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JUNE 2018 - VOLUME 27 NUMBER 5

Cummins Helps Customers


Filter Out Downtime
Page 54

A Kal Tire team member buffs an OTR tyre


as part of the repair process.
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Contents
Contents
03 Comment Engines & Emissions Control
05 News 32 A New Beginning
Sarah Lispet (Australia) and Naoto Sannomiya (Australia), Global
10 Industry View Mining Division of Hitachi Construction Machinery, discuss how
autonomous technologies are marking the dawn of a new era for
the mining industry.
Regional Report
12 Predicting Trends Dust Control
Alexander A. Ignatov, Ignatov & Company Group, UK, provides 36 Fighting Fire
an insight into Russia and Central Asia’s current coal mining Clean conveyor systems, good firefighting capabilities and
industry. ongoing maintenance are the best defence against fires, explain
Dan Marshall and Todd Swinderman, Martin Engineering, USA.
Longwall Mining Equipment
41 Washing Away
18 A Competitive Advantage Eric Tomicek, Australian Diversified Engineering, Australia,
Andreas Westphalen, Caterpillar Global Mining, Germany, discusses the importance of developing innovative ways to
discusses the advantages of variable frequency drive technology combat dust emissions in coal mining, and details two new water-
for face conveyors and plow systems in longwall mining. based dust control solutions for the coal industry.
23 Safe And Sound Coal Washing & Dewatering
Andrzej Kret, FAMUR SA, Poland, provides an overview of
a range of powered roof supports and discusses how their 43 Times Are Changing
implementation can improve the safety of new longwall projects Ernst Bekker and Brent Combrink, Multotec, South Africa, discuss
in underground mines. coal washing and dewatering processes.
Underground Mine Safety Mining Software
27 Extinguished! 47 Adapting To Change
Al Ozment, US Foam Technologies, discusses the prevalence Frank Grima, RPMGlobal, Australia, talks about closing the gap
of underground mine fires in the USA, and details how in mine planning and scheduling solutions.
gas-enhanced foam and direction drilling can increase the
effectiveness of current mine fire suppression technologies. 51 The Significance Of Software
The World Coal team talks to RCT about the introduction of
mining software and how it has benefited the coal industry.

Cover Story
54 A New Era For Mining Maintenance
Domitila Moreno, Cummins Inc., USA, discusses the evolution
of a number of filtration optimisation solutions that can extend
service intervals in coal mining.

Mine Productivity
61 Boosting Process Stability And Output
Nathan Flesher (USA) and Eben van Niekerk (Australia), McKinsey
& Company, describe a data analytics-based approach to improve
the stability of coal mining processes and raise productivity.

Smarter maintenance practices mean a big increase in profit for

This m
month's mining operations. That’s why Cummins is working with mining

front cover customers around the globe on holistic maintenance plans that lead to
longer intervals and more strategic scheduling of service events. The

○ winning combination of Cummins expertise, customer collaboration


and the newest filtration technologies in the industry increases mining
customers’ uptime, productivity and profits. Learn more on p.54.

World Coal is a fully-audited member of the Audit Bureau of Circulations (ABC).


An audit certificate is available from our sales department on request.
Copyright © Palladian Publications Ltd 2018. All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior
follow connect like join permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily
@World_Coal_Mag World Coal World Coal World Coal the opinions of the publisher, neither does the publisher endorse any of the claims made in the advertisements. Printed in the UK.
Uncaptioned images courtesy of www.shutterstock.com
FS 800
LONGWALL SHEARER MACHINERY
& EQUIPMENT FOR
UNDERGROUND MINING

A wide range of FAMUR Group’s products includes advanced longwall shearers


with electric haulage with the powerful capability and the ability to work in high
seams (mining height up to 6.0 m).

THE ADVANTAGES OF FS 800 LONGWALL SHEARER:


KLJKO\HIğFLHQWQHZJHQHUDWLRQVKHDUHUORDGHU
safe and high operating comfort along with high capacity (production rate)
modular design enabling maximum reduction of the transport dimensions
designed in e-mine standard, with the function of advanced parameter
PROVEN SOLUTIONS diagnostics (troubleshooting) and full onground monitoring of the machine
GLOBAL REACH operation
mutual backup arrangement of hydraulic systems
www.famur.com adapted for operations in varying geo-mining conditions

FAMUR Group is a Polish manufacturer and supplier of machinery and equipment


operating in the mining industry all over the world. The main areas of our activity
are underground and open-pit mining, transport, bulk material handling, and the power
industry.
Comment
Comment
E very four years, one of the biggest sporting events in the world hits our screens: the
FIFA World Cup.
As I write, we are only 11 days until the first game takes place – Russia and Saudi Arabia
will kick off the tournament on 14 June at Moscow’s Luzhniki Stadium.
At present, the bookies have Germany and Brazil down as favourites to win, both with
odds of 9/2. Russia is left in the dust at 40/1.
Yet, this is undoubtedly an exciting time for Russia, as it will be the country’s first time
hosting the event. And all eyes will be fixed firmly on the nation.
Let’s go back to the last major football tournament in Europe: the Euro 2016
Stephanie Roker – Deputy Editor
stephanie.roker@worldcoal.com championship held in France. This was a memorable competition for more reasons than one.
Portugal triumphed after defeating host France in the final; the Union of European Football
Managing Editor
James Little Associations (UEFA) decided to expand the tournament to 24 teams rather than the
james.little@worldcoal.com traditional 16; and Wales experienced their first semi-final of a major tournament after a 3-1
Editorial Assistant victory over Belgium in the quarters.
Claire Cuddihy
claire.cuddihy@worldcoal.com These are only some of the best highlights of the event. But Euro 2016 is also remembered
Advertisement Director for the hooliganism that erupted between Russian and England fans. And now, in the
Rod Hardy
rod.hardy@worldcoal.com
build-up to the World Cup, this remains fresh in our minds.
Advertisement Manager
Similarly, at a France-Russia friendly in St. Petersburg in March of this year, racist chants
Ryan Freeman from Russian fans were made to French players on the field. As a result, FIFA fined the
ryan.freeman@worldcoal.com
Russian Football Union £22 000, stating it has a zero tolerance approach to discrimination.
Production
Ben Munro
But it seems that FIFA has been taking note of these incidents. As a means of preventing
ben.munro@worldcoal.com potential racist incidents at the World Cup, an obligatory fan ID system will be implemented
Website Manager during the competition. The system had previously been tested at the 2017 Confederations
Tom Fullerton
tom.fullerton@worldcoal.com
Cup in Russia, and proved to be successful.
Digital Editorial Assistant
With great expectations at home for the host nation, Russia will no doubt be on its best
Nicholas Woodroof behaviour. Especially as the World Cup is set to be worth approximately US$31 billion to the
nicholas.woodroof@worldcoal.com
Russian economy.
Subscriptions
Laura White
By a similar amount, exports from the country increased 17.8% y/y to US$36.9 billion in
laura.white@worldcoal.com March 2018, with coal accounting for 15.64 million t.1, 2
Administration Between January and April 2018, coal exports from the country increased 5% y/y to
Nicola Fuller 59.657 million t.3
nicola.fuller@worldcoal.com
Russia was also third in the line-up of countries that exported the highest dollar value
Correspondents
Barry Baxter worth of coal during 2017, totalling US$13.5 billion.4
Anthony Fensom Exports of Russian coal to Poland increased by a third in 2017, and this year is no
Ng Weng Hoong
exception. Russia is currently set to be the largest thermal coal exporter to Poland in 2018
Palladian Publications Ltd – the country generates approximately 80% of its electricity from coal-fired power plants.
15 South Street, Farnham,
Surrey, GU9 7QU, UK
Vladimir Nefedov, RIA Novosti Trade Representative of Russia in Poland, stated: “Last
year, exports of Russian coal to Poland, according to preliminary estimates, increased by
t: +44 (0)1252 718999
f: +44 (0)1252 718992 about a third – more than 6.7 million t with domestic production at 66 million t.”
w: www.worldcoal.com This month’s regional report on p.12 is provided by Ignatov & Company Group, and
World Coal (ISSN No: 0968-3224, USPS offers an insight into Russia and Central Asia’s current coal mining industry.
No: 020-997) is published monthly by Palladian We also feature technical articles and case studies on longwall mining equipment, dust
Publications Ltd, GBR, and distributed in the
USA by Asendia USA, 17B S Middlesex Ave, control, mining software, and much more. I hope you enjoy the issue!
Monroe NJ 08831. Periodicals postage paid New
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POSTMASTER: send address changes to World
Coal, 701C Ashland Ave, Folcroft PA 19032. References
1. https://tradingeconomics.com/russia/exports
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postage, £200 overseas (airmail). Claims for to-26935807
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New from Palladian Publications...

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Coal News
Coal News
USA Trump to save US coal-fired power plants

O n 1 June, US President Donald Trump directed


Energy Secretary Rick Perry to take immediate steps
to stop the closure of more coal-fuelled power plants.
She noted: “I am very supportive of the Administration’s
decision to take action to preserve our coal-fired power plants
and nuclear power plants. The recent series of winter storms
In response, ACCCE President and CEO Paul Bailey stated: caused thousands of power outages and drove up rates due
“We are pleased the Administration is taking steps that will help to reduced supply, highlighting just how important it is that
ensure that our nation’s electricity grid is resilient and reliable. we have access to affordable and reliable energy sources.
“Almost 40% of the nation’s coal fleet has shut down or is “As it has done time and time again over the years, coal
expected to close. The loss of fuel-secure electricity sources, proved to be exactly what we needed to power the country,
especially coal-fuelled power plants, pose an increasing threat demonstrating its importance in keeping the lights on when
to the power grid, as well as to national security. other resources were unavailable.
“We look forward to working with the Administration and “I am encouraged by the President’s actions to protect our
other policymakers on both near-term and longer-term nation from these plant closures and ensure coal power is
measures to ensure that the grid is not threatened by the loss of available to address future weather, market and cyber
even more fuel-secure resources.” security challenges. Doing so will be vital to our state’s
Similarly, US Senator Shelley Moore Capito (R-W.Va.) issued economy and to our nation’s viability, security and
a statement supporting the Trump Administration’s intentions. independence.”

SOUTH KOREA MHPS to perform environmental upgrade at Boryeong power plant

M itsubishi Hitachi Power Systems, Ltd., (MHPS), jointly


with its group company Mitsubishi Hitachi Power
Systems Environmental Solutions, Ltd. (MHPS-ES), has
MW. Unit 3 designated for upgrading has an output of 550 MW.
EPC will be performed by STX Heavy Industries Co., Ltd., a
leading Korean company with which MHPS has a technical
received an order for environmental systems upgrade work tie-up in flue gas desulfurisation (FGD) systems. MHPS and
at Unit 3 of the Boryeong power plant operated by Korea MHPS-ES received the new order from STX Heavy Industries.
Midland Power Co., Ltd. (KOMIPO). The upgrade is targeted at reducing emissions of sulfur oxide
The Boryeong power plant is located in the city of Boryeong, (SOx), nitrogen oxide (NOx) and particulates in line with the
South Chungcheong province, on South Korea’s west coast Korean Government’s drive to curb air pollution caused by the
approximately 140 km south-southwest of the capital, Seoul. nation’s coal-fired power plants. The new systems are scheduled
The plant was launched in 1983 and has a rated output of 4800 to go into operation in August 2019.

AUSTRALIA Aurizon to end Queensland coal export standoff?

T he Queensland coal industry is prepared to accept


the independent competition regulator’s final
decision on Aurizon’s rail maintenance budget and
QRC has noted the regulator’s preliminary position was for
Aurizon’s rail maintenance budget to be increased by
AUS$73 million over four years, pending Aurizon itself
Aurizon should declare the same immediately and end the providing the QCA with more information to support its
coal export impasse. position.
Queensland Resources Council (QRC) Chief Executive The QRC estimates the cost of Aurizon’s plan to stop the
Ian Macfarlane said Aurizon should co-operate with the movement of up to 20 million tpy under its new maintenance
Queensland Competition Authority, immediately resume its regime would costs up to a AUS$4 billion tpy in lost
normal maintenance programme on the Central Queensland Queensland export revenue and up to a AUS$500 million cut
Coal Network and end coal export impasse it started. in royalties paid to the Palaszczuk Government for to
In its submission lodged with the QCA on 1 June, the reinvest in services and infrastructure for all Queenslanders.

June 2018 | World Coal | 5


Coal News

Coal News
DIARY DATES RUSSIA Maly Port promoting environmental protection

M
25th World Mining Congress 2018
19 June - 22 June 2018 aly Port Stevedoring Company Administration. As part of the
Astana, Kazakhstan has entered into an agreement comprehensive investment and
https://wmc2018.org/en
to promote the environmental environmental programmes, the terminal
protection of the city of Nakhodka has been equipped with unique 4 m
Hillhead 2018 (Russia) and RUB 228 million of its protective walls along the entire perimeter
26 - 28 June 2018 overall RUB 2.1 billion investment will of the production site, which completely
Derbyshire, UK
https://www.hillhead.com/welcome#/ be aimed at minimising the negative shields the coal storage from the wind.
effects of coal transhipment on the local According to the experts, the use of new
population. portal cranes has reduced the number of
Conveying and Handling of Particulate
Solids Conference 2018 At the St. Petersburg International coal transhipment operations, along with
10 - 14 September 2018 Economic Forum, the Ministry of dust emissions, by 20 times.
London, UK Transport of Russia, Rosprirodnadzor, The main upgrade measures deal with
http://www.constableandsmith.com/events/
chops-2018/ Primorsky Regional Administration, the dust suppression system. Loading and
Rosmorport and LLC Maly Port unloading operations involve cranes that
Stevedoring Company signed a prevent spills, which means no dust
Electra Mining Africa 2018 co-operation agreement aimed at formation. The pile spraying system
10 - 14 September 2018
Johannesburg, South Africa completing the transition of Maly Port to includes four mobile fog-generating units,
https://www.electramining.co.za/ shielded coal transhipment and ensuring spraying fog and snow within a radius of
favourable environmental conditions for 80 m. Their capacity is 2400 l/hr.
the population of the city of Nakhodka. As part of the new agreement, four
ACPS Conference and Exhibition 2018
11 - 14 September 2018 In accordance with the agreement, more stationary units will be installed on
Brisbane, Australia Maly Port plans to invest more than 12 m masts. In addition, in
https://www.acps.com.au/
RUB 730 million, including November 2018, a video surveillance
conference-2018/
RUB 127 million in environmental system and automatic dust analysers will
programmes this year. be put into operation. These measures,
Coal Association of Canada 2018 It is significant to note that in along with a climate monitoring system,
Conference
12 - 14 September 2018 September 2016, Maly Port SC concluded operated together with Roshydromet, will
Vancouver, Canada a co-operation agreement with the regulate the humidity of the coal and
http://www.cvent.com/events/2018-cac- Ministry of Natural Resources, prevent dust in the course of loading and
conference/event-summary-937bd414f3df4
07b8f0ece3d5e53894b.aspx Rosprirodnadzor and Primorsky Regional unloading operations.

UK RBS to stop financing new coal plants


Coaltrans World Coal Leaders Network
14 - 16 October 2018

O
Barcelona, Spain
http://www.coaltrans.com/world-coal- n 29 May, Britain’s Royal Bank It also said it would stop lending money
conference/details.html of Scotland (RBS) announced to mining companies that generate over
that it had tightened restrictions on 40% of their revenues from thermal coal, or
BULKEX18 project finance and general lending power companies that generate more than
17 - 19 October 2018 for high carbon energy projects and 40% of their electricity from coal; the
Nottingham, UK
companies. previous threshold for both was 65%.
https://bulkex.co.uk/
RBS said it would cease directly In April, HSBC also said it would stop
financing new coal-fired power plants or funding new coal power plants, oilsands
IMARC thermal coal mines, as well as oilsands or and Arctic drilling, following on from
29 October - 1 November 2018
Melbourne, Australia Arctic oil projects and unsustainable other large banks such as ING and BNP
https://imarcmelbourne.com/ vegetation or peatland clearance projects. Paribas.

6 | World Coal | June 2018


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Coal News

Coal News
USA San Juan coal mine area to be expanded

T he US Department of the Interior’s Office of Surface


Mining Reclamation and Enforcement (OSMRE) is
considering a plan to add approximately 4465 acres to the
and cumulative impacts of the proposed underground mining
operations, alternatives and the potential coal combustion
related impacts at the San Juan generating station.
approved mining plan area of the San Juan mine in New The Notice of Availability for the DEIS was published in
Mexico. The proposed action would add approximately the Federal Register on Friday 25 May 2018. The publication
10 - 15 years to the life of the underground mine, opens a 45 day comment period, closing on 9 July 2018.
authorising the mining of approximately 53 million t of OSMRE will also hold five public meetings on the DEIS
federal coal. The underground facility is located about between 25 June and 29 June 2018. The Bureau also
16 miles west of the city of Farmington in San Juan County announced the times and locations of the public meetings in
and currently employs 282 people. The mine is projected to the Federal Register on 25 May 2018.
produce an average of 3 million tpy. Following the close of the public comment period, OSMRE
In accordance with the National Environmental Policy Act will review all comments received, develop responses and
(NEPA), OSMRE will publish a draft Environmental Impact revise the EIS as necessary. The final EIS is scheduled for
Statement (DEIS) for the San Juan mine deep lease extension release in February 2019. OSMRE expects to issue a Record of
mine plan modification. The DEIS analyses the direct, indirect Decision in March 2019.

AUSTRALIA Eagle Downs coal project to be acquired by SOUTH32

S outh32 Ltd has signed a conditional agreement


(the acquisition) with a subsidiary of China BaoWu
Steel Group to acquire a 50% interest in, and assume
care and maintenance in late 2015 having benefitted from
initial investment that delivered site infrastructure including
water supply and high voltage systems, office buildings and
operatorship of, the Eagle Downs metallurgical coal project water and sediment dams. Dual 2 km drifts are also
in Queensland’s Bowen Basin (Eagle Downs). approximately 40% complete.
The other 50% interest in the project will continue to be Aquila has previously reported on its website a coal
held by Aquila Resources Pty Ltd., a subsidiary of BaoWu. resource (100% basis) of 1122 million t, of which 67%
The consideration payable by South32 comprises an upfront (750 million t) is measured, 12% (139 million t) is indicated
payment of approximately US$106 million upon completion and 21% (233 million t) is Inferred in accordance with the
of the acquisition (excluding transaction costs) and a deferred JORC Code (2012 Edition). Prior work undertaken by Aquila
payment of US$27 million due three years after completion. A has indicated that Eagle Downs has the potential to export
coal price linked production royalty will also be payable and 4.5 million tpy of coal (on average) from one longwall over the
is capped at US$80 million. The acquisition, which will be first 10 years of full production.
funded from the Group’s cash reserves, is subject to Following completion of the acquisition and assumption of
conditions precedent and is expected to close in the first half operatorship, South32 propose to commence a final feasibility
of FY19. study which will seek to optimise the mine’s design and
Eagle Downs is a large, high quality and fully permitted development. Subject to the findings of that study and
metallurgical coal development project located approximately requisite approvals, South32 in partnership with Aquila plan
25 km southeast of the town of Moranbah and immediately to construct a multi-seam underground longwall metallurgical
adjacent to and down dip of BHP Billiton Mitsubishi coal mine and processing plant with a dedicated rail spur and
Alliance’s Peak Downs mine. The project was placed under train loadout facility.

8 | World Coal | June 2018


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Industry View

Industry View
The energy-water nexus
Anne Carpenter, IEA Clean Coal Centre, UK

W ater and energy are basic necessities for human


wellbeing and prosperity. The water industry,
however, is energy-intensive and the energy industry is water
systems. Switching to dry cooling saves the largest amount of water.
Recovering water vapour from the mill or pre-dryer exhausts prior
to coal combustion, or from the flue gas, after combustion, can also
intensive. Water is needed to extract, process and transport the save a significant amount. If sufficient water can be economically
mineral energy resource and it has an important role in thermal recovered from the flue gas, then a dry cooled power plant could
power plant cooling, emissions control and other processes. This become a co-producer of electricity and water.
interdependency of water and energy is often called the energy- Treating and reusing generated wastewater instead of
water nexus, and the policies required to manage them are rarely discharging it is another way of conserving water. Moving to zero
integrated. liquid discharge (ZLD) not only lowers fresh water consumption,
Global demand for energy and water is increasing as a but also eliminates the need to meet regulated discharge limit and
consequence of population and economic growth, as well as higher the associated expensive monitoring and measurement
living standards. But water is becoming a scarcer commodity in requirements.
many parts of the world. An estimated 20% of the world’s aquifers It is even possible to use other water sources as opposed to fresh
are already overexploited, and water quality is deteriorating in water sources in power plants. Alternative water sources include
many regions. Consequently, meeting the growing energy demand municipal wastewater (MWW), brackish and seawater, mine water,
is going to place increasing stress on limited fresh water resources water produced from oil and gas wells, and water extracted from
with repercussions for other domestic users, agricultural users and deep saline aquifers. The economic feasibility of using these
industrial users. Significant areas in almost every continent face a alternatives largely depends on the distance from the power plant,
high level of water stress, including areas in China and India, the amount of water available, its price and treatment costs. MWW
where the majority of electricity is generated from coal-fired power and mine water are currently used for cooling purposes, and more
plants. power plants could use these sources. Using mine water can turn a
Water shortages have already caused power plants to shut pollution liability into a water resource. Coastal power plants have
down for days, or even months, at a time. According to the World the advantage of being able to use seawater for cooling and flue
Resources Institute’s estimates, India lost some 14 TWh of potential gas desulfurisation. Desalination of seawater can supply their fresh
generation from the temporary closure of power plants in 2016. water needs. Integrating the power plant and desalination units
Climate change and the increase in water withdrawals to meet has both economic and environmental benefits. If the desalination
future energy demand and for other uses will exacerbate scarcity plant is designed with excess capacity, then the power plant can
and stress, and lead to an increasingly water constrained future in also become a co-producer of electricity and water.
more regions. A 40% water deficit by 2030 is projected under a But it can be expensive to implement water conservation
‘business-as-usual’ scenario by the Water Resources Group. measures. So policies and regulations will be needed to encourage
Countries need to integrate their energy and water policies so these actions to be taken. This has already been started in China for
that energy policies consider the implications for water and vice example, where all new coal-fired power plants in arid regions
versa. For example, many countries are increasing the amount of must be dry cooled despite the drawbacks of lower power
low carbon power in their energy mix to reduce CO2 emissions. efficiency, higher operating costs and a larger footprint than a
This may, or may not, lower water usage. Concentrating solar similar wet-cooled plant. Both India and China require new power
power and geothermal plants can actually consume similar plants to use nearby municipal wastewater. Several countries have
amounts of water as wet-cooled coal-fired power plants if they are said that any new coal power plant must be supercritical or
cooled with water. One barrier to greater integration of energy and ultrasupercritical. Besides lowering CO2 emissions per unit of
water policies is the lack of water data. Without good data on water electricity generated, these plants also consume 15 - 20% less water
resources, flows and use, it is difficult for policy makers to assess than an equivalent subcritical one. Other policies, in China for
and respond to energy and water trade-offs. example, are beginning to compel power plants to become ZLD.
There are many practical measures that can be taken by the coal Thus, if practical solutions are not economically feasible then fiscal
power sector to reduce water use. Power plant operators can reduce incentives, such as subsidies and tax credits, will be needed to
the losses from cooling, pollution control and bottom ash handling facilitate water conservation by power plants.

10 | World Coal | June 2018


Alexander A. Ignatov, Ignatov & Company Group,
UK, provides an insight into Russia and Central Asia’s
current coal mining industry.

12 | World Coal | June 2018


R ussia needed 30 years to restore its coal mining
industry up to the record levels of the socialist
era. In 1988, Soviet Russia extracted 425 million t
of coal from a total of 467 million t produced in
the USSR, while in 2017, the country manufactured
409 million t, or 96%, of that Soviet record level. It is
believed that this will be exceeded in 2018. The country has
era when all mines were state-run, and to most of the other
‘heavy’ industries in modern Russia, such as oil and gas.
Almost 95% of the output is being provided by just 18
large market players, thus the business concentration in
Russian coal mining is very high.
The presence of foreign investors is very low in the
Russian coal mining industry; operators that were directly
passed through the ‘dark era’ when, in just 10 years, its owned with the foreigners produced less than 3% of the
production decreased twofold to 232 million t in 1998, while Russian coal in 2017.
restoration took 20 years. Nevertheless, after passing Coal mining is one of few large industries capable of
through that painful transformation over last 30 years, a running large-scale greenfield projects in the eastern parts of
new chapter has been opened for the Russian coal mining the country. Projects such as Elga or Elegesta should expand
industry. the resource base of the industry support the growing
Russian coal mining is one of the few ‘heavy’ industries export of Russian coal to the Asia Pacific region.
that is entirely private owned, while the share of state-run In contrast to the Soviet era when 100% of the coal was
mines is close to zero. This is a big difference from the Soviet consumed domestically, now almost half of the coal is

June 2018 | World Coal | 13


being exported. It is possible that the domestic coal ownership of only a number of large steelmakers, the
demand has declined to 50% of the Soviet level, while Russia metallurgical coal segment does not have any lack in
instead became one of the global coal exporters. investments for capacity expansion or technical
After 2009, the coal exports from Russia dramatically modernisation.
changed direction. Prior to 2009, Russia’s coal exports were The future of the metallurgical coal segment looks quite
oriented mainly at Europe, with ¾ of the export sales. optimistic, with the potential acquisition of smaller mines
However, following the coal slump in Europe, with the with the steel-makers that now have a low self-supply of
addition of the 2014 political sanctions, the western route of metallurgical coal (NLMK, Metalloinvest), further capacity
Russian coal exports became less and less attractive. expansion in the larger mines, and technical modernisation
Meanwhile, demand in the Asia Pacific continued to grow, in all mines owned with the metallurgists.
even in the crisis period; 2009 became the period when The thermal coal segment will be impacted with two
several Russian coal tycoons began to shift export interests opposite trends: the shrinking of the internal demand for
from the EU to the Asia Pacific. coal as the fuel (losing to natural gas) vs the fast growing
export sales of high quality grades of thermal coal.
So, what’s next? Over the next 10 - 15 years, Russia will continue to
What shall we see in the Russian coal mining industry in substitute coal with natural gas in electric generation in
next 15 - 20 years? Continuing a series of articles in European part of the country. Currently, coal counts for only
World Coal, Ignatov & Company Group predicts the 15% vs 55% with natural gas. However, some coal burning
following trends in the industry. thermal power plants will be launched even in that part of
The metallurgical coal segment will continue to grow, the country, using new technologies of coal burning. CBL
driven both by internal demand and fast-growing export technology has been used in the Novocherkassk thermal
sales in the Asia Pacific region. Being consolidated in the power plant since 2016.
The role of thermal coal in electric generation will be of
higher importance in Eastern Siberia and the Far East, where
it already holds 50% in energy balance. Many new thermal
power plants that are now being built in the region will utilise
coal, such as Sakhalin 2, Yakutsk 2, Sovetskya Gavan etc.
Generally speaking, the future of the thermal coal
segment is still ‘fuzzy’. While the largest players, such as
SUEK or Kuzbassrazrezugol, will continue to develop their
businesses – both in domestic supply to affiliated power
plants and in Asia Pacific export – the smaller mines may be
closed in next 10 - 15 years, especially in the European
regions and even in Kuzbass.
The future perspectives of Russian coal exports in the
Asia Pacific will be impacted by two major factors.
Transportation infrastructure is still the major bottleneck.
Rail transportation is a good option for coal exports in
Figure 1. Coal production in the FSU (2017). China and Korea. However, rail routes have few serious
limitations, such as an
insufficient number of
border stations, lack of
cars and state-run
monopoly in locomotives.
Marine transportation is
more flexible and, thus,
private miners actively
invest in start-ups in the
Pacific ports. Yet, rail-
seaport conjunction is still
a challenge.
Now, most of the coal
exported to the Asia
Pacific is going from
Kuzbass. The main
challenges in the
metallurgical coal
Figure 2. Coal production in Russia (1980 - 2017). segment refer to the

14 | World Coal | June 2018


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long-term perspectives (next 20 - 40 years), namely to the In 2013, Donbass provided 100% of Ukraine’s
potential depletion of the existing deposits in Kuzbass and, metallurgical coal and around 97% of thermal coal
thus, the necessity to launch new greenfield projects. production, while two other coal basins – the Lvovsko-
Counting the lack of such new reserves in Kuzbass, there Volynsky basin in western Ukraine and the Dneprovsky
will be an inevitable shift from Western Siberia (Kuzbass) to lignite basin west to Donbass – provided 100% of lignite and
Eastern Siberia and the Russian Far East in terms of the only 3% of thermal coal.
metallurgical coal resource base, both for the Russian Following the political events in 2014, the national
steelmaking and for growing Asia Pacific exports. government of Ukraine and Ukrainian private investors
Potentially, it may be accompanied with the launch of new now control only 14 coal mining companies in Donbass.
steelmaking assets there, which would be serving the These companies generally produce approximately 35% of
domestic industrial and construction projects in those areas, metallurgical coal and around 45% of thermal coal (2013
as well as to potential steel exports in the region. Currently, level).
two large (Elga and Elegesta) and two medium sized The opposite party (self-proclaimed Donetsk and
(Mezhegeiskoye and Kaa-Khem) greenfield projects have Lugansk ‘republics’) controls 88 coal mines in the Donbass
been started in the area. basin, with a 65% share in metallurgical coal and 55% in
thermal coal manufacture (if counting by the 2013 results).
Ukraine: I wish I had a union Reintegration of both parts of the once united coal mining
Regrettably, it is clear now that Ukraine has been excluded industry may restore the hope of reaching the proclaimed
from the global coal markets for some period. Energy Strategy 2030 targets. In 2013, Ukraine produced
The National Energy Strategy 2030 planned for the nation to 83.6 million t of coal, from which 23.7 million t was
produce 115 million t of coal in 2030, and to have 100% metallurgical. This is 72% of the target production level, of
self-supply in metallurgical coal. In 2017, the coal mines 115 million t. In order to reach it by 2030, production should
controlled by the Ukrainian government and private grow by 2.5% annually over next 13 years – that is a realistic
investors produced only 34.9 million t of coal, from which rate, assuming the political peace and stability in the country.
metallurgical coal counted only for 6.8 million t. That same Renewal of coal exports, to MENA and maybe even to Asia
year, Ukraine imported 19.8 million t of coal, with almost Pacific, also might be a good opportunity for the industry.
50% coming from Russia, followed by the US and Canada.
Exports counted for less than 1 million t. As it is seen, none Kazakhstan: the new kid on the block
of the targets within the Energy Strategy 2030 plan can be Kazakhstan is a large coal mining country, with coal
fulfilled with the current resources and capabilities. production at 106.7 million t in 2017 and commercial
reserves reaching 35 billion t. The country possesses
metallurgical coal commercial reserves of 5 billion t; all
metallurgical coal is concentrated in Karaganda coal basin.
Currently, ArcelorMittal’s mines produce 100% of
metallurgical coal exclusively for self-supply, so Kazakhstan
does not export metallurgical coal but imports such coal
from Russia in small volumes.
Thermal coal is presented mostly in a giant Ekibastuz
coal basin with commercial reserves of 10 billion t. Three of
the largest opencast mines located in this basin provide 69%
of the country’s thermal coal total production, while 31% of
thermal coal is being produced in smaller mines of
Figure 3. Russian coal export: Asia Pacific shift. Ekibastuz, as well as in the Karaganda coal basin and
Maykubensky coal basin.
Currently, 38 coal mining companies
work in the country. ArcelorMittal is a
single player in metallurgical coal
segment. Bogatyr Komir – a joint venture
between the Kazakhstan Government and
Rusal UC – is the leader in thermal coal,
with production between
40 - 42 million tpy. Eurasian Energy
Corporation, an energy division of ENRC,
exploits Shubarkol, one of three giant
opencast mines in Ekibastuz, as well as
few smaller thermal coal mines, and it is
counted to be the second top producer in
Figure 4. Russian coal export: volume and percentage to production. thermal coal.

16 | World Coal | June 2018


Kazakhstan exports approximately 25 million tpy of
thermal coal, mainly to Russia’s thermal plants located
alongside the Russian-Kazakh border (such plants were
built during the Soviet period for utilisation of Ekibastuz
coal), in China, in Central Asian states and in Caucasus
countries.

Uzbekistan: coal autarky


Uzbekistan possesses 47 million t of bituminous coal
commercial reserves, and almost 1.9 billion t in lignite
reserves. Most of the lignite and sub-bituminous coal is
concentrated in the Angren lignite basin, while bituminous
coal is sourced from two basins – Shargun and Baisun –
located in southern part of the country.
Coal production in Uzbekistan is not high, as the
country’s thermal power plants utilise mainly natural gas
and oil. During the Soviet era, Uzbekistan produced about
5 million t of coal, while in 2017, it extracted 4.1 million t.
Most of the production (97%) is presented with lignite,
while bituminous coal accounts for only 3% of the total
mining. All coal, including bituminous, is used in energy
production.
Uzbekistan does not export any significant volumes of
coal. However, small deliveries are done in neighbouring
Central Asia states, as well as to Iran and Pakistan. Coal
imports are also very small (25 000 - 30 000 tpy) and are
presented with supply from Kazakhstan.
Currently, five coal mining operators produce coal in the
country. One of them, state-run Ozbekkomir (Uzbekcoal),
dominates the market with a 90% share in the country’s total
production; the company incorporates an opencast mine, an
underground mine and an underground coal gasification
facility in the Angren basin.

Other FSUs
Coal mines in Kyrgyzstan produce about 550 000 tpy of coal,
mainly lignite. 100% of thermal coal is used inside the
country. As many of the country’s power plants still utilise
coal, the demand for thermal coal counts for 1.6 million tpy;
domestic supply (0.55 million tpy) counts for only 34% of
the demand, while the country imports about 1 million tpy
of thermal coal, mainly from Kazakhstan.
Mines in Tajikistan produce about 100 000 tpy of lignite
and sub-bituminous coal, with 100% of thermal coal being
used inside the country. As most of the electricity in the
country is produced with its hydropower plants, Tajikistan
consumes no more than 200 000 tpy of thermal coal. With
100 000 tpy of domestic supply, the country imports about
100 000 tpy of coal, mainly from Kazakhstan.
Georgia’s single coal miner, GIG Group, produces about
350 000 tpy of thermal coal. Georgia also imports thermal
coal for its power plants and boilers, mainly from
Kazakhstan. As the country’s power plants work chiefly
with natural gas, the thermal coal import is low and
accounts for only 100 000 tpy. In 2017, GIG Group won the
tender for the supply of 700 000 t of coal to Ukraine.
There is no coal production in countries such as Belarus,
Armenia, Azerbaijan, Moldova and Turkmenistan.
Figure 1. Cat longwall plow system.

18 | World Coal | June 2018


Andreas Westphalen, Caterpillar Global Mining, Germany,
discusses the advantages of variable frequency drive technology
for face conveyors and plow systems in longwall mining.

C at® longwall plow systems and armoured face


conveyors have proven themselves by
efficiently producing millions of tonnes of coal
in mines around the world. Much of that coal
has been produced using conveyors equipped with
controlled start transmission (CST) technology, which
allows soft or abrupt starts, through the use of the motor
body fitted with picks, is attached to a continuously
circulating chain that is driven from the ends of the face. It is
guided along the armored face conveyor and cuts the coal
out of the seam as it moves back and forth between the ends
of the face.
Most commonly, asynchronous motors with squirrel cage
rotors plus Cat UEL overload gearboxes are used for the
stalling torque. This technology has also helped plow plow drives, while gearboxes with CST technology are used
systems achieve production rates of up to 20 000 tpd. for the conveyor. In recent years, inverter-fed drives have
More recently, frequency inverter-equipped drives, also been finding increased use due to the good control
known as variable frequency drives (VFD), have come into characteristics.
use and are demonstrating their capabilities compared to Caterpillar Global Mining simulated a plow system for a
conventional drives. Variable speeds and precise torques are 250 m long face and the associated armoured face conveyor
available without the use of special motors, and active (Figure 2), and the resulting calculations show the
braking of motors takes place via energy recovery. Also, differences between the various drive technologies. A good
improved overload protection for the drives protects system simulation model provides access to all relevant data and
components. Separate positioning of drive motors and parameters under the widest range of operating conditions
inverters saves space at the ends of the face. and allows new concepts to be investigated. Verification of
This article presents the differences between conventional the model used is based on measurements taken in
and variable frequency drive technology on the basis of operating longwall systems.
simulations and measurements in the field. The advantage
of virtual scenarios is the ability to try out new concepts and Simulation model
then observe the expected system responses. Analysis of The simulation model used represents the entirety of the
dynamic processes under selected operating conditions plow system and a conveyor. Like the real system, the
(abrupt starts, blockage, variable process forces, overload) model is divided into individual components: motors,
leads to improved understanding of the system and possibly a frequency inverter, gearboxes, chain sprockets
provides the basis for improvements. and chain. To observe the dynamics of the chain, a chain
strand is divided into discrete individual point masses that
Longwall drives evolve are connected by spring and damping elements, which
Cat products include both shearer and plow cutting reflect the elastic properties of real chains (Figure 3).
machines. This article focuses on plow systems used for low Depending on the system type, the chain drive sprockets
to moderate seam thicknesses of hard coal. The plow, a steel have five, six or seven teeth.

June 2018 | World Coal | 19


Due to the high degree of nonuniformity, the polygon Plow applications
effect cannot be neglected. In addition to the mechanical The conventional Cat GH1600 plow consists of a plow body
parts, the sub-model of the gearbox contains a hydraulic that can cut seam thicknesses of 1 - 2 m, a 42 x 137 mm
part that controls the clutch installed in the gearbox. The chain, two 350/700 kW motors and two Cat UEL gearboxes
asynchronous machines are presented by means of a linear with a ratio of 16:1, which enable the plow speed to be
model for the voltage and flux equations. The simulation varied between 1.5 - 3 m/sec. An associated conveyor for
model is completed through implementation of a control this system has a capacity of 3000 tph.
method that is used for the systems. A blockage situation represents a challenge for every
mining machine. Occlusions in the coal seam, such as a stray
rock, immediately cause the force on the plow to increase
abruptly, and the plow body is blocked. If there was no
overload device, the chain would be pulled apart.
When the plow is blocked, the chain is stretched and the
drives are stalled. Because of the high moment of inertia of
the drives and the transmission ratio, the forced dissipation of
rotational energy would cause the force applied to the chain
to far exceed the breaking force of 2220 kN. Cat UEL
gearboxes have a planetary stage where the ring gear is
supported in the housing by a multi-disc clutch. The
breakaway torque of this clutch is adjustable from the
outside. When the plow is blocked, the clutch begins to slip. If
the slip in the gearbox exceeds a specified limit for a defined
Figure 2. System overview of a longwall face: the plow extracts length of time, the motors are shut off and the clutch opens.
and loads the coal onto the face conveyor, which transports the
The slipping of the clutch limits the forces applied to the
coal away from the face for transfer to a belt conveyor.
chain, and, at the same time, the supporting residual torque
from the drive end is maintained. There is no load shedding,
which would have a disastrous effect on the chain. In this
way, the UEL gearboxes ensure safe control of the plow
system in the event of blockage.
The upper graph in Figure 4 shows the dynamics of the
chain before and after the use of the plow system. The
blockage occurs at 0 sec. The chain force before the plow, in
the chain segment between the directly pulling drive 1 and
the plow, increases immediately but remains far below the
chain-breaking force because of the overload protection. As
a result of the extension of the chain in both the upper and
bottom races (before and after the plow body), the system
settles over a time period of about 10 sec.
Figure 3. Sketch of the model for the plow system and the Except for the gearbox, a system equipped with
conveyor. To represent the dynamics of the overall system, it frequency inverter (variable speed) technology consists of
is divided into individual discrete masses coupled by means of the same components. In this case, CST gearboxes are used.
spring and damping elements. The CST gearboxes are designed for changing speeds and
contain sensitive overload protection consisting of a wet
multi-disc clutch on the ring gear of the planetary output
stage. This clutch can withstand continuous slip, so it is not
essential to shut down the system when the clutch slips, a
situation which can be triggered by brief load peaks.
In the case of blockage, there are several differences with
regard to the UEL technology (see lower graph in Figure 4,
Chain force for VFD + CST). The CST gearboxes have a
somewhat higher moment of inertia. This means that the
force applied to the chain is somewhat greater, but it is far
below the chain-breaking force. Despite the greater force,
system dynamics settle faster with the aid of frequency
inverters.
Figure 4. The upper graph shows the time curve for the force in The greatest advantage of frequency inverter technology
the bottom race of the chain before (orange) and after the plow is the variable speed and the availability of the entire torque
(blue) for a conventional system with UEL gearboxes. range of the motors. In a conventional system, less torque

20 | World Coal | June 2018


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brought into motion through targeted closing (engaging) of
the clutches. In this way, it is possible in extreme cases to
exploit the breakdown torque of the motors to accelerate the
conveyor. During conveying, the load is balanced between
the two drive ends. The CST gearboxes operate with
continuous slip of about 0.2%, which is varied within limits
by a load-balancing controller. This control approach permits
uniform distribution of the load to both drives.
Frequency inverter technology permits a new control
approach in which need-based distribution of the existing
load protects the conveyor chain. With conventional, uniform
load distribution, the tail gate assists the head gate by pulling
its portion of the load indirectly via the chain sprocket of the
head gate. This results in an inappropriate load on the chain
Figure 5. Time graph of the power provided by head gate and chain sprocket. In contrast, need-based load distribution
and tail gate on a conventionally powered conveyor (top) and
enables each drive to handle the directly associated load. If
inverterfed (VFD) conveyor (bottom).
and when the head gate drive can no longer handle its
portion of the load alone, then the tail gate provides
assistance. Through use of this control concept, the amount of
force present in the bottom race of the chain decreases and
indirect pulling via the chain wheel is minimised, which has a
positive effect on the service life of the components. It is
obvious that this can also be applied to the plow system,
where no control was provided by conventional technology.
The different load balancing concepts and their effects can
be seen in the simulation results for both system types
(Figure 5). On a conventional conveyor, the power curves for
the head gate and tail gate are almost identical. The two
drives share the entire load in a ratio of 1:1 regardless of the
sudden load increases at the times 5 sec. and 12.5 sec. On an
inverter-fed conveyor, the head gate provides more power in
Figure 6. Cat VFD system in an underground coal mine. the initial load range up to 5 sec. In the load range from
5 - 12.5 sec. the tail gate contributes noticeably, as expected,
when the load is higher; in the third load range beyond
12.5 sec. the head gate once again provides the greater part.

Conclusion
The technology of plow systems equipped with Cat UEL
gearboxes and that of conveyors operated with CST
technology in combination with asynchronous motors
connected directly to the mains has proven itself under a
wide range of operating conditions. The examples presented
here show that this technology provides robust load
balancing and offers appropriate protection against
unexpected load situations. In this way, the service life of
these systems is extended and chain failures, with the
Figure 7. Cat intelligent CST (controlled start technology) associated costly loss of production, are minimised.
longwall conveyor drive system.
Drives equipped with frequency inverter technology offer
even more advantages. Being able to specify a variable speed
than what may be required is then available. A plow system and/or a defined torque permits new control approaches for
with inverter-fed drives does not have this limitation. the entire system, such as controlling the plow and conveyor
for optimal loading or improved load balancing between the
Face conveyor applications drives. Having the ability to brake the plow by actively
A conventional Cat longwall face conveyor uses CST feeding electrical energy back into the grid also protects the
gearboxes with a 33:1 or 39:1 ratio and asynchronous motors system components. Additionally, when the drives are
connected directly to the mains. The starting process proceeds started, the electrical system of the mine is not subjected to
first with the electric motors accelerating to their nominal even greater loads. Even weaker electrical supply systems can
speed with the CST clutch open, and then the conveyor is increase performance with inverter technology.

22 | World Coal | June 2018


Andrzej Kret, FAMUR SA, Poland, provides an overview of a range of powered
roof supports and discusses how their implementation can improve the safety of
new longwall projects in underground mines.

W hen chosen properly, a powered roof


support is one of the most important
elements of new longwalls in
underground mines. Polish group
FAMUR focuses on adapting such powered roof supports to
individual needs of customers. For decades, the company
has been designing and manufacturing equipment of this
associated with it significantly exceed 50% of total project
costs.
Powered roof supports provide direct protection and
shield for other longwall equipment, but still their crucial
function is to protect the crew against threats posed by
forces of nature.
Apart from ensuring that works are carried out safely,
type not only for Polish mines, but also for mines in Russia, one of the most important expectations of customers is to
Kazakhstan, Mexico, Argentina and Turkey. reduce unit costs of coal production. Consequently, it is
A basic product that determines the success of vitally important to choose the right yield parameters,
equipping a new longwall, which is a very expensive kinematics, including ergonomic solutions that make it
investment project, is a powered roof support. Expenses possible to mechanise and automate the majority of works,

June 2018 | World Coal | 23


especially when the geological and mining conditions are internal diameter of 350 or 400 mm. While the increase in the
sophisticated. investment costs that they brought was relatively low, the
The prerequisite for this goal to be achieved is to ensure oversizing of support yield in relation to the needs resulting
that the quality of each project stage carried out is high, from the geological and mining conditions make it possible to
starting from the appropriate selection of support to become independent from hardly predictable events caused
geological and mining conditions, through drawing up an by local geological disturbances and to maintain a rather
engineering project, design and process documentation, constant longwall progress along its entire panel length.
through manufacturing quality, and ending up with the stage Except for the FRS-18/41-2x4775 support, all supports
of training and starting up the product at the customer's. were equipped with an electrohydraulic control system with
To meet the expectations of contractors, FAMUR has different levels of longwall support automation and
recently manufactured and delivered four longwall systems monitoring. In the most advanced system, virtually
with a support for the Russian market. These systems may be unmanned longwall mining is possible, as well as controlling
used for all heights of mined seams: the longwall system from the main gate. In addition, the
„ For mining low seams – a longwall system with the FRS FRS-18/41-2x4775, which is equipped with a pilot control
GLINIK-10/21-2x3848 powered roof support for the system, has a number of functions carried out in
Chertinskaya-Koksovaya mine. semi-automatic mode for several support movement
„ For mining medium seams – a longwall system with sequences.
the FRS GLINIK-12/26-2x5655 powered roof support All longwall systems with a support are equipped with
for the S.M. Kirov Mine AO SUEK-Kuzbass, as well as specialised sections. They make it possible to protect galleries,
a longwall system with the FRS-18/41-2x4775 powered and they may also be easily retooled and adapted to local
roof support for AO Szachtouprawlienije Tałdinskoje- geological and mining conditions by installing special shields
Kyrgajskoje. at the canopy and the base and by smooth transition from the
„ For mining high seams – a longwall system with the FRS longwall to the gallery when they significantly differ in their
GLINIK-25/55-2x4775 powered roof support for the W.D. height.
Yalevskogo mine AO SUEK-Kuzbass. An example of such a solution is a longwall system with
the FRS GLINIK-12/26-2x5655 roof support, which includes
All deliveries to Russia were dominated by supports with special transition sections of the FRS GLINIK-15/32-2x5655
a centre spacing of 1.75 m and equipped with legs having an support, as well as gate sections of the FRS GLINIK-
16/36-2x5655 support. Solutions of and
installation methods for the section in the
tailgate is shown in Figure 2, which shows
co-operation between the line, transition
and gate sections of the longwall system
with the FRS FRS GLINIK-12/26-2x5655
support.
The use of such diverse types of
supports allows for a complete protection
of the roof at the transition between the
longwall operating within the range of
1.6 - 2.5 m and the gallery with a height of
up to 3.6 m. The last supports operating in
the gates from the sidewall side are
equipped with special deflectable side
shields and a rigid side shield at the base,
Figure 1. Longwall system with the FRS-18/41-2x4775 support for AO making it virtually possible to seal the
Szachtouprawlienije Tałdinskoje-Kyrgajskoje.
gallery space from caving and its side
wall. In addition, gate sections offer the
possibility of widening extendable side
shields of the canopy easily by adding
another segment fixed on the pins. Thanks
to these shields, it is possible to seal the
space between sections completely when
the difference between their height is very
high. All gate sections are universal and
give the possibility of making any changes
Figure 2. Co-operation between the line, transition and gate sections of the longwall and equipping the section with each
system with the FRS GLINIK-12/26-2x5655 support for the S.M. Kirov Mine AO shield type – even at the panel length –
SUEK-Kuzbass. depending on local conditions.

24 | World Coal | June 2018


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ROLLER CHAINS • ENGINEERING CLASS CHAINS • BACKSTOPS • SPROCKETS • CABLE & HOSE CARRIERS • POWER TRANSMISSION PRODUCTS

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Table 1. Technical parameters of line sections changed, practically by 1.5 m
No. Parameter Unit of FRS GLINIK- FRS GLINIK- FRS-18/41- FRS-GLINIK without the need for installing
measurement 10/21-2x3848 12/26-2x5655 2x4775 25/55-2x4775 another section. All sections
1 Minimum support m 1.0 1.2 1.8 2.5 enable position correction
height equipment to be installed; this
2 Maximum support m 2.1 2.6 4.1 5.5 equipment offers the
height
possibility of work
3 Range of operation m 1.2 ÷1.8 1.4 ÷ 2.5 2.0 ÷ 4.0 2.7 ÷ 5.4
mechanisation when the
4 Longitudinal longwall degrees (˚) ±35 ±10 ±28 ±15
inclination section width is changed.
Once stabilisation
5 Transverse longwall degrees (˚) ±15 ±15 ±20 ±10
inclination equipment is installed, the
6 Support centre m 1.75 1.75 1.75 1.75 support may operate at
spacing longitudinal inclinations of up
7 Number of hydraulic pcs 2 2 2 2 to 25˚.
legs
What makes the FRS
8 Internal diameter mm 350 400 400 400
GLINIK-12/26-2x5655 support
of leg
special is the fact that it may
9 Section pitch m 0.8 1.0 0.8 0.8
be used in high performance
10 Operational yield of kN/m2 690 ÷ 784 995 ÷1118 924 ÷ 1100 1105 ÷ 1131
systems. This is a direct
section
consequence of the fact that
11 Operational yield kN 3848 5655 4775 4775
of leg the support is adapted to the
12 Advancing force of kN 643 726 726 726 advance of the 1000 mm
section shearer and uses the
13 Advancing force of kN 392 934 394 394 electrohydraulic control
conveyor system in such a version that
14 Service life Number of 30 000 45 000 30000 60 000 allows for unmanned longwall
cycles
mining with the use of a
longwall control system
operated from the station located in the gallery. The station
features complete monitoring of the support state and HD
video transmission of any longwall area selected. Ergonomic
solutions used in the support ensure trouble-free operation
and maintenance.
The longwall system with the FRS-18/41-2x4775 support,
which is shown in Figure 1, was delivered completely by
FAMUR. Apart from the support, the system features an
FFC-9DM armoured face conveyor, an FSL 10 beam stage
loader with an FLB-10B coal crusher and an FSBE 1200
bootend, plus an FS400 shearer.
Due to similar heights of the longwall in relation to the
support gallery, the system was equipped with one type of
powered roof support, while gallery sections have longer
canopy that allow for the space above the conveyor drives to
be installed and deflectable side shields that protect gallery
sidewalls.
The longwall system with the FRS GLINIK-10/21-2x3848
support is designed for mining low seams and, depending on
the type of shearer used, offers the possibility of driving
seams with a minimum height of 1.25 - 1.4 m. The FRS
GLINIK-10/21-2x3848 support is a two-prop support and
features a centre spacing of 1.75 m; its props have an internal
Figure 3. The FRS GLINIK-25/55-2x4775 roof support for the
W.D. Yalevskogo mine AO SUEK-Kuzbass. diameter of 350 mm and a yield of 3848 kN each.
The delivery of these powered roof supports, which are
Furthermore, all transition and gate sections have side shields highly advanced in terms of technology, serve as confirmation
that are extendable on both sides, allowing for the section of FAMUR’s position as a leading supplier of both supports
width to be changed within the range of 1.7 - 2.0 m. In and entire longwall systems for the needs of international
combination with sliding clevis on the conveyor, the longwall markets and constitutes a good showcase of FAMUR’s ability
may be completely protected when the longwall length is to expand into other markets.

26 | World Coal | June 2018


Al Ozment, US Foam Technologies, discusses the prevalence of underground
mine fires in the USA, and details how gas-enhanced foam and direction drilling
can increase the effectiveness of current mine fire suppression technologies.

A ccording to the Abandoned Mine Land


Inventory System at the Office of Surface Mining
Reclamation and Enforcement (OSMRE), in 2013
there were 98 underground mine fires in nine
states of the US. Experts consider this to be an
underestimate for the actual number of fires nationwide.
Suppressing a coal mine fire requires cooling the hot zones
drilling can be problematic due to topographic and property
constraints. When this occurs, large areas of burning may go
unaddressed or simply left to burn.
Fire Solutions, Inc. has been investigating the use of
gas-enhanced foam along with directional drilling
technology. Gas-enhanced foam has the advantage of using
far less water and adds inert nitrogen gas to displace oxygen
and removing any source of oxygen. If the workings are to infiltrate and suppress a fire. Directional drilling has the
shallow, the fire zones can be unearthed and the burning rock capability to steer a borehole to a specific place
mass can be quenched on the surface. If the workings are too underground. Directional drilling has many advantages
deep to excavate, then the fire must be fought remotely over conventional drilling technology as it can provide the
through boreholes using a variety of agents including water, least disruption to the ground surface, minimise surface
gas-enhanced foam and grout. Access to surface areas for preparation and reclamation costs, multiple sites can be

June 2018 | World Coal | 27


and noxious fumes such as carbon monoxide gas. These
products are released into the atmosphere through fractures
that develop within the ground surface, killing vegetation
and creating serious health hazards.
If left uncontrolled, abandoned mine fires can burn for
years; one of the most well-known mine fires in the US is the
mine fire in Centralia (Pennsylvania), which began on
27 May 1962. Reportedly, officials decided to clean up the
local dump for the upcoming Memorial Day holiday.
Unfortunately, the dump was located on the site of an old
Figure 1. Smoke and steam emanating from fractures in abandoned strip pit mine on the edge of the borough. The
Highway 61, Centralia (Pennsylvania). strip pit had been left open after being excavated in around
1935 and was approximately 75 ft wide and 50 ft deep. It is
believed that the lack of a properly constructed
non-combustible shale barrier in the strip pit enabled the
trash fire to spread to adjacent carbonaceous refuse material
and then to nearby coal mine workings. As time went on, the
fire grew and spread under the borough and directly affected
the residents despite various efforts to extinguish the fire by
the state and federal government (Figure 1). In 1984, a
voluntary programme was begun to move residents from
their homes. Many accepted buyout offers for their properties
and moved elsewhere and after leaving, their homes were
Figure 2. Diagram of Hellfighter. demolished. In 1992, the state used eminent domain to take
control of all the property within the borough. In 2013, after
years of litigation, the eight remaining residents were allowed
to stay for as long as they lived. Today, only a few buildings
remain. This fire has been burning for over 55 years.

Mine fire abatement methods


Suppressing a coal mine fire requires cooling the hot zones
and removing any source of oxygen. If the workings are
shallow and the fire zones can be unearthed then the
burning rock mass can be quenched on the surface. If the
workings are too deep to excavate, then the fire must be
fought remotely through boreholes using a variety of agents
including water, specialty foaming cements or grout and
gas-enhanced foam. Other techniques that may be used
include the use of liquid nitrogen to extinguish the fire by
Figure 3. Nitrogen generated foam entering mine opening the rapid removal of heat. Access to key surface areas (and,
through a borehole. thus, specific mine areas) using conventional drilling
techniques can be problematic due to topographic control
accessed underground from a single site and, thus, treated and property owner constraints. When this occurs, large
simultaneously. It also offers increased efficiency because it areas of underground burning may go unaddressed or
is not constrained by difficult terrain. simply left to burn.
Many mine fires are started by people burning trash
where a coal seam or an abandoned coal mine is close to the Gas-enhanced foam technology
surface. Other fire ignition sources include lightning and The chemicals used to create the foam are claimed to reduce
forest fires. Once ignited, a coal mine fire can easily spread the surface tension of water, greatly increasing the
into the remaining coal pillars and mine entries. Once penetrating and wetting abilities of the water used, and
established, the fire creates its own ventilation system significantly increases the effectiveness of the water supply.
supporting further combustion by drawing air down into Portable skid-mounted nitrogen plants that extract nitrogen
the workings through unsealed mine shafts, fractures and gas from the atmosphere using membrane technology are
surface subsidence depressions. As the coal left in the used to supply the inert gas.
workings from the past mining operations burns, the mine Compressed-air firefighting foams expand water to
void can collapse, causing subsidence and creating between five and 15 times its original volume. Assuming an
dangerous voids, damaging overlying surface structures average expansion of ten times, it follows that the resultant
and roadways. The products of combustion include smoke foam consists of 0.02% surfactant, 9.98% water and 90% air.

28 | World Coal | June 2018


Foam addresses a fire condition through evaporation of
contained water and cooling by energy removal. As the foam
collapses, water is released and increases in temperature by
absorbing heat and eventually turns into steam. Water is
released from foam either through bubble rupture or through
the effects of gravity distorting the bubble walls. Because this
process takes time, foam can act as a water reservoir, releasing
water at a rate that allows absorption into the fuel, rather
than running off the surface. If the foam is enriched with
nitrogen gas, then it can serve a double purpose by robbing
the fire of heat and removal or displacement of oxygen. Given
a sufficient underground life and the ability to efficiently
move and migrate through a mine opening it is thought that
nitrogen-enriched foam provides an ideal platform for
addressing mine fire conditions.
USF Equipment and Services Inc., created a patented
Figure 4. Foam accumulating to mine roof behind crib blocks.
nitrogen-enriched foam delivery method known as the
Hellfighter™ system. This system includes a pipeline
network and a sophisticated mixing chamber. Water is
pumped at a controlled rate under pressure into one of the
inlet ports on the Hellfighter. A surfactant is injected into the
waterline using precision injection pumps. Nitrogen gas
from a membrane plant is then injected at a controlled rate
into another inlet port on the Hellfighter. The fluid blend
(water and foam concentrate) is then mixed with nitrogen
gas in the Hellfighter and nitrogen generated foam flows
from the outlet port of the Hellfighter. The Hellfighter is
connected to a manifold wellhead assembly that is attached
to the injection borehole.
One can vary the quality of the foam (mixture of liquid to
Figure 5. Conventional drilling of a vertical borehole at a mine
gas) by changing the ratio of surfactant to water and also the
site. Note, this location is in an area of high topographic relief.
ratio of gas to liquid. These changes can have a pronounced
effect on the viscosity of the resulting foam changing it from
a slurry to the consistency of shaving cream. Gas-enhanced
foam has the advantage of using less water and adds inert
nitrogen gas to displace oxygen to infiltrate and extinguish a
fire.
The National Institute for Occupational Safety and Health
(NIOSH), in co-operation with USF Equipment and Services
Inc., conducted a series of experiments at the former NIOSH
Lake Lynn Experimental Mine to study the stability,
transport, control and fire extinguishing effectiveness of
nitrogen-enhanced foam technology. Figures 3 and 4 show
this technology in use at the NIOSH underground facility.
The experiments demonstrated the following:
„ Foam stability is a function of the concentration of Figure 6. Sketch of the use of directional drilling and gas-
surfactant in the water flow, the water flow volume enhanced foam at an abandoned mine fire site.
and the gas flow volume, so stability parameters can be
varied based on the particular application. shown to be highly dependent on the slope of the mine
„ The life of foam can be dependent on the mine floor. In two of the experiments, foam flowed quickly and
temperature and wetness or dryness of the did not reach the roof of the mine until it was obstructed
environment, water hardness and pH. by crib blocks. In a third experiment, the foam reached
„ Foam stability can be managed from the surface with a the mine roof very quickly because of the upslope of the
good degree of accuracy. However, periodic monitoring mine floor and the obstructions that did not permit down
of the foam consistency on the surface is recommended dip flow, but the rate of advancement of the foam front
to ensure stable foam is entering the mine. was much slower than in the two early experiments.
„ Foam flow movement, speed and ability to reach the roof „ In confined applications where the objective is to flow
and fill the entire cross-section of the mine entrance was the foam from the bottom of the borehole to a fire

June 2018 | World Coal | 29


11th - 14th September 2018
Royal International Convention Centre (RICC),
B risba
bane
ne, Queensland.
Brisbane, Quee
Queens
nsland.

www.acps.com.au/conference-2018
www.acps
p .com.au/
/conference
f -201
2018

SCHEDULE
Tuesday 11th Wednesday 12th Thursday 13th Friday 14th

10am Golf & Technical Tour (CSIRO/QCAT) Opening Ceremony Technical Sessions Technical Sessions
- Dewatering (I²FLHQF\DQG2SWLPLVDWLRQ
3pm Registration & Exhibition Open Technical Sessions - A Le Page Lecture: Column - General Mine Site Papers
- New Plants and Upgrades Flotation by Prof J Rubinstein
5pm Arrival Function - Dense Medium Separation Conference Concludes 2pm
- Poster Session
- Improved Fine Coal Processing - Fine Coal Treatment
Evening Welcome Function Evening Conference Dinner

The ACPS biennial conference and exhibition is considered to be the premier


technical and professional development opportunity in coal preparation.
A key focus is optimising the utilisation professionals, graduates and students, participate in the 17th ACPS Conference and
of our coal resource and operations. consultants and technology company Exhibition.
We continue to develop a deeper representatives and presents a great
understanding of the coal resource personal and professional development • Draft technical program will be published
DQGTXDQWLWDWLYHPHWKRGVIRUGH²QLQJ and networking opportunities for all. in March 2018 and it is anticipated that
its potential value. Within our plant Some 40 plus exhibitors will showcase there will be more than 30 papers and
operations, we are striving to improve current equipment and services as poster papers from mine sites, engineering
availability, reliability and metallurgical well as new and emerging technology companies, consultants and researchers.
performance of our assets, in order to developments.
reduce operating costs and maximise • Registration available from March 2018
value. 2QEHKDOIRIWKH2UJDQLVLQJ&RPPLWWHH www.acps.com.au/conference-2018
I look forward to warmly welcoming you
The conference is open to mining, to the Royal International Convention Matt Allen
geology, engineering and processing Centre in Brisbane in September 2018 to ACPS National Chairman

Rob Casey Julie-Anne Homan


Conference Secretariat National Secretariat
P +61 2 99708251 P +61 2 49264870
E conferences@acps.com.au E acpsnational@acps.com.au
location some distance from the borehole, foam will disruption to the ground surface, minimise surface
flow around corners, but again the major influence on preparation and reclamation costs, multiple sites can be
its effectiveness was elevation and obstructions. accessed underground from a single site and treated
simultaneously and it offers increased efficiency because it is
The results of these experiments show that localised not constrained by difficult terrain. Figure 5 shows a
underground structure can have a great deal of influence on conventional drilling operation. Here, a vertical borehole had
how fast and where foam will flow. Understanding these to be drilled and completed at this location to intercept a
conditions will greatly aid in the design of an effective mine specific underground area. A road and drill site had to be
fire suppression programme. On a small-scale, deep-seated constructed to this location to accommodate the drilling
coal fire test, the ability to suppress a fire was observed. It is operation.
not clear at this point if the results of that test can be
extrapolated to large coal fire. However, gas-enhanced foam Discussion
has been utilised in this manner at a number of active mine Fire Technologies Inc. has been investigating the application
fire sites and has been a significant contributor to the of gas-enhanced foam on abandoned mine fires in
suppression of these fires. As such, it is believed that this combination with directional drilling technology. It is
technology shows promise for application to abandoned believed that the directional drilling approach presents a
mine fires as well. significant improvement over conventional technology
because one could drill into an abandoned mine opening
Directional drilling technology several times and then use gas-enhanced foam to treat a large
Directional drilling is the practice of controlling the direction underground area simultaneously from one surface location.
and deviation of a wellbore to a predetermined specific To this end, Fire Technologies has developed a patent-
underground location. Directional drilling has been an integral pending process that incorporates the use of observation
part of the oil and gas industry for many years. Since the wells, directional drilling and gas-enhanced foam injection
earliest of times in the drilling industry, boreholes were made for this purpose.
to deviate by placing tapered wedges or ‘whipstocks’ in the Figure 6 shows a sketch of how this combined technology
borehole to force the bit sideways into a new direction, and it would work. The concept would be that an abandoned mine
was known that different bottom hole assemblies had a fire zone is identified and the underground conditions are
tendency either to increase or to decrease the inclination of the monitored through the use of observation wells equipped
hole. Most developments in directional drilling started in the with thermocouples. Several boreholes are drilled from one
petroleum industry and then spread to other fields. Directional central wellbore into multiple locations in the mine fire zone
drilling, coupled with improved hydraulic fracturing using directional drilling techniques. In areas of particularly
technology, has led to the success of the shale gas industry. difficult terrain, this technology could also be used to steer
Advances in drilling sensors have helped to make vast the borehole around the problematic area and complete the
improvements in directional drilling technology. Using borehole at the mine level.
today’s technology, the angle of a drill bit can be controlled Once the boreholes are completed, a Hellfighter system is
with a high degree of accuracy using real time drilling installed on the surface on each central borehole and then
information. This technology provides multiple solutions to each of the down hole legs of the central borehole would be
drilling challenges, increasing efficiency and decreasing costs. injected simultaneously with gas-enhanced foam.
From a single surface location, various boreholes can be Alternatively, some of the directionally boreholes could be
drilled at a myriad of angles. Many times, an angled hole can equipped with wellheads that also accommodates a
be drilled by simply pointing the drill in specific direction. A thermocouple line for down hole temperature monitoring.
more accurate and more complex way of directional drilling These holes would then serve as observation holes to monitor
utilises a bent sub positioned near the drill bit, as well as a the progress of the fire suppression work and later, the same
down hole steerable mud motor. In this case, the bend directs holes could be used as foam injection points as needed.
the bit in a different direction from the wellbore axis while the In boreholes where high temperatures are encountered
entire drill string is not rotating, this is achieved by pumping and the bottom of the borehole is obstructed because the mine
drilling fluid through the down hole mud motor. Then, once opening is filled with gob material, gas-enhanced foam can be
the angle is reached, the complete drill string is rotated, injected under pressure to infiltrate the broken rock mass.
including the bend, ensuring the drill bit does not drill in a Injection of foam would continue until the bottom hole
different direction from the wellbore axis. temperature has been lowered to a level to prevent rekindling
Depending on the overburden depth, directional drilling of the fire zone.
technology has the ability to complete a borehole at any Fire Technologies, Inc. believes that the use of gas-
inclination to the vertical including a horizontal borehole. The enhanced foam and directional drilling can greatly increase
technology also has the ability to drill for many thousands of the effectiveness of current mine fire suppression technologies
feet laterally into a rock formation increasing the exposure of while reducing the costs of site preparation, drilling and
the formation to the wellbore. water consumption. Fire Solutions, Inc. is currently seeking
Directional drilling has many advantages over an abandoned mine site to demonstrate the effectiveness of
conventional drilling technology as it can provide the least this technology.

June 2018 | World Coal | 31


Figure 1. Autonomous technologies are marking the dawn of a new era for the mining industry.
Hitachi is at the forefront of developing these types of groundbreaking technologies.

Sarah Lispet (Australia) and Naoto Sannomiya (Australia),


Global Mining Division of Hitachi Construction Machinery,
discuss how autonomous technologies are marking the dawn of
a new era for the mining industry.

32 | World Coal | June 2018


R ewind to the year 1913. The automobile
industry was forever changed when Ford
Motor Company introduced integrated
moving assembly lines into its factory. The
invention caught on around the world and mass
production became easier, simpler and far more efficient
than ever before.
productive operations, Hitachi is developing
technologies on the forefront of this new era.

Hitachi autonomous haulage


Autonomous haulage systems (AHS) are changing the
landscape of the mining industry, combining navigation,
communication and control to provide what Ford
Much like how the integrated moving assembly line introduced to the world: efficiency.
changed the automobile industry, autonomous In 2012, Hitachi Construction Machinery Co., Ltd.
technologies are marking the dawn of a new era for the commenced development of an AHS for dump trucks,
mining industry. As everyone strives for safer and more which will leap over current market offerings. The

June 2018 | World Coal | 33


integrated system combines technologies and expertise approaches the end of a block section, it sends a request
from Hitachi Group Companies in industries such as to the TCS for permission to the next block section. If the
automotive, communication, robotics, public transport, permission is provided, the dump truck continues; if not,
and mining equipment and fleet management (Figure 2). the dump truck will come to a controlled stop at the end
The AHS can be broken down into three layers that of the permitted block section. This process is known as
combine to provide an intelligent solution. block system for railroad control. By limiting constant
The first layer is the fleet management system (FMS). communication between dump trucks and the FMS,
Wenco International Mining Systems’ innovative Hitachi’s AHS is able to control up to 100 vehicles under
product, Wencomine, is fully integrated into Hitachi’s the one system.
AHS, acting as the primary control system. Its user- These three core layers operate together on an
friendly interface supports site staff in communicating infrastructure consisting of a real time kinematic global
with vehicles and operators, collecting and consolidating navigation satellite system (RTK-GNSS), Wi-Fi network
data, receiving project details and alerts, and more. and server. To ensure seamless communication
Wencomine’s comprehensive interface connects every throughout a site, multiple repeater stations are installed
person and vehicle onsite to streamline and simplify additional to the RTK-GNSS base station.
operations. The intelligent technologies that form Hitachi’s AHS
The traffic control system (TCS) forms the second support manned hauler operations in surpassing safety
layer of Hitachi’s AHS. The DNA of the company’s traffic and productivity targets, forming the base from which
management system is shared with one of the busiest Hitachi has built several other intelligent mining
train systems in the world, the Tokyo metropolitan. The features.
same technology responsible for transporting
approximately 770 000 commuters a day is embedded Aerial Angle object detect assist
into Hitachi TCS to connect designated points, create a Hitachi’s established Aerial Angle technology continues
haul route, divide it into sections and send specific to evolve towards the future of mining. Aerial Angle EX
instructions to each fleet vehicle. Ever-changing haul already assists excavator operators by using machine-
road designs can also be quickly surveyed and adapted installed cameras to provide a continuous, real time
into the haulage network with the TCS. bird’s eye view of machine surroundings. Building on
The third layer of Hitachi AHS is the vehicle from these technologies, haul dump truck operators can
intelligence itself. Autonomous dump trucks contain a now benefit from the new Aerial Angle EH object detect
computer network that receives sectioned haul route assist, built from Hitachi’s proprietary image detection
information, known as block section, from the TCS. The technology.
dump truck then drives within these block sections, Object detect assist operates in two different modes:
sticking to the designated route with a margin of error stationary mode and forward mode. Stationary mode
spanning mere centimetres. As the dump truck detects moving objects around the vehicle while
stationary or moving at slow speed and,
much like Aerial Angle EX, displays a
continuous, real time bird’s eye view of
dump truck surroundings in the truck
cab Aerial Angle monitor. Stationary
mode will also identify and flag moving
objects for the operator as extra
assurance.
When the dump truck is at travelling
speed, object detect assist enters the
forward mode and a vehicle-installed
millimetre wave radar measures the
distance and speed of any objects in front
of the vehicle. A two-phase warning
system informs the operator of the level
of collision risk, taking into account
speeds, distances, payload and haul road
grade. The first warning phase,
characterised by yellow object markers
and an audible alarm, prompts the
operator to begin braking to safely avoid
collision. If an object enters the dump
Figure 2. Hitachi Construction Machinery Co., Ltd. commenced development of an truck’s close proximity, the second
AHS for dump trucks. warning phase will display red object

34 | World Coal | June 2018


markers and increase alarm frequency, alerting the vehicles were overloading and underloading less
operator to activate their service brake immediately to frequently.
avoid collision. These figures proved that the payload management
To ensure reliability, object detect assist continuously system can help operations lower the risk of vehicle
analyses vehicle speed, steering angle and payload in damage and faults by minimising overloading, and avoid
conjunction with object detection to identify potential wasted time and costs by minimising underloading.
false alarms. Aerial Angle EH object detect assist’s Because productivity was not compromised, sites using
intelligent design can help give dump truck operators this system can continue to benefit from the same level of
peace of mind and potentially increase site safety. output while improving the efficiency of their entire
operation.
Payload monitoring system
In another step towards effortless and intelligent mining, Industrial Internet of Things
Hitachi is currently developing its payload monitoring The data-driven technologies connecting modern
system to further improve the productivity of its latest industrial machines are often referred to as the Industrial
range of excavators and dump trucks. By monitoring the Internet of Things (IIoT). IIoT has been transforming
payload of truck trays and excavator buckets, Hitachi dump trucks by empowering onboard controllers
productivity and profits can be maximised while to gather huge amounts of sensor data and turn it into
maintenance and operational costs can be minimised. actionable insights.
While Hitachi’s payload monitoring system for dump As time goes on, degradation of vehicle components
trucks is not a new feature, industry innovations are will inevitably occur due to wear and tear and exposure
enabling it to become smarter than ever before. The to harsh environments. This can eventually lead to
established truck payload monitor calculates and reduced dump truck reliability and, in some cases, safety.
displays the accumulated and remaining weight to help To combat this problem, Hitachi is developing a
dump truck and excavator operators achieve target component life prediction system to evaluate vehicle
payload. However, a challenge customer's still face while health and predict ‘remaining useful life’ on its parts.
using this system was trying to reach exact target truck This prediction helps site staff to develop appropriate
payload towards the end of loading, without knowing and timely component change-out plans, increasing
the excavator bucket payload. economic returns.
Hitachi’s new bucket payload monitoring system for To develop the component life prediction system,
excavators works like its counterpart by monitoring and dump truck operations have been analysed to model
displaying exact bucket payload, taking the guesswork ‘normal’ and ‘abnormal’ operating conditions for certain
out of reaching precise target payload. The system will components. If a dump truck is affected by influences
give operations the power to minimise costs and such as harsh environments or component degradation,
maximise productivity more than ever before. built-in truck sensors will pick up small differences in
the machine including temperature, hydraulic pressure
Payload management system case and acceleration changes. Data taken from these truck
study sensors is used to develop a machine learning model,
Studies undertaken at a coal mine in Queensland which can not only calculate the remaining useful life of
(Australia) have shown just how much potential the a component, but also alert the operator of abnormal
payload management system has in improving site operating conditions, which could increase risk of
efficiency. damage to certain parts. No prediction made under the
In 2016, dump trucks with no payload management component life prediction system is generic; each is
systems installed were monitored over a total of 10 shifts. specific to the vehicle and its site.
Observations made included how often dump trucks Results with the machine learning model have been
achieved target payload, how often and how far promising so far, with Hitachi successfully predicting the
payloads strayed from target payload, and how much life of a strut cylinder on an EH5000AC3 dump truck
total material was moved. Target payload was achieved within industry standard acceptable tolerance. Although
just over 14% of the time, with a deviation of 6.3% from this is just an experimental case, Hitachi’s machine
the most frequent payload. These kinds of statistics are learning model will soon be able to analyse more and
characteristic of most operations. more components to minimise lost time, improve
In early 2017, the same dump trucks were monitored productivity and alert operators of potential issues
again over 10 shifts, but with one vital difference from before they escalate.
the first study: the dump trucks now had payload There is no doubt that the mining industry is at a
management systems installed. The improvements were turning point. Within the next 10 years, drastic changes
significant. Target payload was achieved 17% of the time; in the industry will bring safer, more efficient, more
3% more often than when no payload management sustainable operations. During the time of the Industrial
systems were installed. Deviation also decreased to 4.9%; Revolution, coal was dug by hand; perhaps by 2020 it
a 1.4% reduction from the previous study, meaning the will be dug by fingertip.

June 2018 | World Coal | 35


Clean conveyor systems,
good firefighting capabilities
and ongoing maintenance
are the best defence against
fires, explain Dan Marshall
and Todd Swinderman,
Martin Engineering, USA.

36 | World Coal | June 2018


A fire is one of the worst catastrophes in any
manufacturing facility, but operations involving large
conveyor networks are at particular risk of large-scale
fire events and the hazards they pose to worker safety
and company profitability. There are a number of underlying
reasons. First, the nature of bulk material conveying generates dust
that can serve as fire fuel and even an explosion hazard, and
mines occur in excavations equipped with belt conveyors.1 With
enough friction and heat, many conveyor belt constructions are
capable of self-sustained fire propagation, whether they are made
from natural materials, synthetics, or a combination of the two.
Once ignited, they tend to produce a thick, black smoke resembling
a tyre fire, which is often a far worse risk to personnel than the
flames themselves. Smoke and heat can quickly travel through
controlling fugitive material in these operations is an ongoing shafts, limiting visibility, access and escape, and it can take days to
challenge. Second, conveyors are notoriously under-maintained; completely extinguish the event. If a burning belt should split
they are often huge, complex structures that are only serviced under tension, the burning ends can fly apart, leading to multiple
when a component fails. As such, a seized idler or mistracking belt fires at different locations, as well as the splatter of burning rubber.
can create sufficient frictional heat to cause ignition.
In addition, the size and speed of modern conveyors presents Causes of belt fires
the ability to spread even a modest fire outbreak over great Although heat caused by friction is the principal trigger of
distances in a very short time frame. Complicating matters further conveyor fires, there can be several underlying causes. Seized
is the fact that conveyor fires are typically difficult to fight. The belt components, such as rollers, brakes or bearings, are a common
is a long structure, often easily ignited itself, and a fire can spread source, often exacerbated by fugitive material that acts as an
along this extended route with frightening speed. If it is not spotted abrasive. Carryback on pulleys can also cause belt slip, creating
in time, burning material can even be transferred from one friction between the two. Static electricity can also trigger an event,
conveyor to another. The belt path will often run around or particularly when significant amounts of airborne dust are present.
through a variety of enclosures and structures, all of which carry It has been estimated that frictional and static ignitions may
the risk of ignition, where the fire can be very difficult to account for up to 40% of all belt fires (Figure 1).
extinguish. Inclined conveyors can develop a flue-like effect that Other causes are less predictable, such as overheated motors,
intensifies the air flow, feeding the blaze and magnifying the electrical fires, incidental ignition of surrounding spillage and
damage. In many operations, elevated conveyor systems can also foreign material entering the cargo stream producing sparks. These
prevent easy access, presenting additional firefighting obstacles. sudden ignitions can be spontaneous and, in some cases, leave
In underground applications, the danger is far more acute. little trace as to the trigger for the fire. With the addition of factors
Statistical data reveals that up to 70% of fires in underground coal such as wind and other flammable agents near the conveyor, fires

June 2018 | World Coal | 37


potentially result in extreme wear on the belt, degrading the
main fire-retardant layer and exposing the heat-sensitive
materials found in the belt’s inner construction.

Belt testing for friction


Tests have been developed to study the resistance of conveyor
belts to ignition, glowing, or sparking when under intense
friction conditions. The 'Drum Friction Test' uses a sample of
conveyor belt suitably mounted around a drum that rotates at a
Figure 1. Number and causes of belt fires from 1986 - 1991. specified speed and belt tension. This allows testers to simulate
Reported in the HSE topic report, 'Safe Use of Belt Conveyors the conditions of a stalled belt in contact with a fast rotating
in Mines'. drive pulley, or a belt passing over a seized idler. The desired
results are as follows:
„ The belt should resist catching fire due to friction.
„ The belt should be difficult to ignite with an open flame.
„ An ignited belt should not propagate a fire.

The test measures different specified tensions for a given time


period until the belt breaks. The presence, or absence, of flame or
glow is noted and the temperature of the drive drum is
measured. Conducted in either still air and/or in moving air
Figure 2. Causes of belt fires as reported in the 2008 Verakis
and Hockenberry presentation,'Conveyor Belt Entry Fire depending on conditions, in most standards, the belt or the belt
Hazards and Control'. debris emitted from the drum rotation must not catch fire during
a specified test duration.
can spread quickly, leaving little evidence of their true source Although the sample may break, or remain intact depending
(Figure 2). on the test standard, testers must specify the maximum
To create a fire there must be three elements: oxygen, heat, temperature the drum reaches during the testing. For example,
and fuel (aka, 'the fire triangle'). One factor that makes conveyor testers for coal mine applications set the maximum drum
fires so hazardous is that the belt itself can be the fuel. According temperature to approximately 325˚C, which is below the ignition
to a study of belt fires conducted by the National Institute for temperature of coal dust. However, some standards allow drum
Occupational Safety and Health, any of the standard neoprene, temperatures of up to 400˚C for nonflammable cargos.
PVC, chloroprene and BELT-approved SBR belts can ignite.2
Although some belts were hard to extinguish and burned Controlling fugitive material
completely, while others ignited quickly and went out on their Fugitive material control and regular cleaning of spillage
own (self-extinguishing), the conclusion is that there is no are imperative. Without proper belt cleaning, chute sealing, and
non-flammable belt, particularly when accompanied by a belt tracking, spillage that collects around the loading/discharge
combustible material.3 areas and along the belt path, can damage moving components,
restrict access by fire crews, and potentially act as fuel.
Friction Dust control is extremely important when handling
What leads to friction can often be sourced back to either the combustible substances, and it is recommended, instead of just
discharge zone or the loading zone, or both. Inadequate belt taking into account the fire triangle, operators consider the 'Dust
cleaning in the discharge zone can lead to dust and carryback Explosion Pentagon'. Examples of highly combustible materials
on the return side of the belt, causing a fouled tail pulley to run include:
under a stalled belt, which creates tremendous heat. A fouled „ Coal – a carbon-based, highly flammable material that burns
tail pulley can also cause the belt to enter the loading zone at high heat, with dust that is easily ignited by a spark.
unevenly. As a result, cargo dropped from the transfer chute „ Petcoke – a carbon-rich derivative of oil processing
can settle on one side of the belt, causing the belt to drift used as a coal alternative for power generation, among
further and come in contact with the structure or fixed other applications. In dense concentrations, the dust is
components, resulting in high temperatures caused by friction combustible with a high energy spark.
that can ignite a fire. „ Cellulose – a naturally occurring polymer found in wood,
Dust emissions of any kind (combustible or noncombustible) paper and grains; dust readily ignites.
originating from the loading or discharge zones have a tendency
to foul rolling components, leading to failure of the seals, Significant amounts of dust can collect on the walls of the
contamination in the bearings, and eventually causing the roller loading zone chute. If a foreign metal object is accidentally
to seize. A rolling component can also stall if impact or cargo introduced into the enclosed area, a spark can potentially create
weight causes the bearings to collapse. Continuous frictional an explosion. Additionally, common maintenance within the
contact with a seized idler or the roller face can cause a loaded chute, such as removal of the wear liner using a cutting torch,
belt to exceed safe operational temperatures. It can also often requires confined space entry by workers. If the inside of

38 | World Coal | June 2018


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Tailings from the washery are pumped to the plant where hydrocyclones are used for separating
solids at 0.15mm and thickening to 50 percent solids. Thickened solids are dewatered using six
HI-G Dewatering machines, and the -0.15mm fraction is sent for dewatering in filter presses.
Nearly 75 percent of the total 240 t/h solids are recovered in Derrick screens and 25 percent are
dewatered in the filter presses. Clear water containing less than 100ppm solids is pumped back to
the respective washeries, while solids are stored for disposal/sale. This environmentally friendly
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rolling equipment from fouling and seizure. The decrease in
spillage mitigates the collection of potential fuel around the
conveyor and requires considerably less labour for cleanup.
Modern belt trackers with troughed idlers or gripping
return idlers are so sensitive that they detect mistracking the
moment it happens and correct the belt path immediately,
significantly reducing the chance of a friction fire due to belt
drift. This also reduces spillage along the belt path from
uneven cargo loads.
A heavy-duty belt cleaner system, featuring modern primary
and secondary cleaners with an effective tensioner, increases the
volume of discharge and limits the amount of carryback and
Figure 3. Dust explosion pentagon. fugitive dust. Along with limiting spillage, tail pulley health is
improved and there is less fouling of rolling components.
the chute is not adequately cleaned, this task could pose a
serious hazard. Conclusion
Improving the fire retardance of its belting is just one of the ways
Think like an inspector that an operation can reduce the risk of conveyor fires. The
When examining conveyor equipment, one should approach the development of fire-retardant conveyor belting has made an
task with the same critical mindset as an inspector from OSHA, important contribution to safety, but even fire-retardant belts can
MSHA, or the local fire department. Prior to concentrating on burn in the presence of another fuel. These potential fire hazards
specific components of the conveyor, safety professionals can only be minimised through high standards of conveyor
recommend a holistic view of the system, taking into account the installation, maintenance and cleanliness.
combustibility of the material being conveyed and how the areas Operators should regularly contain airborne dust at transfer
around the conveyor could be impacted. The following should points and remove accumulated dust from beams, pipes,
also be assessed: conduits, equipment and fixtures; and minimise spillage from
„ Spillage levels and cleaning schedules. belts. Damaged rollers must be identified so that they can be
„ The conveyor’s proximity to work stations. replaced as soon as possible before the damage leads to frictional
„ How the conveyor design (enclosures, narrow walkways heating that can result in a fire. Operators should use flame
etc.) could create a hazard for employees. resistant grease and other lubricants. Fire detection and
„ Safe storage of flammable liquids. suppression systems and equipment must be tested in
„ Compliant signage. accordance to industry and regulatory standards.
Conveyor belt alignment is also an essential prerequisite to
Finally, take a common sense look at the current state of fire belt safety. Belts must be aligned and trained to prevent frictional
suppression apparatus. Conveyor designs are ever-evolving and heating where the belt rubs against the conveyor structure.
often retrofitted with new equipment based upon changes in Another significant fire-prevention measure is control of ‘hot
production and volume. In older facilities, fire suppression work’ permits and procedures (for employees and outside
systems were most likely designed for the conveyor that was in contractors), and restrictions on the placement of flammable
place years, if not decades, prior and may no longer be effective liquids and gases.
in the event of a fire on the current system. It is incumbent upon employers to protect workers from one
of the most potentially hazardous pieces of mechanical
Considerations for conveyor fire equipment at any facility: conveyors. Knowing the risks of fire,
prevention facilitating periodic inspections, and striving to implement the
Often, the potential return on investment (ROI) for prevention steps and equipment needed for a safer workplace should be the
equipment is not recognised until managers are inspecting burnt goal of every operation.
rubble and negotiating with insurance adjustors. However, Experience has shown that clean conveyor systems, good
safety-minded operators understand that the same equipment firefighting capabilities, and ongoing maintenance form the best
they would implement for increased efficiency, such as belt defence against fire.
cleaners and impact cradles, can also help prevent fires.
Impact cradles and support cradles help reduce fugitive References
material by providing a flat, stable belt surface that facilitates 1. CHEREMUSHKINA, M. S. and PODDUBNIY, D. A., 'Reducing The
effective sealing. Risk Of Fires In Conveyor Transport', Institute of Physics Conference
Transfer chute design is a critical element of fugitive material Series, Earth Environ, Sci. 50 012043, 2017.
control, with sufficient settling zones and confinement. New 2. ROWLAND III, J. H. and SMITH, A. C., 'Flammability of wider
conveyor belts using large-scale fire tests', National Institute for
raised chute designs also allow for external wear liners that
Occupational Safety and Health (NIOSH), Pittsburgh, PA, 2010.
eliminate the need for confined space entry or torch removal.
3. FERNÁNDEZ, M. and RODRIGUEZ, Á., 'Early Detection and
When paired with improved skirt seal designs, fugitive spillage Fighting of Fires in Conveyor Belt', Edaffic, Publications Office of the
and dust emissions are drastically reduced, which protects European Union, EUR 25364, Luxembourg, 2013.

40 | World Coal | June 2018


Eric Tomicek, Australian Diversified
Engineering, Australia, discusses the
importance of developing innovative ways
to combat dust emissions in coal mining,
and details two new water-based dust
control solutions for the coal industry.

W ith populations growing and the number of


major industrial developments increasing,
the global market for dust control is also
expected to expand significantly in the
coming years. Controlling airborne dust, particularly on
mining sites, is incredibly important and developing
innovative ways to manage this is a continuing necessity.
Australian Diversified Engineering (ADE) is a pioneer in
the field of airborne dust control. It delivered major change
for numerous mine and construction sites following the
launch of its highly regarded water truck spray system, ‘ADE
Spray’, back in 2014.

Optimal water application


ADE is currently developing a new product called the ‘Dust
Nomad’ which is now in test phase but promises to help further

June 2018 | World Coal | 41


minimise airborne dust on mine sites and will work together Typically, truck and digger operators determine the dust
with their existing spray systems. levels themselves before choosing where to send water trucks
For mining operations around the world, dust is an or deciding if shutting down a certain area is necessary. Now,
expected consequence that must be managed. Dust mitigation the Dust Nomad has the ability to remotely gather and log
strategies are regularly implemented to combat the various data, show real time dust level increases, and identify dust
emission sources, the largest of which are caused by the large hotspots over time. The ADE Dust Nomad is designed to work
dump trucks that navigate mine haul roads. High dust levels effectively with large mining vehicles, as opposed to the light
create many concerns for mining operators; indeed, it is bad for vehicle mobile dust monitors currently on the market. The
the environment, detrimental to your health, creates safety Dust Nomad is also capable of measuring airborne dust
hazards, slows down production, increases maintenance costs 24 hr/d, 365 days of the year, on location. Dust mitigation
and affects the surrounding community. strategies can then be established, as the Dust Nomad data is
Some water control methods result in uncontrolled correlated with weather data and truck operations.
movements of vehicles on mine sites, due to too much water With data highlighting the critically dusty roads, and the
being used and resulting in mud slippage. Clearly the issue roads more susceptible to dust generation, efficient water truck
around determining the correct amount of water necessary to deployment strategies can be introduced so that water trucks
reduce airborne dust levels is a serious one, leading to issues of spray roads before dust levels become too high. A simple
safety for all vehicle operators. scenario is the creation of a geographical heat map; using the
ADE Spray addressed this issue and has been implemented recorded dust data we can generate a visual representation of
at 20 mine sites across Australia with numerous others under the dust generated across a mine site. Combine this with the
contract to receive the spray system in the near future. ADE's operational data recorded by the ADE Spray system, we can
water truck control system can consistently spray a specific rate quickly and easily see where the water is being sprayed, and
of water onto the ground, regardless of ground speed, to where the dust is most prominent.
effectively and efficiently control airborne dust. The superior High dust levels obviously cause health and environmental
control of water applies to low speeds, such as on ramps, and at issues, as well as temporary loss of visibility during operations.
typical haul speeds experienced on flat haul roads. This Coal dust is unsafe as it causes black-lung sickness amongst
impressive control of water output can prevent under-watering, coal diggers, and is an explosion risk when scattered in the air.
normally resulting in increased fugitive dust emissions. Additionally, dust created from sand, stone and rock
Additionally, miners can ensure sufficient road friction is preparation contains silica, which is responsible for developing
maintained by preventing over-watering at high hazard silicosis in the lungs. The risk of developing these health issues
locations. By measuring road friction and determining the is likely to be reduced with the use of products such as the
maximum safe water coverage rate, water truck operators can Dust Nomad, as dust control will become easier and more
easily input this rate into the spray system controls decreasing effective.
the risk of an unplanned movement for mobile equipment. Mining locations are also a significant contributor to air
A haul road can be closed for several hours in the event of the pollution, due to the high airborne dust levels created when
unplanned movement of a mobile operations vehicle, costing operating vehicles on unpaved roads and at construction and
both time and money as production is indefinitely halted. By mining locations. The pollution will, however, be minimised
eliminating over and under-watering, costs, fuel and water with the implementation of the Dust Nomad as workers are
wastage are naturally reduced. able to effectively manage airborne dust levels.
ADE developed the Dust Nomad due to the need for further Imagine for a moment a water truck that sprays water on to
innovation around dust control. The company's Spray Suite the haul roads. Determining where it should spray water and
Systems paved the way for dust control in the market but the what route it should take around a mine site can be a very
company has been acutely aware of the need to continue to complex question, and if you get it wrong the result is a very
develop and innovate in this space for even greater safety and dusty mine, which may lead to more capital expenditure to
efficiency in the future. purchase additional water trucks.

Optimal route and cycle time Conclusion


Whilst ADE’s existing solutions determine the optimal water ADE is passionate about haul road operations and understands
application for a single pass, determining the optimal route that technological innovations require a methodology that
and cycle time for a water truck on a mine site is considered a integrates into real world operations. ADE's Spray System can
black art. The Dust Nomad aims to solve this by providing consistently spray at a specific water rate and delivers more
continuous measurement of wheel generated dust from the water to more of the mine, and now with dust monitoring
operating areas on a mine. technology, the company can quickly react to increasing dust
The Dust Nomad and the ADE Spray work collaboratively: levels before they adversely affect the working environment.
the Dust Nomad identifies high dust areas and the ADE Spray ADE recommends that all Australian mines check their
applies the optimal amount of water. Over time, correlations systems and ensure their water usage is up to industry standard.
can be made and predictive models deployed to identify more As a company, ADE’s goal is to provide the Australian mining
efficient water truck deployment strategies to minimise the industry with the most innovative technology, whilst ensuring
onsite airborne dust levels. the safety of all mine workers.

42 | World Coal | June 2018


Times are
Changing
he methods of processing coal have changed

T
Ernst Bekker and
substantially over the years, from manual sorting
Brent Combrink, to advanced processes such as dense medium
Multotec, South Africa, separation and fines beneficiation. With the
associated increase in complexity of the operations, a proper
discuss coal washing and understanding of these modern processes has become a
dewatering processes. prerequisite. To add to the complexity of coal washing,
dewatering processes are also becoming prime focus areas
due to water availability, which is becoming more critical to
the mining industry every year. The coal industry is,
therefore, torn between two extremes: improving washing
technology to handle lower quality coal, or reducing water
consumption as far as possible and cleaning their water for
safe discharge.

Coal washing
Coal washing has progressed over the years from multi-
module operations treating separate size fractions, to less
complex designs sometimes treating complete size fractions
and consisting of one or two modules at most. These types
of designs allow for better operational control which, in
turn, lead to higher separation efficiencies or more
consistent operations over a longer period.
With deteriorating run of mine (ROM) coal qualities
becoming ever more a reality, the standard approach to coal
washing requires some rethinking. The type of equipment
used may have to change to increase the capacity per
footprint in order to allow for the process to stay profitable.
A change from the older design bath washers to centrifugal
washers, such as cyclones, is becoming standard practice.
Depending on the coal washability characteristics, it may be

June 2018 | World Coal | 43


With the higher tonnages per footprint and the higher
medium volumes being processed, the performance of the
screens is also becoming a focus point. Bed depth, spray
water addition and screen panel open area are all chief
factors that influence the desliming screen performance.
Incorrect screen panel design can lead to screening
inefficiencies and/or higher water usage compared to
proper designs. Understanding screening principles also
add to ensuring optimal screen performance, not only to
increase screening efficiency, but also to avoid using too
much water.
Figure 1. TeePee panels from Multotec provide significantly With drain and rinse screens, the ability to drain higher
increased drainage capacity compared to conventional flat volumes of medium being processed becomes paramount
panels. The increased exposed surface areas enabling screens to minimise medium losses from the circuit. In many
to operate at a higher capacity and ensures a 50% increase in processes, the screen size remains unchanged since
effective drainage area. replacing the screen with a larger version may not be
practical. Alternative screen panel designs may be an
option to improve the drainage capability of existing
screens. Optimal performing drain sections reduce the
need to add more spray water on the rinse section of the
screen, which promotes optimal water usage. The Multotec
'short course on screening principles' helps to transfer
knowledge to its customers and the industry on these
topics.
An area that sometimes gets overlooked is the medium
recovery circuit. Neglecting this section of the process can
lead to unnecessary monetary losses associated with
medium recovery, as well as poor water management.
Properly designed spray nozzles can optimise water usage
when recovering medium, while the proper operation of the
Figure 2. This filter press is one of Multotec’s large production magnetic separators can increase the efficiency of medium
designs and is capable of treating 35 tph of fine coal.
recovery.
To ensure optimal use of a given coal resource, fine coal
necessary to use higher medium to ore ratios, which equates beneficiation has become the norm in modern plants. The
to larger volumes being processed through the circuit, beneficiation of fine coal involves equipment such as spirals,
equating to more water and medium being used in the reflux classifiers, teeter-bed separators, froth flotation and,
circuit. in some cases, dense medium separation.
There are a number of practical aspects that could have a With increasing feed tonnages being fed to coal
positive influence on the resultant clean coal product. A preparation plants, the fine coal circuit can become the
proper understanding of the dense media circuit is a must. bottleneck in the process if this section is unable to process
The parameters surrounding the operation of the DMS the full fine fraction stream. Overloading of the circuit
cyclone must be clearly understood. The cyclone efficiency often leads to poor product qualities or yield losses,
is determined by the nature of the feed, the cyclone defeating the purpose of processing the coal resource as
dimensions and maintenance, and the circuit influences on effectively and efficiently as possible. Understanding the
the equipment. If the feed material characteristics change, limitations of the installed equipment, as well as the
the mechanisms of separation in the cyclone will be impact it has on the economics of the overall process, is
influenced and, thus, should be compensated for as soon as important to ensure proper steps are taken to either
possible. Proper measurement of the parameters within the optimise the existing equipment or increase the capacity of
circuit is critical, as changes can only be made if the this section. Multotec's training courses also focus on
operating variables are known. The DMS cyclone might improving the client and operator's understanding of the
seem a simple piece of equipment, but if the physics of equipment used in this section, as well as how to improve
operation and mechanism of separation are not clearly the performance.
understood, inconsistent separation efficiencies will be Since this part of the process is normally water-based, it
experienced. To assist with knowledge transfer to the also uses the most water. Therefore, optimising this section
industry, Multotec has introduced short courses for its not only impacts on the economical side of the process, but
customers to assist in the proper understanding of these also on the environmental side with regards to water
principals. Topics include principles of separation, operation management. Multotec offers CleanTeQ technology to clean
and fault finding. discharge effluents.

44 | World Coal | June 2018


UNMATCHED.

TO SEE HOW CUMMINS IS UNMATCHED IN THE INDUSTRY,


VISIT CUMMINSENGINES.COM/MINING.

©2018 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A.


process and the smaller particle sizes being processed. The
use of dewatering screens in water-based gravity separation
processes is the norm but, with increasing feed tonnages to
this section, a limitation on drainage ability may be
experienced, leading to products with higher moisture
contents and higher water losses from the process.
One solution is to increase the screen aperture size in
order to increase the drainage rate. Although this is possible,
the drawback is that the saleable ultrafine product is lost to
the water recovery section. This not only results in a
monetary loss, but also places strain of the equipment
capability the handle the additional tonnages.
A second option that can be used to alleviate this
problem is the incorporation of hydrocyclones, which are
installed ahead of the dewatering screens. In most cases, the
Figure 3. Multotec has optimised dense medium separation retrofit of hydrocyclones is possible due to the small
in the pre-concentration of minerals, specifically in coal and footprint of these units. The purpose of the hydrocyclones is
diamonds, for over 40 years. to dewater the material before it enters onto the dewatering
screens which, in turn, prevents overloading of the screen
itself.
Some designs incorporate a fine coal centrifuge after the
screen, which reduces moisture contents too close to the
maximum practical limit. Again, the option of retrofitting
the centrifuge after the plant has been built could be difficult
and will depend on a commitment to save water.
The last section of the process that accounts for
significant water losses is the tailings disposal area, where
thickener underflow is generally pumped out to slimes
dams. Recovered water from the tailings ponds is reused in
the process, but evaporation and water lockup can
contribute to a significant loss of water.
The presence of slimes dams can also pose environmental
hazards such as spontaneous combustion and polluted
Figure 4. Multotec offers an extensive programme of customer
water that is consumed by wildlife. In addition, slimes dams
training workshops that focus on principles of separation,
occupy land that could have been used for other purposes,
operations and fault finding.
community development or agriculture for example.
A new trend in the coal processing industry is the
Dewatering incorporation of filters after the thickener, which allows for a
As mentioned previously, water management in a coal final product that is dry enough to be transported by
processing facility has been prioritised, resulting in changes conveyor. The slimes are then co-disposed with the other
in the flow sheet of the modern coal processing facility. reject material originating from the coal processing facility,
In the dense medium section, the use of coal centrifuges before being transported to the discard dump. This option not
is becoming more common. The dense medium circuit only reduces the amount of water lost from the process, but
product is usually split between a coarse and a fine coal also reduces the environmental impact that coal processing
stream. Each of these streams are treated in centrifuges that has on the environment by eliminating slimes dams.
differ in design depending on the size of material treated. Equipment training provided by suppliers to the
Depending on the particle size, surface moisture contents industry helps to transfer knowledge on optimising
can range between 5% and 12%. Without the use of equipment performance. However, this training can also
centrifuges, moisture contents would typically range help customers and industry personnel to assess
between 8% and 15%. opportunities as to where and how water usage can be
Unfortunately, the retrofit of centrifuges after the plant minimised, and what options exist to improve the process
has been built is not always easy or possible, and options of design to minimise the water footprint of the process.
using surfactants on coal to reduce water consumption have The same argument applies to suppliers. Where sales
been tried with mixed results. The area of reducing surface presentations have been the norm in the industry for many
water without the use of centrifugal force remains an area of years, changing operational requirements from the industry
interest for the industry. will dictate that training be taken to a level where shared
With fine coal processing, the importance of proper information could be used to benefit not only the operation,
dewatering escalates due to the amount of water used in the but also the environment.

46 | World Coal | June 2018


to change
T he industry’s digital capabilities have
significantly increased over recent years,
and technology now has the potential to
deliver unparalleled operational
improvements. Companies that are willing to leap
into the digital mining era before their competition
have the ability to accelerate past their competitors
level by 2019 will deliver productivity, efficiency
and/or revenue gains of up to 25%.” Organisations
that embrace this digitisation will not only have a
more profitable business, but one that empowers
employees with the data they need to make
decisions with certainty.
A holistic approach to mine planning can create
in the future. In November 2017, the International value for any mining company in both existing and
Data Corporation (IDC) published a report called new sites. The recent advances in mathematics and
‘IDC FutureScape: Worldwide Mining 2018 3D computational geometry has enabled software to
Predictions’. The report stated “companies that become more intuitive, comprehensive and robust
prioritise digital transformation at the executive than ever before. It is now possible to have mine

Frank Grima, RPMGlobal, Australia,


talks about closing the gap in mine
planning and scheduling
solutions.

June 2018 | World Coal | 47


The coal-specific XPAC Solutions are the only solutions
in the industry built on the principles of parametric
scheduling. By leveraging the power of technology, users
have the ability to analyse how changes to one or more
key parameters will affect the schedule. By imposing
sophisticated mining logic and automated rules on the
scheduling model, XPAC Solutions prevent invalid
mining sequences and ensure that each schedule is
practical and achievable. This enables planners to adjust
parameters and produce multiple new schedules within
hours. The automated nature of the mining logic allows
Figure 1. Parametric modelling. rigorous, long-term schedules to be developed without
spending months building the rules. It removes the need
for complicated excel spreadsheets and allows planners to
focus on providing real value to their mine site.

Mining case study


A tier one mining company was experiencing the usual
challenges surrounding mine planning and scheduling
amidst tight economic conditions. The company
understood that players, large and small, were looking to
digital technologies as a vehicle to help increase
production, reduce costs and improve operational
efficiency. To meet their mine planning and scheduling
Figure 2. Steeply dipping coal block model.
objectives, the company evaluated five vendors.
RPMGlobal’s XPAC Solutions provided a robust,
planning and scheduling solutions that are capable of consistent and highly capable technology platform to
updating in real time and through an enterprise address their challenges. Prior to their implementation of
approach, as well as being able to feed the relevant data XPAC, planners were using over 10 separate excel
across the entire mining value chain. spreadsheets to develop the company’s schedules. The
In the past, mining companies have experienced an process was not only time-consuming, but the company
array of challenges in the mine planning and scheduling felt as though they were missing opportunities to
space, which was compounded by the economic optimise their mine planning and the value these plans
downturn. The mine scheduling processes used today are delivered.
still time-consuming and often rely on a variety of Now, with XPAC Solutions the company has reduced
spreadsheets that sit on user’s computers. This manual their timeline to create schedules by 85%. It now takes
effort to determine the best approach to planning and days rather than weeks. Alongside this, users could
scheduling often results in mistakes, inefficient plans or answer the ‘what if’ type of questions and update their
missed opportunities for scenario analysis due to schedules with the revised commodity price in 5 min. By
imposing deadlines. By employing the correct software implementing a 100% script-free solution, the repeatable
with an enterprise approach, mining companies can process removed the need for costly consultants and gave
eliminate the need for multiple, complicated spreadsheets the power back to engineers to focus on providing value
with one single data source, and can finally answer the to their site. The flexibility offered by XPAC Solutions
elusive ‘what if’ questions with certainty. allowed the company to respond to real constraints, in
RPMGlobal has capitalised on the advancements real time and propelled them to an 8% increase in
offered by the digital mining era with its continued productivity within the first 12 months of
development of XPAC Solutions. With 5000 software implementation.
installations in 120 countries, RPMGlobal has leveraged Engineers can not only schedule the mining sequence,
its worldwide experience to create the most but also schedule dumps automatically, which are directly
comprehensive mine planning and scheduling solutions related to the dig sequence. Performing the dumping
for the coal industry. To answer the coal industry’s need simultaneously to the excavation allows the mining
for commodity and methodology-specific solutions, schedule to be influenced by the dig schedule. For
RPMGlobal has released the world’s first steeply dipping engineers, it also means that if their pre-existing dump
coal solution. This solution builds upon the core designs or landforms have been created in a third party
capabilities of the company’s opencast coal and package, the design can be incorporated into the schedule
underground coal solutions, but with a focus on the to determine the viability of the dump designs.
unique demands of steeply dipping coal operations XPAC Solutions also features integrated haulage
utilising terrace mining methods. modelling program capabilities. The program

48 | World Coal | June 2018


automatically connects
all the main haulage
roads to every mining
block with the mining
reserve. This is distinctly
different from other
solutions because it is
spatially aware when it
comes to mining blocks
and haul roads. In a
more practical sense, the
software can turn ramps
on or off based on
scheduling interactions
at any given period.
Therefore, post-schedule
haulage analysis is no
longer required, saving
both time and money,
and in just two hours an Figure 3. Material flow product optimiser.
accurate view of fleet
interactions is visible to the user. After the schedule has finance and HR, but this has not been extended to their
been completed, travel time, truck hours, fuel burn and technical mining operations. Consequently, technical
tonne-kilometres per hour will be reported out for every mining operations is a complex web of point solutions,
block mined. data sources and siloes that deliver complicated
structures and inadequate functional collaboration.
Overcoming challenges Effectively, information remains trapped in these isolated
In the past, it has been extremely difficult to manage systems and will only be freed by the adoption of open
interactions between planning horizons. A wide range of standards, such as ISA-95. Through the adoption of
planning applications being used by different planning ISA-95, users can plug and play with a variety of
departments have resulted in data siloes. Using an solutions from a variety of vendors and still achieve the
enterprise approach, users can view, analyse and approve same seamless communication. This recognises that the
mine plans from the ultra-short-term all the way through modern mining ecosystem consists of a number of
to the life of mine. This plan can be published in a variety different solutions, and companies need the flexibility to
of formats (ISA-95, B2MML) up to the enterprise level. use different vendor’s products to meet the unique
The consolidated mine plan can then be consumed by demands of their mine site. This initiative is already
enterprise financial systems, process control and fleet being driven by global mining companies and leaders in
management systems, before being analysed through the mining vendor system, including Caterpillar, Modular
corporate business intelligence systems. This breaks Mining Systems, Schneider and RPMGlobal.
down the rigid data siloes and ensures that the right data
is reaching the correct decision makers. Conclusion
All of the effort can be futile if coal blending processes Adapting to the changes that are occurring to the
and quality monitoring are not able to meet the industry and harnessing the best technology on offer will
requirements of the coal’s intended application. The allow mining companies to emerge as industry leaders.
XPAC Solutions Product Optimiser runs simultaneously, At the core of every mining operation is planning and
and removes the need for pre-schedule or post-schedule scheduling. To become one of these leaders in mining,
blending strategies. XPAC Solutions’ specific in-built companies must implement a strategy that unites
features allow users to easily set quality targets or operations into one single platform across the mining
production targets to achieve the desired outcome and value chain. For example, by integrating opencast coal,
ensure accuracy. Planners now understand the mines underground coal or steeply dipping coal XPAC solutions
blending strategy by using available linear programming, with an enterprise approach, the coal industry will be
and can ensure that the site is blending the most suitable able to achieve the consistency it requires in the modern
product based on their objectives. mining era. Technology has presented the coal industry
The true potential of growth for the coal industry will with the opportunity to experience unparalleled gains in
only be realised if these industry leading solutions are productivity, safety, efficiency and profitability. However,
partnered with an enterprise approach. Most mining to achieve these gains, the industry must employ the most
companies have realised the value in implementing an efficient planning and scheduling solutions that are
integrated strategy into corporate functions, such as unlike anything currently available in the market.

June 2018 | World Coal | 49


24 - 28 September 2018
St Anne's College, Oxford, United Kingdom

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The World Coal team talks to RCT
about the introduction of mining software
and how it has benefited the coal industry.

L ast year the coal industry made a slight


comeback after five consecutive years of
declining coal prices and it was during this time
that many coal companies started looking at
ways in which they could accurately gauge the areas of
their business they needed to improve.
While it is widely known that opencast coal mining is
become somewhat non-existent, and the need to improve
inefficiencies became paramount in order to improve
bottom line profits.
The decline in coal prices coincided with a time when
the mining industry in general was looking towards
innovating in order to bridge the gap and remain
profitable.
comparatively cheaper than underground coal mining, This saw a number of companies look to experts in
both industries have had improvements to make. Years other industries to better gauge how inefficiencies can be
ago, coal companies had the luxury of having room to corrected, focusing on those industries that operate on very
move on profits. However, in recent times, this has small profit margins, such as logistics markets for example.

June 2018 | World Coal | 51


This is when data management started to play a vital maximise their fleets and reduce costs – which is what all
role and inevitably resulted in a surge of mining software coal companies are striving for in the current economic
being available on the market today, and it is fair to say it environment.
is transforming the industry across the globe. Software is
providing companies with the data needed to help Before mining software
For thousands of years, the opencast coal mining
industry operated adequately without the need for
mining software.
Before mining software’s existence, the industry
was heavily reliant on its operators to provide the
valuable feedback needed for mine planning, machine
maintenance and even keeping a record of productivity
at the site.
This method was particularly time consuming as it
involved a lot of paperwork at an operational and
management level in addition to lengthy meetings to
discuss said paperwork before planning could even
begin. In addition, this method of collating data was
also somewhat unreliable, as it left room for human
Figure 1. Data collected on the EarthTrack Fleet Management error. For example, operators carrying out long shifts
solution can be accessed by any smart device with internet access.
would get complacent and important information,
such as the number of loads completed, would be
missed and reported inaccurately. For independent
sites, these oversights can be estimated based on
paperwork; however, this is not the case for those
using onsite contractors. Contractors are often paid
for the work they have completed and inaccurate
reporting can often result in excess costs for the site.
Machine maintenance was also carried out with the
help of paperwork. Before having the relevant data
needed to identify the machines that actually required
service, fleets underwent servicing based on the
amount of time they had been operational for. An
opencast coal site relies on expensive, heavy
Figure 2. Operators can have immediate access to data via the machinery, day in and day out, and more often than
operator interface. not these fleets were either over or under-serviced,
resulting in unnecessary costs
and unplanned downtime that
could possibly reduce the
machines lifespan, causing a
site to have to unnecessarily
purchase new equipment
sooner.

Why mining
software?
The mining industry is very
much turning into a paper-free
industry with the majority of
information being documented
on a computer now – mining
software was the logical step
forward. It is being used to
significantly improve several
aspects of opencast coal
mining, including mine
Figure 3. Mining software systems are helping the opencast coal industry to improve bottom planning, fleet management,
line profit. data analytics and machine

52 | World Coal | June 2018


optimisation. Not only does it eliminate the need for All data collated by the solution can be accessed by
paperwork, it delivers accurate, relevant information, selected personnel via the EarthTrack website. All
saving time and, as a result, money, which allows information is displayed on an interactive dashboard,
companies to improve their bottom line profit where which can be accessed via any smart device with internet
possible. access – anywhere, anytime. In addition an operator can
In an opencast coal mining environment, mining receive relevant information via an in-cabin graphical
software can be extremely beneficial when used on user interface, which they can access via an operator
mobile mining equipment, such as front end loaders, login. The EarthTrack Fleet Management system is backed
excavators and dump trucks, allowing sites to track the by worldwide support.
entire mining process from the mining of exposing of the Having valuable, accurate information at hand is
coal seam to transporting the coal via truck to the coal enabling opencast coal operators to make educated
preparation plant. decisions when it comes to mine planning and managing
While there is quite a selection of mining software fleets, resulting in savings to increase bottom line profit.
programmes available on the market today, not all of
them are the same. Therefore, it is important to
evaluate exactly what each solution provides because
too much information can be just as problematic as no
information at all.
RCT’s EarthTrack® Fleet Management solution is an
example of a system that delivers relevant information
that mine managers can act upon to make changes
onsite, quickly, to deliver significant and measurable
benefits.
This solution provides the tools to monitor the
payloads of haulage fleets and streamline machine
availability and utilisation. EarthTrack Fleet
Management is able to predict and prevent machine
downtime as the relevant data on both the machines
and its operators is captured in real time, meaning
mine management are alerted to problems instantly,
whereas previously there was a significant time delay. Figure 4. An excavator loads a truck with ore at an opencast coal
The solution is versatile and can be easily fitted on mine.
any mobile mining machine in a surface coal fleet,
regardless of brand or model, making it ideal for sites
operating a mixed fleet. It requires a connection to the
cloud via either WiFi or cellular where the data is first
correlated.
Hardware is simply installed and wired into the key
area of the machine to allow for data to be collected.
Mine management can choose what data to collate. It is
possible for the solution to gather data on essential
information such as excessive idle time, machine
utilisation, payload, impact monitoring, as well as data
on operator performance. The solution can also
incorporate a pre-start checklist to ensure the machine
is safe and in working order before the operator begins
work. This checklist can be customised to each
individual sites’ needs, and must be completed before
the operator can start the machine.
The more relative information an operator is
provided with, the more productive they can be. The
user-friendly system captures this data in real time,
meaning information is delivered faster and, as a
result, changes can be implemented promptly. There
is also the option for mine managers to receive live
alerts, bringing serious issues to their attention
immediately in order to minimise damage and reduce Figure 5. The Fleet Management solution can be adapted to any
downtime. machine, regardless of make or model.

June 2018 | World Coal | 53


54 | World Coal | June 2018
Domitila Moreno, Cummins Inc., USA, discusses the evolution of a number of
filtration optimisation solutions that can extend service intervals in coal mining.

M ining customers worldwide are requesting


extended service intervals as a way to reduce
total cost of ownership (TCO). Requests to
expand maintenance and service intervals up
to 1000 hr and beyond are being made from the mine site
maintenance departments, to the equipment manufacturers
and their suppliers.
Whether one is looking at air, fuel or lubrication
filtration, the Cummins approach to the technology it
applies and the innovation it achieves is centered on three
key principles to filtration design:
„ High filter efficiency is critical to effectively remove the
contaminants that are known to cause engine wear.
„ A filter’s capacity must be able to hold this contaminant
Cummins is tackling this challenge by employing a throughout the desired service interval and beyond.
holistic approach to managing and maintaining the engine’s „ The filter needs the lowest flow restriction possible to
critical systems to assure maximum performance is ensure proper operation of the equipment, regardless of
achieved. A retrofit programme and extensive field tests operating conditions.
across different equipment has demonstrated a reduction in
equipment stops and an increase in mine productivity with The Cummins filtration system concentrates on five
minimal investment. ways of improving the supply chain – affordability,

June 2018 | World Coal | 55


availability, efficiency, productivity and sustainability – to major cost savings through the use of new technology
help its mining customers improve their money spent per Fleetguard™ filters to extend service intervals.
tonne of mining products. Cost savings of 60%, through reduced filter and oil
consumption alone, were confirmed following a
Affordability 12 month field test involving a Komatsu 830E haul truck
Cummins products are designed to lower maintenance powered by a Cummins QSK60 HPI engine.
costs by streamlining innovative filtration systems that Applied to the fleet of 14 Komatsu 830E trucks at
are efficient, productive and sustainable, so miners can Dawson mine, savings in excess of US$220 000/yr would
get more from less product. be realised while slashing downtime for servicing by
Filtration optimisation extends service intervals and 74%, or 439 hr.
addresses customer concerns by providing a programme Add in the reduced labour costs resulting from the 439
that covers maintenance and contamination control with fewer hours of servicing time, and total savings would
the flexibility to adjust current service practices. exceed US$250 000 across the fleet of 14 trucks.
Gary Johansen, Cummins Power Systems Engineering Following the 12 month test, all 14 Komatsu 830E
Executive Director, commented: “Implementing trucks were fitted with the new technology filters.
innovative testing and technology in the field while One Australian miner, who was not new to
leveraging our OEM’s equipment expertise to help discovering ways to reduce the overall maintenance costs
identify areas of improvement has launched us into a in his coal mine, was a part of three case studies carried
new era in maintenance cost reduction. Customers can out by Cummins. The directive was clear that the
see the monetary and time benefit of significantly maintenance manager was to deliver cost reductions and
improved service intervals of between 500 and 1000 hr.” his first call was to Cummins. Representatives from
As an example, a filter optimisation programme Cummins Filtration arrived onsite to see where
carried out by Cummins Filtration and Komatsu at Anglo improvements could be made, using the Hitachi EX800
American’s Dawson coal mine in Queensland resulted in excavator with dual QSK60 engines.

Availability
By implementing site assessment check sheets, Cummins
engineers are able to obtain baseline data and identify
areas for potential improvements to enhance TCO. Once
common issues are identified, new product designs can
be created and existing products given fixes.
Cummins provides TCO savings. These include
optimised service intervals, reduced equipment
downtime through condition-based maintenance, better
consumable product life use, monitored, extended and
synchronised service events through predictive analysis,
effective inventory management and oil life monitoring.
Supporting documents, which range from marketing
literature to installation instructions, are all easily
accessible from their site. This allows information to be
readily available to consumers worldwide.
“Cummins filter optimisation programme provides
Figure 1. Cummins QSK60 HPI mining engine. additional availability of the equipment to miners
through extended intervals as demonstrated around the
world,” according to Johansen.
Cummins field tests took place in Australia, Brazil,
Canada, Chile, Colombia, Peru, Russia, South Africa and
the US, with miners including Anglo American, BHP
Billiton, Cleveland-Cliffs, Glencore, Goldcorp, Rio Tinto,
Suncor, Teck Resources, Vale and others.
The first task in one of the company's Australian coal
mine case studies was to move the miner to the newly
released NanoForce® air filtration products. Once in
place, the NanoForce air filters delivered up to three
times more protection, enabling the site to extend service
intervals and increase operation of the equipment. The
availability of the product, though, means nothing if it
Figure 2. Cummins NanoForce filter. does not work well.

56 | World Coal | June 2018


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Efficiency because the filter becomes full faster, which decreases
the life of the filter.
Innovation in filter media In addition to the laboratory tests, Cummins
Traditional filter media use a blend of coarse (15 - 30 μm) NanoForce and NanoNet® filters have been extensively
cellulose fibres and varying amounts of sub-micron subjected to real world trials around the globe in a broad
synthetic, glass and polyester fibres. This method for range of mining equipment. Even in the most severe
developing filter media results in inconsistency with environments in coal, copper, iron ore and platinum
filtering out different sized particles and enables those mines, with temperatures ranging from -45˚C to 50˚C,
trapped particles to pass through the filter through these filters have proven able to reduce maintenance
vibrations consistent with equipment operations. With intervals and reduce overall cost for the miners.
the advanced emissions regulations being adopted For example, if 100 000, 4 μm sized particles enter the
globally, operating tolerances on equipment are much filter and 1333 make it through, then the filter’s efficiency
tighter, thus making them less tolerant to debris. is 98.7% with a Beta ratio of 75. The best traditional
Typically, improvements in traditional media filters media filters available today would offer this type of
focus on either filter efficiency or capacity. By performance. However, nanofibre media can remove the
improving efficiency, the filter will need to capture same four micron sized particles 99.9% of the time. While
more of the smaller particles. Flow restrictions increase that is only a 1.2% improvement, in reality it means that
of the same 100 000 particles flowing
into the filter, only 100 particles are
able to get through the media. A 1.2%
improvement in efficiency is actually
a 13 times improvement over
traditional filtration.

Practices that drive


productivity
Similar to its approach to driving
innovation in filter media, Cummins
established key factors that help
mines realise maintenance cost
savings that extend beyond filter
changes. Since filters help remove
contaminants from air and fluids,
additional cost savings can be
achieved by reducing those
contaminants even before they reach
the filters.
Fuel contamination is a common
Figure 3. HHP particle rentention testing results. occurrence at a mine site. Injectors,
pumps and just about every other
surface is susceptible to the damage
caused by dirty fuel. Not only do
contaminants enter the fuel during
refuelling procedures, they also enter
during bulk oil refining and
transportation. Global fuel analysis
demonstrates that fuel contamination
levels have doubled over the past
several years. In a single gallon (3.8 l)
of fuel, the average contamination
level is over 18 million particles
greater than 4 μm.
The fuel supply, which includes
the processing, transportation and
long-term storage of diesel fuel, is a
critical stage that can lead to
contamination and degradation of
Figure 4. Anglo American coal mine in Brazil. the fuel. Onsite storage tanks can

58 | World Coal | June 2018


harbour thick, viscous fuel components, which can pose challenges in areas of limited space. Thus, filtration
expensive problems. Customers that apply nanofibre science reveals that improving efficiency, capacity and
filtration technologies to their onsite storage ensure that flow restriction simultaneously is not possible with
the fuel delivered to the equipment is both water-free traditional media.
and does not contain any contaminants. The Cummins Filtration created a new type of
downstream impact is the avoidance of sludge and proprietary, multi-layer synthetic media that allows
slime build-up that can accumulate on fuel filters filter performance to progress past the hurdles that
leading to premature plugging and reduced traditional media presents. Cummins Filtration first
performance. introduced this nanofibre media to achieve the optimum
A customer at a Peruvian copper mine wanted in filtration efficiency, capacity and cold flow ability.
increased productivity from a fleet of Hitachi shovels Using a scanning electron microscope reveals that
while increasing the protection to its installed dual nanofibres are somewhere between two-tenths of one
Cummins QSK50 engines.
Cummins worked with the
customer to identify suitable
upgrades that deliver savings
while minimising the costs

LESS DOWNTIME
involved.
In these extensive field tests,
Cummins identified a number of

IS MORE UPTIME
critical factors and control criteria
to achieve improved
performance. The different
systems on the equipment, with CleanScrape® Belt Cleaner
including air, fuel, lube, coolant
and hydraulics, were taken into
consideration together. This
holistic approach to smarter
maintenance management,
coupled with Cummins
innovative filtration technology,
realised increased productivity
with minimal investment.

Productivity
Productivity is often a result of a
well-oiled machine. Yet, some
machines lack systems that
increase filtration in common
lubricants.
Consider that contaminants
found in today’s lubricants are
generally measured in microns.
A micron, which is a metric
term, refers to 1 millionth of a
metre, or 39 millionths of an inch.
A human hair, which is in the LESS IS MORE WITH
range of 50 - 70 μm, is CLEANSCRAPE® BELT CLEANER.
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the most wear of vital – only one tensioner adjustment ever
components is in the 5 - 15 μm
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By increasing the size of the
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through the filter, but run into visit martin-eng.com
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® Registered trademark of Martin Engineering Company in the US and other select locations. © 2018 Martin Engineering
A GLOBAL FAMILY
Company. Additional information can be obtained at www.martin-eng.com/trademarks and www.martin-eng.com/patents.
micron and eight-tenths of one micron, whereas Sustainability
traditional synthetic fibres could be in the 5 - 20 μm dia.
size range. Proven capability through testing
Prior to the upfit of the new air filters in an Australia Its commitment to protecting and enhancing equipment
coal mine, the site requirement for air filter changes was performance means Cummins Filtration is dedicated to
250 hr, resulting in the company’s use of over 190 filters creating sustainable products. Therefore, proprietary
per year. Once fitted with NanoForce air filters, the tests were developed in addition to industry standard
equipment sustained 1645 operating hours before testing to evaluate filtration. Beta ratio is an industry
requiring the air filters to be changed. Considering safe measure of particles of contamination introduced to the
operating margins, the site released a newly revised filter to the number of particles of contamination that
service interval of 1000 hr that resulted in a reduction of pass through the filter. The beta ratio gives us a true
annual filter use from 190 filters to 48 filters. A 75% indication of a filter’s efficiency for a given size particle.
reduction in filter services (from 24 to six) and The NanoForce media used in Cummins air cleaners
maintenance hours (from 48 to 12) was also achieved and the NanoNet media used in fluid filtration has been
due to the lengthened change intervals. tested and proven in controlled laboratories using ISO
A global mining customer requested support to 5011 and proprietary test methods to ensure an optimum
reduce operating and maintenance costs while balance of engine protection, performance and life.
increasing production. The customer selected a coal
mine in Australia with 16 Komatsu 830E haul trucks Connectivity ensures uptime
powered by Cummins QSK60 engines as one of three In this digital age, some miners are finding even greater
demonstration sites for a global pilot. savings by turning to electronic solutions to make
A fuel and site assessment was conducted jointly on smarter maintenance choices. Recently released Cummins
the operation and opportunities were identified to FleetguardFIT™ – Filtration Intelligence Technology –
improve site bulk filtration and specific equipment revolutionises conventional maintenance by enabling the
filtration upgrades. The customer implemented key decision makers to better predict downtime,
Cummins NanoForce air filters, NanoNet fuel filters, synchronise service events and optimise maintenance
improved oil filtration rotors for Eliminator units, long spend.
life coolant filters, and fuel tank vent filtration FleetguardFIT is a real time filtration monitoring
upgrades. system that provides full visibility to filter (fuel, lube and
Service intervals on the truck fleet were extended air) and oil life enabling proactive problem detection
from 500/1000 hr to 1000/2000 hr, delivering increased through the use of intelligent sensing and advanced data
productivity and operational savings with lower filter analytics. Cummins FleetguardFIT is part of Cummins
consumption, lower oil consumption and lower Electronic Service Tools that provide customers with
consumables. software, mobile applications and digital hardware to
The Peruvian copper mine customer implemented an provide real time connectivity, monitoring and service
extended interval package for the Hitachi shovels on support that optimise the performance and reliability of
their fleet. As a result, it achieved an extended air filter engines and fleets.
interval from 500 hr to 750 hr using NanoForce air At one Australian coal mine, a follow-up study was
filters. The switch to extended interval filters resulted in conducted a year later, jointly between the customer, the
a lower cost per hour or 45% savings. OEM and Cummins. This study found no negative
The customer was able to extend oil drain intervals impact on engine wear from the oil drain and service
from 250 - 350 hr while increasing the protection to the interval extensions. The results and improvements are
engine, using a Fleetguard remote centrifuge being replicated at the miner’s other operations around
supplementing the Fleetguard on-engine lube filters. the world.
The Fleetguard remote centrifuge helps in the The continuous work to optimise maintenance
elimination of large particles lowering the engine wear. practices while reducing costs is dependent on
The oil drain extension represented a savings of 28% in implementing innovative filtration products. Nanofibre
oil consumption. media has proven its way to become the filter media of
The customer was satisfied with the test, modified choice for miners looking to align and expand
the rest of the shovel fleet, and has begun using air maintenance intervals.
filters, centrifuge rotors and lube filters following the Johansen concluded: “The field testing has shown that
modifications made. new technology filters combined with a holistic approach
Filter optimisation lowers the TCO by providing to smarter maintenance management provides exceptional
holistic solutions that optimise productivity: enhancements and long-term sustainability. Some of these
„ Up to 13 times enhanced engine protection. trials have delivered results beyond our service interval
„ Up to three times longer service intervals. target and miners have seen the benefit of a significant
„ Up to 30% less annual commodity costs. reduction in total operational costs through increased
„ Up to 50% less annual maintenance hours. equipment availability and lower consumable costs.”

60 | World Coal | June 2018


Nathan Flesher (USA) and industry performance worldwide on truck and shovel output (as
measured by McKinsey’s MineLens Productivity Index, which
Eben van Niekerk (Australia), benchmarks mine performance across 250 mines worldwide). The
McKinsey & Company, describe investment required to cover data capture, analytics and
workforce training is in the range of US$1 - 3 million, which is low
a data analytics-based approach to relative to the impact typically achieved; initial benefits can be
improve the stability of coal mining captured within three months.
processes and raise productivity.
Coal mining’s productivity pain point:
lack of process stability

C oal is by far the highest volume mined commodity,


but to date, the coal industry has not taken a lead
in embracing the new approaches being made
possible by digital advances. Coal companies now
have large amounts of data generated on the mine site. There is an
important opportunity for the coal industry to benefit from the
ways that other parts of the mining industry are already using
It is well recognised in coal mining, as in mining overall, that
achieving stable operations is one of the industry’s greatest
challenges. This lack of stability is a major contributor to the way
that mining lags behind many other industries on measures of
productivity performance. Mines can have very good days when
all the systems are working together and there are no equipment
breakdowns, but they typically struggle to consistently perform at
this kind of data to make mining processes run more consistently this level (Figure 1).
with improved process stability and to boost output. The consequences of this lack of stability are familiar to coal
The gains from these approaches can be substantial. One large mine management. It causes inaccurate planning and suboptimal
opencast mine was able to raise its overall productivity by 25% scheduling, which – at the mine face – can lead to excessive
over a two year period, and now far exceeds top quartile mining drilled inventory that is liable to collapse, spontaneous

June 2018 | World Coal | 61


combustion of coal stockpiles and excess fleet capacity. Further Applying Weibull analysis to individual mines shows the
down the product delivery chain, unstable operations make it range of performances seen in the mining industry, as well as how
necessary to hold higher volumes of coal in stockpiles to ensure far mining lags behind other industries (Figure 2).
supply is always on hand, and to carry excess buffer supply at The performance comparisons between median, top quartile
wash plants. and 90th percentile mines point to how substantial the output
What can the coal mining industry do to increase process improvements could be. For example, raising a median mine’s
stability? The first step is to understand the nature of the process stability performance to the performance level of a mine
instability. McKinsey has undertaken a series of analyses using a at the 90th percentile would translate to a 27% output increase.
methodology, which is well established in the reliability It is important to underline here that this kind of performance
engineering field, called Weibull analysis (see sidebar). improvement is very much within these mines’ grasp. Median
mines have shown themselves to be capable of frequently having
days of operation where daily output is in the top quartile, but
they fall behind because they have not achieved it on a consistent
basis.
How could the process be made more stable? The basic
principle is to eliminate the excursions from the regular process
steps. Most mining companies are making good progress on
resolving major outages, such as longwall equipment failure. The
bigger challenge is capturing gains in the more routine steps of
the mine’s operation. Here, McKinsey’s experience working at a
large number of mines worldwide suggests that mines have made
major progress on availability and utilisation performance of their
equipment, but there are still substantial challenges around
operating rates. Achieving optimal rates under a mine’s particular
Figure 1. Typical daily mine production is unstable. conditions and avoiding upsets to the process stability of all the
interlocking steps of the mine’s operations are high priorities.

The way to increase process stability in


coal mining
How can coal mines identify and correct the places where the
process cycle is not functioning correctly and improve stability?
Proven approaches from manufacturing industries, called short
interval control analysis, can identify the excursions from the
regular process. This can then be followed up by action steps to
correct the problems.
The short interval control approach is based on breaking the
mine’s processes down into pieces of ‘standard work’, which
make up the mine’s overall operation. The mine’s real life
performance on these pieces of work is then compared to the
standard work model. This must be done in a detailed way which
Figure 2. Process stability comparison.
takes full account of particular conditions across the mine,
and expectations for rates should be tailored accordingly.
Where there are shortfalls from the model, the causes can
be investigated and steps taken to correct them. This kind
of approach is used widely in manufacturing industries
and is proven to generate performance improvements.
Mines typically start by analysing historic data, then move
to daily data, to shift data and, for mines at the leading
edge of performance improvement, analysing cycle by
cycle.
How has this been successfully deployed? Here are the
steps that mines have followed:

First
A fleet management system (FMS) – common at most
mines – provides the foundation mechanism to generate
Figure 3. Detailed fleet management opens the way to continuous data on location, payload, speed and often additional
improvement (haul cycle example). information such as engine temperature, tyre pressure,

62 | World Coal | June 2018


suspension load and throttle position. Even in mines without a Continuous improvement can also include reallocating
formal FMS, options are available to provide basic information to equipment and workers to tasks where they are best able to
a central location. This data is gathered over cellular or other function. For example, one mine temporarily reassigned an
radio connections in real time to the dispatch system. underperforming truck to less demanding tasks, such as flat
hauls, so that it does not slow down the overall production
Second process until the truck could be repaired. Targeting and
At a central dispatch location, this data is then processed and maintaining rates that can be sustained on a consistent basis is of
structured to allow its use in managing
operations. Many mines use this data in
real time for dispatch and historically for Bringing insights from reliability engineering to
analysis, but mines can capture bigger improve coal mining process stability
gains by fully exploiting the system’s The coal mining industry is not alone in needing to turn data into insights: many
capability, which allows more real time other industries have faced the same need to better understand their production
analytics and automation than is usually processes and improve stability. One approach that has been successfully applied is
taken advantage of. Weibull analysis (also known as life data analysis). Originally used for failure
analysis in reliability engineering, it is now being employed more widely. It is
Third well-suited to mining because daily throughput can be used as the input parameter
In parallel, a detailed theoretical model of to assess process stability.
the mine’s existing operations must be The methodology consists of plotting daily production (on the X axis) on a
built and broken down into a series of logarithmic scale against the cumulative probability of the mine achieving less than
process tasks so as to make short interval planned daily production (termed ‘unreliability’) on the Y axis (Figure 4). Once this
control possible. Figure 3 shows an is done, a best fit line (called the ‘demonstrated capacity line’) is drawn through the
example of the detailed way in which linear portion of daily data points. The slope of this demonstrated capacity line
load and haul cycles can be analysed and – referred to as ‘beta’ – indicates the mine’s process stability, and this metric can be
managed. used to identify improvement potential. The steeper the line, the more consistent
and, therefore, stable the process is.
Fourth The analysis identifies two potential improvement areas. The first is reliability
The operations of the mine are then losses (‘R’), indicating an increase in potential daily throughput levels if major
monitored on a real time basis to find out system failures are reduced. Examples of such failures include breakdown of
how the mine performs vs the standard primary equipment or key pieces of equipment such as a longwall miner or
work model, using short interval control dragline, or flooding of the mine. The second is efficiency losses (‘E’), indicating the
tracking analysis to identify the potential to improve output by consistently producing at a higher level – in other
excursions from the standard process. words, with better process stability – which moves the demonstrated capacity line
The key to achieving substantial towards the nameplate capacity line. Improvements include raising cutting rates in
performance improvements is that when underground coal mines, accelerating loading and hauling rates for trucks and
the mine supervisor identifies the shovels, and getting better equipment utilisation and higher quality maintenance.
excursions, he or she can address them
right away. If the data shows that Truck A
has taken the wrong road, then steps are
immediately taken to get it back on the
correct route. Analysis of performance
across different time periods can also be
undertaken: if the analysis shows Truck B
is running slower than Truck C,
regardless of which worker is driving
over several days, it can be followed up
with a checkup on the maintenance state
of Truck B. Alternatively, if the data
shows that Truck B only runs slower
when driven by Driver X, Driver X can
be assigned to additional training so that
he learns to safely drive faster.

Fifth
Using this approach, it is possible for a
mine to continuously work on improving Figure 4. Using Weibull analysis identifies losses and points to ways to improve
its performance, so that cycle times performance.
converge to the planned, ideal time.

June 2018 | World Coal | 63


paramount importance: interruptions from outages caused by capacity to be able to use them. Supervisors must not already be
going too fast will upset the process stability of all the overwhelmed in their tasks, and must have the skills to discuss
interlocking steps of the mine’s operation as badly as going too and improve performance with frontline operators. The key to
slowly. success here is well organised training and supervision, and
planning a programme of incremental and continuous
Sixth performance improvements so the supervisors can properly
Successful mines typically back up these initiatives by building a learn the new approaches.
mentality of continuous performance improvement across the Thirdly, successful mines create a mindset from the beginning
workforce. They do this by training programmes and design of that the purpose of the analysis is to help capture performance
remuneration plans to create incentives for the workforce improvements on a regular basis, and they do not let the analysis
collectively and individually to constantly pursue continuous simply get used to justify reasons for poor performance. Again,
improvement. Here, there are many parallels with how the successful approach is best underpinned by well-organised
workforces in manufacturing plants can be managed and training and supervision.
incentivised, and the same kinds of approaches employed. Where mines have implemented this approach, they have
seen significant performance improvement. As noted, one large
Lessons learned and ways to maximise opencast mine was able to raise its overall productivity by 25%
gains over a two year period. Its truck and shovel outputs are now
It is important to stress that the primary objective of the FMS is 18% and 15% respectively, above top quartile mining industry
to actively manage the mine’s operations, and that successful performance worldwide, and the comparison to median level
mines invest a significant amount of time in carefully defining performance is even more impressive, surpassing median level
the tasks that constitute the mine’s overall process. At many performance by 43% and 54% respectively.
mines, the FMS is not used to its full power – for example, if its These types of programmes typically follow a S-curve pattern
automatic dispatch capability has been switched off – or if of gains: an initial round of performance gains is captured within
auxiliary sources of information are not integrated – for example, 2 - 3 months, with a much more substantial set of gains captured
from equipment health monitoring or eye gaze tracking. The full over a period of 6 - 18 months as the mine supervisors and
power of the site data is only realised by closely integrating all of management learn how to deploy the analysis and start to build
these systems and feeding the insights back to operators and a mentality of continuous improvement across the mine
frontline supervisors to adjust operations in real time. workforce. The rate of gains then slows, which makes necessary
There are three major pitfalls that coal mine operators must a new round of performance improvement idea generation,
avoid if they want to capture the greatest potential benefits. The prioritisation and implementation.
first is to accept from the outset that the insights generated by the Coal prices may currently be on an upward trajectory, but as
data collection and analysis must be put to work: buying the coal CEOs know only too well, coal markets are inherently
equipment is just the first step and is not going to solve a mine’s volatile as coal suffers the whiplash effects of oil and gas prices
productivity problems. and emerging market demand growth for steel. That is when the
Secondly, mine supervisors who are going to use the data and kinds of gains provided by the approaches described in this
analysis outputs must truly have access to them, and have the article could be all the more valuable.

Advertiser’s Index
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Coaltrans Conferences 50 Sandvik Mining OBC
Cummins OFC, 45 Somerset Coal International 21
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Geometrica, Inc. IFC WIRTGEN GmbH 15
Global Mining Review 4 World Coal 57
Jennmar Corp. IBC

64 | World Coal | June 2018


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