Michael Bauersachs
Analyst · Clarksons
Thank you, Randy. We definitely have some very positive developments, milestones and updates to discuss during this call. The geologic conditions that we are encountering and the productivities we are experiencing are very exciting. Once the Elk Creek preparation plant is online, coupled with unleashing our mines for coal production, we anticipate that we will meet and hopefully exceed our expected results. With the above being said, let me preface everything for the second quarter and for the third quarter, for that matter, by reminding everyone that we are indeed in development mode. In many cases, we have purposefully limited staffing and delayed equipment deployment to align our production with stockpile space, coal sales and the ultimate startup of our Elk Creek preparation plant. Although we are in development mode, that does not mean that we are not experiencing an increasing number of employee hours. Our current number of employees is 113. We anticipate that headcount to rise to 187 employees by the end of the third quarter and 213 by year's end. Our nonfatal days lost rate continues to be 0. We believe that says a lot about our operational execution to date to not have incurred a lost time accident, while initiating production alongside interaction with our sizable infrastructure build-out. One of the key positions that we've hired in the second quarter is a Vice President of Administration, Legal and Environmental. Our addition of Dan Zaluski will allow us to address more administrative and legal tasks internally, rather than through consultants.
Let me provide an update on our operations. One major change that we made during the second quarter was to switch our Alma Mine from a contracting mining operation to a company mine. In some respects, this mine is still in transition for a couple more weeks. There are a number of things that impacted this decision, but perhaps the most critical was the fact that we wanted to address some adverse mining condition related issues more quickly. Once in control of this section, we have gone to great lengths to address areas where problems existed. These efforts and the ongoing transition have negatively impacted our productivity and costs for this mine during the second quarter. Some of these impacts were mitigated by encountering thicker coal seams than initially expected. We believe that the measures we have taken will create a safer work environment and send a strong positive signal to federal and state officials relative to our commitment to safety. This is a mine that, unlike the normal life cycle for mines in Central Appalachia, should operate for 20 years. It is important to establish a firm foundation from which to operate. An additional consideration in converting to a company mine was the fact that we wanted to alter the operation's mining techniques and install a super section, which the contractor was not required to do. This is a necessary and planned enhancement, as the mining section migrates to an area where conditions are anticipated to be a good fit for this technique as well as coinciding with the startup of our preparation plant. Once our transition and capital enhancements are implemented, we believe that this mine will become one of the most productive, low-cost metallurgical mines in Central Appalachia.
Speaking of productivity, we have been pleased by the development mining productivity that we are experiencing at the new Eagle deep mine. The feet of advance have exceeded our plans and expectations, routinely coming in at over 300 feet per shift for the last couple of weeks. This combined with the favorable mining conditions we are currently experiencing point to a mine that will likely match or improve upon the planned Alma Mine cost structure. During the next week or so, we will have a fully staffed Eagle Mine with all of the equipment necessary to operate as a super section. During the third quarter, this mine is expected to intersect the area where the Eagle seam and #2 gas seam will be mined together. We expect the total mineable height to regularly be in the 12-foot range once that occurs.
Looking prospectively, I thought that it would be a good idea to highlight the startup of our surface mine at Elk Creek. First of all, I'd like to welcome Toby Edwards, our new Vice President of Surface Mining, to our team. Toby brings decades of experience in the type of mining that we will be conducting. We completed the access road to our surface mine in mid-July. Our first hourly surface position was filled on July 19. We expect sporadic production to begin from the surface mine during the week of August 28. We project about 17,000 clean tons to be produced in September, and our Highwall Miner is scheduled to begin production in October. We remain confident that everything will be in place for our surface mine to run as projected in 2018 as well as contribute just shy of 150,000 tons during 2017. While we still plan to start up our Elk Creek plant in the third quarter, it now looks like the startup will be towards the end of September. The primary delay relates to the completion of the thickener, which is, in essence, a pool formed out of concrete. The time that it has taken to stabilize the foundation for the thickener is the key cause for delay. Let me emphasize that there are no issues with components or time-sensitive steel fabrication. I will also note that we have mitigated the impact by permitting a series of on-site raw coal stockpiles to help us manage inventories, especially during the next few months. Fortunately, stockpile permit work was completed long ago, in case we experience some sort of delay. It is likely that we will have more than 150,000 raw tons in a series of stockpiles when the plant is commissioned. We project being enabled to decrease our stockpiles to a more normalized level by the end of the fourth quarter. On a related topic, all of our rail work that will serve the plant has been completed, and our general contractor has demobilized all of its equipment. CSX has approved the work, and we look forward to shipping our first train from the 150-car unit train loadout early in the fourth quarter.
Moving to our Berwind development, as we recently announced, we received our mining permit at the end of June. We broke ground on the new phase up immediately after the 4th of July holiday. All of the major capital equipment for this mine has been procured, and we anticipate being development production mode in November. This mine will have an extended development time frame as we migrate from the seam where our phase-up is located up to the more prolific Pocahontas #4 seam. As we have done with our Elk Creek build-out, we have placed picture updates on our website, so you can view our progress during the next few months.
Our active deep mine sections company-wide produced approximately 74,000 clean tons during the second quarter. Our temporary second section in the Alma Mine became active in May. We currently have 3 active sections, although none were fully staffed or fully capitalized from an equipment standpoint during the second quarter. We now anticipate production of 195,000 tons in the third quarter and 395,000 tons in the fourth quarter. This points to anticipated total 2017 production of 720,000 tons, down from our prior guidance.
We have not entered into new coal sales arrangements for our Elk Creek coal. We have approximately 338,000 remaining committed tons for 2017 at an average FOB mine price of slightly less than $70 per ton. We expect to produce and sell an additional 280,000 tons prior to the end of the year. We shipped our first train in June under a contract entered into earlier in the year. Due to rail and vessel issues, we did not ship an additional train until August 1. We anticipate an additional shipment before month's end. We continue to sell tons to a nearby producer who also washes and ships tons for us to our customers. Obviously, we look forward to eliminating the added cost of trucking raw coal long distances as well as third-party washing costs.
As we think about the current marketplace, we believe that our uncommitted tons available in the fourth quarter could be well timed to be placed into an improved marketplace. We remain optimistic that the remaining uncommitted tons can be placed into the market at a margin that is significantly greater than our base load tons.
At this point, our outlook for third-party purchased coal for all of 2017 is 120,000 tons. We shipped 39,637 purchased tons in the second quarter. Currently, most of this revenue is generated from high-quality, low-volatile coal that we are purchasing for resale to third parties. These tons are all being washed and shipped out of our Knox Creek wash plant. All of the coal generated from our near-term Berwind development production estimated at 14,000 tons during 2017 is expected to be washed and shipped out of Knox Creek. Let me also note that we terminated our coal washing arrangement early in the third quarter. And alongside washing lower volumes of purchased coal, we are also able to make improvements to the plant.
Like other metallurgical coal producers, we have and will be focusing on 2018 solicitations. We find that we are encountering a receptive audience among our potential customers. We are in the midst of bidding for 2018 business. In support of our efforts, it has been helpful to provide property visits to numerous customers, so they can become more comfortable with our ability to perform. As those investors and analysts who visited Elk Creek during the second quarter can attest, visually seeing deployment of capital and the developments in process as well as exposure to our operational advantages is a powerful tool. Let me also add that our domestic customers appear to be gaining strength from better pricing and demand. The latest earnings releases from both domestic and international steel producers have been very positive. Our guidance relative to capital expenditures is expected to be between $65 million and $70 million in 2017. The significant spending range relates to whether we were able to move some development work forward from 2018 into 2017. The slight increase in capital also relates to the purchase of equipment and other assets from our contract miner as well as some timely equipment purchases at a substantial discount to market.
One of the most common questions that I receive from investors and analysts relates to whether the Trump administration is making a difference. The Trump administration's Section 232 action assumed that some sort of action that's ultimately taken will likely strengthen the domestic marketplace for steel producers. We are of the mind, taking into account what could be some adverse international reactions, that almost all of the possible actions being reviewed will have an overall positive impact on U.S. metallurgical coal demand. Additionally, I believe that most of you have seen the recent press release from the Department of the Interior relative to the crayfish issue that caused a significant delay in the issuance of our Berwind permit as well as some important permits at Elk Creek. Indeed, I can confirm that the Department of Interior officials worked with us to reach a mutually acceptable resolution of the issue with the U.S. Fish and Wildlife. The new EPA Director's decision to repeal the Waters of the United States initiative, which we believe was regulatory overreach, is also likely to have a substantial positive impact on mining in Central Appalachia. From a forward-looking standpoint, we are hopeful that the new head of MSHA will have the same pragmatic approach that we have witnessed from the new administration's environmental regulatory approach for reaching an appropriate balance, allowing mining activities to proceed, while maintaining strong legal and regulatory standards. Hopefully, this will also result in MSHA taking a fresh look at their efficiency and rule-making. Most importantly, this new official will inherit a slow-moving bureaucracy that needs to act more quickly. We believe that mining operations can be conducted safely and efficiently, while loosening some regulatory constraints that hamper productivity and that inordinately increase costs. In summary, it does appear that the Trump administration is beginning to make a positive difference for the coal sector.
I would also like to mention that we are diligently working to provide a more timely quarterly release and corresponding conference call. We are implementing a new accounting system in the third quarter that should be fully operational in the fourth quarter. This will speed up our financial close and allow for more efficient communication with our shareholders. Ideally, we want to be one of the first to report earnings.
In summary, Ramaco is close to unleashing the full impact of its capital deployment and hiring efforts. To date, we have not been in a position to allow our minds to run at the planned potential. The majority of these barriers will be removed prior to the fourth quarter. More importantly, our vision for 2018 becomes clearer by the day, and we anticipate having all the key building blocks in place by year's end. Thank you for your interest in Ramaco Resources, and I will now ask Marc Solochek to provide some comments relative to our second quarter financial results.