mark elliott - ellton group

Informa Conveyor

Conference 2014

Mark Elliott

Case Study

Caledon Coal Cook Colliery

Main Conveyors Upgrade Project

Innovative Solutions in Energy, Mining and Materials Handling

Overview

Caledon are making a significant

investment in Cook Colliery:

New Longwall

CHPP Upgrade

New Mobile and other plant

Main Conveyors Upgrade


Overview

Currently bord and pillar operation Production 600,000 TPA CHPP 300 TPH

Expansion Project:

Longwall in Argo Seam Production 3.5 MTPA CHPP 500 TPH


Overview

Main Conveyors Upgrade:

CV01 - Stockpile Conveyor

CV02 - Drift Conveyor

CV03, CV04 & CV05 Main Trunks


Overview – The Client

Guangdong Rising Assets Management (GRAM)

(Chinese State Owned Investment Group)

Caledon Coal Pty Ltd

Caledon Resources

C.C. Pty Ltd

Blackwater Coal Pty Ltd


Overview - Cook Colliery

30km south of Blackwater, Queensland.

An underground mining operation

Produces both coking and thermal coal

Approx 80:20 coking : thermal split


Overview - Cook Colliery

There are two substantial seams Castor seam Depth of 130m to 350m

Argo seam Depth approx 15m to 20m below the Castor

seam.

Castor seam has been extensively mined Insight into what can be expected in the

lower Argo seam


Overview - Existing Elements

Existing Drift Head & Transfer



Existing Stack Out Conveyor


Ancient History


Overview - The Project

Design and Supply contract awarded: CV01, CV02, CV03, CV04, CV05 Mechanical, Structural, Power and Control Refurb and integration of ex Dartbrook

Subsequent Installation contract: Install surface lump sum incl civils Install underground on schedule of rates Miscellaneous mining heading completion


Overview – The Project

Design rate 2500 TPH Belt Width 1400 mm Equipment ex Dartbrook closure

CST drives (320 kW) Various Drive pulley assemblies Loop take up units

Assess, rework and integrate No compromise on performance targets


Overview - Design Challenges

Drift at 17 degrees incline CV02 Tail end concave curve

Existing layout at drift bottom Lift off / edge buckling / spillage

Belt run on issues across system Dewatering Assessing Dartbrook hardware Available timeframe for supply Cutting in with minimum down time


Overview - System Data

Conveyor: CV01 CV02 CV03 CV04 CV05

Belt Width (mm): 1,400

Design Tonnage (TPH): 2,500

Belt Speed (m/s): 4.5

Belt Type: PN 600/3 ST2240 SW8000

SW8000 SW8000

Length (m): 210 740 200 988 2388

Lift (m): 15 212 10 -30 -39

Head Drive Power (kW): 1 x 280kW 2 x 1000kW 1 x 320kW - 2 x 320kW

Tripper Power (kW): - - - 1 x 320kW -

Drive Type: CST VVVF CST CST CST

Flywheel Inertia (kg.m²): - 2 x 200 kg.m² - - -

LS Equivalent Brake Torque (Nm): - 140,000 - 56,000 66,000

Takeup Type: Counterweight C/wt Fixed – 2 Lap Fixed – 2 Lap Fixed – 4 Lap

Takeup Location: Incline Tail Head Tail Head

Takeup Tension (kN): 21 65 30 120 110

Takeup Carriage Travel (m): 8 10.5 4 15 20

Min Concave Curve Radius (m): - 350 - 900 1200

Min Convex Curve Radius (m): 75 - - 350 300

Number of Pulleys

Drive: 1 2 2 2 2

HT Bend: 2 1 2 2 5

LT Bend: 5 3 3 - -

HT Large Bend: - - - - 2


Drift Incline

Incline 17 degrees vs. water ex longwall

Material slump and spillage issue Limited head height at transfer to drift Dewatering of coal stream inbye locn.

(tripper drive)


Drift Tail - Low Transfer


Drift Incline - Dewater Tripper

Flow Separation at Discharge Cutter blade and sieve bend at transfer


Drift Incline - Dewater Tripper


Drift Geometry - Tail Curve

Vertical curve - Over constrained solution

Existing mine heading profile R =165 M Belt Lift off Edge Buckling computation (various) The factors could alter belt selection:

ST2240 ST2500 Belt mass in curve vs buckling calc. vs T1



Satisfy edge buckling -increase T (tail) Increase T (tail) required increase R (lift)

Increase belt spec at increased T1

Increased Edge Buckling required T(tail)

Reduced R (lift) due to mass



Complexity due to differing methods for buckling assessment

Troughing Angle (°): 35

Method: CEMA APEX Goodyear Dunlop

Belt Tension (kN) Minimum Radius (m)

15 2,105 1,915 718 2,052

20 1,272 1,436 539 1,539

25 912 1,149 431 1,231

30 710 958 359 1,026

35 582 821 308 879

40 493 718 269 770

45 427 638 239 684

50 377 575 215 616 0

500

1,000

1,500

2,000

2,500

15 20 25 30 35 40 45 50

Min

imu

m R

ad

ius (

m)

Belt Tension (kN)

CEMA

APEX

Goodyear

Dunlop



Altered Trough Angle At Curve ST2240 belt

Troughing Angle (°): 20

Method: CEMA APEX Goodyear Dunlop

Belt Tension (kN) Minimum Radius (m)

15 1,255 1,142 428 1,224

20 759 857 321 918

25 544 685 257 734

30 424 571 214 612

35 347 489 184 524

40 294 428 161 459

45 255 381 143 408

50 225 343 128 367 0

200

400

600

800

1,000

1,200

1,400

15 20 25 30 35 40 45 50M

inim

um

Rad

ius (

m)

Belt Tension (kN)

CEMA

APEX

Goodyear

Dunlop


Assess & Recover Hardware



CST Drives Full strip inspect and rebuild New Gear couplings at output New pipe work and hydraulics New radiator sets Assess and reuse of bases Motor assessment and rewind to 1000 V


Preconstruction & Cutting In

Drift operation required for critical mine development

Therefore: Required progressive change out ROC Required outbye construction CV01 and

CV02 Leave minimum closure works at

change over and drift tie in.


Preconstruction


Preconstruction Model


Preconstruction CV01

CV01 Stacker and Tower


Preconstruction to Portal


Drift Drive Issues

Stopping dynamics for underground system required extended drift run

Limited head room for over run capacity Hence flywheels on CV02 drives 2 x 1 MW VVVF drives (flywheel accln) Braking on flywheels (CV01 overrun) Holdback function / failsafe control Limited Space for construction


Drift Belt Profile

New Transfer Tower and Drive Arrangement New Tail + Active TU


CV02 Drive Tower


Run On Control

Limited underground head room Bunkering at transfers not viable Matching belt run down required CV02 Flywheels and Brakes Fixed Take ups on underground system Brakes on conveyors CV04 & CV05

Fail safe with UPS controls


Results

Satisfied Drift Tail Geometry Resolved system run on issues Supplied hardware on tight schedule Constructed surface plant on agreed

schedule Achieved 26,000 Man hrs LTI free Assisted underground mining Supervised underground construction


Questions ?

mark elliott - ellton group

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