methane Archives - International Mining

Caterpillar Inc says Jastrzębska Spółka Węglowa SA (JSW), the largest producer of high-quality hard coking coal in the European Union, has selected Cat dealer Eneria Poland to supply an integrated cogeneration system at its Knurów-Szczygłowice coal mine in southern Poland.

Commissioned in June, the system uses coal mine methane (CMM) to produce up to 12 MW of power and 12 MW of thermal energy. The electricity is used to supply power for conveyors, compressors, coal processing, mine ventilation systems, and other operations, Cat says. The captured thermal energy is processed through heat exchangers to maintain the proper temperature in the mining workspace.

Designed, installed and commissioned by Eneria Poland, the system is anchored by three Cat CG260-16 generator sets capable of operating on gas from the mine with methane content ranging from 40-70%. Eneria Poland will also provide ongoing support for the system through a three-year customer value agreement, according to Cat.

Andrzej Szymała, Chief Investment Engineer at the Knurów-Szczygłowice mine, said: “Safeguarding the health of our employees and minimising the environmental impact of our operations on neighbouring communities are key pillars of our corporate social responsibility strategy.

“The cogeneration system designed by Eneria Poland for the Knurów-Szczygłowice mine will reduce methane emissions and improve the safety and comfort of our employees’ working environment while providing electricity and heat through innovations that improve our bottom line.”

The cogeneration system at the Knurów-Szczygłowice mine is the latest in a series of initiatives by JSW to improve its environmental footprint. The coal miner is currently building a facility to convert by-products of the coking process into critical industrial materials, including lightweight, durable carbon fibres, carbon adsorbents for purifying liquids and gases, and carbon nanostructures used in lithium-ion batteries and numerous other applications, according to Cat.

JSW employs other equipment supplied by Caterpillar in its operations, including Cat plow systems for longwall mining at its Borynia-Zofiówka and Pniówek mines.

Sven Buehler, Territory Manager for Gas Product Sales at Caterpillar, said: “JSW has made a demonstrated commitment to sustainability that has delivered tremendously positive results for the communities where it operates as well as its employees. The system will support the expansion of JSW’s environmental initiatives and further improve the quality of life for its many stakeholders.”

Caterpillar and its dealer network offer power systems for mines ranging from the largest surface and underground operations down to the smallest quarries, it says. The solutions are engineered to keep operations running reliably and efficiently while protecting the safety of crew members.

A trial of pressure sensors to remove power from the longwall face and the expedition of longwall automation are two of the areas Anglo American is hoping will improve safety at its underground coal mines in Australia, following a methane ignition incident that occurred at its Grosvenor mine, in Queensland, on May 6.

The company began to brief its Queensland-based workforce on the progress of its expert investigation into the methane ignition last week, with Tyler Mitchelson, CEO of Anglo American’s Metallurgical Coal business, saying the company’s focus continues to be on providing ongoing support for the five personnel injured during the incident, four of whom have now been released from hospital, while the fifth remains in a stable condition.

While investigations were progressing and may take some time to formally conclude, Mitchelson said the company would continue to review controls in place across its underground mines as any technical or other findings become available from the investigations.

“We know from our expert analysis that there was a significant and unusual overpressure event on May 6, where a large amount of methane was released into the longwall area, and, seconds later, a brief ignition occurred,” he said. “At this stage, the ignition source has not been conclusively determined and testing continues.

“We also know that in the hours leading up to the incident, there were no non-compliant methane readings in the longwall area.”

Since 2016, the company has invested around A$230 million ($161 million) on gas drainage and gas management activities at the Grosvenor Mine, according to Mitchelson.

“Despite this investment, and extensive controls in place to prevent an underground ignition of methane, we need to further improve our controls to respond to the specific combination of factors of an unusual and large overpressure event in the vicinity of the longwall with a potential ignition source,” he said.

“By drawing on technical learnings and information as it becomes available from the investigations, we have begun a review of our site methane management controls, which includes assessing additional technology options and applying any further improvements across our underground mines.”

As a first step, the company is beginning a pilot study at its Moranbah North mine to assess the use of pressure sensors to remove power from the longwall face as an additional control if a significant overpressure event occurs, he said.

“Whilst pressure sensors are already in use today, across the industry they have not been integrated for this particular purpose,” Mitchelson explained. “Learnings from the pilot will be incorporated across our underground mines and shared with industry.”

Mitchelson said the company has already invested “considerably” in progressing the automation of its longwall equipment, and “expediting this work will also be part of the solution to reducing risks in underground mining”.

Among more recent elements of longwall automation the company has pursued is the ability to operate its longwall shear from an above-ground remote operating centre at the Grosvenor mine.

The company added: “As the largest underground coal miner in Queensland, Anglo American has been at the forefront of technical innovation and has invested significantly in technology to improve safety in its mines, including additional methane detection equipment above and beyond regulatory requirements, digitisation to improve underground communication, and automation of equipment.

“We will continue to prioritise this work.”

Mitchelson said it was unacceptable five personnel were seriously injured on May 6 and that the company would ensure all relevant learnings from investigations underway and the Board of Inquiry are incorporated across its business.

“We continue to support our injured colleagues and their families as they continue their recovery,” he said.

He reiterated that safety comes first, and mining would not resume until it was safe to do so.

While mining activities have been suspended, the Grosvenor workforce has continued to be supported on full pay since the incident to enable the company to work through its future plans, step by step.

Cat cogeneration system helps JSW power Knurów-Szczygłowice coal mine

Anglo American to test pressure sensor tech following Grosvenor methane ignition incident