European Coal Exploitation TechnologiesState of the Art and RTD Needs
Industrial Technologies 201219-21 June 2012
Concert Hall, Aarhus, Denmark
presented byFranco Cozzani – Deputy Head of Unit, EC Research Fund for Coal and Steel
on behalf ofJürgen Czwalinna – Chair, Euracoal Technical Research Committee
Aarhus 10-21 June 2012 - Figure 2
EU coal production and imports, 2010 (Mt)
Coal’s economic importance grew with enlargement
Aarhus 10-21 June 2012 - Figure 3
Power generation in selected EU countries, 2008
source: Eurostat - Annual Energy Statistics 2008 (data accessed 06/2010) (Peat and oil shale included in other/hydro)
Coal accounts for >50% in some Member States
Aarhus 10-21 June 2012 - Figure 4
0
1
2
3
4
5
gas
hydropower andother energies
nuclear
coal
3.4
4.4
Forecast: EU Commission 2008 baseline scenario
million GWh
oil
29%35%
4.1
35%
2008 2020 2030
Share of coal based electricity generation in the EU-27 could even rise
Power generation in EU 27
Aarhus 10-21 June 2012 - Figure 5
World hard coal production 1990 – 2010
Source: VDKI
Aarhus 10-21 June 2012 - Figure 6
Admittedly European deposits are more challenging than elsewhere in the world (deep, hot, laterally extended workplaces)
However, thanks to RFCS funded research the European Mining industry and related technology suppliers master these challenges and
As a consequence European mining technology has a world leading position – something research politicies are repeatedly calling for with the Framework Programmes!
And inevitably, the geological situation worldwide is developing into a similar direction, i.e others will face the same problems!
Assists in application of safe and environmentally friendly coal production and use in emerging countries like China and India
European coal mining situation – problem or chance?
Aarhus 10-21 June 2012 - Figure 7
3D-modelling now standard for mine planning and support management
Significant safety and productivity improvements
less roof falls, less downtimes, simplified support, record production)
Increased productivity and safety in the face - roadway junction
New automated, universal 3D-modelling tools Support management systems (SMS) SMS logical tree covering all underground coal
mine types (arched, rectangular, multi-slice)
Benefit
State of the art - PROSAFECOAL
SMS
Aarhus 10-21 June 2012 - Figure 8
Advanced drivage and intelligent roadheading systems
Increased lifetime
Reduced number of failures and downtimes
Increased driving efficiency
Increased precision of roadway profile cut
Increased work safety
Cost reduction
“Intelligent”, fully automated, self- controlled system for road headers
Applicable to a variety of specimen, manufactured by several companies in different countries
Benefit
State of the art - ADRIS
Aarhus 10-21 June 2012 - Figure 9
Optimization and automation of longwall and drivage equipment
Automated shearer loader 3D-modelling of cutting drums drum design analysis software Machinery monitoring and visualization system Maintainability assessment software package
Performance nearly doubled Shearer efficiency improved by 60% Maintenance and repair effort significantly reduced Cutting tool abrasion reduced Downtime reduction & machine lifetime extended Time and money savings at drum design and testing
Benefit
State of the art - NEMAEQ
Aarhus 10-21 June 2012 - Figure 10
Three driving forces for R&D effort
Geology
Enhancing performance efficiency & reliability
Intelligent & sustainable post- mining activities
Aarhus 10-21 June 2012 - Figure 11
Growing depths causes
Higher temperature mine climate ventilation & air conditioning issues Higher rock pressure rock mechanic challenges & support issues Higher risk of rock and gas outbursts Need for more precise geological information
Longer distances cause
Safety & rescue issues Transportation issues
1) Geology
Aarhus 10-21 June 2012 - Figure 12
by
Higher
Performance
Efficiency
Reliability
Automation
Condition monitoring
Sensors
System optimisation
Improved exploitation of existing machinesthrough higher “intelligence” and system integration
Open and compatible monitoring and automation systemsinstead of individual solutions
2) Performance, efficiency & reliability
Aarhus 10-21 June 2012 - Figure 13
Obtaining knowledge of the status of old mine workings by improvements in geophysical analysis
Long- term stability and behaviour of mine workings
Energy- efficient long- term post- mining activities (pumping, monitoring, …
Environmentally friendly mine closure and brownfield recultivation
Pumped- storage hydroelecricity or compressed- air power storage in shafts, mineworkings or spoil heaps – to balance eratic wind power generation
Efficient use of CH4 vented from abandoned shafts and mines
Investigation of sites for CO2 storage in coal basins
Mastering the mining legacy
Sustainable and smart follow- up use
3) Intelligent and sustainable post mining activities
Thank you for your attention
Industrial Technologies 201219-21 June 2012
Concert Hall, Aarhus, Denmark
presented byFranco Cozzani – Deputy Head of Unit, EC Research Fund for Coal and Steel
on behalf ofJürgen Czwalinna – Chair, Euracoal Technical Research Committee
Aarhus 10-21 June 2012 - Figure 15
Arguments for indigenous coal productionand respective RTD
Coal represents 80 % of EU fossil fuel reserves;
Security of energy supply for citizens through reduction of reliance on imports;
Coal mining and value chain create wealth in the EU;
EU’s coal industry is leading in health and safety and environmental protection;
Base for mining technology development and transfer
Aarhus 10-21 June 2012 - Figure 16
RFCS and FP7- different but complementary
Different origin of assets
RFCS
– Budgetwise „Dwarf against FP Goliath“
– Incremental R&D, application orientated
– Industry driven
– Rapid implementation of results
FP
– Disruptive breakthrough innovations
– Wide scope of themes
– Broad range of funding instruments (e.g. IP, CSA, NoE, …)
Aarhus 10-21 June 2012 - Figure 17
Coal related funding topics in FP 7
NMP-2008-4.0-2: Catalysts and sustainable processes to produce liquid fuels from coal and natural gas
ENERGY.2011.6.1-1: Optimisation of IGCC technologies for use with high ash content coal
Topic ENERGY.2008.6.1.4: Advanced Gas Turbines for Solid Fuel Gasification Processes
Topic ENERGY.2007.6.1.1: Solid fuel gasification development – improvement of gasifier technologies
NMP-2012.4.1-1:New environmentally friendly approaches in minerals processing (expected)
Aarhus 10-21 June 2012 - Figure 18
Common Issues with an international dimension:
1. Information deficiencies and poor situational awareness
2. Poor communicatios infrastructure resilience
3. Location and status of workforce
4. Delays in rescue initiation
5. Secondary explosion risks
6. Impacts of heat and humidity
How do we safely increase the ´penetration distance`envelope limitations imposed on rescuers due to heat and humidity?
How do we access inbye refuges in severe conditions?
What are the respective roles for hydration, active-passive cooling and core body temperature monitoring?
How do we assess secondary explosion risk and possible ´windows of opportunity`in order to commit rescue teams?
How do we advance the state of escape respiratory protection, exploiting the best features of SCSRs and FSRs?
EGRESS issues and strategies in the case of ‘incidents’ (safe havens, personal physical conditions of ‘evacuees’ with regard to mine climate and longer distances
advanced sensors for fire detection and ‘control’ ( conveyors, spontaneous combustion
Safety, rescue & mine emergency support
Aarhus 10-21 June 2012 - Figure 19
Safe & efficient sublevel caving through a monitoring and control system
Based on results of several RFCS (and ECSC) projects (e.g. EPCWCMS, RAINOW)
Environmental control, CH4 and CO monitoring, ventilation control, safety interlocks
High speed tx to surface, UCR-AV, remote controls, Digicom, new cabling, bluetooth
Safe and flexible operation
Suited to the particular requirements in sublevel caving mine types (complex ventilation system, single entry faces, multiple levels, frequent changes and re-configurations)
Applicable and promoted outside Europe
DIGICOMUCR
Inputs/OutputsInputs/Outputs
Inputs/OutputsInputs/Outputs
TO SURFACE PC
BUS 1
BUS 8
MASTER STATION• Power supply• Local data display• Data gateway to surface• Voice on IP
VOICE AMPLIFIERS• Speech communication• Sound alarm and warning signals
UCR
UCR
UCR
FIELD BUS• Power supply to sensors• Voice & data transmission• Hardware emergency stop
FIELD CONTROL UNITS• Input/output controller• Local data display (optional)• Hardware emergency stop
DIGICOM
DIGICOM
Benefit
State of the art - RELIA
Aarhus 10-21 June 2012 - Figure 20
Improving performance, reliability, safety and environmental aspects of mining transport systems
Software tools for designers and users, improving safety in underground mine transportation systems
“Knowledge repository” on internet platform including design guidelines, safety criteria, legal acts, regulations, standards and manufacturer’s documentation
More efficient design process
Improved quality of transportation route designs
Means of transport and route configurations are better selected
Improved work safety due to minimized accident probability
Benefit
State of the art - Mintos