Coal [ Uses and Production]
Uses
Coal has many important uses worldwide. The most significant uses of
coal are in electricity generation, steel production, cement
manufacturing and as a liquid fuel.
Different types of coal have different uses.
- Steam coal - also known as thermal coal - is mainly used in power generation.
- Coking coal - also known as metallurgical coal - is mainly used in steel production.
Other important users of coal include alumina refineries, paper
manufacturers, and the chemical and pharmaceutical industries. Several
chemical products can be produced from the by-products of coal. Refined
coal tar is used in the manufacture of chemicals, such as creosote oil,
naphthalene, phenol, and benzene. Ammonia gas recovered from coke ovens
is used to manufacture ammonia salts, nitric acid and agricultural
fertilisers. Thousands of different products have coal or coal
by-products as components: soap, aspirins, solvents, dyes, plastics and
fibres, such as rayon and nylon.
Coal is also an essential ingredient in the production of specialist products:
- Activated carbon - used in filters for water and air purification and in kidney dialysis machines.
- Carbon fibre - an extremely strong but light weight reinforcement
material used in construction, mountain bikes and tennis rackets.
- Silicon metal - used to produce silicones and silanes, which are in
turn used to make lubricants, water repellents, resins, cosmetics, hair
shampoos and toothpastes.
Production
At Griffin Coal, coal production takes place through a five step
process to deliver a quality product with a focus on reducing long term
environmental impact.
The five steps of the coal production process include:
Step 1. Exploration & Development
The
first stage to any coal production operation is exploration and
development. This takes place to locate and determine the most
appropriate methodology to extract the mineral.
Exploration and development involves the combined efforts of
geologists, geotechnical engineers, mining engineers, coal technologists
and surveyors.
The geologist is responsible for defining the shape, size and quality of the coal reserves and for producing a computer model.
This model is used by the mining engineers to plan and manage the mining process taking into consideration:
- Mine wall stability.
- Scheduling of coal production at a consistent rate and quality.
- Controlling groundwater seepage and rainwater runoff.
- Mining block and backfill designs for minimal possible overburden removal distance.
- Optimising equipment deployment and productivity.
- Minimising operational interruptions.
- Optimising drill and blast practices.
Surveyors support both the geologists and mining engineers by
ensuring that the data required for deposit modelling is correctly
gathered in the first instance. Surveyors also confirm that the
engineers’ mine plans are accurately reflected in the mine development.
As Griffin Coal’s mining occurs in soft, saturated sediments,
sometimes at great depth, Griffin Coal has had to achieve high standards
of professionalism in the above disciplines.
Step 2. Mining
Mining can take place through open cut or underground mining methods.
At Griffin Coal’s Collie mines open cut mining methods are used. The
mining process involves the removal of overburden and extraction of coal
but can be considered as four distinct operations:
1. Topsoil
Topsoil is removed ahead of mining and either spread directly on
shaped rehabilitation areas or stockpiled for later use. This operation
is performed using dozers, front end loaders and trucks.
2. Laterite
The cap rock (up to 2 metres thick) is either ‘ripped’ by dozers or blasted and recovered for use as road surfacing material.
3. Overburden
All overburden apart from the ‘Nakina Formation’ is drilled with
rotary ‘blast hole’ drilling rigs and charged with bulk explosive,
typically a mixture of ammonium nitrate and fuel oil (ANFO).
After blasting, overburden is loaded by hydraulic excavator or front
end loader into rear dump trucks and placed in overburden dumps.
Initially these had to be placed out of the pit in order to create a
large enough hole to work in. The worked over areas of the pit are now
filled in, a process known as backfilling.
When the mine gets to the back firing stage, the hole gets bigger and
moves slowly across the deposit. Then overburden materials are removed
from the operating faces and dumped into backfill on the other side of
the mine.
In its operations, Griffin Coal places all overburden into mined out
areas and focuses on the rehabilitation of the newly created final land
surface.
4. Coal
When overburden has been removed from the coal seam, the roof of the
seam is cleaned using bulldozers. The coal seam is then drilled and
blasted. Bulldozers clean down to the floor of the coal seam and front
end loaders and coal trucks transport coal to either the Ewington
Crushing Facility or direct to Muja Power Station.
In some areas, coal can be loaded directly into trucks using a large
backhoe, without need for bulldozing. Once the coal has been extracted
it is then processed.
Step 3. Processing
Processing involves crushing, screening and beneficiation.
Processing takes place at Griffin Coal’s Ewington Mine. It is a
process wherein coal is converted from Run of Mine to a product that
meets the customer’s requirement.
Crushing
Mined coal can include lumps up to a metre in size, so crushing to a
manageable size is required. Coal crushing can include a two stage
process dependant on deposit size.
Crush One: Feeder Breaker
Coal is crushed in a feeder breaker, a chain conveyor under a toothed drum that breaks the biggest lumps.
Crush Two: Sizer
Coal size is further reduced through a sizer, where each oversize particles are reduced to less than 75 millimetres.
Screening
Screening is used to separate different sizes of crushed coal. In
this process coarse and fine coal is separated so to accommodate for
specific markets and industrial usage. Screening takes place at a
processing plant adjacent to Ewington Mine.
Griffin Coal’s screened coal is ideal for burning in horizontal
kilns. In these kilns uniform particle grading is used to create even
combustion along the length of the kiln. Coarser coal is also required
by customers who burn coal in grate–fired applications.
Beneficiation/Washing
Beneficiation has been trialled at Ewington. During beneficiation,
coal is processed to remove impurities reducing ash and sulphur thereby
improving the market value of the coal. Beneficiation can improve the
quality of contaminated coal that would otherwise be wasted.
Most cleaning processes involve washing the coal in order to separate
coal particles from stone particles as coal is considerably lighter.
Charring
Coal can be charred, a process wherein hydrogen and oxygen are
removed from the coal to make it purer form of carbon. Once processed
according to specifications, coal is loaded and transported accordingly.
Step 4. Loading & Transportation
At Muja, ROM coal is delivered directly to the adjacent Muja Power Station.
Preparation of coal for sale to industrial customers is an integral
aspect of Ewington operations. Coal preparation involves crushing,
screening and loading trucks and trains. A variety of products are
produced to specification for size and quality.
All coal consignments are sampled to Australian and International
Standards and analysis is undertaken by an independent NATA accredited
laboratory.
At this point it is important to rehabilitate the environment so as to return it to its natural state.
Step 5. Rehabilitation
Mine site rehabilitation is important to environmental
sustainability. Rehabilitation involves returning the land to it’s
natural state post mining through strict, well researched strategies of
revegetation and the regeneration of natural ecosystems. Work to restore
disturbed areas is carried out progressively as soon as practicable.
Griffin Coal’s environmental commitment includes the progressive
rehabilitation of its mining operations. The objective of mine
rehabilitation is to create a structurally stable landform capable of
future productive use.
Rehabilitation also occurs to return land to a scale and morphology similar to that which exists elsewhere in the Collie Basin.
Rehabilitation involves a comprehensive process of classifying overburden material, land recontouring, seeding and regeneration.
1. Overburden Material Classification
Overburden material is classified according to its potential to cause
geochemical impacts (acid rock drainage) on the environment. Dumping of
waste material is undertaken so the best materials end up near the
surface of waste landforms and the other material is encapsulated in the
middle.
2. Land Recontouring
When the landforms are no longer needed for mining or dumping
purposes the slopes are recontoured to around 10 degrees to control
surface runoff and to ensure a stable slope. Topsoil is then spread to a
depth of 150 millimetres before the area is contour ripped, fertilised
and seeded with local natives.
3. Seeding
Rehabilitation areas are seeded at the break of the winter rainy
season, and initially are susceptible to erosion damage until
germination and root development has occurred. Historically dumps were
rehabilitated to pasture species. This approach was chosen to stabilise
the dump outslope quickly to prevent erosion. More recently efforts have
been directed to the re-establishment of native flora.
4. Regeneration
Native species do not germinate and develop until the following
spring, therefore the potential for massive erosion is present during
the winter. A strategy has been developed whereby native bush species
comprising grasses, groundcovers, shrubs and trees, are sown together
with a “nurse” crop of cereal rye.
The cereal rye germinates quickly and stabilises the surface through
the winter and the natives emerge the following spring. The seed mix
includes Jarrah, Wandoo, Flooded Gum, numerous Acacias and understorey
species.
Sources : worlcoal.com and griffincoal.com