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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
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
Overview
Main Conveyors Upgrade:
CV01 - Stockpile Conveyor
CV02 - Drift Conveyor
CV03, CV04 & CV05 Main Trunks
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
Overview - Cook Colliery
30km south of Blackwater, Queensland.
An underground mining operation
Produces both coking and thermal coal
Approx 80:20 coking : thermal split
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
Overview - Existing Elements
Existing Drift Head & Transfer
Innovative Solutions in Energy, Mining and Materials Handling
Overview - Existing Elements
Existing Stack Out Conveyor
Innovative Solutions in Energy, Mining and Materials Handling
Overview - Existing Elements
Innovative Solutions in Energy, Mining and Materials Handling
Overview - Existing Elements
Innovative Solutions in Energy, Mining and Materials Handling
Ancient History
Innovative Solutions in Energy, Mining and Materials Handling
Overview - Existing Elements
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
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)
Innovative Solutions in Energy, Mining and Materials Handling
Drift Tail - Low Transfer
Innovative Solutions in Energy, Mining and Materials Handling
Drift Incline - Dewater Tripper
Flow Separation at Discharge Cutter blade and sieve bend at transfer
Innovative Solutions in Energy, Mining and Materials Handling
Drift Incline - Dewater Tripper
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
Drift Geometry - Tail Curve
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
Innovative Solutions in Energy, Mining and Materials Handling
Drift Geometry - Tail Curve
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
Innovative Solutions in Energy, Mining and Materials Handling
Drift Geometry - Tail Curve
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
Innovative Solutions in Energy, Mining and Materials Handling
Assess & Recover Hardware
Innovative Solutions in Energy, Mining and Materials Handling
Assess & Recover Hardware
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
Assess & Recover Hardware
Innovative Solutions in Energy, Mining and Materials Handling
Assess & Recover Hardware
Innovative Solutions in Energy, Mining and Materials Handling
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.
Innovative Solutions in Energy, Mining and Materials Handling
Preconstruction
Innovative Solutions in Energy, Mining and Materials Handling
Preconstruction Model
Innovative Solutions in Energy, Mining and Materials Handling
Preconstruction CV01
CV01 Stacker and Tower
Innovative Solutions in Energy, Mining and Materials Handling
Preconstruction to Portal
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
Drift Belt Profile
New Transfer Tower and Drive Arrangement New Tail + Active TU
Innovative Solutions in Energy, Mining and Materials Handling
CV02 Drive Tower
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
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
Innovative Solutions in Energy, Mining and Materials Handling
Questions ?