By Kris Maher
WHARTON, W.Va. -- Slowing growth in China is
taking a brutal toll on Appalachian coal mines and
coal towns.
Appalachia has one of the world's richest
deposits of high-grade coal used to make steel.
Thanks to Chinese demand, the price for premium
metallurgical coal, whose low-ash and low-sulfur
content makes it ideal for steelmaking, hit a
record $330 a metric ton in early 2011.
Now, the Chinese economy is slowing and so is its
steel industry. That has sent the price of coal
used for steelmaking down nearly 50% to $170 a
metric ton. Those coal producers who counted on
Chinese sales are reeling.
"When someone had coal to move, China was your
big box store," said Ernie Thrasher, chief
executive of XCoal Energy & Resources, a major U.S.
marketer of such coal to Asia. This year, "the
switch went off."
While many have blamed the downturn in the U.S.
coal industry on cheap natural gas supplanting coal
and tougher environmental regulations, the slide in
metallurgical coal demand has been equally
devastating.
Coal companies were caught flat-footed after
ramping up production last year with the
expectation that steep prices would cover their
rising costs, despite coal's past cyclicality.
Instead, demand in China began to falter just as
Australian metallurgical coal production --
interrupted by floods last year -- surged back into
the market.
In July, Patriot Coal Corp. of St. Louis filed
for bankruptcy protection, shortly after it lost a
contract for coal bound for an Asian steelmaker.
Patriot's stock slid 18% the day after it announced
that news, taking other coal stocks down with it.
Earlier this month, Patriot said it would
temporarily idle metallurgical coal operations at
three mining complexes in southern West Virginia
and lay off 250 miners, in addition to 1,000
layoffs earlier this year. On top of that, Patriot
has said it will need to reduce "unsustainable"
pension and health benefits to 2,000 miners and
some 20,000 retirees and surviving spouses.
China's metallurgical coal imports dropped to 2.6
million metric tons in August, from an average of
4.5 million metric tons per month through July. Now
coal mines are closing throughout Appalachia.
Earlier this month, Alpha Natural Resources Inc.,
of Bristol, Va., which derives a large share of its
profits from metallurgical coal, said it was
cutting 1,200 jobs, or 9.2% of its workforce.
Earlier this year, Alpha laid off more than 700
miners and trimmed production at more than 20
mines. Consol Energy Inc. of Pittsburgh, which
sells more coal into China than any other U.S.
producer, earlier this month idled the nation's
biggest metallurgical coal mine, which employs 620
miners. Arch Coal Inc. trimmed its metallurgical
coal production estimate by 21% this year.
Miners like Phillip Powell, 38 years old, of
Wharton, have been swept up by the collapse. "A lot
of guys that I worked with are scared of losing
everything they own," said Mr. Powell, who was laid
off in March from a section foreman job at a
Patriot metallurgical coal mine. Mr. Powell said he
sees no chance of finding another job that would
come anywhere close to paying the $108,000 he
earned last year. After 17 years in mining, he
plans to go back to college to get certified to
teach physical education.
Appalachian coal industry executives had been
counting on metallurgical or "met" coal -- which is
sold at a premium to steelmakers -- to offset the
dwindling market for lower-grade thermal coal used
by power plants. The thermal coal market has been
weakening because utilities are buying
cleaner-burning natural gas instead. Natural-gas
prices have plummeted as energy companies used
hydraulic fracturing to extract gas from vast shale
formations.
In April, natural gas and coal each fueled 32% of
the nation's electricity, achieving parity for the
first time in the decades that the Energy
Information Administration has tracked the data.
For decades, coal powered about 50% of the
electricity to the nation's businesses and homes.
Metallurgical coal exports were supposed to fill
the gap. Only a year ago Patriot was posting record
revenue and operating earnings and embarking on a
plan called the "Met Built-Out" to open new
metallurgical mines and hire up to 200 new miners.
Other coal companies were buying rivals to
strengthen their metallurgical coal operations and
reserves. Four publicly traded U.S. coal companies
made acquisitions in North America totaling $14
billion in 2011, the largest being Alpha's $7.1
billion purchase of troubled Massey Energy.
Alpha now has 1.5 billion tons of metallurgical
coal reserves, and the ability to export up to 30
million tons a year. It is hoping to weather the
weak market by being the low-cost producer of
premium met coal. "While it's a bit soft now, we
have a very valuable metallurgical coal franchise,
and we're hitching our wagon to it," said Alpha
Chief Executive Kevin Crutchfield.
The cost to pull a ton of coal out of the ground
varies widely from mine to mine based on geologic
conditions and the degree of automation. In
Appalachia, average mining costs are about $65 to
$75 per ton. A ton of thermal coal is currently
selling for $52 a ton on the spot market, making it
impossible to operate some mines at a profit.
Before the China steel market took off,
metallurgical coal was valued much like thermal
coal and was often sold to power plants where it
was burned like lower-grade coals. "It was like
using an expensive bottle of red wine to make
spaghetti sauce," said Paul Forward, an analyst
with Stifel, Nicolaus & Co.
That changed with China's industrial boom. Up
until 2004, the price for metallurgical coal stayed
below $40 a ton in the U.S. Prices hit an all time
record of $330 a metric ton in the second quarter
of 2011 after flooding in Queensland, Australia,
disrupted coal supplies headed for China.
China couldn't seem to get enough metallurgical
coal to feed its steelmaking industry. In 2009,
U.S. met coal exports to China grew nearly
six-fold, and grew by the same rate in 2010,
linking Appalachia more closely to the global steel
trade.
Now the China spigot is closing. The Chinese
steel industry -- which consumes half of all
metallurgical coal mined each year -- faces the
possibility it could operate at a loss in 2012 for
the first time as a result of overcapacity and weak
steel prices, according to the China Iron & Steel
Association.
That would mean tougher times in West Virginia,
where rail, barge, trucking and other jobs depend
on coal.