade and/or quality are computed from
information similar to that used for proven (measured) reserves, but the sites
for inspection, sampling, and measurement are farther apart or are otherwise
less adequately spaced. The degree of assurance, although lower than that for
proven (measured) reserves, is high enough to assume continuity between points
of observation.
We estimate that there are approximately 242 million tons of coal reserves (pro
forma for the Anker and CoalQuest acquisitions) that can be developed by our
existing operations which will allow us to maintain current production levels
for an extended period of time. ICG Natural Resources, LLC and CoalQuest own and
lease all of our reserves that are not currently assigned to or associated with
one of our mining operations. These reserves contain approximately 645 million
tons of mid to high Btu, low and high sulfur coal located in Kentucky, West
Virginia, Maryland, Illinois, Pennsylvania and Virginia. Our multi-region base
and flexible product line allows us to adjust to changing market conditions and
sustain high sales volume by supplying a wide range of customers.
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Our total coal reserves could support current production levels for more than
49 years. The following table provides the "quality" (average Btu content,
sulfur content and ash content per pound) of our coal reserves as of January 1,
2005:
Quality characteristics
(as received)
Recoverable
reserves proven Total tons
and probable (in millions Tons by market
as of 1/1/2005 of tons) Reserve Heat classification
(in millions life content Sulfur Ash
Mining companies State of tons)(1) Owned Leased (years) (Btu/lb) (%) (%) Steam Metallurgical(4)(5)
Northern Appalachia:
Vindex Energy Corporation MD 10.64 0.00 10.64 14.2 11,500- 1.2%- 7.0%-
13,000 2.0% 19.0% 7.98 2.66
Patriot Mining Company WV, PA 1.05 0.71 0.34 1.4 11,700 2.1% 16.2% 1.05 0.00
Spruce Fork Division WV 48.57 46.70 1.88 19.4 13,000 1.2% 9.0% 1.30 47.27
Philippi Development Division WV 40.97 32.34 8.63 20.5 13,100 1.4% 8.3% 0.00 40.97
Harrison Division WV 17.51 0.23 17.28 9.7 12,500 3.2% 12.5% 17.51 0.00
Mount Storm Division WV, MD 6.01 0.47 5.54 10.0 13,200 1.0% 9.0% 0.00 6.01
Sycamore Group, LLC WV 1.21 0.17 1.04 2.4 12,500 3.2% 12.0% 1.21 0.00
CoalQuest Development LLC WV 194.30 194.30 0.00 21.6 13,000 1.3% 9.8% 32.70 161.60
Northern Appalachia Total 320.27 274.92 45.35 61.75 258.52
Central Appalachia:
ICG - Knott Country KY 6.73 5.81 0.92 5.2 12,700 1.3% 8.4% 6.73 0.00
ICG - Hazard KY 71.38 0.23 71.15 11.9 12,000 1.6% 11.2% 71.38 0.00
ICG - East Kentucky KY 2.62 0.00 2.62 2.0 12,400 1.2% 12.2% 2.62 0.00
ICG - Eastern WV 23.69 7.27 16.42 7.4 12,300 1.1% 12.2% 23.69 0.00
ICG - Natural Resources(2) WV 44.90 2.20 42.70 NA 12,000 0.8% 12.2% 44.90 0.00
ICG - Natural Resources(3) KY 5.9 4.4 1.5 NA 12,000 1.1% 12.0% 4.40 0.00
Beckley-Smokeless Division(4) WV 28.97 1.28 27.70 29.0 13,800 0.7% 4.8% 0.00 28.97
Anker Virginia Mining Company VA 27.50 0.00 27.50 27.5 14,000 0.6% 4.0% 0.00 27.50
Central Appalachia Total 211.69 21.19 190.51 153.72 56.47
Other:
ICG - Illinois IL 29.63 11.38 18.25 12.9 10,500 3.2% 9.5% 29.63 0.00
ICG - Natural Resources 325.21 305.10 20.1 NA 11,000 3.0% 9.0% 326.71 0.00
Other Total 354.84 316.48 38.35 356.34 0.00
Total Reserves 886.81 612.51 274.3 571.81 314.99
(1) Recoverable reserves represent the amount of coal reserves that can actually
be recovered taking into account all mining and preparation losses involved
in producing a saleable product using existing methods under current law.
The reserve numbers set forth in this table exclude reserves for which we
have leased our mining rights to third parties. Reserve information reflects
a moisture factor of approximately 6.0%. This moisture factor represents the
average moisture present on our delivered coal.
(2) ICG - Natural Resources (Jenny's Creek)
(3) ICG - Natural Resources (Mount Sterling)
(4) Beckley Smokeless and Anker Virginia meet historical metallurgical coal
quality specifications.
(5) Currently, ICG reports selling coal with ash and sulfur contents as high as
10% and 1.5%, respectively into the current metallurgical market from the
Vindex Energy, Spruce Fork, and Phillipi Divisions. Similarly, all
production Mount Storm and portions of Hillman could be sold on this
metallurgical market when production begins.
Our reserve estimate is based on geological data assembled and analyzed by our
staff of geologists and engineers. Reserve estimates are periodically updated to
reflect past coal production, new drilling information and other geologic or
mining data. Acquisitions or sales of coal properties will also change the
reserve base. Changes in mining methods may increase or decrease the recovery
basis for a coal seam as will plant processing efficiency tests. We maintain
reserve information in secure computerized databases, as well as in hard copy.
The ability to update and/or modify the reserve base is restricted to a few
individuals and the modifications are documented.
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Actual reserves may vary substantially from the estimates. Estimated minimum
recoverable reserves are comprised of coal that is considered to be merchantable
and economically recoverable by using mining practices and techniques prevalent
in the coal industry at the time of the reserve study, based upon then-current
prevailing market prices for coal. We use the mining method that we believe will
be most profitable with respect to particular reserves. We believe the volume of
our current reserves exceeds the volume of our contractual delivery
requirements. Although the reserves shown in the table above include a variety
of qualities of coal, we presently blend coal of different qualities to meet
contract specifications. See "Risk factors-Risks relating to our business."
Periodically, we retain outside experts to independently verify our coal reserve
base. The most recent review was completed during the first quarter of 2005 and
covered all of our reserves. The results verified our reserve estimates, with
very minor adjustments, and included an in-depth review of our procedures and
controls. As of January 1, 2005 (pro forma for the Anker and CoalQuest
acquisitions), Marshall Miller & Associates, Inc. confirmed our reserve base of
887 million tons on a consolidated basis.
We currently own approximately 69% of our coal reserves, with the remainder of
our coal reserves subject to leases from third-party landowners. Generally,
these leases convey mining rights to the coal producer in exchange for a
percentage of gross sales in the form of a royalty payment to the lessor,
subject to minimum payments. Leases generally last for the economic life of the
reserves. The average royalties paid by us for coal reserves from our producing
properties was $1.48 per ton in 2004, representing approximately 4.2% of our
coal sales revenue in 2004, pro forma for the Anker and CoalQuest acquisitions.
Consistent with industry practice, we conduct only limited investigations of
title to our coal properties prior to leasing. Title to lands and reserves of
the lessors or grantors and the boundaries of our leased priorities are not
completely verified until we prepare to mine those reserves.
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Coal Resources
Coal resources are coal-bearing bodies that have been sufficiently sampled and
analyzed in trenches, outcrops, drilling, and underground workings to assume
continuity between sample points, and therefore warrants further exploration
stage work. However, this coal does not qualify as a commercially viable coal
reserve as prescribed by SEC standards until a final comprehensive evaluation
based on unit cost per ton, recoverability, and other material factors concludes
legal and economic feasibility. Resources may be classified as such by either
limited property control or geologic limitations, or both.
The following table provides the "quality" (average Btu content, sulfur content
and ash content per pound) of our coal resources as of January 1, 2005:
Quality characteristics
(as received)
Recoverable Tons by market
resources Resource Heat classification
as of 1/1/2005 life content Sulfur Ash
Mining company State (in millions of tons)(1) (years) (Btu/lb) (%) (%) Steam Metallurgical(4)
Northern Appalachia:
Patriot Mining Company WV, PA 1.89 2.5 1.89 0.00
Spruce Fork Division WV 2.42 1.0 13,000 1.2 % 9.0 % 2.42 0.00
Philippi Development
Division WV 2.40 1.2 13,100 1.4 % 8.3 % 2.40 0.00
Harrison Division WV 1.28 0.7 12,500 3.2 % 12.5 % 1.28 0.00
CoalQuest Development
LLC WV 37.04 4.1 37.04 0.00
Upshur Property WV 92.96 46.5 8,000 2.0 % 43.0 % 92.96 0.00
Northern Appalachia Total 137.99 137.99 0.00
Central Appalachia:
ICG - Knott County KY 0.00 12,700 1.3 % 8.4 % 0.00 0.00
ICG - Hazard KY 3.00 12,000 1.6 % 11.2 % 3.00 0.00
ICG - East Kentucky KY 0.00 12,400 1.2 % 12.2 % 0.00 0.00
ICG - Eastern WV 0.02 12,300 1.1 % 12.2 % 0.02 0.00
ICG - Natural
Resources(2) WV 0.22 12,000 0.8 % 12.2 % 0.22 0.00
ICG - Natural
Resources(3) KY 0.01 12,000 1.1 % 12.0 % 0.01 0.00
Beckley - Smokeless
Division(4) WV 1.88 1.9 13,800 0.7 % 4.8 % 0.00 1.88
Anker Virginia Mining
Company VA 2.57 5.1 13,500 0.6 % 7.4 % 2.57 0.00
Central Appalachia Total 7.70 5.82 1.88
Other:
ICG - Illinois IL 38.47 10,500 3.2 % 9.5 % 38.47 0.00
ICG - Natural Resources 522.52 11,000 3.0 % 9.0 % 522.52 0.00
Other Total 560.99 560.99 0.00
Total Resources 706.68 704.80 1.88
(1) Currently, ICG reports selling coal with ash and sulfur contents as high as
10% and 1.5%, respectively into the current metallurgical market from the
Vindex Energy, Spruce Fork, and Philippi Divisions. Similarly, all of Mount
Storm and portions of Hillman can be sold on this metallurgical market.
(2) ICG - Natural Resources (Jenny's Creek)
(3) ICG - Natural Resources (Mount Sterling)
(4) Beckley Smokeless and Anker Virginia meet historical metallurgical coal
quality specifications.
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OPERATIONS
As of December 31, 2004, we operated a total of 13 surface and 10 underground
coal mines located in Kentucky, Maryland, West Virginia and Illinois.
Historically, approximately 64% of our production has come from surface mines,
and the remaining production has come from our underground mines. These mining
facilities include eight preparations plants, each of which receive, blend,
process and ship coal that is produced from one or more of our 23 active mines.
Our underground mines generally consist of one or more single or dual continuous
miner sections which are made up of the continuous miner, shuttle cars, roof
bolters and various ancillary equipment. Our surface mines are a combination of
mountain top removal, dragline, highwall contour and cross ridge operations
using truck/loader equipment fleets along with large production tractors. Most
of our preparation plants are modern heavy media plants that generally have both
coarse and fine coal cleaning circuits. We currently own most of the equipment
utilized in our mining operations. We employ preventive maintenance and rebuild
programs to ensure that our equipment is modern and well maintained. The mobile
equipment utilized at our mining operation is scheduled to be replaced on an
on-going basis with new, more efficient units during the next five years. Each
year we endeavor to replace the oldest units, thereby maintaining productivity
while minimizing capital expenditures. The following table provides summary
information regarding our principal mining complexes as of December 31, 2004.
Number and
type of mines
Tons
Preparation Under- Mining produced
Mining complex Location plant(s) ground Surface Total method(a) Transportation in 2004
(in thousands)
ICG Eastern, LLC Cowen, WV 1 0 1 1 MTR-DL-TSL Rail 2,712.1
ICG Hazard, LLC Hazard, KY 1 (1) 0 6 6 R&P-CM, HW Rail 3,978.0
ICG Knott County, LLC Kite, KY 1 4 0 4 MTR-TSL CM Rail 1,386.6
ICG East Kentucky, LLC Pike Co., KY 0 0 1 1 MTR-TSL Rail 1,576.3
ICG Illinois, LLC Williamsville, IL 1 1 0 1 R&P-CM Truck 2,117.6
Vindex Energy Corporation Garrett Co., MD 1 0 2 2 CRM & CTR Truck, Rail (2) 170.7
Patriot Mining Company Monongalia Co., WV 0 0 3 3 CTR Barge, Rail 921.3 (3)
Spruce Fork Division Upshur Co., WV 1 2 0 2 R&P Rail 1,213.9
Philippi Development Division Barbour Co., WV 1 (4) 1 0 1 R&P Rail 255.4
Beckley-Smokeless Division Raleigh Co., WV 1 0 0 0 R&P Rail 0.0 (2)
Sycamore Group Harrison Co., WV 0 2 0 2 R&P Truck 259.3 (5)(6)
CoalQuest Development LLC Taylor Co., WV 0 0 0 0 R&P & LW Rail 0.0 (7)
Juliana Complex Webster Co., WV 1 0 0 0 R&P & CTR Rail 0.0
(a) CRM = Cross Ridge Mining; CTR = Contour Mining; R&P = Room and Pillar; LW =
Longwall; MTR = Mountain Top Removal; DL = Dragline; HW = Highwall; CM =
Continuous Miner; TSL = Truck and Shovel/ Loader
(1) Expected to begin operation in second half of 2005
(2) Utilizing third-party loadout
(3) Including waste-fuel
(4) Currently utilizing one circuit
(5) Mine permitted but undeveloped
(6) Represents Anker's 50% share in The Sycamore Group LLC joint venture plus
the Sycamore No. 2 mine, expected to begin production in 2005
(7) Undeveloped, permit in progress
The following provides a description of the operating characteristics of the
principal mines and reserves of each of our mining operations.
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MINING OPERATIONS
Northern and Central Appalachia mining operations
Our Northern and Central Appalachian mining facilities are strategically located
across West Virginia, Kentucky, Maryland, Pennsylvania and Virginia and are used
to produce and ship coal to its customers located primarily in the eastern half
of the United States. We believe that the quality and experience of our
workforce in Northern and Central Appalachia are among the highest in the coal
mining industry. All of our Northern and Central Appalachia mining operations
are union free.
Our mines in Central Appalachia produced 9.7 million tons of coal in 2004 and
our mines in Northern Appalachia produced 2.8 million tons of coal in 2004,
pro forma for the Anker and CoalQuest acquisitions. The coal produced in 2004
was, on average, 12,207 Btu/lb, 1.2% sulfur and 12.4% ash by content. This year
we estimate that our mines in Central Appalachia region will produce
approximately 10.5 million tons, pro forma for the Anker and CoalQuest
acquisitions. This year we estimate that our mines in the Northern Appalachian
region will produce approximately 4.5 million tons, pro forma for the Anker and
CoalQuest acquisitions. This high Btu, low sulfur coal is very marketable to
major utility customers throughout the eastern United States. Shipments to
electric utilities, accounted for approximately 78% of the coal shipped by these
mines in 2004, compared to 80% of shipments in 2003. Within each mining complex,
mines have been developed at strategic locations in proximity to our preparation
plants and rail shipping facilities. The mines located in Central Appalachia
ship the majority of their coal by the Norfolk Southern and CSX rail lines,
although production may also be delivered by truck or barge, depending on the
customer. ICG Natural Resources, LLC owns two idle river docks along the Kanawha
River from which we could ship coal to our customers.
As of March 31, 2005, these mines had 1,481 employees.
ICG Eastern, LLC
ICG Eastern, LLC operates the Birch River surface mine, located 60 miles east of
Charleston, near Cowen in Webster County, West Virginia. Birch River started
operations in 1990 under Shell Mining Company, was purchased by Zeigler Coal
Holding Company, or "Zeigler," in 1992, and was subsequently acquired by AEI
Resources, Inc. from Zeigler in 1998.
Birch River is extracting coal from five distinct coalbeds: (i) Freeport;
(ii) Upper Kittanning; (iii) Middle Kittanning; (iv) Upper Clarion and (v) Lower
Clarion. Coal mined from this operation has an average sulfur content of 1.1%,
an average ash content of 12.2% and an average Btu content of 12,300. We
estimate that Birch River controls 23.7 million tons of coal reserves.
Approximately 69% of the coal reserves are leased, while approximately 31% are
owned in fee. Most of the leased reserves are held by four lessors. The leases
are retained by annual minimum payments and by tonnage-based royalty payments.
All leases can be renewed until all mineable and merchantable coal has been
exhausted.
Overburden is removed by a dragline, shovel, front-end loaders, end dumps and
bulldozers. Approximately one-third of the coal can be marketed run-of-mine,
while the other two-thirds is washed at Birch River's preparation plant. Coal is
transported by conveyor belt from the preparation plant to Birch River's rail
loadout, which is served by CSX. The loadout is a batch weigh system capable of
loading unit trains in less than four hours.
The preparation plant is rated at 800 raw tons per hour. The preparation plant
is comprised of heavy media vessels, heavy media cyclones, and spirals. The
plant, overland conveyor system, and rail loadout are in excellent condition.
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ICG Hazard, LLC
ICG Hazard, LLC is currently operating six surface mines, a unit train loadout
(Kentucky River Loading) and other support facilities in eastern Kentucky, near
Hazard. The coal reserves and operations were acquired in late-1997 and 1998 by
AEI Resources.
ICG Hazard's six surface mines include: (i) County Line; (ii) Flint Ridge;
(iii) Vicco; (iv) Rowdy Gap; (v) Tip Top; and (vi) Thunder Ridge. The coal from
these mines is being extracted from the Hazard 11, Hazard 10, Hazard 9,
Hazard 8, Hazard 7 and Hazard 5A seams, and has an average sulfur content of
1.2%, an average ash content of 12% and an average Btu content of 12,000. Nearly
all of the coal is marketed run-of-mine. We estimate that ICG Hazard controls
71.4 million tons of coal reserves, plus 3.0 million tons of coal that is
classified as resources. Most of the property has been adequately explored, but
additional core drilling will be conducted within specified locations to better
define the reserve base.
Approximately 99.7% of ICG Hazard's reserves are leased, while 0.3% are owned in
fee. Most of the leased reserves are held by seven lessors. In several cases,
ICG Hazard has multiple leases with each lessor. The leases are retained by
annual minimum payments and by tonnage-based royalty payments. Most leases can
be renewed until all mineable and merchantable coal has been exhausted.
Overburden is removed by front-end loaders, end dumps, bulldozers and blast
casting. Coal is transported from the mines to the Kentucky River Loading rail
loadout by on-highway trucks. The loadout is served by CSX, and is a batch weigh
system capable of loading 120-car trains in less than three hours. Most of the
coal is transported by rail, but some coal is direct shipped to the customer by
truck from the mine pits.
An existing preparation plant structure is being extensively upgraded. It will
process coal from ICG Hazard's new Flint Ridge underground mine complex. Flint
Ridge will be a room and pillar mine, producing coal from the Hazard 8 coalbed.
It will utilize continuous miners and shuttle cars. Both the plant and the
underground mine are scheduled to begin operation in July 2005.
ICG Knott County, LLC
ICG Knott County, LLC operates four underground mines, the Supreme Energy
preparation plant and rail loadout, and other facilities necessary to support
the mining operations in eastern Kentucky, near Kite. ICG Knott County was
acquired by AEI Resources, Inc. from Zeigler in 1998.
ICG Knott County is producing coal from the Hazard 4 and the Elkhorn 3 coalbeds.
Three mines are operating in the Hazard 4 coalbed: Calvary, Clean Energy and Elk
Hollow. The Classic mine is operating in the Elkhorn 3 coalbed. The coal
produced from the four mines has an average sulfur content of 1.3%, an average
ash content of 9%, and an average Btu content of 12,700. We estimate these
properties contain 6.7 million tons of coal reserves. Most of the property has
been extensively explored, but additional core drilling will be conducted within
specified locations to better define the reserve base.
Approximately 86% of ICG Knott County's reserves are owned in fee, while
approximately 14% are leased. The leases are retained by annual minimum payments
and by tonnage-based royalty payments. The leases can be renewed until all
mineable and merchantable coal has been exhausted.
ICG Knott County's four underground mines are room and pillar operations,
utilizing continuous miners and shuttle cars. Nearly all of the run-of-mine coal
is processed at the Supreme Energy preparation plant; some of the Hazard 4
run-of-mine coal is blended with the washed coal.
Nearly all of ICG Knott County's coal is transported by rail. The loadout is a
batch weigh system that is served by CSX.
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ICG East Kentucky, LLC
ICG East Kentucky, LLC is a surface mining operation located in Pike County,
Kentucky, near Phelps. ICG East Kentucky currently operates the Blackberry
surface mine and the Phelps Loadout. ICG East Kentucky was acquired by
AEI Resources in the second quarter of 1999.
Blackberry is an area surface mine that produces coal from three separate
coalbeds: (i) Taylor; (ii) Fireclay; and (iii) Lower Fireclay. All of the coal
is sold run-of-mine, with an average sulfur content of 1.2%, an average ash
content of 12% and an average Btu content of 12,400.
We estimate that the Blackberry mine controls 2.6 million tons of coal reserves;
no additional exploration is required.
After Blackberry is depleted, ICG East Kentucky will begin mining the Mount
Sterling property, which contains an additional 5.9 million tons of coal
reserves. Mount Sterling is located in Martin and Pike Counties, Kentucky near
the Tug Fork River. Although Mount Sterling is expected to be mined by ICG East
Kentucky, the property is held by ICG Natural Resources, LLC. The leases are
retained by annual minimum payments and by tonnage-based royalty payments. The
leases can be renewed until all mineable and merchantable coal has been
exhausted.
Overburden at the Blackberry mine is removed by front end loaders, end dumps,
bull dozers and blast casting. Coal from the pits is transported by truck to the
Phelps Loadout, which is a batch weigh system.
Vindex Energy Corporation
Vindex Energy Corporation operates two surface mines, the Island mine and the
Douglas mine, in the Potomac Basin in Garrett County, Maryland. The reserves at
Vindex are leased primarily from one major landowner. The lease expires in 2010
and is renewable on a year-by-year basis with a minimum annual holding cost.
Vindex Energy is a cross-ridge mining operation extracting coal from the Upper
Freeport, Middle Kittanning and Upper Kittanning seams. Both mines are
truck-and-shovel/loader mining operations utilizing dozers, hydraulic
excavators, loaders and trucks. Operations are conducted with relatively new
equipment and exploration and development is conducted on a continual basis
ahead of mining.
Vindex has been operating its mines at full production since the first quarter
2005, and it is projected that the mines will produce a combined 654,000 tons in
2005. Approximately 20% of the raw coal production is screened at the Island
Mine for sales directly to the customers. Such an arrangement increases our
margins by reducing transportation costs to and from preparation plants,
resulting in cost savings. The remainder of the coal is processed at our 200 TPH
heavy media preparation plant located near Mount Storm, West Virginia, where the
product is shipped to the customer by either truck or rail using a third-party
rail loading facility.
Four new surface mines are under development in the Potomac Basin in Garrett
County, Maryland. Anker anticipates mining to commence at one of these
operations in 2007, an additional two in 2008 and the last mine producing by
2009. Like the Island and Douglas mines, these four mines will utilize
truck-and-shovel/loaders and will be extracting coal from the Bakerstown, Upper
Freeport, Mahoning, Upper Kittanning and Middle Kittanning seams. These future
reserves are currently being explored and permitted for mining.
Patriot Mining Company
Patriot Mining Company consists of three active surface mines near Morgantown,
West Virginia: Crown No. 2 and New Hill East located in Monongalia County, West
Virginia and Keener located in
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Green County, Pennsylvania. The majority of the coal and surface is leased under
renewable contracts with small annual minimum holding costs. Patriot's mines are
extracting coal from the Waynesburg seam using contour mining methods with
dozers, loaders and trucks. As mining progresses, reserves are being acquired
and permitted for future operations. The mining equipment is maintained in good
condition.
We have projected that Patriot's three mines will produce approximately
750,000 tons in 2005. Patriot is planning six new mines on property currently
being acquired, explored and permitted that will begin phasing into production
starting next year through 2009. These mines will also extract coal from the
Waynesburg seam using contour mining methods with dozers, loaders and trucks.
Spruce Fork Division- Anker West Virginia Mining Company
The Spruce Fork Division currently consists of two active underground mines;
Spruce No. 1 and Sago located in Upshur County, West Virginia, near the town of
Buckhannon. The Spruce No. 1 Mine is extracting coal from the Upper Freeport
seam and the Sago mine is extracting coal from the Middle Kittanning seam.
Nearly all of the reserves in the Spruce Fork Division are owned by ICG. The
Spruce No. 1 Mine opened in 1997 and we anticipate that its reserves will be
depleted sometime during the third quarter of 2005. The Sago mine, which was
originally opened in 1999 as a contract mine, closed in 2002, and then reopened
as a captive operation in the first quarter of 2004. Sago is expected to reach
full production by the fourth quarter of 2005.
Both operations utilize the room-and-pillar mining method with continuous miners
and shuttle cars for coal removal from the face. The Sago mine was re-opened
using brand new mining equipment and infrastructure from the original portal
location. All of the coal extracted from these mines is processed at a rate of
nearly 750 TPH through the nearby Sawmill Run heavy media preparation plant
where coal is then primarily shipped by CSX rail, although some coal is trucked
to local industrial customers.
We have projected that the Spruce Fork Division will produce approximately
1.3 million tons of coal in 2005. The Sago 3 mine, scheduled for production in
2007, is a replacement for the Spruce No. 1 Mine. The reserves at Spruce Fork
have characteristics that make it marketable to both steam and metallurgical
coal customers.
Sycamore Group
Sycamore Group consists of The Sycamore Group LLC and the Harrison Division. The
Sycamore Group LLC is a joint venture between ICG and Emily Gibson Coal Company.
The joint venture operates one underground mine, the Sycamore No. 1 Mine
(a.k.a. the Fairfax No. 3 Mine), in Harrison County, West Virginia,
approximately ten miles west of Clarksburg, where coal is extracted from the
Pittsburgh seam by room-and-pillar mining methods with continuous miners and
shuttle cars for coal extraction.
The majority of the coal is leased with an annual minimum holding cost. It is
anticipated that this reserve will be depleted and the mine closed during the
second quarter of 2006. Operations are conducted utilizing the room and pillar
mining method. Newly rebuilt mining equipment was recently installed to
facilitate the complete extraction of the remaining reserves. We expect that
ICG's 50% share of the 2005 production to be approximately 210,000 tons, all of
which is sold on a raw basis and shipped to Allegheny Power Service
Corporation's Harrison Power Station by truck.
The Harrison Division consists of the Sycamore No. 2 Mine, which is located in
Harrison County, West Virginia, approximately ten miles west of Clarksburg The
Sycamore No. 2 Mine is expected to begin producing coal from the Pittsburgh seam
using room-and-pillar mining methods with continuous miners and shuttle cars in
the second quarter of 2005. The reserve is primarily leased from one major
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landowner with an annual minimum holding cost and an automatic renewal based on
an annual minimum production of 250,000 tons. The coal is being accessed with a
box-cut and will be mined utilizing room and pillar mining methods with new
mining equipment.
The planned annual production is expected to increase from approximately
430,000 tons in 2005 to over 1.6 million tons in 2006. The coal produced from
the Sycamore No. 2 mine will be sold on a raw basis and shipped to Allegheny
Power Service Corporation's Harrison Power Station by truck under a new life of
mine, total production coal supply agreement.
Philippi Development Division- Anker West Virginia Mining Company
The Philippi Development Division operates the Sentinel mine, in Barbour County,
West Virginia near the town of Philippi. The mine was acquired by Anker in 1990
and has been operating ever since. Historically, coal was extracted from the
Lower Kittanning seam; however, mining is currently conducted in the Upper
Kittanning seam by room-and-pillar mining method with a new low-seam continuous
haulage mining system which was installed in the fourth quarter of 2004. The
current operations are expected to be supplemented with a second continuous
haulage mining system in the first quarter of 2007.
Coal is fed directly from the mine to a 600 TPH heavy media preparation plant
and loadout facility served by the CSX railroad. The product can be shipped on
steam or metallurgical markets. The Sentinel Mine is projected to produce
approximately 317,000 tons in 2005. Production is expected to increase to
634,000 tons by 2008 with the addition of the second continuous haulage mining
system.
New Appalachian mine developments
Hillman property
The Hillman property, located in Northern Appalachia, includes 194 million tons
of deep coal reserves of both steam and metallurgical quality coal in the Lower
Kittanning seam covering approximately 65,000-acres located predominantly in
Taylor County, West Virginia, near Grafton. The reserve extends into parts of
Barbour, Marion, and N. Harrison Counties as well. ICG owns the Hillman coal
reserve in addition to nearly 4,000 acres of surface property to accommodate the
development of three projected mining operations. In addition to the Lower
Kittanning reserves, we also own significant coal resources in the Kittanning,
Freeport, Clarion and Mercer seams on the Hillman property.
The Hillman reserves are currently being permitted for the development of three
mining operations; two longwall and one room and pillar. Production from the
first complex is projected to begin in 2007 with a full annual production of
9 million tons expected from the three mines by 2010.
Upshur property
The Upshur Property, located in Northern Appalachia, is a 88 million tons of
resource owned or controlled by us in the Middle and Lower Kittanning seams. The
resource is surface mineable at a ratio of slightly greater than 2 to 1. Both
Kittanning seams will be mined as a 7,500 Btu fuel by extracting all of the coal
splits and associated partings. The low product heat content limits the distance
over which the fuel can be transported and sold; however, the low mining cost
makes Upshur an attractive location for an on-site power plant. Some preliminary
research, including air quality monitoring, has been completed in association
with the future construction of a circulating fluidized bed power plant at
Upshur.
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Big Creek property
Our Big Creek reserve, located in Central Appalachia, covers 10,000 acres of
leased coal lands located north of the town of Richlands in Tazewell County,
Virginia. Total recoverable reserves are 27.5 million tons in the Jawbone,
Greasy Creek and War Creek seams. The largest coal block is a deep reserve in
the War Creek seam, which is a high-quality metallurgical coal ranging from low
to mid vol. The Big Creek reserve is all leased from Southern Regional
Industrial Reality. Production from the permitted War Creek Mine is expected to
begin in 2007 utilizing the room and pillar mining method with continuous
haulage. The mine is expected to reach full production of nearly 1 million tons
per year by 2008. The coalbed methane at Big Creek is currently leased to and
being produced by Pocahontas Gas Partnership with an overriding royalty paid to
us.
Bay Hill property
The Bay Hill reserve, located in Central Appalachia, is a 29 million-ton deep
reserve of high quality low-vol metallurgical coal in the Pocahontas No. 3 seam
in Raleigh County west of Beckley, West Virginia. The southwest portion of the
reserve underlies part of the recently closed BayBeck Mine in the Beckley seam.
Most of the 16,800 acre Bay Hill reserve is leased from three land companies:
Western Pocahontas Properties, Crab Orchard Coal Company and Beaver Coal
Company. We have permitted a portion of the Bay Hill reserve for deep mine
development.
Juliana Complex
Mining on the Juliana property, located in Central Appalachia, in Webster
County, WV, began in 1979 and was stopped in December 1999. Contour and mountain
top removal stripping methods were utilized to produce coal from the Kittanning
and Upper Freeport seams. In addition, a substantial amount of deep-mined coal
was produced from the Middle Kittanning seam. A 500 TPH preparation facility
with 100,000 tons of raw and clean coal storage and a unit-train loadout was
used to process and load coal on the CSX railroad.
Currently at Juliana, there are two Kittanning deep mine permits and one surface
mine permit in place. Permitted deep and surface coal resources are 1.2 million
tons and 1.9 million tons, respectively. The ratio for the surface reserve is
17.3 to 1 bulk cubic yard per clean ton. The projected clean coal quality for
deep and surface-mined coal combined is 7.5 ash, 0.82% sulfur and 13,100 Btu, on
an as received basis.
Illinois Basin mining operations
ICG Illinois, LLC operates one large underground coal mine, the Viper mine, in
central Illinois. Viper commenced mining operations in 1982 as a union free
operation for Shell Oil Company. Viper was acquired by Ziegler in 1992 and
subsequently acquired by Horizon in 1998.
The Viper Mine is working the Illinois No. 5 Seam, also referred to as the
Springfield Seam, with all raw coal production washed at Viper's preparation
plant. Coal mined from this operation has an average sulfur content of 3.2%, an
average ash content of 9.5% and an average Btu content of 10,500. We estimate
that Viper controls approximately 29.6 million tons of coal reserves, plus an
additional 38.5 million resource tons. Viper has an ongoing exploration program
to accurately assess floor and roof conditions within the immediate mine plan.
Approximately two-thirds of the coal reserves are leased, while one-third is
owned in fee. The leases are retained by annual minimum payments and by
tonnage-based royalty payments. The leases can be renewed until all mineable and
merchantable coal has been exhausted.
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The Viper mine is a room and pillar operation, utilizing continuous miners and
shuttle cars. ICG Illinois is one of the lowest cost and highest productivity
mines in the Illinois Basin. All of the raw coal is processed at Viper's
preparation plant. The clean coal is transported to the customers by on highway
trucks. A major rail line is located a short distance from the plant, giving
Viper the option of constructing a rail loadout.
ICG Illinois ships by independent trucking companies to utility and industrial
customers located in North Central Illinois. Shipments to electric utilities
account for approximately 71% of coal sales. Currently 1.7 million tons (80%) of
ICG Illinois' 2005 production is under contract. The City of Springfield Water,
Light and Power purchases nearly 50% of Viper's production and the contract does
not expire until 2020.
The preparation plant is rated at 800 raw tons per hour. It is comprised of
heavy media vessels, heavy media cyclones, and spirals.
The underground equipment, infrastructure, and preparation plant are well
maintained. The underground equipment will be replaced or rebuilt over the next
five years.
OTHER OPERATIONS
Coal sales
In addition to the coal we mine, from time to time we also opportunistically
secure coal purchase agreements with other coal producers to take advantage of
differences in market prices.
ICG ADDCAR Systems, LLC
In our highwall mining business, we operate or lease six systems using our
patented ADDCAR highwall mining system and intend to build additional ADDCAR
systems as required. The ADDCAR highwall mining system is an innovative and
efficient mining system. The system is often deployed at reserves that cannot be
economically mined by other methods.
In a typical ADDCAR highwall mining system, there is a launch vehicle,
continuous miner, conveyor cars, a stacker conveyor, electric generator, water
tanker for cooling and dust suppression and a wheel loader with forklift
attachment.
A five person crew operates the entire ADDCAR highwall mining system with
control of the continuous miner being performed remotely by one person from the
climate-controlled cab located at the rear of the launch vehicle. Our system
utilizes a navigational package to provide horizontal guidance, which helps to
control rib width and thus roof stability. Also, the system provides vertical
guidance for control out of seam dilutions. The ADDCAR highwall mining system is
also equipped with high quality video monitors to provide the operator with
visual displays of the mining process from inside each entry being mined.
The mining cycle begins by aligning the ADDCAR highwall mining system onto the
desired heading and starting the entry. As the remotely controlled continuous
miner penetrates the coal seam, ADDCAR conveyor cars are added behind it,
forming a continuous cascading conveyor train. This continues until the entry is
at the planned full depths of up to 1,200 to 1,500 feet. After retraction, the
launch vehicle is moved to the next entry, leaving a support pillar of coal
between entries. This process recovers as much as 65% of the reserves while
keeping all personnel outside the coal seam in a safe working environment. A
wide range of seam heights can be mined with high production in seams as low as
3.5 feet and as high as 15 feet in a single pass. If the seam height is greater
than 15 feet, then multi lifts can be mined to create an unlimited entry height.
The navigational features on the
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ADDCAR highwall mining system allow for multi lift mining while ensuring that
the designed pillar width is maintained.
During the mining cycle, in addition to the tractive effort provided by the
crawler drive of the continuous miner the ADDCAR highwall mining system bolsters
the cutting capability of the machine through an additional pumping force
provided by hydraulic cylinders which transmit thrust to the back of the miner
through blocks mounted on the side of the conveyor cars. This additional energy
allows the continuous miner to achieve maximum cutting and loading rates as it
moves forward into the seam.
We currently have the exclusive North American distribution rights for the
ADDCAR highwall mining system.
Coalbed methane
Through a planned joint operating agreement still under negotiation, CoalQuest
will exploit and develop coalbed methane which is pipeline quality gas that
resides in coal seams. In the eastern United States, conventional natural gas
fields are typically located in various sedimentary formations at depths ranging
from 2,000 to 15,000 feet. We believe this is the first such development and
exploration in the region. Exploration companies often put their capital at risk
by searching for gas in commercially exploitable quantities at these depths. By
contrast, gas in coal seams that we anticipate drilling is typically in
formations less than 2,500 feet deep which are usually better defined than
deeper formations. We believe that this contributes to lower exploration costs
than those incurred by producers that operate in deeper, less defined
formations. We have not filed reserve estimates with any federal agency.
CUSTOMERS AND COAL CONTRACTS
Customers
Our primary customers are investment grade electric utility companies primarily
in the eastern half of the United States. The majority of our customers purchase
coal for terms of one year or longer, but we also supply coal on a spot basis
for some of our customers. Our three largest customers for the three months
ended March 31, 2005, pro forma for the Anker and CoalQuest acquisitions, were
Georgia Power Company, Carolina Power & Light Company and Duke Power and we
derived approximately 49% of our coal revenues from sales to our five largest
customers, pro forma for the Anker and CoalQuest acquisitions.
Long-term coal supply agreements
As is customary in the coal industry, we enter into long-term supply contracts
(exceeding one year in duration) with many of our customers when market
conditions are appropriate. These contracts allow customers to secure a supply
for their future needs and provides us with greater predictability of sales
volume and sales price. For the three months ended March 31, 2005 (pro forma for
the Anker and CoalQuest acquisitions), approximately 70% of our revenues were
derived from long-term supply contracts. We sell the remainder of our coal
through short-term contracts and on the spot market. We have also entered into
certain brokered transactions to purchase certain amounts of coal to meet our
sales commitments. The purchase coal contracts expire between 2006 and 2010 and
provide us a minimum of approximately 10.7 million tons of coal through the
remaining lives of the contracts.
As a result of the Horizon bankruptcy process, we were able to renegotiate
certain contracts at significantly higher prices that reflected the current
pricing environment and not purchase unfavorable contracts. However, we do have
certain contracts which are set below current market rates because
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Anker entered into these contracts before the recent rise in the coal prices. As
the net costs associated with producing coal have risen, such as higher energy,
transportation and steel prices, the price adjustments within several of our
long-term contracts have not caught up to the new coal prices. This has resulted
in certain counterparties to these contracts benefiting from below market prices
for our coal.
The terms of our coal supply agreements result from competitive bidding and
extensive negotiations with customers. Consequently, the terms of these
contracts vary significantly by customer, including price adjustment features,
price reopener terms, coal quality requirements, quantity parameters, permitted
sources of supply, future regulatory changes, extension options, force majeure
provisions and termination and assignment provisions.
Some of our long-term contracts provide for a pre-determined adjustment to the
stipulated base price at times specified in the agreement or at other periodic
intervals to account for changes due to inflation or deflation. In addition,
most of our contracts contain provisions to adjust the base price due to new
statutes, ordinances or regulations that impact our costs related to performance
of the agreement. Also, some of our contracts contain provisions that allow for
the recovery of costs impacted by modifications or changes in the
interpretations or application of any applicable government statutes.
Price reopener provisions are present in most of our long-term contracts. These
price reopener provisions may automatically set a new price based on prevailing
market price or, in some instances, require the parties to agree on a new price,
sometimes between a specified range of prices. In a limited number of
agreements, failure of the parties to agree on a price under a price reopener
provision can lead to termination of the contract. Under some of our contracts,
we have the right to match lower prices offered to our customers by other
suppliers. These price reopener provisions have enabled us to negotiate higher
selling prices in several contracts over the last several months.
Quality and volumes for the coal are stipulated in coal supply agreements, and
in some instances buyers have the option to vary annual or monthly volumes. Most
of our coal supply agreements contain provisions requiring us to deliver coal
within certain ranges for specific coal characteristics such as heat content,
sulfur, ash, hardness and ash fusion temperature. Failure to meet these
specifications can result in economic penalties, suspension or cancellation of
shipments or termination of the contracts. Assuming steady or increasing coal
prices over the near-term, we expect to renew many of our expiring sales
contracts at significantly higher prices.
Transportation/logistics
We ship coal to our customers by rail, truck or barge. We typically pay the
transportation costs for our coal to be delivered to the barge or rail loadout
facility, where the coal is then loaded for final delivery. Once the coal is
loaded in the barge or railcar, our customer is typically responsible for the
freight costs to the ultimate destination. Transportation costs vary greatly
based on the customer's proximity to the mine and our proximity to the loadout
facilities. We use a variety of independent companies for our transportation
needs and typically enter into multiple non-contract agreements with trucking
companies throughout the year.
In 2004, approximately 85% of our coal from our Central Appalachian operations
was delivered to our customers by rail on either the Norfolk Southern or
CSX rail lines, with the remaining 15% delivered by truck. For our Illinois
Basin operations, 100% of our coal was delivered by truck to customers,
generally within an 80 mile radius of our Illinois mine.
We believe we enjoy good relationships with rail carriers and barge companies
due, in part, to our modern coal-loading facilities and the experience of our
transportation and distribution employees.
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SUPPLIERS
We have historically spent more than $188 million per year to procure goods and
services in support of our business activities, excluding capital expenditures.
Principal commodities include maintenance and repair parts and services,
electricity, fuel, roof control and support items, explosives, tires, conveyance
structure, ventilation supplies and lubricants. We use suppliers for a
significant portion of our equipment rebuilds and repairs both on- and off-site,
as well as construction and reclamation activities.
Each of our regional mining operations has developed its own supplier base
consistent with local needs. We have a centralized sourcing group for major
supplier contract negotiation and administration, for the negotiation and
purchase of major capital goods, and to support the business units. The supplier
base has been relatively stable for many years, but there has been some
consolidation. We are not dependent on any one supplier in any region. We
promote competition between suppliers and seek to develop relationships with
those suppliers whose focus is on lowering our costs. We seek suppliers who
identify and concentrate on implementing continuous improvement opportunities
within their area of expertise.
COMPETITION
The coal industry is intensely competitive. Our main competitors are Massey
Energy Company, Alpha Natural Resources and Foundation Coal Holdings. The most
important factors on which we compete are coal price at the mine, coal quality
and characteristics, transportation costs and the reliability of supply. Demand
for coal and the prices that we will be able to obtain for our coal are closely
linked to coal consumption patterns of the domestic electric generation industry
which has accounted for approximately 92% of domestic coal consumption in recent
years. These coal consumption patterns are influenced by factors beyond our
control, including the demand for electricity which is significantly dependent
upon economic activity and summer and winter temperatures in the United States,
government regulation, technological developments and the location,
availability, quality and price of competing sources of coal, alternative fuels
such as natural gas, oil and nuclear and alternative energy sources such as
hydroelectric power.
EMPLOYEES
As of March 31, 2005, we had 1,926 employees of which 21% were salaried and 79%
were hourly. We believe our relationship with our employees is good. All of our
workforce is union free.
LEGAL PROCEEDINGS
From time to time, we are involved in legal proceedings arising in the ordinary
course of business. We believe we have recorded adequate reserves for these
liabilities and that there is no individual case or group of related cases
pending that is likely to have a material adverse effect on our financial
condition, results of operations or cash flows. With respect to any claims
relating to Horizon which arose prior to November 12, 2002, such claims are
subject to an automatic stay of the U.S. Bankruptcy Code. In limited
circumstances, the Bankruptcy Court has lifted the stay but only to the extent
of insurance coverage relating to Horizon. In any event, we believe all or
substantially all of the claims will be resolved in accordance with Horizon's
plan of reorganization.
EQUIPMENT AND CAPITAL EXPENDITURES
As of December 31, 2004, our leased equipment was, on average, 8.5 years old. We
believe that a significant portion of our equipment needs to be upgraded in the
near-term. Accordingly, we expect to retire much of our current equipment and
invest approximately $304 million in new equipment and for mining development
operations in the next two years. We believe our capital investment plan will
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provide us with a cost-effective fleet of equipment and enable us to improve
production efficiencies. As we take advantage of planned expansion opportunities
from 2007 through 2009 principally as a result of the Anker and CoalQuest
acquisitions, we expect to spend approximately $627 million on capital
expenditures which may require external financing.
While we currently operate our mines with a high percentage of leased equipment
due primarily to Horizon's preference for leasing, we will be purchasing
equipment in the future. Current equipment is leased primarily from Caterpillar
Finance, GE Capital and other leasing companies. Our operating leases typically
have a term of three to five years, with us having the right to purchase the
equipment at the end of the lease at fair market value.
RECLAMATION
Reclamation expenses are a significant part of any coal mining operation. Prior
to commencing mining operations, a company is required to apply for numerous
permits in the state where the mining is to occur. Before a state will approve
and issue these permits, it typically requires the mine operator to present a
reclamation plan which meets regulatory criteria and to secure a surety bond to
guarantee performance of reclamation in an amount determined under state law.
These bonding companies, in turn, require that we backstop the surety bonds with
cash and/or letters of credit. While bonds are issued against reclamation
liability for a particular permit at a particular site, collateral posted in
support of the bond is not allocated to a specific bond, but instead is part of
a collateral pool supporting all bonds issued by that particular insurer. Bonds
are released in phases as reclamation is completed in a particular area.
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Environmental and other regulatory matters
Federal, state and local authorities regulate the U.S. coal mining industry with
respect to matters such as permitting and licensing requirements, employee
health and safety, air quality standards, water pollution, plant and wildlife
protection, the reclamation and restoration of mining properties after mining
has been completed, the discharge of materials into the environment, surface
subsidence from underground mining, and the effects of mining on groundwater
quality and availability. These laws and regulations have had and will continue
to have a significant effect on our costs of production and competitive
position. Future legislation, regulations or orders may be adopted or become
effective which may adversely affect our mining operations, cost structure or
the ability of our customers to use coal. For instance, new legislation,
regulations or orders, as well as future interpretations and more rigorous
enforcement of existing laws, may require substantial increases in equipment and
operating costs to us and delays, interruptions, or a termination of operations,
the extent of which we cannot predict. Future legislation, regulations or orders
may also cause coal to become a less attractive fuel source, resulting in a
reduction in coal's share of the market for fuels used to generate electricity.
We endeavor to conduct our mining operations in compliance with all applicable
federal, state and local laws and regulations. However, due in part to the
extensive and comprehensive regulatory requirements, violations during mining
operations occur from time to time in the industry.
MINING PERMITS AND APPROVALS
Numerous governmental permits or approvals are required for mining operations.
In connection with obtaining these permits and approvals, we may be required to
prepare and present to federal, state or local authorities data pertaining to
the effect or impact that any proposed production or processing of coal may have
upon the environment. The requirements imposed by any of these authorities may
be costly and time consuming and may delay commencement or continuation of
mining operations. Regulations also provide that a mining permit or modification
can be delayed, refused or revoked if an officer, director or a stockholder with
a 10% or greater interest in the entity is affiliated with or is in a position
to control another entity that has outstanding permit violations. Thus, past or
ongoing violations of federal and state mining laws could provide a basis to
revoke existing permits and to deny the issuance of additional permits.
In order to obtain mining permits and approvals from state regulatory
authorities, mine operators must submit a reclamation plan for restoring, upon
the completion of mining operations, the mined property to its prior condition,
productive use or other permitted condition. Typically, we submit our necessary
mining permit applications several months before we plan to begin mining a new
area. In our experience, mining permit approvals generally require 12 to
18 months after initial submission.
SURFACE MINING CONTROL AND RECLAMATION ACT
The Surface Mining Control and Reclamation Act of 1977, or SMCRA, which is
administered by the Office of Surface Mining Reclamation and Enforcement, or
OSM, establishes mining, environmental protection and reclamation standards for
all aspects of surface mining as well as many aspects of deep mining. Mine
operators must obtain SMCRA permits and permit renewals from the OSM or the
appropriate state regulatory agency for authorization of certain mining
operations that result in a disturbance of the surface. If a state regulatory
agency adopts federal mining programs under SMCRA, the state becomes the
regulatory authority. States in which we have active mining operations have
achieved primary control of enforcement through federal authorization.
SMCRA permit provisions include requirements for coal prospecting, mine plan
development, topsoil removal, storage and replacement, selective handling of
overburden materials, mine pit backfilling and
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grading, protection of the hydrologic balance, subsidence control for
underground mines, surface drainage control, mine drainage and mine discharge
control and treatment and revegetation.
The mining permit application process is initiated by collecting baseline data
to adequately characterize the pre-mine environmental condition of the permit
area. This work includes surveys of cultural resources, soils, vegetation,
wildlife, assessment of surface and ground water hydrology, climatology and
wetlands. In conducting this work, we collect geologic data to define and model
the soil and rock structures and coal that it will mine. We develop mine and
reclamation plans by utilizing this geologic data and incorporating elements of
the environmental data. The mine and reclamation plan incorporates the
provisions of SMCRA, the state programs and the complementary environmental
programs that impact coal mining.
Also included in the permit application are documents defining ownership and
agreements pertaining to coal, minerals, oil and gas, water rights, rights of
way and surface land, and documents required by the OSM's Applicant Violator
System, including the mining and compliance history of officers, directors and
principal owners of the entity.
Once a permit application is prepared and submitted to the regulatory agency, it
goes through a completeness review and technical review. Public notice and
opportunity for public comment on a proposed permit is required before a permit
can be issued. Some SMCRA mine permits take over a year to prepare, depending on
the size and complexity of the mine and may take six months to two years or even
longer to be issued. Regulatory authorities have considerable discretion in the
timing of the permit issuance and the public has rights to comment on and
otherwise engage in the permitting process including through intervention in the
courts.
Before a SMCRA permit is issued, a mine operator must submit a bond or otherwise
secure the performance of reclamation obligations. The Abandoned Mine Land Fund,
which is part of SMCRA, requires a fee on all coal produced. The proceeds are
used to reclaim mine lands closed or abandoned prior to 1977. This program is
currently set to expire September 30, 2005, and Congress is considering various
reauthorization proposals.
SMCRA stipulates compliance with many other major environmental statues,
including: the Clean Air Act, the Clean Water Act, the Resource Conservation and
Recovery Act, or RCRA, and the Comprehensive Environmental Response,
Compensation and Liability Act, or either CERCLA or Superfund.
SURETY BONDS
Federal and state laws require us to obtain surety bonds to secure payment of
certain long-term obligations including mine closure or reclamation costs,
federal and state workers' compensation costs, coal leases and other
miscellaneous obligations. Many of these bonds are renewable on a yearly basis.
Surety bond costs have increased in recent years while the market terms of such
bonds have generally become more unfavorable. In addition, the number of
companies willing to issue surety bonds has decreased.
CLEAN AIR ACT
The federal Clean Air Act, and comparable state laws that regulate air
emissions, directly affect coal mining operations, but have a far greater
indirect affect. Direct impacts on coal mining and processing operations may
occur through permitting requirements and/or emission control requirements
relating to particulate matter, such as fugitive dust or fine particulate matter
measuring 2.5 micrometers in diameter or smaller. The Clean Air Act indirectly
affects coal mining operations by extensively regulating the air emissions of
sulfur dioxide, nitrogen oxides, mercury and other compounds emitted
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by coal-fired electricity generating plants and coke ovens. The general effect
of such extensive regulation of emissions from coal-fired power plants could be
to reduce demand for coal.
Clean Air Act requirements that may directly or indirectly affect our operations
include the following:
Acid rain
Title IV of the Clean Air Act required a two-phase reduction of sulfur dioxide
emissions by electric utilities. Phase II became effective in 2000 and extended
the Title IV requirements to all coal-fired power plants with generating
capacity greater than 25 Megawatts. The affected electricity generators have
sought to meet these requirements by, among other compliance methods, switching
to lower sulfur fuels, installing pollution control devices, reducing
electricity generating levels or purchasing sulfur dioxide emission allowances.
We cannot accurately predict the effect of these provisions of the Clean Air Act
on us in future years. At this time, we believe that implementation of Phase II
has resulted in an upward pressure on the price of lower sulfur coals, as
coal-fired power plants continue to comply with the more stringent restrictions
of Title IV.
Fine particulate matter and ozone
The Clean Air Act requires the EPA to set standards, referred to as National
Ambient Air Quality Standards, or NAAQS, for certain pollutants. Areas that are
not in compliance (referred to as "non-attainment areas") with these standards
must take steps to reduce emissions levels. In 1997, the EPA revised the NAAQS
for particulate matter and ozone; although previously subject to legal
challenge, these revisions were subsequently upheld but implementation was
delayed for several years.
For ozone, these changes include replacement of the existing one-hour average
standard with a more stringent eight-hour average standard. On April 15, 2004,
the EPA announced that counties in 32 states fail to meet the new eight-hour
standard for ozone. States which fail to meet the new standard will have until
June 2007 to develop plans for pollution control measures that allow them to
come into compliance with the standards. For particulates, the changes include
retaining the existing standard for particulate matter with an aerodynamic
diameter less than or equal to 10 microns, or PM10, and adding a new standard
for fine particulate matter with an aerodynamic diameter less than or equal to
2.5 microns, or PM2.5. On December 17, 2004, the EPA announced that regions in
20 states and the District of Columbia did not achieve the fine particulate
matter standard. Following identification of non-attainment areas, each
individual state will identify the sources of emissions and develop emission
reduction plans. These plans may be state-specific or regional in scope. Under
the Clean Air Act, individual states have up to twelve years from the date of
designation to secure emissions reductions from sources contributing to the
problem. In addition, on April 25, 2005, the EPA issued a finding that states
have failed to submit State Implementation Plans that satisfy the requirements
of the Clean Air Act with respect to the interstate transport of pollutants
relative to the achievement of the 8-hour ozone and the PM2.5 standards. Because
of this finding, the EPA must promulgate a Federal Implementation Plan for any
state which does not submit its own plan. Meeting the new PM2.5 standard may
require reductions of nitrogen oxide and sulfur dioxide emissions. Future
regulation and enforcement of these new ozone and PM2.5 standards will affect
many power plants, especially coal-fired plants and all plants in
"nonattainment" areas.
The EPA continues to review these ambient air standards. For example, EPA is
under a court imposed deadline to decide by the end of 2005 whether to propose a
revision to the fine particulate matter standard. EPA is also considering
whether to revise the ozone standard.
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Ozone
Significant additional emissions control expenditures will be required at
coal-fired power plants to meet the current NAAQS for ozone. Nitrogen oxides,
which are a by-product of coal combustion, can lead to the creation of ozone.
Accordingly, emissions control requirements for new and expanded coal-fired
power plants and industrial boilers will continue to become more demandin |