ACARP ACARP ACARP ACARP
Coal Preparation

Impact of Sub Optimal Operation

Coal Preparation » Fine Coal

Published: July 16Project Number: C24039

Get ReportAuthor: Bruce Firth | BA Firth

The objective of this project was the 'Quantification the effects of sub-optimal operation' in a coal preparation plant. This was achieved by the analysis of particular operational issues and how they can affect the recovery of saleable coal.

Previous work in this area was piecemeal and focussed on particular issues. This has resulted in there being considerable variation in the approaches which makes comparative consideration difficult. It was decided that the conceptual framework and the outcomes from 'The Intelligent Plant' project would be employed to assist in conducting this project.

The starting position was the development of a language to describe the situation:

· Process element - unit operation in the plant;

· Measurement and symptoms - values, output from models;

· Health issues - unwanted operational situation;

· Root faults and actions - underlying problem and possible solution.

In this context, the health issues are also sub-optimal operation conditions.

While the entry mechanism into 'The Intelligent Plant' diagnostic system was via the symptoms/measurements, this project required the inversion of the system to allow entry via a health issue. The selection of a health issue, that is a sub-optimal event, allows symptoms to be identified. This required some commentary on discussing the difference. The level of the impact required the use of a model (termed 'Linkage Map') in this report. From this, comments on the potential root faults and actions can be made. It needs to be noted that the system was reviewed and updated.

The outcomes are:

· A template methodology to allow this type of analysis to be conducted on a particular coal preparation plant and mine site; and

· A number of case studies illustrating the use of the methodology and the outcomes from its application.

A total of 19 case studies were considered in this project. These were selected with consultation with the ACARP Coal Preparation Sub-Committee.

The analysis methodology used in all of the case studies can be summarised as:

· Development of a Linkage Map between the relevant variables via an appropriate model;

· Clear definition of the Sub-Optimal Operation (Health Issue);

· Identification of associated Symptoms and Measurements; and then

· Identification of the Root Faults and what Actions that potentially can be applied.

In all the cases, it was found that this methodology was capable of providing a summary of the situations on a consistent basis.

That is, the objective of the project has been achieved, hence it is recommended that a second stage project is supported.

The objective would be to modify the existing 'Intelligent Plant Diagnostic' System to allow access not only from a Symptom/Measurement entity, but also via a Health Issue (Sub-Optimal Operation) entity. Since the current System is now eight years old, it is also considered that the EXCEL worksheet is updated.

The outcome of the current project will allow an experienced metallurgist/process engineer to describe a sub-optimal operation in a consistent manner and permit estimates of the costs of the situation given a particular feed washability to the plant. The approach to overcome the situation can also be identified and a cost/benefit analysis constructed.

It needs to be recognised that some of Root Faults are due to undisciplined mining practices.

Underground

Health and safety, productivity and environment initiatives.

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C19024Establishing Ecologically Sustainable Mine Water Release Criteria In Seasonally Flowing Streams

Extreme rainfall conditions in the Fitzroy Catchment over an approxi...

C25030Coal Mine Open Pit Final Void Closure And Relinquishment - Addressing Uncertainty In Coal Mine Environmental Planning

This report addresses uncertainties faced by coal mine operators whe...

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27004Improving Coal Flotation With Oscillatory Air Supply

This report provides detailed information on coal flotation with os...

C25018Improving Solids Recovery And Moisture Reduction In Ultrafine Coal Dewatering

This report provides detailed information on fine coal dewatering in...

C27028Lab Froth Flotation Testing Guide With Coal Quality

Correct outcomes from laboratory froth flotation testing in coal bor...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL) - Phase 2 Demonstration In A Packed Bed Reactor

An alternative approach to high temperature oxidation of ventilation...

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC