Tag Archives: coal mining

CONSOL Energy wins NMA plaudits for safety initiatives

Coal technology, Mine operation news, Mining safety, Steel and iron ore, , , , , ,

CONSOL Energy Inc has become the 10th mining company to be fully certified under the National Mining Association (NMA)’s CORESafety® initiative.

The certification, which aims for zero fatalities and a 50% reduction in rate of injuries within five years, is the culmination of a multi-step, multi-year process that requires dedication at every level of an organisation, according to Rich Nolan, NMA President and CEO.

“Safety is an area where complacency has no place and the CORESafety framework is an important tool to drive constant vigilance and awareness,” he said.

Jimmy Brock, President and CEO of CONSOL Energy, said it was a “tremendous” honour and testament to the work and dedication of its miners, to receive the certification.

“Safety is more than a core value at CONSOL Energy, it is a condition of employment and a way of life,” he said. “Reaching this milestone demonstrates our employees’ commitment to safety and our focus on continually integrating best-practices while embracing technology and innovation, as we strive towards an incident-free workplace.”

For over 10 years, CONSOL has operated under an “Absolute ZERO value system” based on the premise that having zero accidents is normal and that any accident is uncharacteristic and inconsistent with company values, according to the NMA.

Consol owns and operates the Pennsylvania Mining Complex and the Baltimore Marine Terminal, in addition to controlling over 1 billion tons (907 Mt) of undeveloped reserves, according to its website.

CORESafety’s approach to safety and health emphasises accident prevention and uses a risk-based management system anchored in leadership, management and assurance, the NMA says. The framework is designed to go beyond what is required by regulations, focusing on a goal of continuous improvement. Its objective is zero fatalities and a 50% reduction in mining’s injury rate within five years of implementation. In 2017, companies participating in the CORESafety system closed the year with zero fatalities across US operations.

CORESafety is a risk-based mine safety and health management system developed by NMA. The NMA said: “CORESafety participants agree to: commit to the CORESafety system; implement a functionally-equivalent version of the CORESafety safety and health management system; submit to NMA annual self-assessments of progress toward implementation of the CORESafety safety and health management system; and, if the company elects to become or maintain CORESafety certification, complete a thorough third-party assessment of its safety and health management system to verify that it is functionally equivalent to CORESafety and submit the assessment report to NMA.”

M&S Insurance and Safety Consultants Inc conducted the independent audit in September 2019.

Strata enhances North America roof support, ventilation offering with Burrell Mining pact

Coal technology, Environmental, Mine ventilation, Mining equipment, Mining services, Power supply for mines, , , , , , , , ,

Strata Worldwide says it has signed a distribution agreement with Burrell Mining International for the promotion and distribution of the Burrell CAN® and Burrell Omega Block coal mining products to the North America mining market.

These products will be added to Strata’s line of secondary roof supports and ventilation product offerings, available immediately, the company said.

The CAN is a “yieldable secondary roof support” made from a confined core of cementitious composite encased in a cylindrical steel canister, Strata said. “When installed correctly, the CAN has never failed. Its flexible design can be engineered to meet mine-specific load conditions regardless of adverse roof or floor conditions, while the smooth steel skin of the CAN also improves ventilation by reducing air resistance in the mine entry,” the company added.

Omega Blocks for ventilation are specifically formulated building block, three times the size of regular concrete blocks, but significantly lighter in weight to help reduce labour and the installation process, according to Strata. The Omega Blocks are composed of non-toxic, incombustible materials that are fire resistant and impermeable to air. The blocks are fully MSHA approved and ideal for quick construction of underground ventilation stoppings, Strata said.

Bob Weil, President & CEO of Burrell Mining International, said: “Burrell’s reputation as an industry innovator with a history of quality products and excellent customer service makes our partnership with Strata Worldwide a great strategic fit. Working together, we can provide customers throughout North America with efficient and safer secondary roof support products for the mining industry.”

Mike Berube, President and CEO at Strata Worldwide, said: “We are very excited to enter this agreement with Burrell Mining. They are a premier supplier of secondary roof support for coal mining and have an excellent reputation in the industry. The CAN will be a strong addition to Strata’s line of roof support systems and with this agreement we will offer the most complete portfolio of roof support products on the market.”

Strata Worldwide has grown from a company focused on roof supports in underground coal operations, to service mines of all types, all sizes, all commodities and all locations. It says it develops advanced safety solutions for mines all over the world.

Burrell Mining International, meanwhile, is a wholly owned subsidiary of Burrell Group Inc, a family-owned company with business interests in mining products, insurance, real estate and technology. Burrell Mining International operates three plants in the US and two in Australia.

Multotec’s SX10 low density spiral opens up coal separation options

Coal technology, Mineral processing, Mining equipment, Mining services, Steel and iron ore, , , , , , , ,

Multotec Gravity Division says its new SX10 low density spiral further extends the benefits this innovation offers in fine coal beneficiation, with the technology able to produce both thermal and coking coal on one spiral.

The Multotec SX10 low density spiral’s reduced cut point of 1.55 g/cm3 delivers considerable advantages over the cut points of between 1.6 and 1.8 g/cm3 typically achieved in the coal industry today, according to Multotec Technology Manager, Faan Bornman.

The result, he says, is cleaner coal with less waste being achieved in a single stage. This helps achieve savings on capital costs as no further spiral stages are required for cleaning down the line.

“The approach taken with the Multotec SX10 spiral is to remove the gangue, or mineral containing particles, from the trough in two off-takes,” Multotec said.

The first off-take removes ash, opening up the available separation surface of the spiral and allowing the remaining material to separate more easily. This separates clean coal from less-clean coal.

“The low density spiral is essentially a primary and secondary stage on one centre column,” Bornman said. “Rejects are discarded into the centre column and the remaining product is re-pulped before being sent to a secondary off-take.”

Facilitating the two off-takes is a longer spiral on the Multotec SX10. This increases the residence time and gives the particles sufficient time to separate, according to the company.

Depending on the setting of the product box splitters, this new spiral has the ability to produce both thermal coal and coking coal on one spiral, Multotec claimed. Bornman said this was proven through test work done in the US where the two offtakes enable the removal of most of the gangue leaving a middlings and cleaner coal products to be collected at the dart splitters.

Experimental work was carried out using coal from two South Africa collieries as well as doing site test work in the US. Promising results were obtained leading to the first order for Multotec SX10 spirals from a North America-based mine, it said.

Solar power up and floating at former coal mine in Anhui, China

Coal technology, Environmental, Mining services, Power supply for mines, , , , , , , ,

China state-owned developer CECEP has completed a 70 MWp floating solar plant on a former coal mining area, in Anhui Province, China, following tests and monitoring, according to the company that supplied the plant.

France-based Ciel & Terre said the floating photovoltaic (PV) plant will mainly aim to improve the energy structure in the province and quality of the environment on site. Constructor China Energy Conservation Solar Technology Co and the engineering procurement and construction contractor China Energy Engineering Group Shanxi Electric Power Design Institute Co contributed to the build, the biggest floating solar plant in the world.

To connect the 70 MWp floating PV power generation project to the national grid, a brand new 18-km-long 110 V overhead line was built to optimise the transport of electricity.

Ciel & Terre said: “Behind the installation of this complex is the will to improve the energy structure of Anhui Province as well as the ecological environment quality of the Lianghuai mining subsidence area.

“In the meantime, the initiative enables the promotion of the development of the ‘floatovoltaic’ technology, which also preserves water bodies. It prevents them from algae proliferation and oxidation, and even conserves water sources by reducing evaporation.”

The floating solar plant covers an area of 1.4 km² and is expected to generate up to 77,693 MWh in its first year, according to Ciel & Terre. This represents the electricity consumption of some 20,910 households.

“Within 25 years, the solar farm should generate around 1.94 million MWh,” the company said, saying the project adds to another 32 MWp GCL floating PV plant it supplied in Anhui.

Headed by CECEP, the complex was built using the tried-and-tested Hydrelio® technology designed by Ciel & Terre.
Ciel & Terre said: “CECEP chose Ciel & Terre for this major project for three complementary main reasons: the 13-year experience of the company in the field, the broad portfolio of 140 projects worldwide and the characteristic reliability and bankability of the Hydrelio system.”

Through this technical system, the company contributed to the Chinese National Energy Agency’s aim to “bolster energy infrastructure and environmental quality”, Ciel & Terre said.

Central inverters integrating medium voltage transformers have been used on this project – they stand on the water and not on the banks – while concrete poles support the electrical installation.

The anchorage system was designed and installed under the supervision of Ciel & Terre China, a subsidiary of the French company. Overall, 1,500 helical anchors were used for the project and buried from 8-m to 15 m-depth to fit the configuration of the site.

Robotics and automation projects among latest METS Ignited funding recipients

Automation, Bulk handling, Careers in mining, Coal technology, Environmental, Equipment maintenance, IoT, Mineral exploration, Mineral processing, Mining equipment, Mining finance, Mining industry recognition, Mining maintenance, Mining safety, Mining services, Mining software, Mining techniques, Precious metals, Steel and iron ore, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , , ,

Australia’s Minister for Industry, Science and Technology, Karen Andrews, has announced seven mining supply businesses as the recipients of A$4.1 million ($2.9 million) in innovation funding under the METS Ignited Collaborative Project Funds.

The recipients of the funding will now be able to launch eight collaborative industry projects delivering highly-advanced solutions to a variety of mining challenges and contribute to the growth and capability of the METS sector, according to METS Ignited.

This funding is part of a four-year, A$15.6 million commitment made by the Australian Government to incentivise collaboration and address METS sector priorities. The funding established the METS Ignited Collaborative Project Funds, which support industry-led projects to improve the productivity, competitiveness and innovative capacity in the METS sector.

Today’s announcement at Mineral Technologies, on the Gold Coast of Australia, is the third tranche of funding. METS Ignited received 26 grant applications and has awarded the funds to businesses specialising largely in robotics and automation, data analytics, data platforms, Internet of Things and business and professional services. The recipients are: Mineral Technologies, Premron, Austmine, Roobuck, Process IQ, AMOG (x2) and Magotteaux.

Acting CEO of METS Ignited, Ian Dover, said: “Active collaboration across the ecosystem is core to accelerating commercialisation of innovation and has been lacking in the METS and mining sector, where historically relationships have been in the main transactional.”

“Facilitating such innovation is part of the mandate for METS Ignited. It’s vital we support the application of influential future technologies across the METS sector and maintain Australia’s competitiveness.”

Recipients of the Collaborative Project Funds are required to secure equal or greater investment from an industry partner. As a result, the total value of the eight projects is A$11 million.

The largest fund recipients were Queensland-based Mineral Technologies and Premron, awarded A$1 million each. Mineral Technologies’ automation of the Roy Hill Iron Ore beneficiation plant project automates the gravity separation spiral process used in the mine to optimise the concentration of lower-grade ore into higher value ore for export, METS Ignited said.

Roy Hill CEO, Barry Fitzgerald, said: “I am delighted the government is supporting our partnership with Mineral Technologies – a project that seeks to enhance the operational efficiency of our mine, delivering more high-grade product while reducing waste for the same operational cost.”

The automation of spiral control in the Roy Hill beneficiation plant will materially improve the concentration of ore into high value product for export, according to Roy Hill. More high-grade product and less waste will be produced for the same feed and processing cost, delivering value to both the environment and Roy Hill’s bottom line, the company said. Once proven effective at Roy Hill, the technology can be commercialised and rolled out at similar operations across the world.

“This innovation project will deliver a step-change improvement through real time control of our 720 spirals, enabling our processing plant to dynamically respond to the natural variability of the material it is treating,” Fitzgerald said.

Premron’s Continuous Haulage System (CHS) project, meanwhile, will revolutionise coal mining in underground mines, according to METS Ignited. It eliminates the use of shuttle cars, used to take the coal cut from the wall of the mine to a transfer point further away in the mine (dead time). CHS will see the coal go straight to a conveyor belt and out of the mine.

Other projects that received funding in this round include: sensor technology to monitor the location of people and equipment underground; artificial intelligence technology to emulate the role of a grinding expert; automated sensor detection for oversized rocks; a predictive analytics tool that pinpoints the best time for equipment descaling; a METS career pathway programme; and a device to give more detailed information on the chemistry inside the grinding mill while it is operating.

METS Ignited said: “Collectively, the projects will benefit the mining sector by optimising the value chain, increasing productivity for mining and mineral processing, supporting and enhancing environmental management, and improving operational safety.”

The project fund recipients include:

Automation of the Roy Hill Iron Ore beneficiation plant

  • Recipient: Mineral Technologies
  • Partners: Roy Hill
  • Collaborative project funds: A$1 million
  • Industry investment: A$1 million
  • This project automates the gravity separation spiral process used in the mine to optimise the concentration of lower-grade ore into higher value ore for export.

CHS

  • Recipient: Premron
  • Partners: Gauley Robertson Australia, Kestrel coal mine
  • Collaborative project funds: A$1 million
  • Industry investment: A$1.13 million
  • Continuous haulage will revolutionise coal mining in underground mines. It eliminates the use of shuttle cars, which are used to take the coal cut from the wall of the mine to a transfer point further away in the mine. CHS will see the coal go straight onto a conveyor belt and out of the mine.

Austmine METS career Pathway Program

  • Recipient: Austmine
  • Collaborative Project Funds: A$240,000
  • Industry investment: A$1.76 million
  • This project places university students as interns in METS companies around Australia, increasing the interest level and uptake of graduates into the METS sector

The OVERwatch Platform

  • Recipient: Roobuck
  • Partners: Redpine Signals, Northparkes Mines, University of Wollongong
  • Collaborative project funds: A$600,000
  • Industry investment: A$1.5 million
  • This project develops sensors and software to track the location of people and machinery working in underground mines and ensure that collisions are avoided. This is a complex project as there is limited communication options underground (eg no Wi-Fi).

Remote grinding optimisation and support centre

  • Recipient: ProcessIQ
  • Partners: Orway Mineral Consultants, Jamieson Consulting, Curtin University
  • Collaborative Project Funds: A$620,000
  • Industry investment: A$780,000
  • This project enables grinding experts to interact directly and in real time with grinding circuits on remote mine sites to ensure they are operating at their most productive levels. The project will develop automated artificial intelligence software to emulate the experts as there is very limited supply of this specialist expertise, leading to increased processing efficiency globally.

Automated Oversize Detection

  • Recipient: AMOG
  • Partners: Omniflex
  • Collaborative Project Funds: A$150,000
  • Industry investment: A$220,000
  • This project involves developing sensor equipment that alerts the mine when rocks are too big to process through the crushing and grinding equipment. Blockages in the crushing and grinding circuits are costly and time consuming. Haulage trucks with oversized rocks will be diverted to a separate location in the mine, which avoids stoppages.

Smooth Operator leach circuit process optimisation

  • Recipient: AMOG
  • Partners: Lithium Consultants
  • Collaborative Project Funds: A$220,000
  • Industry investment: A$220,000
  • This project involves developing a predictive analytics tool that allows copper and nickel mines to pinpoint when they should close equipment for descaling. Closing equipment too late or early is very costly. There is a very large global market for this product.

Commercialisation of pulp chemistry monitor for the mining industry

  • Recipient: Magotteaux
  • Partners: Hydrix, Manta Controls, Newcrest Mining
  • Collaborative Project Funds: A$250,000
  • Industry investment: A$310,000
  • This project involves developing a device to give more detailed information on the chemistry inside the grinding mill while it is operating. Grinding and flotation circuits use many chemical inputs in order to extract minerals from the ore. Getting the chemical balance right in the mill and the next stage of floatation is critical to removing as much of the valuable mineral as possible. The percentages of the yield vary between 85% and 95% and a 1% improvement in yield will deliver a very large financial benefit to the mine.

Sandvik and SUEK sign major mechanical cutting machine contract

Coal technology, Mine operation news, Mining equipment, Mining services, Steel and iron ore, , , , , , , ,

Sandvik Mining and Rock Technology is to supply SUEK (Sibirskaja Ugolnaja Energetitscheskaja Kompanija) with 12 mechanical cutting machines for various coal mines in Siberia, Russia, the mining OEM has confirmed.

SUEK is one of the world’s leading coal producers, the largest coal producer, supplier and exporter in Russia, as well as a leading heat and electricity producer in Siberia.

The recently signed order includes the delivery of 10 Sandvik MB670-1 Bolter Miners (pictured) and two Sandvik MH621 Roadheaders – with an option for another two Sandvik MH621 Roadheaders. The new machines will provide improved reliability and operating performance for the mines as well as provide a wide range of productivity features, Sandvik said.

Delivery of all machines is scheduled for the second half of 2019.

The Sandvik MB670-1 Bolter Miner is purpose-built for longwall coal mining. These wide-head continuous miners combine special design features for cutting, loading, ground support and face ventilation in a balanced machine with superior productivity and strong environmental, health and safety performance, according to Sandvik.

Meanwhile, the Sandvik MH621 Roadheaders are equipped with powerful, geometrically optimised cutter heads, designed to continuously excavate roadways, tunnels and other underground caverns without using explosives. These electro-hydraulic machines cause no harmful vibrations and are ideal for mining coal and other soft rock minerals, according to Sandvik.

Roman Tonyshev, Business Line Manager, Mechanical Cutting Division, Sandvik Mining and Rock Technology, said: “Sandvik was awarded the contract having delivered a good technical proposal to the customer, showing the ability to provide excellent technical solutions based on Sandvik’s vast experience in designing bolter miners and roadheaders in the area of mechanical cutting equipment.”