Transcript RFCS 2006 Results, Analysis and Consequences

European Coal Exploitation Technologies
State of the Art and RTD Needs
Industrial Technologies 2012
19-21 June 2012
Concert Hall, Aarhus, Denmark
presented by
Franco Cozzani – Deputy Head of Unit, EC Research Fund for Coal and Steel
on behalf of
Jürgen Czwalinna – Chair, Euracoal Technical Research Committee
EU coal production and imports, 2010 (Mt)
Coal’s economic importance grew with enlargement
Aarhus 10-21 June 2012 - Figure 2
Power generation in selected EU countries, 2008
Coal accounts for >50% in some Member States
source: Eurostat - Annual Energy Statistics 2008 (data accessed 06/2010) (Peat and oil shale included in other/hydro)
Aarhus 10-21 June 2012 - Figure 3
Power generation in EU 27
Share of coal based electricity generation in the EU-27 could even rise
5
million GWh
4
4.1
3
3.4
4.4
hydropower and
other energies
nuclear
2
gas
oil
1
29%
0
2008
Forecast: EU Commission 2008
baseline scenario
Aarhus 10-21 June 2012 - Figure 4
coal
35%
35%
2020
2030
World hard coal production 1990 – 2010
Source: VDKI
Aarhus 10-21 June 2012 - Figure 5
European coal mining situation – problem or chance?
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
Aarhus 10-21 June 2012 - Figure 6
State of the art - PROSAFECOAL
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
SMS
 3D-modelling now standard for mine planning and
support management
 Significant safety and productivity improvements
 less roof falls, less downtimes, simplified support,
record production)
Aarhus 10-21 June 2012 - Figure 7
State of the art - ADRIS
Advanced drivage and intelligent roadheading systems
 “Intelligent”, fully automated, self- controlled system for
road headers
 Applicable to a variety of specimen, manufactured by
several companies in different countries
Benefit
 Increased lifetime
 Reduced number of failures and downtimes
 Increased driving efficiency
 Increased precision of roadway profile cut
 Increased work safety
 Cost reduction
Aarhus 10-21 June 2012 - Figure 8
State of the art - NEMAEQ
Optimization and automation of longwall and drivage equipment
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Automated shearer loader
3D-modelling of cutting drums
drum design analysis software
Machinery monitoring and visualization system
Maintainability assessment software package
Benefit
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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
Aarhus 10-21 June 2012 - Figure 9
Three driving forces for R&D effort
Geology
Enhancing performance efficiency & reliability
Intelligent & sustainable post- mining activities
Aarhus 10-21 June 2012 - Figure 10
1) Geology
Growing depths causes
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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
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Safety & rescue issues
Transportation issues
Aarhus 10-21 June 2012 - Figure 11
2) Performance, efficiency & reliability
Automation
Higher
 Performance
 Efficiency
 Reliability
by
Condition
monitoring
Sensors
System
optimisation
Improved exploitation of existing machines
through higher “intelligence” and system integration
Open and compatible monitoring and automation systems
instead of individual solutions
Aarhus 10-21 June 2012 - Figure 12
3) Intelligent and sustainable post mining activities
Mastering the mining legacy
 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
Sustainable and smart follow- up use
 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
Aarhus 10-21 June 2012 - Figure 13
Thank you for your attention
Industrial Technologies 2012
19-21 June 2012
Concert Hall, Aarhus, Denmark
presented by
Franco Cozzani – Deputy Head of Unit, EC Research Fund for Coal and Steel
on behalf of
Jürgen Czwalinna – Chair, Euracoal Technical Research Committee
Arguments for indigenous coal production
and 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 15
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 16
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 17
Safety, rescue & mine emergency support
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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
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How do we safely increase the ´penetration distance`envelope limitations imposed on rescuers
due to heat and humidity?
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How do we access inbye refuges in severe conditions?
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What are the respective roles for hydration, active-passive cooling and core body temperature
monitoring?
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How do we assess secondary explosion risk and possible ´windows of opportunity`in order to
commit rescue teams?
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How do we advance the state of escape respiratory protection, exploiting the best features of
SCSRs and FSRs?
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EGRESS issues and strategies in the case of ‘incidents’ (safe havens, personal physical
conditions of ‘evacuees’ with regard to mine climate and longer distances
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advanced sensors for fire detection and ‘control’ ( conveyors, spontaneous combustion
Aarhus 10-21 June 2012 - Figure 18
State of the art - RELIA
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
Benefit
TO SURFACE PC
MASTER STATION
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Power supply
Local data display
Data gateway to surface
Voice on IP
VOICE AMPLIFIERS
• Speech communication
• Sound alarm and warning signals
 Safe and flexible operation
DIGICOM
DIGICOM
UCR
UCR
BUS 1
FIELD BUS
 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
Aarhus 10-21 June 2012 - Figure 19
• Power supply to sensors
• Voice & data transmission
• Hardware emergency stop
Inputs/Outputs
Inputs/Outputs
DIGICOM
UCR
UCR
Inputs/Outputs
Inputs/Outputs
FIELD CONTROL UNITS
• Input/output controller
• Local data display (optional)
• Hardware emergency stop
BUS 8
State of the art - Mintos
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
Benefit
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More efficient design process
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Improved quality of transportation route designs
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Means of transport and route configurations are better
selected
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Improved work safety due to minimized accident probability
Aarhus 10-21 June 2012 - Figure 20