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