AUGUST 2021
CURRENT PROJECTS
This report is a summary of current projects for the months May, June and July 2021
ACARP CONTACTS
PROGRAM MANAGEMENT PROJECT ADMINISTRATION
Australian Coal Research Limited Australian Research Administration Pty Ltd Suite 3, Level 9 Level 12, 167 Eagle Street Brisbane Qld 4000 307 Queen Street PO Box 7148 Riverside Centre Qld 4001 Brisbane Qld 4000 Phone: 07 3225 3600 Phone: 07 3607 3824 Anne Mabardi RESEARCH COORDINATORS Ian Neill [email protected] Executive Director Peter Bergin [email protected] Patrick Tyrrell Underground NSW [email protected] [email protected] Marilyn Keenan Levy Administrator Nicole Youngman Cam Davidson [email protected] [email protected] Open Cut – Mining [email protected]
Ashley Conroy Technical Market Support [email protected]
Nerrida Scott Coal Preparation [email protected]
David Drakeley [email protected]
www.acarp.com.au
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ACARP Current Projects Report August 2021 Underground Projects
C27020 UNDERGROUND Management of Coal Bursts and Pillar Burst in Deep Mines Coal Burst University of Adelaide C25004 Giang Nguyen Murat Karakus Review of Australian and International Coal Burst
Experience and Control Technologies Value: $380,240
Report Expected: September 2021 University of New South Wales Industry Monitor/s: Coal Burst Task Group Ismet Canbulat ACARP Contact: Peter Bergin
Value: $404,000 We are currently in the finishing stage of this project, Report Expected: August 2021 which collaborates the theoretical framework with the Industry Monitor/s: Coal Burst Task Group numerical modelling approach to evaluate the burst ACARP Contact: Patrick Tyrrell potential of coal. This project utilises the longwall mining scenario in the coal seam under the geological A draft report is with the industry monitor(s) for review. arrangements with Coal Cliff Sandstone (upper) and Loddon Sandstone (lower) rock mass layers, delineated C26066 in (Yardimci and Karakus 2020). The majority of the key Energy, Burst Mechanics Required for Coal Bursts project objectives have been successfully achieved. and Energy Release Mechanisms For instance, a theoretical framework for laboratory University of New South Wales scale coal burst assessment is developed and applied to Ismet Canbulat the cuboidal coal specimen under true triaxial loading- Winton Gale unloading conditions imitating the coal exposed to the in-situ polyaxial stress with unloading effect after Value: $357,500 excavation. The coal specimen's strength, elastic, and Report Expected: August 2021 fracture properties, determined from laboratory Industry Monitor/s: Coal Burst Task Group experiments (including uniaxial compression and AUSBIT ACARP Contact: Peter Bergin – Adelaide University Snapback Indirect Tensile Strength test), were utilised to develop the burst envelop for A draft report is with the industry monitor(s) for review. rocks/coal from the above three in-situ geological units. In-situ horizontal stress ratio (k) in Australian mining C26068 conditions was determined from the detailed literature Use of Real Time Rib Drilling Data to Determine review. This theoretical assessment indicates the coal the Propensity for Coal Bursts During Roadway burst potential in the in-situ coal seam, ie burst index Development ( )>1. In comparison, the rock specimens from the upper (ie coal Cliff Sandstone) and lower (Loddon sandstone) ₽ Dynamic Efficiency geological strata demonstrate zero/no burst tendency. Peter Mastalir These theoretical predictions were further verified via the numerical strain burst experiments conducted on Value: $150,000 specimens from all three geological units. Additionally, Report Expected: June 2022 the experimental data from coal burst experiments Industry Monitor/s: Coal Burst Task Group conducted in China is also considered to validate the ACARP Contact: Peter Bergin laboratory scale theoretical and numerical results.
This project is on hold due to the following reasons: The numerical framework utilised in this study includes • COVID-19 (access restrictions); and developing a cohesive contact model with elastoplastic- damage coupling (Verma 2020). It was implemented in • Mine site 2 has agreed in principle to take up project. the hybrid numerical modelling framework, ie 3DEC-
Itasca. In addition to the laboratory scale strain bursts The estimated date to restart work is October 2021. numerical experiments, the applications of the developed numerical framework were further extended
to conduct the field scale burst evaluation, providing an
additional layer of verification to our theoretical burst prediction. In this view, the sample scale coal and rock
properties were upscaled to field-scale rock mass using
the Hoek-Brown criterion (Hoek et al. 2002; Hoek and
Brown 2019). For field-scale coal mining simulation, two approaches were adopted: continuum and
Page 1 ACARP Current Projects Report August 2021 Underground Projects discontinuum. In the first approach, the coal and rock C27041 layers, interacting via rock joints, are considered Ground Support Requirements in Coal Burst continuum blocks. The stress state and resultant Prone Mines deformation at the excavation face indicate burst occurrence in the coal seam immediately after the University of New South Wales excavation. The movable shield equipped with a canopy Ismet Canbulat as a portable roof support system is idealised as a steel platen structure across the excavation face. In the second Value: $150,000 approach, each geological unit is further discretised into Report Expected: September 2021 deformable tetrahedral blocks interacting via a cohesive Industry Monitor/s: Coal Burst Task Group contact model. It provide an exlicit rock damage and ACARP Contact: Peter Bergin failure/bursting scenario on coal seam mining face, further verifying the results from field scale continuum The objectives of this project are to: approach. • Review the international best-practice ground control systems in burst prone mines; The results obtained are promising, as per our • Evaluate and characterise ground support principles expectations, marking the achievements of the key and considerations; objectives of this study. Few results from continuum • Assess yielding support technologies and determine simulation are further refined for better clarity. We are the energy absorption requirements for the ground currently drafting research article/s aimed towards top support systems for coal burst control; international mining journals to publish the key results • Identify engineering principals and failure from this study. We are also planning to finalise the mechanisms of yielding support; and to project report to include the key results obtained during • Establish functional requirements of appropriate and this project's second half/extended duration. effective ground support technologies for coal burst
control that are in line with Australian experience, The final report for this project is being drafted and will regulations, mine design, and operational practices. be submitted to the industry monitors for review.
The project has been impacted by the lack of access to a C27039 numerical modelling code that is located at UNSW, due True Triaxial Strength of Coal Measure Rocks and to COVID-19 lockdowns. its Impact on Stability of the Roadways and Coal Burst Assessment Work undertaken during the quarter includes: • A database of currently available yielding roof bolts SCT Operations and mesh has been compiled; Mahdi Zoorabadi • A risk based approach has been developed to identify Winton Gale the risk categories (ie risk zoning) in development and longwall faces. This approach has been enhanced Value: $187,000 with the outcomes of C26066; Report Expected: August 2021 • The framework for coal burst management plan, Industry Monitor/s: Coal Burst Task Group which was proposed as part of C25004, has been ACARP Contact: Peter Bergin updated to reflect the new risk based approach; • A new analytical model has been developed that A draft report is with the industry monitor(s) for review. assesses the ground support requirements in the case of a coal burst event. This methodology considers roof bolts, mesh, straps and cables. The final program that contains the gas expansion energy, strain energy and seismic energy as well as the assessment of the support adequacy is being compiled and will be made available shortly; • Using the above methods, the mines sites will be able to determine the safe distances in remote mining and ground support requirements under coal burst prone conditions; and • Final report is being compiled.
Page 2 ACARP Current Projects Report August 2021 Underground Projects
C27060 C28012 Damage and Risk from Seismic Events Coal Micro Fabric as a Trigger for Coal Bursts
SCT Operations SCT Operations Winton Gale Winton Gale
Value: $435,000 Value: $215,000 Report Expected: September 2021 Report Expected: September 2021 Industry Monitor/s: Coal Burst Task Group Industry Monitor/s: Coal Burst Task Group ACARP Contact: Peter Bergin ACARP Contact: Peter Bergin
No report received. This project is on hold while the task group determine a way forward after notifications from the project leader C28009 regarding change of circumstances. Advanced Fracture Propagation and Rupture Testing of Coal Measure Rocks Under Dynamic C29007 Condition to Replicate Coal Burst Innovative Coal Burst System to Investigate the Influence of Confinement Loss and Pre- Monash University Conditioning on Coal Burst Mechanism Amin Heidarpour University of Adelaide Value: $287,500 Giang Nguyen Report Expected: November 2021 Murat Karakus Industry Monitor/s: Coal Burst Task Group ACARP Contact: Peter Bergin Value: $329,000 Report Expected: May 2022 This project aims to make improvements in health and Industry Monitor/s: Coal Burst Task Group safety as well as sustainability of underground coal ACARP Contact: Peter Bergin mining operations by conducting a thorough study on dynamic behaviour of Australian coal. This project aims to investigate coal burst due to loss of confinement by using state-of-the-art hollow cylinder To date, the work undertaken includes: loading/unloading systems which will enable replication • The majority of conventional and non-conventional of the excavation process in underground coal mining. static tests (over ten different tests) has been This innovative approach will provide reliable, cost- completed and the rest is progressing; effective data for direct use in mine design and • A designed large scale biaxial testing program is geotechnical monitoring. The hollow cylinder system also progressing as the equipment is under modification removes the reliance on expensive true-triaxial testing to simulate the field conditions in lab; and frames. The research team will investigate how the rate • The dynamic tests were performed on the prepared of damage accumulation influences coal burst due to in- cubical coal samples. Uniaxial, true biaxial and triaxial situ stress and confinement loss at the laboratory scale. tests have been conducted through the Split Hopkinson Pressure Bar (3D-SHPB) apparatus. Some With the help of the improved coal burst system, a series complex field scenarios are investigated under this of coal burst tests were conducted. The real-time scheme. deformation characteristics of coal during bursting were digitally captured using a borescope and Acoustic Emission responses. The evolution of coal burst exhibited local particle/grain ejection, fragments exfoliation accompanied by crack generation and propagation and coal bursting (Fig. 1).
The complex nature of fracture patterns of coal was Example of a true biaxial test. From left to right; DIC revealed by qualitative and quantitative analysis based analysis demonstrating the and at peak strength, on the μCT system. The 3D-reconstruction of fracture coal sample at the failure moment, and the fragments 𝜀𝜀𝑦𝑦𝑦𝑦 𝜀𝜀𝑥𝑥𝑥𝑥 network represents that the coal damaged due to coal after the test. burst accompanied with ejected fracture zones and a shear band generated and propagation from the zone of COVID-19 lockdowns have caused access restrictions at highly tangential stress concentration. The damage Monash Laboratory so some experimental works have during coal burst was described with some measurable been affected adversely. parameters, such as crack surface area, crack volume and crack density by μCT. The energy characteristics of coal are also calculated and the average energy consumed by the induced cracking during coal burst are estimated. The
Page 3 ACARP Current Projects Report August 2021 Underground Projects surface fracture energies at the time of coal burst were studied on the stress memory by preloading specimens calculated that will allow us to quantify the energy levels between of 30% and 90% of UCS. The data has been that can initiate bursting. Using the recently developed analysed and results are compiled in a research paper. convergence measuring system in the hollow cylinder, potential correlation between bursting stresses and As reported earlier coal specimens in seven different radial strains has been investigated. directions were prepared and tested for the stress measurement. The experiments were successfully completed with the desired goals of two successful tests in each direction. The data acquired through the monitoring systems were analysed and initial results were prepared. During the fourth quarter specimens were prepared in two more directions to analyse their influence on the results. The specimens were tested and the acquired data has been analysed and incorporated with the existing data. Results would be compiled and presented in a research paper.
Furthermore, due to the presence of cleats and fractures it is assumed that the coal will exhibit some scale and Fig. 1. Coal burst failure at various stages, and qualitative directional dependency. In order to investigate the effect and quantitative analyses of fracture evolution in coal of scale and its directional dependency, cubical samples using μCT. were prepared in five different size cubes (15mm, 20mm,
25mm, 30mm, 35mm) and in five different directions ie C29010 0˚, 30˚, 45˚, 60˚ and 90˚. The experiments will be In-situ Stress Measurements using Cored conducted during the next quarter and the results will be Coal/Rocks for Coal Burst Management analysed for subsequent publication. Figure 1 below shows the sample. University of Adelaide Giang Nguyen Murat Karakus
Value: $228,600 Report Expected: July 2022 Industry Monitor/s: Coal Burst Task Group ACARP Contact: Peter Bergin
This project aims to develop and improve the method of Figure 1. Prepared coal specimens to investigate scale in-situ stress measurement from the oriented cored and directional dependency of coal. rocks based on deformation rate analysis (DRA) and acoustic emission (AE). As per the approved plan of work, C29038 the fourth quarter of the project was dedicated for Data Processing Strategy for Distributed Optic conduct of DRA and AE experiments. The project is Fibre Sensing and Development of Methods for currently in the end of the fourth quarter and all the Real Time Data Processing milestones for the first four quarters have been achieved. CSIRO Joey Duan The Secant Modulus Method (SMM) was proposed in the Xun Luo last quarterly report as a new method for in-situ stress measurement from the oriented cored rocks. This Value: $196,460 method is believed to be simple and more accurate than Report Expected: July 2022 the DRA method. To validate the potential of the Industry Monitor/s: Coal Burst Task Group method, large number of tests were conducted on coal ACARP Contact: Peter Bergin specimens and a clear bending point is observed when the specimens are prestressed and uniaxially The objective of this project is to develop a strategy to compressed to a higher stress level. Since the rock stress deal with the huge DOFS (distributed optic fiber sensing) memory is sensitive to various conditions, some primary data set in real-time, and to develop new approaches and factors which could influence the stress memory and the algorithms for rapid data processing. Investigation of SMM were studied. The specimens were first tested efficient data storage procedures will be conducted for under three different types of loading conditions and archiving the big data set for back analysis. All the subsequently under five different strain rates. Moreover, investigations and developments will be done based on the influence of the time delay on the rock stress the big data sets collected from previous project C27048, memory and SMM was also studied for time delays of up from laboratory and field experiment at a mine site. to one week. Lastly, the influence of prestress levels was Page 4 ACARP Current Projects Report August 2021 Underground Projects
A method using black-and-white (BW) brightness ratio to footwall can moderate the stress concentration. Higher automatically identify seismic event from background in-situ horizontal/vertical stress ratio will lead to higher noise has been developed and is being tested on DOFS stress concentration near faults. data collected from our previous ACARP project. The microseismic events recorded in this project were C33032 classified to three classes: Strong Events (magnitude Application of US Coal Burst Practical greater than -1), Moderate Events (magnitude -2 to -1) Experience/Research to Identification of Elevated and Weak Events (magnitude -3 to -2). The preliminary Risk Domains in Australian Operations results have shown that the event identification accuracy can reach 100% for the Strong Events, 85% for the Maleki Technologies Inc Moderate Events and 70% for the Weak Events. It has Hamid Maleki been approved that using this event discrimination strategy the data size to be stored for back analysis can Value: $150,000 be significantly reduced by approximately 85%. Test on Report Expected: February 2022 more data is being conducted to further improve the Industry Monitor/s: Coal Burst Task Group event identification accuracy for real-time reporting of ACARP Contact: Peter Bergin seismicity associated with mining. Using Edge Detection for automatic event location will be conducted in the The objective of this project is to quantify mining, following three months. geologic and geotechnical risk factors in US mines through re-examination of burst prone case studies C29039 addressing failure mechanism for three different coal Forecasting Coal Burst Risks Near Various Types fields; these coal fields have diverse geologic, stress and of Faults, Folds and Dykes mining conditions including deep mining under adverse depositional, structural and far field stress conditions. CSIRO Transfer properly documented US experience/control Baotang Shen technologies to enhance stability and guide research in Jane Hodgkinson Australian operations. Following is a summary of the activities completed during the quarter. Value: $190,666 Report Expected: January 2022 Research completed on failure mechanisms using Industry Monitor/s: Coal Burst Task Group measurements and stress analyses from Utah mines ACARP Contact: Peter Bergin including a report on failures which occurred during development mining. The latter was requested by Stress state and geotechnical conditions often change Industry Monitors and included a few boundary-element significantly near major geological structures (eg faults, analysis. This is a deliverable under Task 1A. shear zones, dykes) which is the cause of most major mine instabilities and/or safety hazards including coal Research expanded for completion of deliverables under burst, roof falls, water inrush, gas outburst etc. A Task 1B, scheduled for completion within the first six previous and complete project (C26053) investigated months of the project. This task includes summarising stress change and/or microseismic activities near a major any pertinent monitoring data and stress analysis in dyke using field monitoring and numerical modelling order to identify failure mechanisms, critical stress levels techniques. This project is an extension of that previous and remedial actions in select Colorado operations. Work project. This project aims to investigate various types of is based on two comprehensive case studies focusing on geological structures to determine their effects on the sudden failure of mine floor accompanied with seismic risk of coal burst. events within the North Fork Valley. These single and multiple-seam case studies analyse geologic and stress During the last three months, the study has been focused conditions and address the degree of structural on an integrated analysis of stress redistributions around complexity, displacement, intense jointing, thermal and several different types of faults in Mine C, a third mine fluid conditions that appear to have played a key role in planned in the project scope. The other two mines (Mine occurrence of sudden floor failure, or lack of it. A and Mine B) have been investigated in the previous quarters. Mine C is one of the deepest coal mines in At the August review meeting, a presentation will be Australia and all three types of faults (normal faults, given detailing progress since the previous review reverse faults, and strike-slip faults) and dykes exist in the meeting. Some 60 slides will cover geologic and mining panels. geotechnical design factors of both sudden and gradual failures in the two neighbouring mines. By comparing the The numerical modelling results to date have shown that two cases, it is hoped to improve understanding of failure significant stress concentration occurs near faults and mechanism under relatively similar geologic conditions in dykes before and during mining. The “footwall” side of a these two neighbouring mines. In both mines, sudden fault often has higher stresses than “hanging wall” side. floor failure occurred in areas with complex structural, Mining direction has a major effect on stress fluid and stress conditions compounded by historic concentration at fault, and mining from hanging wall to thermal effects at some locations.
Page 5 ACARP Current Projects Report August 2021 Underground Projects
Detection and Prevention of Fires and C29013 Explosions Evaluating GAG Docking Connections / Simulations
C28013 University of New South Wales Use of Compressed Air Foams (CAFs) to Alter Goaf Duncan Chalmers Air Circuits and Mitigate Spontaneous Guangyao Si Combustion Events Value: $82,100 Mines Rescue Report Expected: September 2021 Clive Hanrahan Industry Monitor/s: Bharath Belle Matthew Fellowes John Grieves Ken Singer Value: $392,500 Phil Fletcher Report Expected: September 2021 ACARP Contact: Peter Bergin Industry Monitor/s: Bharath Belle David Webb The project highlighted deficiencies in the knowledge on Paul Wild GAG performance with respect to its ability to deliver Peter Baker product over a range of pressures. This knowledge gap Rae O'Brien will need to be filled to appropriately determine its Sharif Burra effectiveness. ACARP Contact: Patrick Tyrrell After discussions with industry monitors further The project aims to provide an additional spontaneous simulations were conducted and are being incorporated combustion control technique for use by industry and to: into the final report. • Procure a full system ready for deployment in the Australian coal industry; C29026 • Deploy the system in at least one underground Investigation into the Thermal Ignition Caused by longwall panel(s); IS Power Supplies • Evaluate the cost and effectiveness of using CAF’s to alter goaf ‘micro ventilation circuits’; Simtars • The system will be retained by NSW Mines Rescue, Andre De Kock and maintained similarly to the MineShield for use by Gareth Kennedy both the New South Wales and/or Queensland mining industry as a tool to assist manage accelerated Value: $153,700 oxidation of coal. Report Expected: April 2022 Industry Monitor/s: Brad Lucke The system has again been successfully deployed and is Graham Café assisting a New South Wales underground longwall mine ACARP Contact: Patrick Tyrrell with pro-active management of the current working longwall panel. Evaluation of data from this deployment The objectives of the project are to determine: will allow some longwall panel project objectives to be • The fault conditions arising in an intrinsically safe analysed and reported on. This data and analysis will be electrical circuit that could ignite combustible included in the final report which is being written. material on a mining machine; • The role and extent that combustible material accumulation can cause or contribute to the risk of equipment fires, when ignited by intrinsically safe power supplies; and • The parameters to be considered in installing an intrinsically safe circuit in an area where they could be an accumulation of flammable materials.
All information received on the power supplies and oils used at the mines have been entered into a database. Most of the data sheets and certification documentation for the common power supplies in the database are acquired. During the next quarter:
• A selection of power supplies most commonly used in underground Australian coal mines will be identified
and purchased; and
• The testing method will be developed.
Page 6 ACARP Current Projects Report August 2021 Underground Projects
Environment - Subsidence and Mine Water C28004 Monitoring Hydrological Status of Complex C27059 Upland Heath Communities Using Canopy Swamp Hydrology Modelling for Advancing Conductance and Thermal Imaging
Rehabilitation Planning and Management Queensland University of Technology
University of Queensland Value: $230,964 Mandana Shaygan Report Expected: November 2021 Neil McIntyre Industry Monitor/s: Gary Brassington Thomas Baumgartl Peter Corbett
ACARP Contact: Patrick Tyrrell Value: $424,270
Report Expected: July 2022 This project is on hold while ACARP and QUT reach Industry Monitor/s: Bernie Kirsch agreement on a way forward following the project Gary Brassington leader’s departure. Peter Corbett
ACARP Contact: Patrick Tyrrell C28024 This project aims to investigate the resilience of Optimisation of Water Management for Coal Temperate Highland Peat Swamps on Sandstone Mines - Water Tracer Tools (THPSS), in response to changes in soil moisture content induced by underground mining activities and climate Deakin University variability. This project also aims to develop a Wendy Timms hydrological model that can predict soil moisture variability under a range of swamp conditions. Value: $296,100 Report Expected: January 2022 For mine site one, fieldwork was conducted on 12th May Industry Monitor/s: Peter Corbett to collect the soil moisture data and check the Steve Downes functionality of installed sensors in swamps. As a result, ACARP Contact: Patrick Tyrrell the sensors that were not working were changed or repaired, with the exception of two sensors that could The objective of this project is to improve water not be repaired. Additional sensors were purchased to management by applying advanced water tracer tools replace the ones that could not be repaired, although the that will benefit underground mining. These tracer replacement of these sensors has been delayed due to techniques will reduce business risk with current border closures. The calibration of soil hydrological operations, project approvals and extensions. The models for the prediction of soil moisture fluctuations in project includes the following objectives: mine site one was completed using collected data by the • Review options for local industry to apply water sensors. Currently, the validation of the models and tracers in black coal basins based on case studies sensitivity analyses are underway. from mining industries around the world to address the limitations of physical hydrogeology methods; For mine site two, the calibration of soil hydrological • Demonstrate opportunities for water tracers in soil models for corrected soil moisture data recorded by moisture and surface-water management by applying Sentek sensors has been completed. The validation and suitable water tracers for: identifying non-mining sensitivity analyses of calibrated models for mine site water sources and potential mixing with mine sources two are also being conducted. or discharges; evaluate surface rehabilitation success by measuring pore water for vegetation versus The next step of this project is to complete the validation evaporative and recharge; independent estimates of and sensitivity analyses of 1D modelling and conduct 2D recharge and water sharing plan sources; modelling for mine sites one and two. This will be • Demonstrate opportunities for water tracers in followed by scenario modelling to evaluate the effect of groundwater management by applying suitable climate variability and groundwater level on soil water tracers at mine sites for: distinguishing moisture fluctuations of swamps. between aquifer interference that is due to pressure effects versus flow; quantifying surface water-aquifer interactions particularly for multi-seam areas complement groundwater models and geomechanical predictions of height of fracturing (or subsidence effects); and identifying specific flows to voids for in situ treatment.
Page 7 ACARP Current Projects Report August 2021 Underground Projects
The project has shifted to processing laboratory testing C28030 results up to July, after site sampling of water tracers was Reducing Brine Volume through Membrane completed in the previous quarter. Most tracer results Distillation Crystalliser have been received from laboratories, however some radiotracers such as tritium results are yet to be received. CSIRO In the meantime, a preliminary report of tracers was Ramesh Thiruvenkatachari delivered to site A, and mix modelling has continued for sites A and B. Some additional consultation has been Value: $214,350 undertaken with site A personnel regarding tracer Report Expected: August 2021 interpretation and priorities. Planning for final reporting, Industry Monitor/s: David Baker delivery of data and brief training videos is progressing. David Randall Jason Fittler C28028 Paul O'Grady Inclusion of High Interest Native Plants in Mine ACARP Contact: Patrick Tyrrell Site Restoration Programs: Propagation, Translocation and Field Reintroduction A draft report is with the industry monitor(s) for review.
Royal Botanic Gardens and Domains Trust, Sydney C29016 Cathy Offord Southern Coalfields Coal Washery Reject (CWR) Nathan Emery Characterisation and Classification, including Management Strategies for Applications in Civil Value: $444,055 Engineering Report Expected: June 2023 Diana Barnes Industry Monitor/s: SLR Consulting Australia Gary Brassington Christopher Meikle ACARP Contact: Patrick Tyrrell
Value: $160,000 The overarching objective of the project is to successfully Report Expected: September 2021 translocate and monitor multiple populations of Industry Monitor/s: Bernie Kirsch Persoonia hirsuta Persoonia hindii and in mining offset Gary Brassington and rehabilitation areas. Scientific research will be Julian Potten conducted in parallel with the translocation work, with a Rae O'Brien strong focus on understanding the seed biology and ACARP Contact: Patrick Tyrrell reproductive system of both species. The project seeks to promote the beneficial use of Coal Stage 2 translocations were successfully undertaken in Washery Rejects (CWR) in civil engineering applications, P. hirsuta late May. A total of 90 plants were planted in a providing a robust data set that supports the mining rehabilitation area where the species has environmental and geotechnical merits of existing and naturally recruited. Plants were translocated new applications, including mine site and landfill haphazardly in a 50x25m area with genotypes mixed rehabilitation, back-filling quarry voids and placement throughout the site, and robust guards were erected beneath the groundwater table. P. around the plants to prevent herbivory. A total of 80 hindii plants were also planted in a mining rehabilitation Through consolidation of existing environmental and area. Plants were translocated in four blocks of geotechnical data sets, updated laboratory testing and 20 individuals and each block contained a pre- comparison to other commonly used engineered fill determined number of genotypes. Temporary plant materials, the outcome of this research will provide a guards were installed to minimise the effect of frosts and number of contemporary reference resources (eg translocation shock. handbook/guideline/peer reviewed publication) for industry professionals, enabling greater confidence, COVID-19 restrictions in New South Wales has stopped demand, diversified usage and recognition of CWR as an fieldwork and laboratory work during June and July, economic resource. including translocation monitoring, seed burial exhumation and germination testing. Meanwhile, the The Phase 1 – Literature Reviews scope was completed P. hirsuta data from germinating seeds on a bi-directional on-time and on budget. thermogradient plate are being analysed using a newly developed statistical framework that predicts The Phase 2 – Analysis and Testing scope has been germination at the seed source site under current and subjected to a number of delays and impacted by COVID- future temperatures. Our manuscript on the 19 lockdowns. In addition, the project has experienced P. hirsuta reproductive biology of was completed and the following challenges: submitted to a scientific journal for peer review. • Unintentional delayed access/provision of samples
for testing;
Page 8 ACARP Current Projects Report August 2021 Underground Projects
• Testing backlog at testing facilities – still awaiting C33021 primary results; Pilot Scale Membrane Distillation Crystalliser • Key research team personnel on interstate (MDC) with Renewable Heat Source for Mine secondment with movements limited due to border Water Brine Management closures. CSIRO Other than these factors other elements have progressed Ramesh Thiruvenkatachari well, including environmental and geotechnical evaluation. Following completion of the combustion Value: $362,131 testing we’ll be pressing to expedite the write-up in Report Expected: October 2023 September. Industry Monitor/s: David Baker David Randall In the coming weeks, the research team will be liaising Paul O'Grady with the industry monitors to present findings to date Tim Kendrick and discuss options for future engagement with ACARP Contact: Patrick Tyrrell regulators, with objective of establishing a framework for new generator specific exemptions. This project aims to develop a pilot-scale MDC unit for treating mine impacted water and hyper saline brine C33015 from reverse osmosis process. The main objectives are to Regional Ground Movement on Bedding Planes design and develop a modular, pilot membrane and Potential Impacts on Groundwater distillation unit coupled with crystalliser, conduct tests with a hypersaline waste brine sample and obtain the SCT Operations optimum operating parameters. Ken Mills The project commenced in June. Project planning is being Value: $150,000 undertaken. Mine water and reverse osmosis brine Report Expected: May 2022 samples are currently being tested using the existing lab- Industry Monitor/s: Gary Brassington scale MDC test unit to obtain process performance and John Watson design information. The data obtained will help in the Peter Corbett pilot plant development. ACARP Contact: Peter Bergin C33028 Bedding plane shears are emerging as features that Fire Resilience of Temperate Highland Peat define and control the magnitude of horizontal Swamps on Sandstone movements within the overburden strata adjacent to extracted longwall panels. Measurements and University of Queensland observations of the how the features influence Mandana Shaygan horizontal stress relief and hydraulic conductivity of the overburden strata above and to the sides of extracted Value: $279,450 longwall panels have been made over the last two Report Expected: March 2023 decades, but the information is distributed across Industry Monitor/s: Bernie Kirsch multiple sites and hasn’t been collated into a cohesive Gary Brassington form. This project aims to draw together existing Peter Corbett information from multiple sites. ACARP Contact: Patrick Tyrrell
The project recently commenced and initial focus has This project aims to assess the resilience of endangered been on collecting information from contributing mine Temperate Highland Peat Swamps on Sandstone (THPSS) sites. to fire (both wildfire and controlled fire) and to evaluate how resilience varies between mine-impacted swamps and non-impacted swamps.
Field trips to visit swamps in mine sites one and two and collect soil samples were cancelled due to COVID-19 restrictions. For mine site one, the pre- and post-fire soil water potential fluctuations, which were recorded by UQ installed tensiometers as part of the project C27059, were analysed. Remote sensing data (Landsat 8) were used to calculate the land surface temperature (LST) and soil moisture index (SMI) of swamps using Google Earth Engine and Arc-GIS pro. The calculation of soil moisture fluctuations (depth of 5cm) for before and after fire is underway, using SMI data and observed soil water Page 9 ACARP Current Projects Report August 2021 Underground Projects potential data collected by the sensors. Soil erosion potential is also being estimated using the soil erodibility factor calculated from the measured soil hydraulic parameters of swamps.
Fire severity and post-fire recovery maps have been created for each swamp using the NDVI (Normalised Difference Vegetation Index) of pre- and post-fire Constructed 3DUID tags for installation at the mine site. Surface Reflectance. For mine site two, fire severity maps have also been created for each swamp using the NDVI C28031 of pre- and post-fire Surface Reflectance. Longwall Geological Risk Minimisation using Advanced Electromagnetic and Sonic The next step is to calculate soil moisture fluctuations Technologies and soil erosion potential in response to fire for swamps located in mine site two. CoalBed Energy Consultants Scott Thomson When the border restrictions are lifted, field trips will be organised to collect soil samples from mine sites one and Value: $178,750 two, followed by characterising soil chemical and Report Expected: November 2021 physical properties. To reduce delays due to interstate Industry Monitor/s: Jonathan Lowe travel restrictions, additional project partners qualified Owen Salisbury to undertake the field work are being considered. ACARP Contact: Patrick Tyrrell
Exploration This project aims to integrate geophysical exploration data provided by both electromagnetic and sonic C27057 technologies (the Radio Imaging Method (RIM), v6 and In Seam Seismic (ISS) Summit II System respectively). These Automated Structural Mapping using a Mobile technologies should provide a unique evaluation of Laser Scanner geological integrity within a longwall panel prior to mining. Integrating the latest versions of these University of New South Wales technologies has never been tried before. Both Simit Raval proposed methods have been used only sporadically and
in isolation in Australian coal mining and for separate Value: $168,646 reasons, these systems are generally under utilised and Report Expected: February 2022 potentially poorly understood by most operators. Industry Monitor/s: Brian Vorster Patrycja Sheffield Geological surprises that halt or slow longwall production Roger Byrnes are still relatively common in Australian coal mining and ACARP Contact: Patrick Tyrrell may have severe financial consequences for an operation. This is despite the benefit of development The main objective of this project is to evaluate a mobile driveage from both sides and, in many cases, extensive laser scanner for routine mapping of underground mine inseam drilling. There is a need to apply modern environments and embedded structural features. scientific technologies and analytical techniques to the
problem and provide operators with an accurate The project developed automated algorithms to identify assessment of geological risk prior to the structural and support features in the mining commencement of the longwall. environment. Efficacy of the developed approach was demonstrated by testing the algorithms on datasets that The original site for the trial of both techniques was include surface rock mass and subsurface tunnel rock selected in January 2020 and did not proceed due to mass. However, structure mapping demonstration on COVID-19 restrictions. In the past month, the same site rock mass present in underground coal mine remains to has agreed to support reinitialising the project for July- be addressed. During the last quarter, innovative 3DUID August this year. Site preparation is currently underway. tags were constructed at the Laboratory for Imaging the The German ISS team have agreed to quarantine upon Mining Environment (LIME) at UNSW (see following arrival in Australia in order to make this project a reality. figure) for installation at the mine site. A detailed The trial site operation has agreed to provide extra planning of the experiment has been completed in funding to support this. consultation with the identified mine site. However, the planned mine visit has been delayed due to COVID-19 RIM is being undertaken at the site routinely and this restrictions. data has already been processed and reported. Additional data may be gathered in order to get the most out of the comparison between ISS and RIM. Transmission and reflection ISS are planned.
Page 10 ACARP Current Projects Report August 2021 Underground Projects
C29032 C33038 Improving Coal Seam Model Accuracy for Statistical Analysis of Methods for Selecting Longwall Automation by In-Seam Borehole Radar Coal/Non-Coal Boundaries from Density Logs Imaging and Data Integration GeoCheck CSIRO Brett Larkin Binzhong Zhou Value: $70,000 Value: $210,072 Report Expected: February 2022 Report Expected: May 2022 Industry Monitor/s: Mark Laycock Industry Monitor/s: Julian Potten ACARP Contact: Patrick Tyrrell Mick Stadler ACARP Contact: Patrick Tyrrell This project has the following objectives: • Compare the current methods for selecting the points Longwall automation depends on the development of on the downhole geophysical density curve that automatic coal seam (horizon) tracking and lateral indicate the coal/non-coal boundary depths. guidance systems to maintain mining the target coal • Assess statistically which method is the most accurate seam while steering to the desired target. It requires and whether this depends on the geological spatial accuracy for changes in a horizon’s depth in the environment and/or make of the geophysical tool order of 10cm, and positions of structures (faults and that collected the data. rolls) with a spatial resolution or wavelength of 10s of • Most current methods make an additional metres. In this project, we propose to use borehole radar adjustment on the selected boundary depths for thin (BHR) to survey the in-seam drill holes to accurately coal bands and thin partings within coal seams. This locate the seam roof or floor. This will fill the gap is related to tool resolution. The study will compare between the coarse and less accurate exploration data these adjustments. (drilling, borehole logging and seismic) and the detailed • Assess which adjustment method is the most seam knowledge (GPR, thermal and optical) at the accurate and determine if a better method can be longwall face and gate roads. Integrating these data sets developed. Again, the most suitable method may could provide a more accurate horizon model that can be depend on the geological environments and/or make used for longwall machine automation and guidance. of the geophysical tool that collected the data.
Recent discussions with a mine in Queensland led us to a To date, one site visit has been undertaken at which the possible site for an in-seam BHR trial in surface-in-seam project aims were explained to those on site, geologists (SIS) holes in early September. Lucas Drilling, the drilling were interviewed about their methods for selecting provider to the mine, is reviewing the proposed BHR coal/non-coal boundaries from the geophysics and data survey and assisting with the design of a pump down was provided by the site for the project. Analysis has system for BHR deployment in SIS holes. We have been performed on this data set. Due to lockdown engaged Hard Metal Industries to make the necessary restrictions over much of this quarter, it has not been components and we have sourced a pump-down unit possible to make any further site visits to demonstrate from Boart Longyear. results, obtain feedback on them or obtain further data.
We have also sourced a tactical radar capable of doing Maintenance the job, had its firmware modified to be able to match its internal delays to those specified by the pump-down operators, established that it can stand the worst-case C25063 hydraulic pressures – designed for a crush depth of Photocatalytic Destruction of Diesel Particulate 4600m, the BHR survey tool didn’t crush when the test- Matter bomb static pressure head rose to over 5600m. CSIRO Surface to in-seam boreholes are not very easily wire- Yonggang Jin lined. For a start, survey tools cannot be fed downhole gravitationally. Casing, too, can be a problem. Should Value: $527,192 tools stick, they can be hard to retrieve. We are presently Report Expected: October 2021 contacting mines to select sites with low gas and Industry Monitor/s: Brad Lucke sufficient fault mapping problems to support hosting an Greg Briggs in-seam BHR trial. ACARP Contact: Patrick Tyrrell
The second stage of the project is focused on developing a prototype photocatalytic reactor for destruction of diesel particulate matter (DPM) and test DPM photocatalytic oxidation by connecting the prototype reactor with the diesel engine exhaust. The main
Page 11 ACARP Current Projects Report August 2021 Underground Projects objective is to test and demonstrate the performance of C28003 photocatalysis technology in removal of DPM under the Lithium Traction Battery for Underground Coal real diesel exhaust condition. 3ME Technology Testing of CSIRO prototype photocatalytic reactor with Justin Bain real diesel exhaust is carried out in an external Martin Kime collaborator’s diesel engine laboratory. During the Richard Eveleigh quarter the CSIRO protype reactor has been installed in Steve Howell the collaborator’s lab. At the beginning of commissioning of the reactor, some technical issues with the engine Value: $1,268,500 system occurred. The problems with engine control and Report Expected: November 2021 data logging have been resolved and the calibration of Industry Monitor/s: Brad Lucke engine power output is being currently undertaken. It is Greg Briggs expected that commissioning of the prototype reactor Paul Wyatt will resume from mid-August. Sharif Burra ACARP Contact: Patrick Tyrrell C27006 Lightweight/Compact IS 12VDC UPS Portable or The objective of the project is to design, build, and certify Fixed Supply a high-performance battery for use in an Electric Vehicle (EV) system that meets Australian hazardous area KRS Technologies (KRS Drive Systems) compliance requirements. In Stage 1, 3ME Technology Kurt Schober conducted a successful design verification of the battery. In Stage 2, 3ME progressed from a mark one (MK1) to Value: $141,800 mark 2 (MK2) battery design and commenced Report Expected: September 2021 certification activities. Stage 3 will support the final Industry Monitor/s: Graeme Relf development and certification requirements for the Graham Café battery modules and supporting drive systems Greg Briggs components as a complete hazardous area EV system. ACARP Contact: Peter Bergin Key activities conducted to date: The aim of the project is to produce a Light Weight and • Design, manufacture, testing and validation of Compact IS Portable 12VDC UPS with an extended prototype components; capacity of up, but not limited to 50Ah capacity. The • Battery Management System (BMS) software intention is to supply clean 12VDC @ 2Amps power to development; underground field devices such as WAP’S, Cameras, • Ongoing Bladevolt design review through internal Sensors, Communications routers and LED lighting and and independent certification; personnel tracking systems. The package shall be easy to • Assembly, mechanical and electrical integration carry and deploy for both temporary and fixed validation; installations. • Heat rise tests started for motor and controller - Documentation completed; and During the quarter we supplied all the documentation as • Production validation testing of underground battery required to complete the Test Report. charger.
TestSafe is now working the Test Report which should be The integration planning and preparations have available in the coming weeks. COVID-19 restrictions are continued to progress in collaboration with 3ME’s slowing things down. However, they will not issue the mechanical integration partner: Final Approval Certificate until we have completed their • Completion of the personnel transporter EV design QAR. (Quality Assessment Report). The QAR is required and engineering for the ancillary integration; by TestSafe to issue the Final Approval Certificate. We • Wiring of main enclosure Hazardous area enclosure. are currently in the process of dealing with the above requirements. Key tasks to be conducted include: • Ongoing Design and safety reviews of hazardous area We have received a quotation for the QAR Audit from battery; TestSafe. We are also speaking with a consultant to help • Integration of battery components into the proof of with getting all the correct documentation in place so concept EV; and that a QAR audit can take place successfully. • Charger testing and final certification.
Page 12 ACARP Current Projects Report August 2021 Underground Projects
C28005 C29009 Low Cost, Wireless, Intrinsically Safe Sensors for Control of Touch Potential Transients During Underground Coal Mines Switching
Vayeron ResTech Mark Walter Peter Stepien Ryan Norris Value: $114,000 Value: $170,000 Report Expected: September 2021 Report Expected: August 2021 Industry Monitor/s: Barrie Alley Industry Monitor/s: Brad Lucke ACARP Contact: Patrick Tyrrell Dave Young ACARP Contact: Patrick Tyrrell During a number of investigations into electric shock incidences in the past, machine frames measured touch A draft report is with the industry monitor(s) for review. potential transients when switchgear closed or opened. There were no faults present in the equipment of the C28025 earth fault limited supply, yet touch potentials occurred. Integration of DAS Conveyor Monitoring into The aim of this project is to understand the method by SCADA to Enable Smart Maintenance Scheduling which these touch potentials occur and determine a method to eliminate them to improve mine safety. An Mining3 ELV hardware equivalent model has been developed for Edward Prochon convenient experimentation. Solutions to eliminate Paul Lever touch potentials will be demonstrated on typical mining equipment at normal system voltage as a find proof of Value: $300,147 concept. Report Expected: September 2021 Industry Monitor/s: Brad Lucke A presentation covering this project was made in June at Clinton Vanderkruk the Mining Electrical Safety Conference (MESC) in Kevin Rowe Brisbane. The presentation was well received, with a ACARP Contact: Patrick Tyrrell number of good questions after the presentation and discussion afterwards. Some of these discussion have led This project engages new research to detect rapid to further investigation to ensure that all aspects of the failures (using DAS monitoring) in real-time or “near real project is covered. time” to enable smarter and more responsive operational performance and maintenance. Progress has been slower than planned due to a number of factors. ResTech has moved location, including The research challenge is to identify rapid failure events laboratory. The ELV hardware simulator has also move to in real-time without detailed processing of large volumes the new laboratory facility. A 3-phase supply is being of data in a signal with significant noise. organised to allow continued use of the hardware simulator. In the meantime, further software simulation In this quarter all project work has been completed has been done to explore some of the ideas from MESC. and the final report was written. We are currently working with our patent attorney to finalise the aspects Further planning for testing on a shuttle in the workshop of this work that will be patented and will submit the final is on hold until there is some certainty with the COVID- report straight after this is done. 19 lockdowns in New South Wales.
We are discussing this work directly with existing Further presentations are planned, with a paper commercial partners to improve possibility of a accepted for the Down to Earth Conference (DTEC) and commercially available product. Our commercial an abstract submitted for the Electrical Engineering partner was involved in reviewing the work that we Safety Seminar (EESS). conducted in this project.
Page 13 ACARP Current Projects Report August 2021 Underground Projects
C33009 Completed work to date includes the following: Ceramic Wall Flow Filter Commercialisation • Review of Guidelines, Standards and Legislation; • Industry workshops and survey for New South Wales PPK Mining Equipment and Queensland underground mines; Bradley Drury • Review of information on BEV supplier; • Review of information on BEV electrical system Value: $888,778 suppliers; Report Expected: December 2021 • Review of information on BEV charger suppliers; Industry Monitor/s: Andrew Esdaile • Review of metal mines using BEV; Bharath Belle • High level load flow study; Greg Briggs • Stage 1 – Draft report; Steve Coffee • Risk Assessment delayed to stage 2 due to COVID-19 Trevor Hartley restrictions. ACARP Contact: Patrick Tyrrell Stage 2 will start in August and will look at specifications The purpose of this project is to develop a commercially and case studies. available improved diesel particulate filter (DPF) for widespread use in underground coal mines. C33017 Specialised Instrumentation and Data Processing This project builds on work undertaken in projects for Real Time FEA Condition Monitoring of AFC C25073 and C26070. An industrialised filter was developed under C26070 and requires the following to Chain be commercially available: Vayeron • Technical refinements to allow retro-fit to existing Ryan Norris Diesel Engine Systems; and
• Testing against certification and regulatory Value: $185,000 requirements – emissions and Ex-protection. Report Expected: February 2022
Industry Monitor/s: Brad Lucke The focus during May, June and July has been on Jarrod Sampson enclosure design and arrangement, as well as functional ACARP Contact: Patrick Tyrrell testing of the filter element. Sooting and regeneration tests of the filter element have shown promising results The project objectives are to: in terms of the ability of the filter element to quickly • Develop EX ia battery operated accelerometer data regenerate stored soot, however more testing is acquisition hardware, embedded within Longwall required to confirm the results. AFC Chain Link/Joiner and wirelessly network the
information back to a Gateway. Will also have a strain Field testing of a prototype unit will begin in August, with gauge; explosion-protection and emissions testing scheduled to • begin in September. Develop data gathering, processing algorithms to handle acquired data and battery life of the sensor. Target is for mining one block – approx. 12 months – C33016 need to look at load sharing; BEV Battery Charging Infrastructure Study • Deploy and test units on an operational longwall.
Target operational life at least 12 months; and to Palaris Australia • Certify sensor against IECEx ia will be wireless. John Snape
Tony Goodwin The project deliverables are:
• Commercially ready (viable battery life and data Value: $262,881 acquisition); Report Expected: December 2021 • Battery operated Ex ia Devices which remotely Industry Monitor/s: Brad Lucke acquire the following data - Greg Briggs XYZ accelerometer data, Paul Wyatt o Gateway to communicate with devices and make Sharif Burra o data available for interrogation. ACARP Contact: Patrick Tyrrell
Progress over the last quarter is as follows: The project objective is to produce a study that highlights • the challenges, impacts and solutions for charging Awaiting delivery of parts and materials ordered; • infrastructure to operate “Battery Electric Vehicles” Full System Specification developed; (BEV) in underground coal mines in Australia. The project • Complete Product Risk Analysis conducted; commenced in March and is on track as per the project • Feasibility Research is on-going including the schedule. following: o Radio technology selection tests:
Page 14 ACARP Current Projects Report August 2021 Underground Projects
- components/equipment procurement in undertake the necessary engineering tasks required to progress, enable a long-term trial of this sensor on a production - machined Billet to represent Joiner Cavity longwall. This includes the development of a suitable has been produced. This will be used for non-metallic explosion protected enclosure. preliminary radio and size constraint tests. Final design will be based on the outcomes As reported previously, samples of the non-metallic from this step; enclosure base were provided to the certifier for testing • Rubee Technology investigation resulted in a dead- and assessment against AS60079. The final test for the end due to commercial constraints; enclosure, being a leak test, has been undertaken by the • 3rd Party RF expert has been consulted. certifier and passed. Given this successful result, the unit certification process of the entire system is underway.
Mining Technology and Production The skid base and AFC adapter bracket previously fabricated were tested in the lab. Results from these C20033 tests showed that the skid base would easily become Development of a Safer Underground Explosive snagged on a step up, and then uncontrollably slam down onto the floor when it became unsnagged. It is highly University of New South Wales likely this effect would damage the GPR system in a Andres Castro production environment. Furthermore, it couldn’t Duncan Chalmers overcome any steps greater than 50mm. After consultation with the project monitor, modifications to Value: $323,500 the bracket and skid base were undertaken to improve Report Expected: October 2021 performance and increase the step-up and step-down Industry Monitor/s: Bharath Belle range. The modified base and adapter bracket were Brad Elvy successfully tested and have now been provided to the Paul Wild host test site for installation and testing on a production Russell Thomas longwall. ACARP Contact: Patrick Tyrrell Once unit certification is complete and the skid base tests Explosives for research testing are awaiting to be shipped successfully in production without becoming damaged, however with the current COVID-19 lockdowns the the certified floor horizon sensor will be installed and the project is stalled. Once lockdown restrictions have been long-term system trial will commence. lifted testing will commence. C29028 A second explosive type has been made available for Delivering the Remotely Operated Longwall testing and a test batch can be manufactured. Both explosives should allow this project to finally get CSIRO completed. Craig James Jonathon Ralston Discussions with Queensland and New South Wales Mark Dunn regulators should be ongoing as planned so that acceptance of the findings can be facilitated. Value: $1,980,890 Report Expected: April 2022 C28018 Industry Monitor/s: Bharath Belle Longwall Floor Horizon Sensing Brad Lucke Dave Young CSIRO Glenn Owens Andrew Strange Loz Hemmings Zak Jecny Samuel Zerner Sharif Burra Value: $269,680 ACARP Contact: Patrick Tyrrell Report Expected: September 2021 Industry Monitor/s: Jarod Chadwick This project responds to the need to accelerate the ACARP Contact: Patrick Tyrrell development of remotely operated longwall systems. This is of major importance to the underground industry Effective horizon control is essential for both safety and to meet ongoing safety, productivity, operational and productivity in underground longwall mining. The key to sustainability issues. Key objectives are: achieving this outcome is a reliable means of actively • Establish an industry-directed project delivery sensing the geological strata. A ground penetrating radar approach to select, direct and monitor priorities sensor was demonstrated on a longwall for this purpose throughout the project using series of flexible Work in project C25064. However, it was not in a suitable form Package (WP) periods. for installation on a production longwall. This project will
Page 15 ACARP Current Projects Report August 2021 Underground Projects
• Development of new and improved solutions in high This project aims to achieve the following: impact priority areas such as horizon sensing and • Prepare initial design; control, gate-end systems, monitoring for • Circulate to industry for comment; maintenance, and integrated information systems • Build initial prototype system; • Conduct controlled evaluations of respective • In-house testing; technology developments directly on production • Work with certifiers to determine test suits and longwall operations to demonstrate validate, refine requirements; and integrate towards full system integration and • Manufacture several units and submit them for commercialisation. certification; • Industry trials of certified units; Effort for the past quarter focussed on completion and • Incorporate this system into the type 2550 enclosure; close-out of priority development areas associated with and the two first work packages, namely maingate grade • Pursue Ex.p certification for the 2550 enclosure. tapering, lead-lag monitoring and control, on-face monitoring and face profile monitoring. This involved a The schematics and PCB layout have now been finalised, series of sustained development activities performed at the PCBs are currently being manufactured, delivery is the primary hosting mine site as well as data collection expected in the next couple of weeks. Once boards arrive and assessment at additional mine sites. assembly of the PCBs will begin, followed by final software development and testing before the boards are Highlights for the last quarter included: fitted to an enclosure and sent off for unit certification. • Trials of creep measurement based on the use of Several design options have been identified to enable reflective markers instead of a reference rope for electrical pass-though and for filling / purging of the simpler operational installation; enclosure. The current semiconductor shortage has led • Provided an updated assessment of longwall horizon to major supply issues for several key components used control practice and requirements representing over in the design, work is underway to identify alternatives 21 mine sites; where possible and procuring enough of these parts to • Finalised trial of on-face event/object monitoring in ensure at least several prototypes can be built for testing. production conditions; • Conducted preliminary trial of roof detection C29037 performance for maingate grade tapering. Intrinsically Safe RFID Sensors for Underground Coal Mining The project team also hosted a Longwall Advisory Group session in June to provide participants with an update on CSIRO project progress as well as report on the state of longwall Lance Munday horizon control across industry. Recommendations to target horizon control as next priority area for work Value: $136,050 package development were presented and agreed by the Report Expected: September 2021 industry monitors and chairs. Industry Monitor/s: Brad Lucke
Flemming Nissen C29033 Greg Briggs Alternative Flameproof Enclosure Protection ACARP Contact: Patrick Tyrrell Techniques The project objectives are: CSIRO • Develop a Radio Frequency Identification (RFID) Peter Reid platform that will enable the installation of a range of powerful sensors onto longwalls and other Value: $119,500 underground mining equipment with minimal effort Report Expected: January 2022 and cost; Industry Monitor/s: Brad Lucke • Gain Ex.ia Group I certification for the RFID sensors; Colin Hoyle • Trial the system in an underground coal mine and Gary Bowman evaluate performance. ACARP Contact: Patrick Tyrrell The goal of the project is to fulfil these objectives to The aim of this project is to design and manufacture a deliver a pre-commercial system that can be rapidly certified pressure sensing module which will be able to brought to market by a commercial partner. Key benefits be certified as Ex ia/ib. This module will be designed to of the system are: automatically and safely de-energise the payload quickly • Low installation cost and negligible maintenance if the atmosphere inside the enclosure has been cost, since the RFID sensors are cheap, wireless, and compromised. This module can then be incorporated do not contain batteries; inside a wide range of existing enclosures to help them • Increased safety and reduced cost for a range of to be certified as Ex P and achieve a higher protection mining processes including longwall control, roof level. bolting, personnel tracking, equipment localisation, Page 16 ACARP Current Projects Report August 2021 Underground Projects
machine condition monitoring and asset A major hurdle has been to gain access to mine personnel management; and for interviews. It would seem that face-to-face interviews • At-face measurement of machine and environmental would be more preferable than via video. Face-to-face parameters, even where there is a continuous interviews could still be recorded for processing with the presence of an explosive gas mixture. NVivo software. Ways of reducing the interview time is currently being evaluated. However, this would lead to During this quarter development continued of the new reduced response to the scenarios as set by the project prototype RFID tag, however, progress has been affected steering committee. by: • A shortfall in staff resourcing; and C26047 • A lack of availability of certain electronic Real Time Dust Monitor components. University of New South Wales The first factor slowed down the hardware design Charles Harb process; it also meant that development of the Duncan Chalmers standalone software had to be rescheduled to Q3. The second factor of electronics shortages is an ongoing Value: $184,300 worldwide issue (primarily due to COVID-19) and is Report Expected: August 2021 affecting all electronics supply chains. The lack of certain Industry Monitor/s: Bharath Belle components necessitated several hardware design Brad Lucke changes to the prototype RFID tag. ACARP Contact: Peter Bergin
Subsequent work will involve modifications to the A draft report is with the industry monitor(s) for review. system documentation, testing and revising the prototype PCB, writing stand-alone software for the RFID C26048 reader, and submitting a full set of documentation for Improving Respirable Coal Dust Exposure the Ex.ia certification process. Monitoring and Control
Health and Safety University of Queensland David Cliff C24010 Mark Shepherd Proximity Detection Systems Specification for Nikky La Branche
Underground Coal Mining Machines Value: $250,000
Report Expected: August 2021 Simtars Industry Monitor/s: Bharath Belle Andre De Kock Peter Smith
ACARP Contact: Patrick Tyrrell Value: $565,988
Report Expected: September 2021 A draft report is with the industry monitor(s) for review. Industry Monitor/s: Brad Lucke
ACARP Contact: Patrick Tyrrell C27010 The objectives of the project are to: Occupational Assessment and Centralised • Develop a proximity detection system specification Repository for Coal Mine Dust Lung Disease and minimum acceptance criteria for the underground coal mining industry; Uniting Care Medical Imaging • Determine the gap between the specification from I-MED Queensland the coal mining industry and the performance of Katrina Kildey systems offered to the industry by proximity Katrina Newbigin detection system manufacturers; and to • Determine if future developments by the proximity Value: $294,090 detection manufacturers will address the Report Expected: August 2021 specification from the coal mining industry. Industry Monitor/s: Bharath Belle Brad Lucke At the project start meeting it was decided to add a Sharif Burra literature review to the project. The aim of the literature ACARP Contact: Patrick Tyrrell review was to document: • The status of suppliers, and their systems involved in A draft report is with the industry monitor(s) for review. the original project C24010;
• Identify any new entries into the underground coal
mining proximity detection arena.
Page 17 ACARP Current Projects Report August 2021 Underground Projects
C27049 under high production scenarios with different cutting Mine Rescue Vehicle Radar Sensing Integration heights. The project work will involve both field studies and modelling investigations. The project aims to obtain CSIRO fundamental understanding of the effect of air velocities Gareth Kennedy on dust entrainment from various dust sources with Lance Munday different dust characteristics. The project also aims to investigate dust entrainment vs dust dilution at different Value: $254,405 velocities and investigate the influence of air velocity on Report Expected: September 2021 effectiveness of various dust control technologies and Industry Monitor/s: Brad Lucke strategies. The project studies also provide greater ACARP Contact: Patrick Tyrrell insights into the effects of air velocities on gas and dust distribution patterns at different locations along the The project objectives are: longwall face. • Develop an integrated radar sensor and user interface that is applicable to a wide range of fixed Most of the modelling studies have been completed. The and mobile sensing applications underground; results of various modelling simulations are being • Provide robust ranging and mapping that is tolerant analysed to evaluate the effect of air velocity and water of both airborne and sensor-surface contamination sprays on dust distribution profiles and re-entrainment caused by dust, smoke and water vapour; and of the dust generated at various locations along the face. • Trial the system in an underground coal mine and evaluate performance. C28023 Developing Suitable Gas Separation Membrane The goal of the project is to fulfil these objectives in order for Breathing Apparatus to deliver a pre-commercial prototype system that can be rapidly brought to market by a commercial partner. Monash University Key benefits of the system are: Victor Wei-Chung Chang • Improved health and safety, whereby persons in any part of a mine, who are subject to disorientation or Value: $196,500 severely impaired visibility, are able to find their way Report Expected: September 2021 out of the mine; Industry Monitor/s: Bharath Belle • Enhanced productivity for mining machinery, where Ken Singer operation is impaired due to dust, smoke or water Lee Earnshaw vapour. Paul Wild ACARP Contact: Patrick Tyrrell This quarter work continued to improve the system hardware and software. The client and server software The main objective of the project is to develop a new underwent further testing to remove bugs and improve prototype for breathing apparatus in underground coal useability. The system is ready for field testing. Ongoing mines using a new membrane. COVID-19 issues, and lack of access to a Drift Runner vehicle have delayed field testing. Arrangements are The team has been working on the final project report being made with a Queensland mine to carry out the field which covered two important objectives of the project, trail next quarter. including • Understand the current gas compositions in selective C28014 sites; and Optimum Air Velocity for Management of Both • Develop the suitable membrane for O2/CO2 Dust and Gas on Longwall Faces separation for a closed-loop system, as well as CH4/O2 for open-loop. CSIRO Rao Balusu The updated results indicated that a new synthesized approach can significantly increase the rigidity of the Value: $275,250 material without losing the separation selectivity. This Report Expected: June 2022 also reduces the negative impact from the moisture. Industry Monitor/s: Andrew Lewis Moving forward, the team aims to compile all the Bharath Belle knowledge developed in the project and submit the final Ken Singer report in due course. Russell Thomas ACARP Contact: Patrick Tyrrell
The objective of this project is to investigate the effect of various mining and ventilation parameters and determine optimum air velocities for management of both dust and gas concentration levels on longwall faces Page 18 ACARP Current Projects Report August 2021 Underground Projects
C28029 C29020 Personal Real Time Dust/Particulate Monitor Resilience and Mental Health in Mining (Direct Mass Based Measurement) Macquarie University Lear Siegler Australasia Rebecca Mitchell Peter Phaedonos Value: $201,666 Value: $941,780 Report Expected: April 2022 Report Expected: January 2022 Industry Monitor/s: Bianca Matthews Industry Monitor/s: Bharath Belle Rae O'Brien Brad Lucke Sharif Burra Glenn Owens ACARP Contact: Patrick Tyrrell Ian Marshall ACARP Contact: Patrick Tyrrell This two phase project is investigating the work related factors contributing to the resilience of coal mining The PDM Real time dust monitor is a safety tool and a employees. It is hoped that the findings will contribute to safety companion to the miner. At any point in the an understanding of the organisational factors, practices, miner’s working shift the PDM will display the exposure and strategies, that will promote resilience, and in turn levels you will have and allow the operator to make reduce the psychological distress associated with decisions and withdraw to a safe area. Standards exist for workplace stressors. limiting exposure to the respirable fraction of coal dust in most industrial settings, the PDM will provide the Data collection for the first qualitative phase of the study miner with the means to monitor and manage such has involved a total of 61 interviews with coal industry exposer. It will have a very low detection limit that will managers, supervisors, professional, administrative, and meet or exceed current and anticipated exposure limits, frontline employees. Most participants were interviewed and AS2985-2009 requirements for such continuous at three mine sites located in different regions of New testing. South Wales. Once COVID-19 restrictions ease, the plan is to conduct interviews with additional participants from Quick dot point status of project: frontline roles and from Queensland. • The IECEx certifying house in SIMTARS is three quarters of the way through certification of the PDM. The second phase of the study will use a confidential • Final design documentation with SIMTARS for online survey to investigate the pattern of factors that evaluation. We are now in the hands of SIMTARS and are most likely to explain and predict resilience at work. their availability to keep working on the IS The survey has been drafted and includes scale items certification. eliciting demographic information as well as measures of • Software / firmware development ongoing, with resilience, well-being, job satisfaction, help-seeking testing continuing. behaviour for mental health, psychological safety, • New prototypes were due to be completed and perceived organisational support, role overload and job available for further testing by end of June, however demands. We plan to meet with our industry mentors that did not eventuate due to several unforeseen soon to finalise which scale items to include, and to factors including the effect of COVID-19 on develop a detailed plan to the disseminate the survey to component availability and feedback from SIMTARS. a wide range of coal mining employees. • Further units for physical and performance testing will be available from the final moulds at around September /October. • This is anticipated to be an ongoing process for at least three months.
• The internal testing has shown so far that we are developing a much more accurate and advance PDM
with performance mirroring and exceeding what’s currently acceptable and available.
• A clearer picture regarding final completion of IS
certification will come in the months of
August/September as SIMTARS recommences the
evaluation process and as we finalise component
availability.
Page 19 ACARP Current Projects Report August 2021 Underground Projects
C29035 C33001 Effect of Rock Dust and Pre-Existing Lung Disease Methodology Development of Free Silica Analysis on the Risk of Mixed Dust Lung Disease (MDLD) of Dust on PDM Filters: Phases 1A&B
University of Tasmania CSIRO Basil Beamish Hsin Wei Wu Graeme Zosky Yonggang Jin
Value: $525,850 Value: $249,200 Report Expected: August 2022 Report Expected: September 2021 Industry Monitor/s: Andrew Lau Industry Monitor/s: Andrew Lau Bharath Belle Bharath Belle Brad Lucke Brad Lucke Kevin Rowe Kevin Rowe Sharif Burra Sharif Burra Tony Egan Tony Egan ACARP Contact: Patrick Tyrrell ACARP Contact: Patrick Tyrrell
This project focusses on the properties of particles in the The latest personal dust monitor (PDM) is a real-time coal mine environment and how they impact on the risk mass-based respirable dust monitor in the coal mines. of developing a dust related lung disease. Specifically, the The objective of the project is to develop a methodology aims of the project are to determine: to enable silica analysis of the PDM-collected respirable • If the presence of rock dust modifies the lung coal dust. response to coal dust; • If prior lung disease modifies the response to coal The methodology has been successfully developed and dust; and recently filed for a patent, which involves a backflush • The impact of exposure to diesel exhaust particles. method for detaching the collected dust sample from the PDM filter into a solvent, followed by a filtration process By addressing these objectives, we will be able to identify to redeposit the detached dust onto a polymer filter. The who is most at risk of adverse health outcomes in the coal resultant filter sample of redeposited PDM-collected mining environment. dust will be ready for silica analysis by FTIR or XRD with either an on-filter method or traditional destructive We have conducted the bulk of the experiments for method involving ashing of the filter sample. The on-filter Phase 1 of the project. This involved exposing three lung FTIR analysis was applied in our studies and a new cell types (epithelial cells, macrophages and fibroblasts) approach of aligning the IR beam with the sample area to 19 different coal samples with a range of ash/silica on the filter has been developed to improve the analysis contents. We have assessed the cell response by accuracy. Parallel PDM and gravimetric samples were measuring cell death and inflammation and have now obtained by pairwise sampling using the dust chamber in included diesel exhaust particles (DEPs) as another our lab. Comparative analysis of these parallel samples contributor to particulates in the underground mine showed the silica contents of PDM samples measured environment. through the developed methodology are very close to those of gravimetric samples. Some redeposited PDM We are in the process of finalising data from Phase 1 samples and gravimetric samples were also sent to an using new software (to ensure the analysis is robust and external laboratory for silica content measurements by accurate) and will be appointing a new technical staff FTIR with filter ashing. Analysis results from the external member to increase throughput in the project. lab confirmed that our detachment process didn’t lead to the contamination of PDM filter glass fibres to the dust sample. To date, the laboratory results have demonstrated that the developed methodology is feasible for enabling silica analysis of PDM-collected dust samples. The project has been delayed by in-lab dust sampling and currently more parallel dust samples are being collected under varied conditions to carry out silica analysis.
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C33006 C33010 Breathing Zone Exposure Quantification and Health Screening “True Positives”, “False Respirators Performance – Review of Exposure Positives” and “Incidental Findings”: An Control Strategies Investigation
CSIRO I-MED Queensland Rao Balusu Katrina Kildey Katrina Newbigin Value: $329,450 Report Expected: January 2023 Value: $160,798 Industry Monitor/s: Andrew Lau Report Expected: May 2022 Bharath Belle Industry Monitor/s: Bharath Belle Brad Lucke Brad Lucke Kevin Rowe Sharif Burra Sharif Burra ACARP Contact: Patrick Tyrrell Tony Egan ACARP Contact: Patrick Tyrrell The objective of this project is to understand the respiratory health of coal mine workers requiring review The objective of this project is to investigate the spatial following an abnormal health screening result; and to variability of dust concentration levels in the breathing determine whether any differences are observed zone and the impact of current dust monitoring between those diagnosed with a Coal Mine Dust Lung strategies on personal dust exposure levels. The project Disease (CMDLD, “true positives”) and those considered also aims to evaluate the effectiveness of respirators, “false positives” or “incidental findings”. such as various types of powered air-purifying respirators (PAPRs), on personal dust exposure levels. At the present time, the research team’s efforts are focused on continued data collection, which involves The project work will involve extensive laboratory retrospectively reviewing the respiratory physician’s investigations and some field studies. The project studies records on the identified coal mine workers who have will provide a better understanding of the effectiveness been assessed following an abnormal screening result; of respirators and integrated unit performance of full- Data collection is now approximately 75% complete. face PAPRs in protecting workers working under high dust concentration zones as well as the actual personal Interim research work was presented at the Health and dust exposure levels of workers wearing full face PAPRs. Hygiene Network meeting hosted by the Queensland Government’s Resources Safety & Health Queensland A large volume dust chamber comprising two (10 June, Emerald). The data was presented with the 2m3 chambers has been constructed for the laboratory intent of raising awareness of our research and seeking studies to evaluate the performance of respirators and to feedback. Attendees from Resources Safety & Health investigate the dust distribution patterns around the Queensland expressed great interest in our research mannequin within the breathing zone. A high-flow fan work, and as a result, further dissemination of this work and large size ducts of 810mm in diameter were is now planned to their broader Occupational Health connected to the chamber to control the airflow inside team (10 August Brisbane). the chamber. Two commercial dust dispersion units are being procured for the project including the PALAS dust Over the next quarter, work will continue to focus on disperser RBG 1000 to feed solid powder into the data collection and concurrent analysis, with an aim to chamber at a constant speed, and the TSI 3400A fluidised complete these tasks by October. bed aerosol generator with a capability of selecting size of dust to be fed into the chamber.
Construction of the entire dust chamber system is nearing completion, and once commissioned, detailed laboratory studies will commence as per the project schedule. Review of current dust monitoring practices, personal dust exposure data, spatial distribution of dust, and use of dust masks and respirators in the field at mine sites in in progress.
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C33011 C33012 Coal Mine Dust Lung Disease: What Happens Respirable Dust Reference Testing Method and Once the Dust Settles? A Longitudinal Study of a Dust Chamber Facility Latent Disease Simtars I-MED Queensland Gareth Kennedy Katrina Kildey Katrina Newbigin Value: $215,950 Report Expected: June 2023 Value: $167,925 Industry Monitor/s: Andrew Lau Report Expected: May 2022 Bharath Belle Industry Monitor/s: Bharath Belle Brad Lucke Brad Lucke Kevin Rowe Sharif Burra Sharif Burra ACARP Contact: Patrick Tyrrell Tony Egan ACARP Contact: Patrick Tyrrell The aim of this project is to provide information on whether individuals with coal mine dust lung disease The aim of this project is establish the methodology for (CMDLD) tend to stay stable or progress, as observed the respirable dust chamber as a reference tool for through quantifiable measures of disease (lung function cyclones and devices used in the coal mining industry. and radiology); and if progression is observed, to This will be achieved through three objectives: determine whether there are any differences between • Establish that the respirable dust chamber those that do progress and those that stay stable. conforming to international testing methodology and accuracy; The present focus of the project is the continued • Verify the methodology utilising a selection of collection of longitudinal data on individuals diagnosed respirable dust cyclones and impactor plate devices with a CMDLD since 2015. For the 52 cases of CMDLD currently used in underground coal mines; that have attended at least one follow-up appointment, • Compare the accuracy of devices when using a the majority of follow-up complex lung function data has different dust types and dust mixtures (stone dust, now been collected. coal dust, silica).
Efforts are now focussed on the collection of radiological The project started in June. The respirable dust chamber data, as well as data on any modifiable lifestyle changes. is currently being built. The method development work At the outset, our intention was to collect results of all will commence on completion of the Simtars respirable available medical imaging tests (chest radiograph, high- dust chamber assembly. resolution computed tomography; HRCT) at diagnosis, and from any follow-up consultations. However, we have C33069 identified key issues with this component of the project, New PDM filter for Direct-on-Filter Silica Analysis including inadequacies in the consistency and quality of of Coal Mine Dust reporting between imaging providers, as well as between reporting radiologists. These inadequacies have made CSIRO collection of measurable radiological changes from Yonggang Jin existing imaging reports infeasible. Therefore, we have modified the data collection method, Dr Newbigin is now Value: $298,240 comprehensively reviewing HRCT imaging at two time Report Expected: April 2023 points only; at diagnosis and the most recent follow-up Industry Monitor/s: Andrew Lau available. Although not as comprehensive as originally Bharath Belle planned, the focus on only the more sensitive imaging Brad Lucke modality (HRCT) and first and last scans (not all interval Kevin Rowe scans), will still allow for conclusions to be drawn on Sharif Burra radiological status. Tony Egan ACARP Contact: Patrick Tyrrell The next quarter will focus on continued data collection. At this time, it is unclear whether the change in approach The main objective of this project is to develop a new to radiological data collection will result in a delay to the type of Personal Dust Monitor (PDM) filter with a non- overall project. silica filter material and a novel filter assembly structure to enable the direct-on-filter silica analysis of the PDM- collected dust sample with a field-based FTIR method. The project work will involve extensive laboratory studies for development, evaluation and prototyping of the new PDM filter. Expected outcomes from this project include a novel type of filter for use in PDM to achieve Page 22 ACARP Current Projects Report August 2021 Underground Projects both real-time respirable dust monitoring throughout C33013 the sampling shift and silica content measurement at the Light Weight Composite Conveyor Support end of the sampling shift, and a rapid reliable field-based Structures approach to be developed for optimal monitoring of personal exposure levels of respirable coal dust and University of New South Wales respirable crystalline silica with one single PDM unit. Ganga Prusty Serkan Saydam The project has very recently commenced. Review studies are in progress to understand the key Value: $280,440 characteristics of PDM filters, select the candidates of Report Expected: June 2023 non-silica filter membranes and design the structure of Industry Monitor/s: Roadway Development the new filter assembly. Task Group ACARP Contact: Patrick Tyrrell Roadway Development This project aims to implement fibre reinforced C27076 composites into conveyor support structures to achieve the light-weighting benefit whilst meeting the safety and Underground Coal Mine Gateroad Development design requirements of an underground mine. Continuous Haulage System
Following is a summary of work that has taken place Premron since the start of the project on 1st June: Mick Whelan • A thorough literature review on the design
requirements for a load-bearing composite structure Value: $6,744,860 in underground mines. Report Expected: June 2022 • Several resin systems and fibre reinforcements have Industry Monitor/s: Roadway Development been evaluated against the design requirements for Task Group the mine environment. ACARP Contact: Patrick Tyrrell • Polyramic® resins are inorganic polymers which
decompose to ceramic form at a temperature greater This project aims to develop a Continuous Haulage than 900°C. It has excellent fire-retardant properties System for mine gateroad development, utilising the and moderate cost ($120 per kg). closed conveyor system of the “Premron CHS” © and is a • ModAR (modified acrylic resin) exhibits superior fire continuation of projects C22009, C23017 and C24023. resistance and excellent low smoke performance Since June the project was approved to continue with the when filled with fire-retardant additive. They also support of a new host mine, within the Bowen Basin. offer significant life cycle costs and are used in
architectural and mass transit applications. The project has been modified around the following key • objectives: Ampreg 21FR is another alternative resin designed to give excellent mechanical and thermal properties. It • Perform modifications to the Premron CHS to allow a is an epoxy laminating system optimised for the more compact machine operating window, making it manufacture of large composite structures. suitable for smaller seam coal mines (<3.0m seams); • Carbon and glass fibre provides excellent fire • Provide a customised fully onboard Services and performance due to their inorganic nature. Carbon Ventilation system within the Premron CHS (currently fibre offers better mechanical properties than glass being assessed and may be included); fibre at a higher price point. • Identify modifications surrounding the Sizer Feeder • Natural fibre, such as flax or jute, is an alternative machine, including the adaptation of drill rig selection for better recyclability and lower cost, but machines to assist spot bolting and mega bolt installs, they are more flammable and have lower mechanical (currently being assessed and may be included); properties. • Perform a mini build to test functionality of the
modifications provided; A test matrix will be developed in the next stage to • Installation and trial operation in a fully working procure the chosen candidate materials and perform underground panel. material characterisation for quantitative assessment for
final material selection. In parallel, an initial conceptual Currently, the Premron team have completed the project frame design, including joint and assembly strategy, will plan, resourced up and are finalising the design stage of be studied using analytical and numerical FE methods. the project. The full scope of works is being determined by the host mine and Premron, which will be completed within the next few months.
The existing Premron CHS is being pulled down at the host mine and is being delivered back to Premron’s Gladstone facility for the modifications to be performed.
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C33020 investigations, namely, literature review, lab testing, Floor Horizon Control for Roadway Development numerical modelling, and back analysis.
CSIRO Over the last quarter, the estimation results from Andrew Strange different mine sites were summarised, and the existing model was further improved. The machine learning Value: $80,000 source code was rewritten in Python, and the Report Expected: May 2022 development of a web-based software that incorporates Industry Monitor/s: Roadway Development the current stress estimation model was commenced. Task Group ACARP Contact: Patrick Tyrrell In this quarter, the development web-based software will be finalised, and final report is being prepared. Effective horizon control is essential for safety and productivity in roadway development and is vital to C27040 sustain faster development rates, improved product Numerical Modelling Approach to Better recovery and effective ground control. A key to achieving Understand the Effect of Cable Bolt Performance this outcome is a reliable means of measuring geological on Roof Failure Mechanisms in Varying Rock Mass strata during the mining process. A ground penetrating Conditions radar floor horizon sensor has been developed to obtain this information for longwall. To decrease technical risk University of New South Wales during the adaptation of this technology to the roadway Ali Mirzaghorbanali development application, this project will design, Guangyao Si fabricate and test a new rugged non-metallic enclosure Joung Oh specifically to house this sensor. This also includes a Najdat Aziz method to mount the enclosure to the miner-bolter directly behind the apron in a way such that the Value: $389,000 enclosure maintains contact with the floor. The new Report Expected: August 2021 enclosure will not contain electronics, and hence, does Industry Monitor/s: Paul O'Grady not require certification. The key outcome of this project Peter Corbett is to install this enclosure on a production miner-bolter ACARP Contact: Peter Bergin to ascertain how well the new non-metallic enclosure, along with the corresponding attaching components, can A draft report is with the industry monitor(s) for review. survive the roadway environment. This project has recently commenced. C27045 Assessment of Longwall Mining Induced Strata Control and Windblasts Connective Fracturing
C26063 CSIRO Reliable Estimation of Horizontal Stress Deepak Adhikary Magnitudes from Borehole Breakout Data Value: $407,438 January 2022 University of New South Wales Report Expected: Joung Oh Industry Monitor/s: Gift Makusha Julian Potten Peter Corbett Value: $232,609 Peter Bergin Report Expected: January 2022 ACARP Contact:
Industry Monitor/s: Brian Vorster Patrycja Sheffield The project deliverables will be a report containing charts/tables and a numerical modelling guideline ACARP Contact: Peter Bergin (including all the source codes developed in the project) The primary objective of this project is to develop a for estimating the height of connective fracturing that simple and reliable method to predict in situ horizontal can create pathways for increased groundwater inflow stress magnitudes from existing borehole breakout data. and excessive gas emission into longwall workings from Stress measurement techniques currently available in adjacent gassy seams. the mining industry are expensive and time consuming. The results of this project will produce an inexpensive The objective of this stage of this project is to complete and reliable method that can be included in stress the logical final stage of the connective fracturing measurement programs to identify high risk areas where projects C24020 and extension 2 of this project that the mining conditions will be adversely affected. To sought to address acknowledged limitations in empirical achieve this objective, the project involves four areas of estimation of the zone of dewatering above longwall goaves.
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The main project objectives are as follows: C28011 • Estimate overburden permeability changes by Prevention Techniques for Stress Corrosion numerically simulating fluid flow through the porous, Cracking Failures of Rock and Cable Bolts fractured rock. The location, connectivity and size of the mining-induced fractures will be predicted using University of New South Wales the fracture-modelling technique developed; Serkan Saydam • Promote uptake by two outcomes; • Further refine the methodology developed in – Value: $298,380 previous stages. Report Expected: October 2022 Industry Monitor/s: Lesley Munsamy The work undertaken includes: Patrycja Sheffield • Conducted review of functionality of existing Peter Corbett software and development of efficient approach; ACARP Contact: Peter Bergin • For consistency, numerical models have been developed for all the five mines sites evaluated; The main objectives of the project are to: • In parallel, code facilitating interoperability of PFC • Develop prevention techniques, eg antimicrobial and MOOSE has been developed; coating, as a long-lasting controlling technique to • Run DEM models of additional three mine sites; and mitigate against SCC in underground coal mines; and • Run MOOSE models to estimate permeability. to • Develop guidelines for preventing SCC, which is C27071 consistent across the industry. Intrinsically Safe Digital Networked 3D Roof Bolt During this quarter, the following tasks have been Holville completed: Anne Wylie • Sulphate reducing bacteria (SRB), which were found in a mine water sample, have been isolated. The Value: $140,000 bacteria were enriched for the immersion test of Report Expected: September 2021 coupons. Industry Monitor/s: Mick Stadler • DHP-Br and T1G compounds were tested in an Paul Buddery established bacterial (SRB) environment. DHP-Br has Roger Byrnes shown satisfactory performance in controlling SRB. ACARP Contact: Peter Bergin • DHP-Br compound was integrated into a coating. The coating was applied on a glass slide and a rockbolt The project objective is to develop an intrinsically safe surface for microscopic analysis against the growth of instrumented digital roof bolt that will: SRB. • Accurately measure axial strain and bending in 3 • The first round of heat treatment experiments has dimensions; been completed (normalising, quench and • Interface to the Holville handheld terminal (project tempering). The quench and tempering have C25060), the wireless network of geotechnical demonstrated a noticeable improvement in sensors project C25059, and the IS certified (IECEx microstructure and hardness properties. 12.0034X) Holville roofAlert™ communications and power backbone; and Following four activities are planned to start in August: • Provide a cost-effective alternative to the routine • Set up immersion tests of both rock bolt and cable monitoring of existing analogue ¼ bridge strain bolt coupons in a bacterial environment containing gauged roof bolts. SRB enriched from collected mine water; • Design the self-tempering method for 1355 rockbolt; The design of the robust bolt end connector has been • Test and compare fusion bonded epoxy and liquid finalised and is now being incorporated into the epoxy coatings on rock bolt surface; and prototype bolt. Software development is ongoing for • Complete the microscopic analysis of the immersion getting the data onto an IS data network. test (bacterial), with a focus on biofilm formation.
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C28015 C28020 Evaluation of the Chinese Outburst Assessment Optimising the Cablebolt Pre-Tensioning Practice Methodology and its Applicability to Australian to Control Roadway Roof Failure Using Advanced Low Permeability Coal Seams Combined Axial and Shear Testing Facility
CSIRO Monash University Qingdong Qu Hossein Masoumi
Value: $238,270 Value: $165,000 Report Expected: April 2022 Report Expected: December 2021 Industry Monitor/s: Bharath Belle Industry Monitor/s: Brian Vorster Ken Singer Peter Corbett Rae O'Brien ACARP Contact: Peter Bergin Russell Thomas Sharif Burra The main objective of the project is to investigate the ACARP Contact: Patrick Tyrrell long history issue of cable bolt pre-tensioning practice in the Australian coal industry. It is aimed to find a sensible The project evaluates China's outburst risk assessment understanding of the selected level of pre-tensioning and methodology and its applicability to Australian low the technical reasons associated with such a selection. permeability coal seams. The objective is to improve outburst assessment methods and control strategies for Reinforced concrete samples have been casted and are mining low permeability coal seams. to be delivered to the lab to undergo testing. Additionally, loading protocols and instrumentation In the last quarter, the project team: setup have also been concluded and equipment required • Finished the review and evaluation of the has been ordered. Pre-tensioning procedure and technologies used or being developed in China for grouting technique has been extensively studied to detecting changes in mining conditions and warning ensure realistic replication of the field condition is signs of outburst. These technologies include the achieved. To provide sufficient data for numerical radio imaging method, ground penetrating radar, modelling calibration, several pull-out testing concrete inseam seismic monitoring, integrated monitoring of samples have also been casted in the lab. Several cable electromagnetic radiation and acoustic emission, and bolts delivered to the lab are to be used for pull-out microseismic monitoring. testing. All the equipment required to secure the large- • Has started preparation for numerical modelling scale samples while grouting and pre-tensioning is studies, which will compare the outburst risk underway, has been identified and ordered to the conditions between typical Australian and Chinese corresponding suppliers. Initial planning to make large- coal mines. The numerical approach can account for scale samples reusable to allow for more testing has the interactions between various risk factors of been completed. outburst, including coal strength, gas pressure, gas desorption rate and permeability. The numerical C29008 modelling study will also evaluate the difference Modelling the Onset of Fracture Induced between gas permeability measured in China and the Instabilities for Underground Mining Applications hydraulic conductivity measured in Australia. • Continued writing of the project report. University of Newcastle Anna Giacomini We are still waiting for some coal samples to test the outburst risk index using the Chinese methods. Value: $203,820 Report Expected: March 2022 Industry Monitor/s: John Grieves Paul O'Grady ACARP Contact: Patrick Tyrrell
This project proposes to deliver practical guidelines for designing bolt and cable roof support systems in anisotropic and jointed rock mass by developing and applying an efficient phase-field finite element code that is capable of computing stresses, displacements, and fracture paths. The code will incorporate a “Phase-field” in addition to the usual displacement field, which allows cracks to be represented as smeared regions of damaged material within a continuum.
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Work undertaken in this quarter has continued to focus • Analysis of stress magnitude data has been started. on testing and extending the capabilities of the The team is calculating vertical stress and horizontal developed phase-field finite element code which will be stress magnitudes to make a database of stress used to simulate the propagation of fractures around magnitude for the northern Bowen Basin (for the roadway roofs. Specific tasks that have been undertaken purpose of model calibration). include: • The 3D geological model has been constructed using • The simulation of additional laboratory scale tests has GoCAD software package and we are in the process been undertaken to validate the developed code and of polishing the model and export different geological mathematical formulation on which it depends. and structural surfaces (faults and different Comparisons between results obtained from stratigraphic units) into geomechanical software simulated tests with laboratory UCS and Brazilian disc package. tests has demonstrated that the code can produce • Following completion of the previous step, the detailed fracture patterns in the vicinity of geomechanical model will be constructed using concentrated loads and model collapse in brittle rock. Hyperwork software package for further analysis. However, careful model calibration is required to However, lockdowns and border closures (interstate ensure that the peak load value and fracture pattern and international) has slowed down this component at failure captured accurately. as we were aiming to do national and international • An efficient data structure for storing and collaborations on this part of the project. manipulating meshes within the phase-field finite element code has been developed. The data C29012 structure is capable of handling elements with Longwall Rock Mechanics in Massive Strata arbitrary: dimension, shape, and number of nodes. This feature is important for solving problems that Sigra involve both continuum elements and connected Tim Gibbons networks of planar joints. Work on generating the geometry of the joint networks that are stored in the Value: $245,000 developed data structure is ongoing. Report Expected: September 2021 Industry Monitor/s: Bob Coutts C29011 Brad Elvy Integrating In‐Situ Stress Patterns with Basin to John Grieves Local Scale Structures in the Nebo Synclinorium, ACARP Contact: Patrick Tyrrell Bowen Basin The objectives of this project are to identify the University of Queensland conditions that will lead to mining problems, and Joan Esterle secondly, to work out the best strategies to deal with Mojtaba Rajabi them. These may include blasting, high energy gas Renate Sliwa fracturing, hydrofracturing and changes to mining practice. All research is complete and documented. The Value: $203,086 draft report is pending, and should be finished very soon. Report Expected: November 2021 Industry Monitor/s: Mark Laycock C29014 Rae O'Brien Definition and Quantification of Long Term Sharif Burra Stability of Coal Pillar Systems ACARP Contact: Patrick Tyrrell University of New South Wales This project aims to investigate the geomechanics and Ismet Canbulat structural geology of Nebo Synclinorium using the John Watson concept of stress mapping and geomechanical modelling. It therefore aims to provide in-situ stress map, 3D Value: $230,000 structural and geomechanical model over the Nebo Report Expected: April 2022 Synclinorium. Industry Monitor/s: Dan Payne Peter Corbett Progress during this quarter: Russell Thomas • The team has completed the analysis of ATV/OTV ACARP Contact: Peter Bergin data compiled from mine sites in the Bowen Basin. • Analysis of other sources of image log data in The objective of this project is to define and quantify the northern Bowen Basin has been completed (> 235 long-term stability of coal pillar systems. borehole image logs from CSG wells have been analysed). Work undertaken this quarter includes: • The first component of the project, which is the stress • A presentation on the progress was recently give at map of the northern Bowen Basin, has been finished. the NUGS meeting on 24th June 2021.
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• A further analysis of the data gathered from the C29022 Subsidence Advisory NSW has been conducted. Mechanical Investigation of Two Critical Standing • Published pillar failure database from Queensland Support Systems (Timber Chock and Pumpable has been analysed. A total of eight failed and five Crib) in Underground Coal Mines unfailed cases have been included in the database. The preliminary results are currently being analysed. Monash University • Coal pillar spalling rates have been measured at two Hossein Masoumi mines in three seams in New South Wales, where the Javad Hashemi pillar ages varied from ten years to 57 years. This data is still being analysed. Value: $295,000 • Models that describe the time-dependent pillar Report Expected: August 2022 failures due to pillar and roof spalling have been Industry Monitor/s: Brian Vorster developed and currently the data is being analysed. Dan Payne • A further database to determine the roof spalling Gift Makusha rates are being compiled together with Subsidence Patrycja Sheffield Advisory NSW. ACARP Contact: Peter Bergin
The numerical modelling part of the project is impacted The main objective of this project is to extensively by COVID-19 lockdowns due to lack of access to a investigate the mechanical behaviour of two critical software located at UNSW. standing supports systems being timber chocks and pumpable crib which are commonly used in underground C29019 coal mines. In addition, a testing standard will be Mechanical Assessment of Time Dependent developed for the selected standing supports based on (Creep) Behaviour of Coal and Coal Measure mechanical parameters, such as loading rates, offset Rocks Under Uniaxial and Triaxial Conditions loading and compressive or shear loadings. Based on Experimental and Analytical COVID-19 restrictions have restricted access to Monash Methodologies and Swinburne Laboratories and consequently some
experimental works have been affected adversely. Monash University
Amin Heidarpour The numerical calibration phase has been progressed,
the structure of the timber standing supports, Timber Value: $205,000 Chocks, have been simulated. The effective factors in Report Expected: November 2022 mechanical behaviours of timber chocks are considered Industry Monitor/s: Brian Vorster wrapping up design of experiment phase. By doing so, Elliot Tembo not only we will be able to test timbers structures in ACARP Contact: Peter Bergin laboratory but also, we can simulate the costly
performance of the standing supports in the field at an The objective of this project is to investigate the time- underground mine site with some perplexing loading dependent behaviour of coal and coal measure rocks by regimes. conducting experiments under various timeframes ranging from a month to a year or more. Researchers will use creep loading frames in temperature and humidity- C29025 controlled conditions which replicate the underground Effectiveness of Shotcrete in Underground Coal mining environment. Mines
COVID-19 restrictions have restricted access to University of New South Wales laboratory so that manufacturing of the components and Chengguo Zhang consequently some experimental works have been Joung Oh affected adversely. Value: $185,000 Literature review of the project has been conducted Report Expected: July 2022 extensively and will be continuing in the next quarter. Industry Monitor/s: Ben Forrest Brian Vorster Sandstone and coal samples have been prepared to run Julian Potten the designed testing program under uniaxial and triaxial ACARP Contact: Peter Bergin conditions. Creep rigs have been activated, equipped by highly precise extensometers and calibrated to start The main objective of the project is to quantify the testing. The uniaxial creep test has been started on a effectiveness, applications and benefits of shotcrete in couple of samples. Numerical modelling works have been underground coal mines. It is well-known that shotcrete progressing to capture the creep behaviour of coal and is a versatile ground support tool and is becoming more coal measure rocks. common in the coal mining industry because it enhances mine safety significantly when properly applied. Page 28 ACARP Current Projects Report August 2021 Underground Projects
Quantitative information of shotcrete properties such as of the concrete blocks differentiated by strength. A adhesion strength to coal or other rock surfaces and its representative number of experiments on various types interaction with other support elements such as mesh, of samples (without and with interfaces) have been rock bolts are important design consideration in planned. application of shotcrete. Other critical factors of shotcrete include shotcrete characteristics, the height of C33022 application, pinning the shotcrete to the ribs and the Understanding and Quantifying the Hydraulic floor, fibres used, among other design and durability Characteristics of the Overburden considerations. CSIRO This quarter, experimental investigations for shotcrete Andy Wilkins strength such as bond strength for different substate Deepak Adhikary properties were not able to perform as COVID-19 restrictions do not allow to hire shotcrete machine and Value: $178,070 conduct lab tests at UNSW. Instead, a detailed numerical Report Expected: February 2023 analysis has been conducted to investigate the bond Industry Monitor/s: Gary Brassington failure mechanisms by incorporating the advanced Peter Corbett contact constitutive model between shotcrete and ACARP Contact: Peter Bergin substrate into the numerical simulations. In the following quarter, we plan to conduct experimental The objective of this project is to enable accurate and studies with shotcrete samples and various substate immediate quantification of the hydraulic characteristics properties and compare the results with numerical of the longwall goaf. This will enable accurate prediction simulations of the impact of mining on the local groundwater and surface water systems. It will also facilitate C33019 understanding of water flows to the mine workings and Monitoring While Drilling Concept on gas flows through the goaf region. The main output will Characterising Coal Mine Roof be tables, charts and formulae expressing hydraulic characteristics as functions of extraction height, CSIRO subsidence, strata strengths, panel width, etc. Manoj Khanal Work during this quarter has involved running numerical Value: $279,989 models to predict the overburden fracture patterns, Report Expected: January 2023 which control the hydraulic characteristics. It is Industry Monitor/s: Brian Vorster envisaged that this numerical modelling will continue for Dan Payne at least one more year, since it comprises the bulk of this Mark Laycock project. In parallel, alternative numerical approaches are ACARP Contact: Patrick Tyrrell being explored with a view to reducing the substantial computational expense of this project. A major cause of roof instability in underground coal mines is the variable nature (for example, thickness, C33031 competence, discontinuities) of the coal mine roof that Reducing the Subjectivity of CMRR Calculation may be composed of different strata including coal roof Using Machine Learning and uncertainty associated with the variation. Normally, the geotechnical and geological data gathered from University of Queensland exploration boreholes, which are drilled at considerable Joan Esterle distances from each other, are used to characterise the Zhongwei Chen thickness and competence, including strength, of the coal mine roof. This limited data cannot capture local Value: $115,100 variability present in the coal mine roof. The objectives Report Expected: March 2022 of this project are to investigate the applicability of the Industry Monitor/s: Brian Vorster MWD concept to perform geotechnical characterisation Dan Payne of coal mine roofs and detect “signatures” of change in Matt Tsang roof strata competence. ACARP Contact: Peter Bergin
One component of the project is the laboratory The main objectives are to: experiments with synthesised concrete blocks. Different • Update the correlation between the sonic data and strength samples are prepared and assembled for drilling rock mechanical properties based on rock types; at the CSIRO laboratory. The preliminary drilling • Integrate geophysical logs with laboratory data, and experiments have been performed with the field scale apply advanced machine learning algorithms to drilling machine. The first set of results from the identify roof geotechnical units and determine synthesised concrete blocks are promising as the drill discontinuity rating of each unit; returned signals are able to detect distinct “signatures”
Page 29 ACARP Current Projects Report August 2021 Underground Projects
• Calculate CMRR values by using the UCS values and heating / spontaneous combustion and incorporated roof unit obtained from the validated machine into TARPs. learning algorithms; and to • Extend the proposed machine learning algorithms to The work status is as follows: estimate other rock properties. • The literature survey of relevant reports and papers is in progress. In this quarter, the following work was undertaken: • The 2m column was switch to ‘adiabatic’ mode on the • The laboratory data and the corresponding 11th May. The 2m column is still running in this mode geophysical logging data have been integrated and at present. analysed. A Python algorithm has been developed for • The top five zones initially increased in temperature, such analysis; for a few days, where after the coal in these zones • The correlation of sonic logging data and rock started decreasing in temperature. The decrease in mechanical properties (UCS) is updated and temperature has continued to date (2nd August). compared with existing widely used correlations; During the last few days it appears that the rate of • Various machine learning models (polynomial decrease in temperature has slowed and possibly regression (PR), random forest (RF), support vector starting to stabilise. machine (SVM), extreme gradient boosting • On switching to ‘adiabatic’ mode, the temperature in (XGBoost), artificial neural network (ANN), genetic the bottom five zones immediately started to algorithm (GA)) were applied to evaluate and predict decrease in temperature. This continued to a point the UCS and other mechanical properties. Our results where the temperature stabilised and zones six to ten show that the XGBoost gives the best prediction; are within three degrees of each other. These zones • The geological interpretation of lithologies is created have started to increase slightly in the last few days. and compared with the ATV interpretation; • Multiple machine learning models have been Early stage 2m Column results: constructed to predict the lithology facies. • General Gas Results . Methane <0.1% The results and outcomes have been communicated with . Carbon Dioxide ≤ 0.1% the industry monitors in June and July. The next step of . Carbon Monoxide – Ports 6, 8 and 10 are now the project will be rock discontinuity evaluation focusing detecting ≤ 3ppm on the machine learning application in the evaluation of . Ethane ≈ 1ppm rock quality designation (RQD) and fracture spacing (FS). • Natural Gas Results . No components yet detected. Ventilation, Gas Drainage and Monitoring • Extended Natural Gas . No Components yet detected C25072 • Aldehyde Results . New Approaches to Mine Gas Analysis and Ratios Aldehydes Below LOR
Simtars C27035 Andre De Kock Automatic Leak Detection for Tube Bundle Systems Value: $416,192 Report Expected: December 2021 Simtars Industry Monitor/s: Bharath Belle Sean Muller John Grieves Snezana Bajic ACARP Contact: Peter Bergin Value: $220,000 The aim of the project is to identify additional gases for Report Expected: June 2022 the detection and monitoring of spontaneous Industry Monitor/s: Bharath Belle combustion. This will be achieved through three John Grieves objectives: ACARP Contact: Patrick Tyrrell • Using a medium scale reactor, profile the gases evolved from the heating of a Queensland coking coal The objective of this project is to develop a fully with a methane / ethane seam gas composition and a automated integrity testing system prototype which is New South Wales coal with a carbon dioxide seam based on information on the flow rates and pressures on gas. tubes from this research. This prototype will be able to • Compare these gas profiles to the normal carbon be retrofitted to any tube bundle system, regardless of dioxide seam gas and methane / ethane seam mine the supplier. The basis for the design of the automated fingerprints identified in the first stage of projects system is Delta Automation’s manual integrity testing C25072 and C10015. system. The project comprises of three phases. The first • Expand the current “Fire Ladder” to include phase is the accumulation and evaluation of presently additional alkanes below the ethylene point which available information relating to flow rates, designs and can be used to give earlier warning of a developing pressures in tube bundle systems in underground coal Page 30 ACARP Current Projects Report August 2021 Underground Projects mines. During the second phase the specifications for C28006 automatic system prototype will be developed. The final Impact of Gas Composition on Outburst phase will be to retrofit the prototype to a tube bundle Propensity of Coal systems at the mines, which have existing tube bundle system supplied by three different manufacturers (Delta University of Wollongong Automation, SICK and ADT). The information from this Dennis Black testing will then be used to compile the final report. Ting Ren
th At the review meeting on 14 July, it was agreed to Value: $125,000 extend the project to the end of June 2022. The Report Expected: August 2021 hardware design has been approved for use in hazardous Industry Monitor/s: Bharath Belle areas in May, and Deltamation commenced the David Webb manufacturing of the prototype. Deltamation estimate Paul Wild the prototype to be ready for testing at the end of Russell Thomas August. Simtars are in the process to confirm site access Sharif Burra and dates with participating mines. ACARP Contact: Peter Bergin
C27072 A draft report is with the industry monitor(s) for review. Intrinsically Safe Borehole Survey Tool C28016 Holville Ventsim Goaf Model Development - Stage 2: Goaf Anne Wylie Flow – Ventilation Interactions
$120,000 Value: CSIRO Report Expected: September 2021 Martin Griffith Industry Monitor/s: Brad Lucke Qingdong Qu Mick Stadler Paul Buddery Value: $319,465 Roger Byrnes Report Expected: June 2022 Peter Bergin ACARP Contact: Industry Monitor/s: Bharath Belle Paul Wild The project objectives are to develop an intrinsically safe Peter Baker borehole survey tool that will: ACARP Contact: Patrick Tyrrell • Capture and store video and still images for later analysis; The final goal of this multi stage project is to develop a • Record 3D spatial and temperature data linked to goaf modelling tool incorporated in Ventsim. The Stage 1 image capture; project delivered an equivalent goaf resistance model • Provide a local display for reviewing data as it is that produces similar goaf gas flow patterns with existing captured, allowing features to be examined in greater understandings. The current stage of the project is to detail. further develop the modelling approach by calibrating against various mine real scenarios. At the completion of the project, it is expected to have a working prototype machine field tested and The work in the last quarter had focused on the continual documentation submitted for Ex certification. Software development of the user interface and code in Ventsim, development for the master controller/display terminal which is nearly done. The goaf permeability model was is ongoing. The casing for the field test borehole tool is further improved for the convenience of assigning being developed. permeabilities to goaf grids. In the next quarter, the project team will start to build models and run simulations in Ventsim.
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C28027 terms of particle size distributions, adsorption isotherms Effect of Occlusions by Coal and Stone Dust on the of CH4 and CO2 and pore size distributions. Using a new Sensitivity and Time Response of Methane Gas Q3 measurement unit commissioned, the effect of Detectors in Underground Coal Mines crusher types (single/double disk pucks and single/double rings) on particle size distribution, temperature and pressure was investigated. 50 mm core Ampcontrol Gareth Kennedy samples were used for the tests. It was found that the Ian Webster particle sizes of pulverised subsamples were significantly affected by crusher types and crushing duration. For the first 30 seconds, the double disk puck crusher resulted in Value: $90,000 ° Report Expected: September 2021 changes in temperature less than 1 C and in pressure less Industry Monitor/s: Bharath Belle than 3.5 kPa. As each gas laboratory uses a different type John Grieves of crusher, the desorption rate index (DRI) can be Ken Singer affected by the crushing method. Further tests are in Patrick Tyrrell progress to measure the initial desorption rate from ACARP Contact: Peter Bergin pulverised coal samples.
The overall objective of this project is to: C29017 • Establish the existing degrees of occlusion of real time Appraisal of Gas Indicators from Goaf Drainage methane sensors in service in underground coal Holes for Spontaneous Combustion and Explosion mines by qualitative survey, and hence determine the Risk Management potential compromise in performance; and to • Verify and quantify the susceptibility of real time University of New South Wales methane detectors to occlusion by coal and stone Guangyao Si dust by controlled laboratory testing of typical methane sensing devices. Value: $119,750 Report Expected: August 2021 The construction of the gas detector test chamber at Industry Monitor/s: Bharath Belle SIMTARS is complete. The investigation of chamber’s David Webb temporal characteristics and performance, including the John Grieves chamber response times, are dependent on the Paul Wild availability of three gas analysers. Delivery of the three Peter Baker gas analysers purchased has been delayed with delivery ACARP Contact: Peter Bergin expected in late August. This has prevented any work from being conducted on this project during the quarter. A draft report is with the industry monitor(s) for review. The testing for this project will still be scheduled as a high priority as soon as the analysers are delivered, serviced C29018 and calibrated. It is expected the testing work and Evaluation of Explosion Resistant Ventilation preparation will commence as a priority in September. Control Devices and Determining Explosion Risk Exclusion Zones C29015 Revisiting the Fast Desorption Method - Initial University of Wollongong Gas Release from Pulverised Coal Alex Remennikov Andre De Kock CSIRO David Carey Jun-Seok Bae Gareth Kennedy
Value: $171,931 Value: $562,560 Report Expected: November 2021 Report Expected: May 2022 Industry Monitor/s: Andrew Lewis Industry Monitor/s: Bharath Belle Bharath Belle David Webb Paul Wild John Grieves Peter Baker Phil Fletcher ACARP Contact: Patrick Tyrrell Russell Thomas ACARP Contact: Peter Bergin This project aims to revisit the fast desorption method, closely looking into the initial gas release during the coal This project has two main objectives: crushing process for Q3 measurement of coal seams that • Identify exclusion zones around mine openings in the are rich in CO2 or mixed with CH4. event of an underground explosion - work has continued over the past quarter. This quarter the characterisation of coal samples • Explosion Resistant Ventilation Control Devices - still collected from four coal mines has been completed in on hold while the noise enclosure is being developed. Page 32 ACARP Current Projects Report August 2021 Underground Projects
This quarter the following project tasks have been extensive FORTRAN code to solve it using the finite performed: element method. The model is capable of 3D fully • Experimental setup – The experimental test platform coupled modelling of coal seam gas drainage by for simulating blast waves exiting mine opening as incorporating data from 3D geological and property well as the holders for the blast instrumentation have models. It can simulate the interactions of coal stresses been fabricated. with gas flow and gas sorption in coal seams during UIS • Noise tests of small-scale Advanced Blast Simulator gas pre-drainage practice. (ABS) – Noise tests have been performed with concrete-expanded polystyrene sandwich noise Over the last quarter and in line with the planned enclosures. This is a requirement prior to schedule of the project, we utilised the developed coal experimental testing at the university campus. model to perform sensitivity analyses on different • CFD simulations – Important progress has been made scenarios of underground-to-inseam gas drainage with the Computational Fluid Dynamics (CFD) borehole patterns with respect to major coal seam modelling work. Generated CFD results of blast anisotropic characteristics such as in-situ stress and cleat propagation outside of mine openings were system orientations. We also assessed the sensitivity of successfully validated with existing empirical the UIS drainage hole pattern to key coal parameters equations found in the literature. Additionally, new such as fracture density, in-situ stress magnitudes/ratio, insights on the effect of different mine opening diffusivity and permeability. Model calibration with field configurations on blast pressure distribution around data including measured hole flows is currently in mine openings were achieved with CFD. These results progress. Based on the results of sensitivity analysis and include blast pressure and impulse contours for model calibration, we are developing procedures for different shapes and configurations of mine optimising UIS hole patterns for the candidate zone of a openings, shaft vs. portal, etc. The CFD models also longwall panel in the study area. provided confirmation that the results from the small-scale blast simulator tests can be scaled up to C29024 the full dimensions of mine portals and mine site Contamination - Ethylene from Timber Supports topographies to establish explosion risks and develop exclusion zones. Simtars Snezana Bajic C29023 Methodology for Efficient Design of the Pattern of Value: $94,750 Drainage Holes Based on Stress Variation and Gas Report Expected: November 2021 Flow Behaviour in Coal Seams Industry Monitor/s: Bharath Belle David Webb University of New South Wales John Grieves Hamid Roshan Julian Potten Hossein Masoumi Paul Wild ACARP Contact: Patrick Tyrrell Value: $164,560 Report Expected: April 2022 Ethylene is a key spontaneous combustion indicator used Industry Monitor/s: Bharath Belle in underground coal mines. This project will deliver the Brad Elvy understanding of the mechanism for atmosphere Owen Salisbury contamination with ethylene through temperature and Paul Wild humidity testing of timber used in the manufacture of Russell Thomas underground supports. The tests will be performed in ACARP Contact: Peter Bergin controlled environment, with special designed sampling equipment and regime. The project will also review The technology of coal seam gas pre-drainage in reported instances at mines where ethylene trace levels underground mines has evolved over the recent decades have been found without the presence of increased to improve its technical and economic efficiency in carbon monoxide and hydrogen. The relationship reducing the original gas content to below the required between atmosphere temperature and humidity and threshold. This project aims to optimise the pattern of timber moisture content with regards to release of underground-to-inseam (UIS) gas pre-drainage ethylene from timber supports will be established. The boreholes by gaining insights into the multiphysics findings will be reported in a reference document to interactions in the process of gas drainage from coal assist underground coal mines in preparing their Trigger seams incorporating downhole geophysical logging (DGL) Action Response Plans (TARPs), eliminating or avoiding data into multiphysics numerical modelling. contamination of gas samples with ethylene and planning timber support construction. Previously, we completed 3D geological and property modelling for the candidate area based on available data The testing of two month old (approx.) timber including DGL acquired from surface boreholes. We also commenced early April. This was the first stage testing of developed a theoretical 3D multiphysics model and an timber straight from a mill. The gas evolution and
Page 33 ACARP Current Projects Report August 2021 Underground Projects environment chamber testing on this sample has been Reporting the findings of the project is currently completed. No apparent contamination was observed. underway, and close to completion.
It was agreed at a recent project meeting to revise the The work was due to be presented at this year’s Bowen methodology and scope of the project. It will now include Basin Geological Symposium, and a paper submitted and fresh (less than one week old) timber in the samples to approved by the organising committee. be tested. In addition, there are now two parts to the testing: environment chamber, and small-scale testing C29036 using a gas bag containing timber samples to be regularly Direct Measurements of Effective Diffusion analysed. The test plan will include Coefficient of Coal 30 representative timber samples, which will be subjected to different air-drying periods before testing. University of New South Wales Peyman Mostaghimi The recent timber delivery was delayed due to COVID-19 restrictions. The timber delivery will be rescheduled Value: $175,000 when restrictions are removed, testing will commence Report Expected: December 2021 immediately thereafter. Industry Monitor/s: Bharath Belle David Webb C29027 Paul Wild Review of the DRI Process and its Role in Setting Russell Thomas Thresholds for Non Bulli Mines ACARP Contact: Peter Bergin
CoalBed Energy Consultants This project aims to expand knowledge about diffusion Scott Thomson processes and physics of gas flow in coal and to develop a method for direct measurement of the effective Value: $128,900 diffusion coefficient of coal. Diffusion of methane in coal Report Expected: September 2021 is of complexity as several physical mechanisms including Industry Monitor/s: Bharath Belle bulk diffusion and Knudsen diffusion are coupled. In David Webb addition, coal has high capacity for adsorbing methane Paul Wild and surface diffusion plays an important role in the Russell Thomas diffusion process. A reliable estimation of the effective Sharif Burra diffusion coefficient of coal and understanding its ACARP Contact: Peter Bergin mechanisms are crucial for identifying the risk of outburst in coal mines. As a part of this project, we This project aims to independently assess the variance in measure the effective diffusion coefficient from outburst thresholds at representative, participating sites Australian coal mines and the obtained values can be across Australian coalfields and to compare this data used for future modelling to estimate the risk of outburst with the fundamental reservoir properties at each site with the aim of increasing the safety of mining that drive outburst risk. The project plans to investigate operations. the evidence regarding the setting of TLV’s and determine whether the current system is appropriate for Work undertaken over the last quarter is as follows: mines other than those of the South Coast. Desorption • Impact of diffusion time on coal diffusion coefficient rate is only one factor in many that affect outburst has been investigated; propensity. An objective of this project is to establish • Krypton-helium counter diffusion process has been whether an alternative metric can be applied, and if not, imaged with micro-CT imaging at several diffusion improve the general understanding of how TLV’s should times; be applied in areas other than the Illawarra. • More samples from industry have been loaded in our experimental setup for diffusion analysis and It is recognised that one of the challenges of this research measurements; and is to overcome industry reluctance to change a system • Variation of diffusion coefficient for samples from that is well established and clearly has had positive safety different mines is investigated. benefits to the industry. In addition, it requires the enlistment of support from enough non-Bulli mining operations to provide a meaningful database. This has been generally achieved over the course of the project.
Work has been completed investigating the relationship between multiple reservoir factors and historical experience of outburst risk at the participating non-Bulli sites.
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C33018 Strata Gas Content using Geophysical Logs and Laboratory Measurements
University of New South Wales Guangyao Si Joung Oh Peyman Mostaghimi Zhentao Li
Value: $128,560 Report Expected: December 2022 Industry Monitor/s: Agi Burra Bharath Belle Mark Laycock Russell Thomas ACARP Contact: David Drakeley
The project objectives are to: Figure 1. Model performance on another borehole • Collect and examine geophysical logging data (testing data) available at mine sites and select relevant data that can be used for gas content estimation; C33025 • Develop correlation models for porosity, gas Evaluating Ventilation Effects on Coal Self Heating saturation, and gas sorption calculation of different Incubation Behaviour coal measures based on routinely acquired geophysical logs; B3 Mining Services • Conduct laboratory measurements of gas storage Basil Beamish properties of key coal measures in Australian gassy mines and use the results for model training and Value: $79,200 validation; and to Report Expected: August 2022 • Establish gas content estimation models for various Industry Monitor/s: Bharath Belle coal measures using multi-geophysical logs. John Grieves Sharif Burra Since project commencement in June the geophysical ACARP Contact: Patrick Tyrrell logging data from over 40 boreholes at four mine sites have been collected and examined. The preliminary The main objective of this project is to evaluate the models are developed based on borehole DH1 at Mine A, ventilation effects on coal self-heating incubation where 46 coal samples were measured for gas content. behaviour across a spectrum of currently mined Nine types of geophysical logs were selected for the gas Australian coals in different coal measure sequences and content estimation purpose. The relation among the well basin settings. The results obtained will be used to log curves, the lithology classification and the gas content physically validate the concept of a “critical velocity in coal measures was investigated. The project team will zone” in a longwall goaf environment, which will assist improve the model accuracy, identify gas source strata, mine personnel to understand the mechanism involved. develop theoretical relationships of gas content between The incubation behaviours of coals with different non-coal strata and well log curves in the next quarter. intrinsic reactivities under different site-specific conditions will also highlight the importance of The main findings were summarised below: quantifying the likelihood of developing a spontaneous • Lithologies at Mine A showed significant relation with combustion event as a result of changes to mine the selected well logs, which indicates that the ventilation. An Australian benchmark will be produced current geophysical logs based characteristion model for reference across the entire underground coal mining can classify critical strata components (see Figure 1). industry. Subsequently, the results can be used to In the target mining level, an overall accuracy of over identify appropriate industry practices for management 80% can be obtained; and control of spontaneous combustion. • Resistivity logs (FE2) and neutron logs (LSN) were found to contribute notably to lithology Detailed testing has been completed on a coal from characteristion; Queensland with an R70 value of approximately 4 °C/h • The gas content of coal was found to have certain and a moisture content of approximately 11% using flow correlation with borehole temperature and depth; rates indicative of sluggish ventilation, natural air leakage • Estimates of the gas content were found to be less ventilation and medium ventilation. At the higher accurate, due to the limited number of coal samples. medium ventilation flow rate, the coal initially self-heats This will be improved later with more dataset from to approximately 8C above mine ambient temperature, other mines. before heat loss from moisture evaporation dominates Page 35 ACARP Current Projects Report August 2021 Underground Projects and the coal begins to decrease in temperature. Under different LW ventilation methods, common issues the natural air leakage flow rate, the coal self-heats to associated with gas-out events, cutting methods and 28C above mine ambient temperature before heat loss parameters/controls affecting gas emission and again takes over due to moisture evaporation. However, accumulation along the face and TG ends. The project at the sluggish ventilation flow rate the coal is able to team has also maintained contact and discussion with incubate to thermal runaway after an extended period of industry mentors for this project and received input from time indicative of a timeframe of approximately three the mentor on a comprehensive set of longwall years. operation scenarios, including changes in goaf, gas composition variations, sources of gas emission, LW A batch of new core samples have been supplied by dimensions etc. The project team has been carefully mines from both Queensland and New South Wales and studying these parameters by referring to published these will be tested over the next quarter. reports and technical papers as well as site specific information. C33029 Review Longwall Face Ventilation to Mitigate A visit was made to an underground coal mine based in Goaf Gas Emissions onto Walkways and Tailgate New South Wales to confirm site support and access to End LW ventilation and gas monitoring data that is needed for this project. The research team has been making contact with other participating mines to source further site University of Wollongong Ting Ren information/data and on-site study to better understand and define the gas emission scenarios of the development CFD models. The current lockdown in New Value: $146,500 South Wales has some impact on the progress of the Report Expected: May 2022 project as planned site visits cannot be made. Effort has Industry Monitor/s: Ventilation Task Group been made to start the base CFD model development ACARP Contact: Patrick Tyrrell based on a mine site data collected from the mine visit This objective of this project is to conduct a study of LW before the COVID-19 lockdown. ventilation control practices for effectively mitigating high gas emission and accumulation at tailgate ends, to C33030 minimise production delays and safety hazards. This VR-CFD Based Simulation and Training Tool for study will make recommendations for best practices and Dust Control in Gateroad Development Panels design of ventilation and gas control measures that can be used for general guidance and training for LW face University of Wollongong ventilation and gas emission management. Specifically, Ting Ren this project aims to: • Conduct a survey and critical review of LW ventilation Value: $349,800 methods, with particular focus on what Report Expected: November 2022 events/factors result in elevated gas levels; Industry Monitor/s: Ventilation Task Group • Study the ventilation and gas control practices used ACARP Contact: Patrick Tyrrell at different mines to manage/prevent elevated gas levels, and identify current practices/procedures that The main objective of this project is to develop an are working and not working effectively; immersive simulation tool that can be used to provide • Develop CFD models, based on specific site enhanced 3D visualisation of monitoring and conditions, to understand gas accumulation computational modelling datasets of dust and ventilation mechanisms near tailgate ends of typical high gas flow in an interactive, virtual environment, and clearly events, the impact of various controls/practices on a demonstrate the exposure impact of certain working range of gas events, and common failure mechanisms condition changes in gateroad development panels. The of these measures, thus identifying the best simulation tool can be used as an educational platform controls/practices; to create effective communication of WH&S awareness • Provide a summary report of the above studies on of dust exposure in the workplace for CM operators (and common cases exceeding acceptable gas levels, engineers) and gain intuitive understanding of dust and major causes of high gas events; common control airflow characteristics around the CMs enabling learning measures (including monitoring) and their failures, of the best practices for dust controls in LW and recommendations for best practices and design development. of gas control measures that can be used for general guidance and training to improve LW face gas The project team researchers have met twice to discuss emission management. and agree work schedule and actions as defined in the proposal. A visit was made to an underground coal mine In this quarter, work has been focused on studying the based in New South Wales to confirm site support and longwall ventilation systems and major parameters that access to dust monitoring data that is needed for this can be clearly defined for CFD modelling studies. This project. The research team has been making contact with included a review of existing reports and publications on other participating mines to source further site
Page 36 ACARP Current Projects Report August 2021 Underground Projects information/data to better understand and define the scenarios of the development panel for CFD modelling and VR environment. The research team has also gained access to consolidated dust monitoring data from the database managed by Coal Services. This data is being used to assist in scenario development by reviewing exceedance contributing factors on JOY 12CM30s which will then lead into areas of further monitoring. Discussion have been held regarding monitoring data requirements for CFD-VR modelling, and contact has been made with other parties who have conducted similar work in this space.
A number of potential scenarios for simulation were identified and determined. These have been further refined considering exceedance contributing factors. The final scenarios for simulation will be determined in consultation with the industry monitors. The team has come to an agreement on the simulation platform (software and hardware) and functionality of the system that can be configured and customised to specific scenarios. A variety of VR visualisation options and strategies have been discussed within the project team, and a preliminary setup of CFD simulations in anticipation of finalising project scenarios has been completed.
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C29030 OPEN CUT Mapping of Elemental Coal Content for Exploration and Mining Exploration CSIRO Jane Hodgkinson C26029 Micaela Preda Controls on Fluorine and Phosphorus Distribution in Bowen Basin Coals Value: $130,894 Report Expected: October 2021 University of Queensland Industry Monitor/s: Shaun Booth Joan Esterle ACARP Contact: Cam Davidson
Value: $141,050 This project investigates the elemental content of Report Expected: September 2021 Australian coal, providing strategic mapping to address Industry Monitor/s: Peter Handley the need for innovative exploration. The project Richard Ruddock objectives are to: Tim Buddle • Analyse elemental content of Australian coals; ACARP Contact: Patrick Tyrrell • Map elemental content spatially; • Assess geological relationships of findings; and to The project is under final reporting internal review. • Present a map of results.
C28033 The motivation is to develop a better understanding of Raw Ash to Yield Relationships coal content and elemental provenance. This will inform decision making about exploring for economic coal McMahon Coal Quality Resources resources that may be of interest to alternative coal Chris McMahon markets other than thermal and coking uses. The aim is to clarify potential targets of value to further improve the Value: $29,120 industry’s long-term potential. Report Expected: March 2022 Industry Monitor/s: Hugo Kaag Over the quarter we have received laboratory analysis John Terrill results for the final ~40 samples for this project: Rod Doyle laboratory analysis of 50 elements in samples from ACARP Contact: Cam Davidson Queensland and New South Wales mines and ash samples from several power plants. In line with prior This project seeks to collate and evaluate data attained results received, the final batch has confirmed higher- by MCQR in raw ash and product yield/ash outcomes than-crustal averages of rare Earth elements in most of across several deposits and methodologies to define the samples. Further spatial clustering of results is being when the methods can be usefully used or not and at assessed, and potential geological influences will be define the error limits for the process. identified in the discussion along with a hypothesis on emplacement and geological relationships. The desktop The outcomes of this project will be the definition of literature review, GIS mapping and data analysis have accuracy (precision and bias) information for varying coal been completed. Interpretation and discussion are being types and efficacy of use of methods. That is, when to use performed and the first draft of the final report is being and not use the method and what the variation from assembled. more traditional methods such as sample pre-treated wash data and sized and float and sunk / froth flotation tested data. This will benefit the industry by providing a guide for use and defined accuracy of outcomes for this method via a variety of testing methods, and potentially saving very expensive mine and resource misrepresentation. The outcomes then will provide a financial risk reduction and / or evaluation criteria.
Initial data mining and organisation has commenced for MCQR projects. Review of other mine site data supplied by monitors has also commenced. Four deposits sets are now targeted for review including set cut-point review. The first database has had data organisation, charting and review plus written reporting commence. The other three databases will be similarly reviewed once the first is completed.
Page 38 ACARP Current Projects Report August 2021 Open Cut Projects
Drilling and Blasting guided BHR waves (Figure 1a and b). The results suggest that sinking the radar into shallow slots cut into the
surface of a stabiliser could generate look-ahead radar C27024 waves. This leads to a preliminary design for embedding Evaluation of Production Trials of HP Explosives a borehole radar into a stabiliser as shown in Figure 1c. The next step is to refine the design, cut the stabiliser, Mining3 embed a BHR into it and test the prototype in the Andrew Kettle laboratory. Ewan Sellers
Value: $477,920 Report Expected: February 2022 Industry Monitor/s: Andrew Lau Benjamin Wood Brett Domrow Ewen Mills Lindsay Ford Travis Zolnikov ACARP Contact: Cam Davidson Figure 1 CST 3D FDTD snap-shots of |E| fields (a) No report received. launched on a 7 ⅝” diameter steel drill rod by a buried Wu-King monopole; and (b) transmitted and reflected by C29053 the bit. (c) A preliminary design for embedding a borehole radar into a drill stabiliser behind the drill bit. Real Time Prediction of Coal Top Through Guided
Borehole Radar Wave Imaging for Open Cut Blast C33041 Hole Drilling Phase 2 Production Trials in Two States of HP Explosives
CSIRO with Custom MMU Binzhong Zhou
Value: $337,910 Mining3 Ewan Sellers Report Expected: April 2022
Industry Monitor/s: Hugh Jennings Troy O'Reilly Value: $342,034 April 2023 ACARP Contact: Patrick Tyrrell Report Expected: Industry Monitor/s: Andrew Lau This is a Phase II to the project C26022 for developing a Benjamin Wood borehole radar (BHR) based technique to predict the coal Ewen Mills seam top in real-time, while drilling blast-holes, by seeing Lindsay Ford ahead of a drill-bit to improve blast hole drilling control, Travis Zolnikov reduce coal top damage and subsequent loss of product, ACARP Contact: Cam Davidson and increase production and profits for open cut coal mining. In C26022, both numerical modelling and field No report received. trials simulating a drill rod as an antenna demonstrated the feasibility of the proposed technique for prediction of the coal top under typical open cut environments and paved the way for maturing this technology for the practical use for blast hole drilling. This extension project aims to investigate and overcome various engineering and technical problems to make the guided BHR waves practical to use for coal top prediction during blast-hole drilling.
A planned site visit since last quarter report has been deferred a few of times due to COVID-19 restrictions. The site visit is to test the developed prototype wireless communication system with the actual drill at the mine and inspect the blast hole drill rig and its operation. Meanwhile, the project team has conducted numerical modelling and laboratory tests on how the drill stabiliser, a hosting unit for embedding the borehole radar and related communication devices, affects the generation of
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Environment C27042 Adaptation of Design Tools to Better Design C27009 Rehabilitation and Capping Over Highly Mobile Tailings Revegetation through the Vegetative Mine Waste
Water Pump University of Newcastle
Greg Hancock CSER Research
Carmen Castor Value: $439,000 Mike Cole Report Expected: July 2022
Industry Monitor/s: Brendan Roddy Value: $447,000 Chris Quinn Report Expected: September 2021 ACARP Contact: Patrick Tyrrell Industry Monitor/s: Chris Urzaa
Shaun Booth A draft report is with the industry monitor(s) for review. Trent Cini
ACARP Contact: Patrick Tyrrell C28035 This project has a primary objective of developing a Topsoil Deficits in Site Rehabilitation Accelerated vegetative water pump to allow tailings dams to be dried Transformation of Spoils to Functional Soils through the plant transpiration stream and make them safer and capable of being capped or used for other University of Queensland purposes. Emma Gagen Gordon Southam The final report is being prepared for submission to industry monitors. Value: $226,450 Report Expected: January 2022 C27030 Industry Monitor/s: Stephen White Examination of Past and Present Mine ACARP Contact: Patrick Tyrrell
Rehabilitation to Grazing Land as a Guide to Topsoil deficits hinder effective rehabilitation of open cut Future Research sites, particularly in the Bowen Basin. The objectives of
this project are to understand and harness the NSW Department of Planning, Industry and microbiological processes behind the transformation of Environment coal mine spoils to functional soils. Harry Rose Justine Cox Based on the initial 42 ha mine site field trial (December
2019 – December 2020), which demonstrated that there $166,203 Value: was no significant difference between commercial bio- Report Expected: August 2021 treatments and the reference soil, the decision was made Bill Baxter Industry Monitor/s: to pursue site/mine specific soil enhancing bacteria and Nigel Charnock fungi. Stephen White
Patrick Tyrrell ACARP Contact: Four, key mine site consortia (physiological groups) have
been pooled, targeting the development of a natural, A draft report is with the industry monitor(s) for review. self-sustaining fertiliser:
• A fungi dominated consortium targeting the role of C27038 enhanced carbon cycling in augmenting soil Self Sustaining Ecological Mine Rehabilitation that structure; Achieves Recognised Ecological Communities • Cyanobacteria, capable of atmospheric nitrogen fixation; Umwelt (Australia) • N cycling in soil; and Travis Peake • P solubilisation from soil-minerals.
Value: $401,670 A pot trial has been implemented to compare the efficacy Report Expected: September 2021 of this endogenous bio-fertiliser strategy versus Industry Monitor/s: Bill Baxter commercial N/P biogeochemical fertilisation, to enhance Jono Deacon soil biodiversity, and to determine their efficacy in Nigel Charnock transforming spoil into functional soil. The pot trial is ACARP Contact: Patrick Tyrrell being conducted under greenhouse conditions and will continue for six months with the aim to measure three A draft report is with the industry monitor(s) for review. seasonal phases; wet-dry-wet, to determine the
Page 40 ACARP Current Projects Report August 2021 Open Cut Projects functional capacity of the bio-treatments under two practice, and to refine the package of decision support moisture conditions: tools through a combination of user-driven training and • Simulated rainfall using historical field site conditions; analysis of results from operational mine rehabilitation and outcomes. The project will also extend the application of • Optimal irrigation (40-50% of field capacity). the existing decision support tools to all mined-land rehabilitation in order to support improved quality and Callide Rhodes Grass was selected as the model plant for cost of rehabilitation outcomes and confidence in the pot trails given its tolerance to drought and capability meeting regulatory commitments. to grow under low soil nutrient conditions. The freeze dried microbial consortia were mixed with 0.1% Full day industry workshops were held at Springsure, sugarcane mulch as a carrier-nutrient and applied in the Moranbah, Brisbane and Muswellbrook during June. A pot trials at the rate of 106 colony forming units (cfu) of further on-line workshop is planned for August. A total nitrogen and phosphorous cycling bacteria, and of 58 registrations were received with feedback from 104 fungal spores (cfu; carbon cyclers)/g soil. 29 participants. Feedback indicated that participants found the tool relatively easy to use and intuitive. T0 (4 June 2021) greenhouse samples have been Participants found working through application of the processed to determine the baseline spoil properties. model using real data to be the most useful element of Preliminary observational data one month into the trial the workshops (55%). A key suggested improvement was has highlighted that infiltration is improved and salt for a standardised soil analysis sheet. This will be crusting is lessened in the biofertiliser treated soil, with implemented as a standardised COC form. the sugar cane mulch showing evidence of fungi and the soil greening up when cyanobacteria are present, demonstrating a proof of concept for the use of lyophilised cultures. Further samples will be collected at the end of each phase (wet-dry-wet) for characterisation of spoil chemistry, biology and structure, versus the time zero (T0) baseline conditions.
C28043 Scale up Leaching Tests for Spoil Salinity Predictions
University of Queensland Mansour Edraki Industry workshop presentation - Brisbane Value: $198,500 Report Expected: August 2021 Detailed site assessments were undertaken across seven Industry Monitor/s: Jason Fittler mines in Queensland and New South Wales throughout Marilena Stimpfl 2019 and early 2020, with an additional assessment in ACARP Contact: Patrick Tyrrell May 2021. The assessments capture a range of rehabilitated site conditions, approaches, and A draft report is with the industry monitor(s) for review. performance outcomes to improve parameterisation of the existing Bayesian Decision Support Model and C28044 associated Best Management Practices. The User Driven Refinement of Decision Support Tools assessments involve application of digital remote and proximal sensing approaches (electromagnetic to Inform Final Mined Landform Outcomes surveying, multispectral surveying and digital terrain
mapping) to characterise fine-scale spatial variation in Verterra spoil properties, vegetation occurrence, and terrain. Glenn Dale Secondary data layers were derived for each pixel across
the sites surveyed, including slope, slope length, Value: $250,220 contributing catchment and vegetation cover. Erosion Report Expected: September 2021 was assessed by mapping the occurrence of gullying from Industry Monitor/s: Craig Lockhart high-resolution UAV photogrammetry. The survey have Jason Fittler been used to: ACARP Contact: Patrick Tyrrell • Develop correlations between point soil data and
proximal/remote sensing data to spatialise the soil An earlier completed project (C24033) developed a data; framework to support practical, cost effective • Compare differences in erosion performance and site management of dispersive spoil, including a Bayesian characteristics between experimental treatments; network based decision support tool to facilitate • Develop regressions of site characteristics explaining application of project results. This project aims to variation in erosion; and facilitate transfer of project C24033 outputs into Page 41 ACARP Current Projects Report August 2021 Open Cut Projects
• Iteratively update and validate conditional requested data, but information conveyed during a probability tables informing the Bayesian Decision meeting with the company provided sufficient Support Model to improve estimation of the information. likelihood of erosion for any given set of site conditions and management practices. A detailed review of available erosion models was undertaken, and two models were identified for In parallel with model updates, the data input interface consideration. A post-graduate student has recently to the Mine Spoil Rehabilitation Decision Support Tool completed a 5-week placement to investigate the has been significantly updated to improve data entry and applicability of the WEPP model to Queensland mines. A allow batch runs by users. The web-tool incorporates model was developed for a case study site and climate and soil nutrition requirement calculators. reasonable results were obtained.
C29041 A review of design criteria adopted for the design of Preconditioning Plants to Withstand Flood on a sediment basins has been completed. The next step is to Tailings Dam test the use of the WEPP model for the design of sediment basins. Hydrological models are being CSER Research developed for a range of catchment sizes to assess the Mike Cole potential to assimilate passive releases from control structures during different design storms. This will Value: $114,000 provide guidance on release criteria from sediment Report Expected: August 2021 basins. Industry Monitor/s: Chris Urzaa Shaun Booth Two separate documents are currently progressing: a set Trent Cini of guidelines for the design and implementation of ESCPs ACARP Contact: Patrick Tyrrell for Queensland mines and a research report containing the details and outcomes of the study. A draft report is with the industry monitor(s) for review. C29047 C29046 Reducing Uncertainty in Long Term Water Quality Erosion and Sediment Control Framework for Predictions for Final Void Management Queensland Mines University of Queensland University of Queensland Sue Vink Claire Cote Mandana Shaygan Value: $245,600 Report Expected: February 2023 Value: $237,200 Industry Monitor/s: Andrew Lau Report Expected: September 2021 Jason Fittler Industry Monitor/s: Andrew Lau Steve Downes Jason Fittler ACARP Contact: Patrick Tyrrell Steve Downes ACARP Contact: Patrick Tyrrell The aim is to generate information to assist management and closure of final voids as permanent water bodies, The aim of this project is to develop technical guidelines particularly with respect to improving predicted water for the design and implementation of Erosion and quality. This proposal will address the following specific Sediment Control Plans (ESCPs) for Queensland coal objectives: mines in accordance with the conditions outlined in their • To analyse existing time series of electrical Environmental Authorities. The objectives are to: conductivity (EC) data from Bowen Basin and Hunter • Provide a methodology for developing a site-wide Valley voids to form a spatial and temporal view of plan with clear objectives and agreement on what void salinity. constitutes non mine-affected runoff; • Use measured temporal changes in salinity and • Guide the assessment of erosion risk and the most temperature depth profiles (over an annual cycle) to appropriate controls; identify and constrain the processes controlling • Develop design criteria for sediment basins; changes in void salinity, in particular with respect to provide realistic ranges of upscaling leaching • Deliver training packages for key target groups; and parameters required to estimate spoil inputs and • Develop an accreditation pathway for the groundwater inflows. preparation and implementation ESCPs. • To incorporate results from previous and current
research (eg C25039) using Goldsim model(s) to The collection of information on the status of erosion and provide a whole of system understanding of void sediment control activities of selected mine sites in salinity and hydrodynamics that will inform closure Queensland was mostly complete pending data from an criteria. additional company. We have not yet received the Page 42 ACARP Current Projects Report August 2021 Open Cut Projects
• To gauge the impact that the refined model results from C27043. Monitoring will continue for an assumptions/parameters will have on long-term final additional year at a reduced intensity (two vs four void salinity predictions. times per year) to investigate interannual variation. Using instrument chains, we will collect data on Field work will begin at the end of August. Vertical stratification and salinity levels hourly during 2020 profiles of a suite of water quality parameters will be and into 2021, providing three years of continuous determined in a pit approximately quarterly over the monitoring. next 12 months. The parameters will be aligned with the • Experimental component to examine rehabilitation site environmental authority. The pit has a record of options: Carbon (in the form of terrestrial organic water quality measurements and an existing goldsim matter) determines the nature of the aquatic food model which will be updated based on sampling results. web and creates important habitat. In C27043, using Access to another mine site and study pit is currently tank mesocosms (1000 L) on site, we tested the being negotiated. effects of adding coarse, low-cost organic matter on lake water and sediments on biophysical and C29049 chemical endpoints (as measured in the lake). Based Saline Pit Lakes as Aquatic Ecosystems: A Design on the positive improvements recorded, in this Manual for Closure project we will reset the mesocosms and test both organic matter phosphorus additions. Low Edith Cowan University phosphorus concentrations were recorded in all the Mark Lund pit lakes studies in C27043 and additions should stimulate primary production, creating more food for Value: $1,089,226 macroinvertebrates. Report Expected: May 2024 Industry Monitor/s: Andrew Lau Littoral areas are well-established as the most important John Watson areas for biodiversity in lakes and yet also represent the Ross Gooley most expensive component of pit lake rehabilitation (due Stephen White to the earthmoving requirements to create these areas). ACARP Contact: Patrick Tyrrell We will conduct detailed sampling at a small rehabilitated saline pit lake to investigate the influence In Australia, many community members and regulators of water depth on biodiversity to determine the littoral expect that final voids will be backfilled. However, a lack area requirements of pit lakes for creating productive of backfill materials combined with prohibitive costs aquatic environments. ensures that pit lakes will be a permanent feature of most post-mining landscapes. Pit lakes are considered As shown in C27043, organic matter additions can the ‘greatest legacy of open cut mining’ due to the enhance biodiversity in saline pit lakes. Experimentally potential for safety issues, ground and surface water we will move from mesocosms to a pit lake to test contamination, and in-lake toxicity. Additionally, pit lake organic matter additions in situ. science has struggled to find a foothold in mainstream literature, limiting wider scientific exposure to the issue Due to COVID-19 restrictions, especially from Western of pit lakes and holding back advancement of the Australia, the start of fieldwork was delayed until April development of remediation and closure approaches. 2021. Seven saline pit lakes across three sites were Therefore, the broad objective of our proposed research sampled and are largely processed. Additional sites will is to understand the biophysical processes in be added in the August 2021 sampling round. A unrehabilitated saline pit lakes and investigate options Postdoctoral Research Fellow has been appointed to the for enhancing ecosystem services in the Hunter Valley project and commences shortly. and Bowen Basin.
Salinity is a key water quality issue with many Australian pit lakes. Many natural lakes are saline and have valuable ecosystem values. Understanding the role of catchments and nutrient inflows in maintaining salinity within useful ranges and driving ecosystem processes is therefore important to determine the range of future uses for these pit lakes. These future uses may include conservation, recreation, and aquaculture.
The overall project approach has two main components: • In situ component: Continuing the monitoring of four saline pit lakes (Hunter Valley and Bowen Basin) for a broad range of water chemistry, physical and biological parameters from C27043, we will introduce some refinements to the approach based on the
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C33035 C33037 High Water Recovery, Low Cost Desalination using Quantifying Recharge to Groundwater Systems in PV-Powered Membrane Capacitive Deionisation the NSW and Bowen Basin Coalfields (mCDI) CSIRO University of New South Wales Andy Wilkins Boyue Lian Matthias Raiber Clare Bales Russell Crosbie David Waite John Fletcher Value: $110,400 Yuan Wang Report Expected: July 2022 Industry Monitor/s: Lu Wang Value: $334,340 Michael Moore Report Expected: March 2023 Nick Cook Industry Monitor/s: Kane Eskola ACARP Contact: Patrick Tyrrell Nick Cook ACARP Contact: David Drakeley This project aims to quantify recharge in the New South Wales coalfields. It will provide a scientifically rigorous The project objectives are to: base upon which estimates of mining impacts can be • Assess, through the implementation of a mine site made, eliminating one of the main sources of uncertainty pilot-scale trial, the viability of use of membrane in groundwater assessments, and expediting the mine capacitive deionisation (mCDI), in combination with approval process. The main output of this project will be appropriate pre-treatment processes, for the maps that show the spatially-varying recharge to the removal of salt and other contaminants from waters groundwater system. generated during coal mining operations, and to • Provide advice on the designs of mCDI units Most of this quarter has been spent sourcing and considered appropriate for the treatment of processing data from federal and state agencies, as well particular process streams and/or wastewaters as from mining companies, principally rainfall and salinity produced during coal mining operations with measured in shallow boreholes. This data-gathering and particular attention given to: processing is expected to continue through most of 2021. • the volume throughput, salt removal capacity, In tandem, estimates of chloride deposition rates have water recovery and fouling propensity of been computed, which is a key ingredient in the chloride particular designs; mass balance method used. • the value and viability of different means of powering the mCDI unit (photovoltaics and/or C33043 mains power); and Best Practice Management and Performance • the potential for use of VR/AR technology in Assessment of Biodiversity Offset Areas remote monitoring and control of the mCDI desalination unit. Eco Logical Australia Andrew Butler The UNSW team has reviewed water quality information provided for the mine site of particular interest to this Value: $335,540 project. Using this information, a draft design of an MCDI Report Expected: March 2022 pilot plant has been developed. Of particular note is that Industry Monitor/s: Jono Deacon the MCDI pilot plant will utilise photovoltaic panels for all Mark Nolan power requirements as mains power is unavailable at Michael Plain this site. It is expected that a Digital Twin of the MCDI Nigel Charnock pilot plant will be developed to facilitate remote ACARP Contact: David Drakeley monitoring and control of this facility. The UNSW team has also developed a design for a full scale RO plant to The overall aim of the project is to produce industry treat water at this site. Both the MCDI pilot plant design toolkits (guides/frameworks supported by decision and the RO design will be discussed with project industry support tools) to help managers to: monitors at the next project meeting in early August. • Select Biodiversity Offset Area (BOA) management measures that are evidence based, best suited to site circumstances and most likely to provide the best achievable outcomes; • Select monitoring and evaluation techniques that reliably measure the achievement of desired biodiversity outcomes and support adaptive management;
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• Consider any emerging bushfire risks associated with C33045 BOA stewardship and identify options for Extent, Spread and Risk of Pasture Dieback on management. Mine Site Rehabilitation using Remote Sensing
Phase 1 of the project (Data Collation and Review) University of Queensland includes three discrete tasks: Phill McKenna 1. Collection and collation of site data; 2. Literature Review; Value: $291,990 3. Collection of supplementary field data. Report Expected: April 2023 Industry Monitor/s: Andrew Lau Phase 1 Tasks 1 and 2 were substantially completed in Nigel Charnock this quarter, with Task 3 initiated. Rod Norris ACARP Contact: David Drakeley Phase 2 and 3 (Draft reporting) tasks were also initiated in this quarter. The aim of this project is to provide an inventory of the areas of pasture dieback located within the rehabilitated Task 1 reviews provided a clear picture of the issues that estate of central and southern Queensland. We plan to need to be addressed in the industry toolkits and will be use high resolution site captured aerial imagery, satellite used to guide the collection of supplementary field data. imagery and selected field visits to detect and map the The literature and site document review revealed that: extent and spread of pasture dieback using remote • Although company approvals obligations varied, sensing techniques. there were many common themes. The industry toolkits will therefore be able to provide guidance Pasture dieback is a disease first detected in buffel grass that is widely applicable across operations and in central Queensland in 1993 and has since spread to geographical areas. infect pastures with an estimated area of between • Performance based objectives and performance 200,000 and 4.4 million hectares throughout the State criteria designed to assess achievement of the (Buck 2020). The issue is complex, and there is no obligations were highly variable across operations. confirmed diagnosis of causal agents at this stage. Note The industry toolkit will need to provide materials to that this project is not aiming to determine causal agents guide the development of SMART objectives and of pasture dieback but is aiming to map the temporal and completion criteria. spatial dynamics using remote sensing methods. The • Monitoring methods are generally uniform across novelty of this project is in the use of aerial imagery operations; largely based on indicators used in which is a resource that is already collected by sites, but standard the New South Wales BioBanking is underutilised for rehabilitation monitoring purposes. Assessment Methodology and the Biodiversity Assessment Method. However, data analysis has not Work this quarter included initial communication with consistently demonstrated unequivocal participating sites and obtaining recent aerial imagery to improvements in biodiversity values. The literature begin remote sensing assessments. Meetings with key review provided potential alternative assessment stakeholders in the project included Department of methods/metrics that will be applied to the large pool Agriculture and Fisheries in Rockhampton, Queensland of available data across sites in Phase 2. The aim will University of Technology and UQ Gatton. The project be to identify, from the available data pool, indicators proposal was also presented at the Central Queensland that predictably respond to management Mine Rehabilitation Group in Springsure in June 2021. intervention and show clear temporal trajectories. Initial classifications and remote sensing mapping of This will inform the development of the framework imagery has focused on a time-series at Mine Site 1 with for BOA monitoring and data assessment to be known pasture dieback occurrence. The first field visit to provided in the industry toolkit. mine site 2 was conducted along with UQ Gatton to • The site data and literature review has revealed some assess an area of suspected pasture dieback. key gaps in the information needed to support restoration management decisions; particularly those related to reliance on regeneration versus active revegetation. Filling the gaps will be the priority for further site data analysis and the collection of supplementary field data.
Fieldwork is currently being planned and will be conducted in Spring 2021. Monitoring databases are being sought from various sites to allow testing of the value of alternative data assessment approaches. The fieldwork and data analysis will be completed by November 2021.
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C33046 C27011 Rationale for the use of Paired Continuous Real Predicting the Impact of Complex Joint Structures Time Noise Monitors to Reduce Uncertainty in the on Mine Operations Quantification of Noise from Open Cut Coal Mines University of Newcastle Umwelt (Australia) Anna Giacomini Steve Lyons Marc Elmouttie Tim Procter Value: $304,711 Value: $125,000 Report Expected: August 2021 Report Expected: February 2022 Industry Monitor/s: Gift Makusha Industry Monitor/s: Ned Stephenson Warren Hitchcock Ngaire Baker ACARP Contact: Cam Davidson ACARP Contact: Patrick Tyrrell A draft report is with the industry monitor(s) for review. No report received. C28038 C33047 Groundwater Pressures and Flows Within Spoil Best Method for Determining Atmospheric Dumps Stability for the Assessment of the Acoustic Environment in the NSW Coal Mining Industry University of Newcastle Stephen Fityus Umwelt (Australia) Steve Lyons Value: $365,200 Tim Procter Report Expected: October 2021 Industry Monitor/s: Kim Peckett Value: $276,000 Leonie Bradfield Report Expected: September 2022 ACARP Contact: Cam Davidson Industry Monitor/s: Ned Stephenson Ngaire Baker Groundwater conditions in waste dumps are critical to ACARP Contact: Patrick Tyrrell dump stability but they are poorly understood. The objectives of this project are to produce a detailed No report received. baseline profile of the hydrological characteristics of an advancing waste rock dump in an active mine, based on factual evidence and laboratory measurements. The Geotech project will record detailed observations of the evolution of the water table(s) and adjacent spoil moisture C25035 conditions in an advancing waste rock dump over a Coal Subsurface Mapping for Open Cut Selective period of 12-18 months and use this data to produce Mining general, high-quality hydrogeological parameter datasets for soils of category 1-1.5 and 2.5 to facilitate CSIRO detailed hydrogeologic modelling of any specific waste Andrew Strange dump.
Value: $412,660 The large permeameter has commenced and preliminary Report Expected: August 2021 results have been obtained. Industry Monitor/s: Brett Domrow Margaret Stewart A modelling study to investigate the development of ACARP Contact: Cam Davidson excess pore pressures in the pit floor, was able to capture the overall trends in pressure observed in the piezometer A draft report is with the industry monitor(s) for review. readings, but it proved difficult to calibrate the model to capture both the trends in pressure fluctuation and pressures in the correct order of magnitude.
A researcher has been engaged to undertake the hydrological modelling and has spent the first month reviewing the state of the art for hydrogeological modelling in open pits.
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C28040 C28041 GSR and Numerical Modelling for Open Cut Rock Improving Blasting Geotech Outcomes Mass Characterisation University of Queensland Monash University Italo Onederra Hamid Roshan Sarma Kanchibotla Hossein Masoumi Value: $242,266 Value: $116,500 Report Expected: September 2021 Report Expected: September 2021 Industry Monitor/s: Dan Stolberg Industry Monitor/s: Matt Tsang Warren Hitchcock Thomas Hahn ACARP Contact: Cam Davidson ACARP Contact: Cam Davidson The main objective of this project is to develop industry The main objective of the project is to expand on the guidelines to minimise geotechnical risks and improve application of geophysical data (inspired by Geophysical blasting productivity. The project has involved building, Strata Rating) to open cut coal mines for developing a applying and testing advanced three dimensional robust and determinist rock mass strength model that blasting models with existing mine based data, focussing can lead to a more accurate numerical analysis based on on floor disruption techniques to reduce the risk of low advanced Machine Learning algorithms. wall instabilities; and also on the potential impact of blast direction and geological structures on rock mass damage. As elastic modulus and Poisson’s ratio have been predicted in the first mine (A) located in Bowen Basin In this quarter, the research team has been focussing on previously, model development has been initiated for developing practical guidelines from the learnings another coal mine (B) in the same Basin. After assessing associated with the many blast modelling scenarios of the data, boreholes which included sonic, density and weak layer disruption and continuity. The research team gamma ray logs in their geophysical data have been also commissioned the development of advanced slope identified. Data sets were then selected from an area stability modelling to understand, quantify and evaluate with relatively high borehole density in the study mine; the impact of layers disruption on the factor of safety of however, the borehole spacing (the distance between low wall slopes. A modelling protocol using FLAC 3D (see holes) were larger compare to mine A. So, five data-sets Figure below) has been tested and demonstrated as a that include 1, 4, 11, 19 and 33 boreholes were resulted proof of concept within the current research scope. for model development in mine B. Three previously Currently, the approach involves transferring disrupted nominated algorithm including Support vector surfaces from our blast models as point clouds into the regression (SVR), K-nearest neighbours (KNN) and multi- FLAC 3D model configuration and meshing application. variable linear regression (similar to mine A) were also Slope stability analysis is then conducted by considering considered for developing VP estimation models. the disrupted surface as well as the geometry, location, and any other potential blasted material property As the next step, profiles of elastic modulus (E) and effects. Poisson’s ratio will be generated for boreholes in mine B using the sonic velocities predictive models. Available lab Future work should involve testing the proposed measured mechanical properties will then be extracted protocol with other slope stability analysis techniques and compared with estimated profiles. The performance applied in industry; and further investigate the of the developed predictive models of mine A and B will effectiveness of the technique to be included in standard be ultimately compared and analysed. geotechnical analysis processes. The final report is currently being compiled for revision by industry monitors.
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C29005 C29044 System for Rock Fall Analysis Field Trial Baseline Data for the Development of Automated Characterisation of Waste Materials CSIRO Marc Elmouttie University of Newcastle Peter Dean John Simmons Xun Luo Klaus Thoeni Simit Raval Value: $321,268 Stephen Fityus Report Expected: January 2023 Industry Monitor/s: Matt Tsang Value: $197,850 ACARP Contact: Cam Davidson Report Expected: February 2022 Industry Monitor/s: Adrienna Robotham Systems to detect, monitor and analyse rock falls in open Kim Peckett cut mining operations have the potential to improve Leonie Bradfield operational safety, improve calibration of rock fall Ned Stephenson simulators (restitution coefficients), and importantly ACARP Contact: Patrick Tyrrell provide quantitative data to justify current standoff designs. A monitoring system that can accumulate a large Good waste dump design and analysis requires accurate database of rock fall events across the full strike length physical models of the distribution of waste types of highwalls is required. The use of existing monitoring throughout the dump. The detailed mapping of spoil systems (radar, vision, lidar) as well as knowledge of the types in the evolving dump is an arduous task, and the wall geometry, geology (rock mass types) and structural high variability of spoils makes automatic categorisation characteristics (defect orientations and intensities) has difficult. Machine learning from large data has the potential to support detection of events (potentially in potential to facilitate automated categorisation, real-time) and detect rock fall movements accurately however large data on categorised spoils does not yet enough for determination of trajectories (bounce exist. This project will carry out a series of detailed spoil kinematics), impact locations and final resting positions. mapping studies across many different mine sites, in the Sydney and the Bowen Basins, where a range of spoils In 2020, the feasibility of a monitoring system that can from each studied site are classified in detail according to accumulate a large database of rock fall events across the the BMA framework. This will provide comprehensive full strike length of highwalls was assessed. This new data in support of project C29048, which aims to stage of the project has just commenced and will field demonstrate that machine learning can be used to infer trial a prototype system which will consist of software spoil strength from spectral analysis of multispectral and computing hardware to integrate data from data. In conjunction with C29048, the greater aim is to commercially available radar, vision and fibre‐optics prove that real-time, automated spoil categorisation monitoring systems. Data for wall geometry, geology through multispectral analysis is a feasible concept (rock mass types) and structural characteristics (defect orientations and intensities) will additionally be used. COVID-19 restrictions during the past three months has The system performance will be tested in terms of real‐ impacted progress during the last quarter. Good progress time detection of rock fall movements, and post‐ has been made securing in principle access to sites, but processing for determination of trajectories (bounce as this research does not constitute essential operational kinematics), impact locations and final resting positions. business, physical access has not been possible. Three To achieve these objectives, IDS GeoRadar, sites had been surveyed prior to the recent tightening of GroundProbe, and Silixa have been consulted to ensure travel and access restrictions. that coordinated field trials involving the latest variants of these sensing technologies will occur within the Work on the project has focussed on laboratory testing required timeframes. There has been a significant of samples collected from the three field campaigns to increase in the in‐kind support provided by CSIRO since date. the short proposal submission. The major contribution is an Interrogator which has been purchased to support the fibre‐optics based microseismic monitoring research at a value of approximately AUD$200k.
In this quarter, previously derived system requirements are being refined in consultation with mines and technology providers, and a detailed system design is being developed to support prototype development.
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C29048 data at very low cost. The current project aims to deliver Image Based Automated Characterisation of a new low cost terrestrial stereo-pair photogrammetric Waste Materials monitoring system specifically developed for highly hazardous unstable areas. University of New South Wales Simit Raval The system consists of a pair of high-resolution DSLR Stephen Fityus cameras with interchangeable lenses controlled by a micro-computer. The cameras are integrated in two Value: $190,040 heavy duty camera boxes that can be installed on a pole. Report Expected: June 2023 Initial tests of the system have been performed at an Industry Monitor/s: Adrienna Robotham abandoned quarry near the university and additional Kim Peckett refinements have been made over the last two months. Leonie Bradfield The system has also been calibrated and is ready to be Ned Stephenson deployed at a mine site for more rigorous testing. ACARP Contact: Patrick Tyrrell Unfortunately, due to COVID-19 restrictions the installation has been delayed. In the meantime, the The project aims to enable automated characterisation current focus is on the development of the interface for of waste materials through a database of large number controlling the system and processing the data. of images acquired from Unmanned Aerial Vehicles (UAVs) from several dump-sites. To this end, a parallel C29052 project (C29044) has been initiated to conduct Autonomous Water Pressure Sensors for Spoil comprehensive field sampling and geotechnical analysis Dumps and Dams: Phase 2 that will form the baseline data to advance image-based characterisation for this project. Mining3 Byron Wicks A comprehensive guideline to improve the data collection has been developed for the partner project Value: $286,400 C29044. The procedural guidelines for UAV data Report Expected: December 2021 collection includes optimal resolution, the timing of data Industry Monitor/s: Brit McArdle collection, sensor parameter tuning, etc. Appropriate Kim Peckett field sampling protocols to suit the UAV based data ACARP Contact: Cam Davidson processing were formulated and advised including accurate geolocation procedures, spatial distribution and The geotechnical integrity and stability of a mine spoil coverage of sampling location, data curing, etc. The dump or tailings dam can be weakened by factors acquired UAV images are assessed for developing including abnormal pore pressures and movement methodologies for textural and spectral characterisation induced by ground water permeating the embankment of dump piles. Ground truth data has been geo- or the foundation of these structures. These factors spatialised and preliminary investigation in the greatly affect the design, layout, safety, and potential for classification of dump piles is being conducted. Overall, slope failure to affect surrounding areas. two sets of UAV data were collected from one mine dump-site area, with corresponding ground truth data. The onset of unwanted ground water-dependent Additional mine dump-sites for the collection of a diverse responses is difficult to monitor pervasively and composition of material type (BMA) has been scoped. autonomously using the techniques of ground- monitoring and instrumentation currently available. C29050 Mining3 designed and validated components of a Low Cost Terrestrial Stereo-Pair Photogrammetric prototype system to communicate the health of the Monitoring System for Highly Hazardous Areas earth structure from sensor data.
University of Newcastle A complete integrated solution is being developed in this Anna Giacomini phase with the following progress in the quarter: • A prototype fully validated the beacon design and Value: $210,720 assumptions for the system. Variables including Report Expected: April 2022 power requirements, operating temperatures, Industry Monitor/s: Brit McArdle torque of motor, mechanical strength, and effects of Dan Stolberg vibration were assessed. The performance of the John Latilla transmitter exceeded the requirements during our ACARP Contact: Patrick Tyrrell lab validation and the design has proceeded to design for manufacture stage. Validation of the mechanical Photogrammetry provides a valuable alternative and including pressure durability and shock resistance cost-effective solution to terrestrial laser scanners and was performed. The prototype system was field ground-based radar systems. It features simplicity of trialled at the Mining3 validation facility, with components and high scalability and provides true 3D
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successful transmission of the sensor pressure data. C28049 Image of the field validation below. On‐board Energy Recovery and Battery Storage • Final system receiver validation was performed prior Systems for Diesel‐Electric Haul Trucks: Scoping to the field trial with refinement of the system Study transmission and receiver algorithms performed this quarter. Enterprise Improvement Solutions
Value: $50,000 Report Expected: September 2021 Industry Monitor/s: Maintenance Task Group ACARP Contact: Patrick Tyrrell
Project leader has left organisation. Project on hold while a way to completion is determined.
C29031 Acoustic Sensing for Machinery Using Lasers
Validated and verified system ready for the field trials. University of Queensland Mining3 Maintenance and Equipment Karsten Hoehn
Value: $292,818 C26020 Report Expected: April 2022 Preventing Fatigue Cracking Via Proactive Surface Industry Monitor/s: Brendan Wilkins Dressing Justin Goodreid ACARP Contact: Cam Davidson Bureau Veritas AIRS Simon Krismer The goal of this project is to provide background research, methods and approaches for the development Value: $126,940 of laser vibrometer technologies that are able to provide Report Expected: September 2021 diagnostic information of mobile machinery and which Industry Monitor/s: Shane Saunders can be used in maintenance planning. ACARP Contact: Patrick Tyrrell The two primary objectives are to: No report received. • Establish the proof of concept, and hence the likelihood of being able to develop a commercial C28036 product of use to the mining industry; Wireless Health Monitoring Mine Equipment • Establish the viability, practical and commercial Using RFID and Machine Learning suitability, of the proposed technology.
Monash University Following the review of critical components on mobile Nemai Karmakar machines and their reliability, a short list of high interest components for condition monitoring has been created. Value: $250,000 The list is based on several parameters, including the Report Expected: August 2021 likelihood of component failure and frequency of Industry Monitor/s: Tim Gray maintenance orders. Currently, Mining3 is in the process ACARP Contact: Cam Davidson of obtaining sample components in new and, if possible, condition states for testing and comparison. A draft report is with the industry monitor(s) for review. Subsequent to the familiarisation of the newly procured scanning laser vibrometer, a series of early exploration experiments has been conducted to verify the signal responses match the manufacturer’s specifications in the context of component condition monitoring for mobile machinery.
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In collaboration with Bridgestone Mining Solutions Australia, Phase 2 of this project (currently pending approval) proposes to apply the test rig to conduct a series of tests on site in order to establish force-slip curves for handling tyres under different conditions (unpressurised/pressurised, new/worn tread and sidewall conditions, wet/dry surfaces) as well as a set of preliminary industry guidelines for safe lifting practice using tyre handling equipment.
Figure 2: Laser Vibrometer unit setup at Mining3. Photo taking during familiarisation and manufacturer's specification tests.
Following the familiarisation and early experimentation, a Design of Experiment test plan to further refine and optimise the signal performance of the laser vibrometer for mining applications was drafted and it is currently Figure 1: Handler grab test conducted at BMSA Oxley, under review. Brisbane, 22 July 2021.
In the coming weeks, the team will start collecting and A draft report is with the industry monitor(s) for review. analysing acoustic signals from the sample component(s). C29051 Predicting Failure of Hydraulic Pumps and Motors C29043 Develop Skid Mounted Tyre Handler Testing Rig GEM Innovations Graham Manuel University of Queensland Michael Heitzmann Value: $72,358 Peter Knights Report Expected: December 2021 Industry Monitor/s: Brendan Wilkins Value: $313,8560 Tim Gray Report Expected: August 2021 Weylon Malek Industry Monitor/s: Rob Fraser ACARP Contact: Cam Davidson Tim Gray ACARP Contact: Cam Davidson The objective of this project is to install case drain flow meters and monitoring equipment on the hydraulic The project aim was to design, construct, and pumps on an excavator. The monitoring equipment will commission a transportable tyre handling testing rig. The send a daily email to the maintenance planner with the frame and structural elements of the test rig were average daily case drain flow recordings. From the daily manufactured and assembled at Cascade Australia’s flow readings, the maintenance planner will be able to manufacturing facilities in Darra, Brisbane. Electrical change hydraulic pumps prior to failure, during a service wiring, instrumentation, and fit-out was conducted by interval. the Faculty of Engineering, Architecture and Information Technology at The University of Queensland. Functional This quarter saw the monitoring equipment operate performance testing and initial tyre slip tests were without incident. There was above average wet days carried out from 20-23 July 2021 at Bridgestone Mining during the quarter which resulted in less machine hours Solutions Australia Service Centres in Oxley, Brisbane. than expected.
Initial tests were conducted using a new 42/90R57 tyre. Below is the data that was collected during the quarter. A safe operating procedure (SOP) was established by No significant issue have been detected in the six pumps. arranging the restraining harness (slings and chains) on the ground, positioning the tyre on the harness and then securing the remaining side tension and tie-down chains. The tyre is then lifted and rotated vertically, complete with harness and chains. Three tests were conducted on the unpressurised tyre in order to assess the repeatability of grab force slip measurements.
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C33033 C33034 Vibration Energy Harvesting for Self Powered Dozer Suspension Seat to Reduce Body Vibration Sensors at Mine Sites University of Queensland University of New South Wales Danellie Lynas Binghao Li Value: $78,1070 Value: $313,850 Report Expected: February 2022 Report Expected: September 2021 Industry Monitor/s: Shane Apps Industry Monitor/s: Brendan Wilkins Ellen Roots Tim Gray Troy O'Reilly Peter Walsh Tim Gray ACARP Contact: Patrick Tyrrelln ACARP Contact: Cam Davidson
The objectives of this project are to: This project extends projects C23022 and C26026 • Identify the potential vibration sources at mine sites through an evaluation of a potential engineering (focus on underground); control. The project objective is to evaluate the • Evaluate the vibration energy capacity available to effectiveness of an innovative passive vibration and harvest from the vibration sources at mine sites; movement cancelling seat prototype in reducing dozer • Review and test the existing vibration energy operator exposures to excessive whole-body vibration harvesting (VEH) devices in the market; during normal operation at surface coal mines. • Design and develop new VEH devices for mining applications; and to Previous project data indicates dozers are associated • Test the new VEH device. with whole-body vibration levels that frequently exceed the upper limit of the Health Guidance Caution Zone We have identified relevant vibration sources on mine defined by ISO2631.1. Project C26026 has provided the site 1. Some data has been collected using a device technology to allow continuous remote monitoring of developed by the research team. Sources of vibration floor and seat accelerations, as well as simultaneous GPS have been investigated including Jumbo, Truck, Air data. Compressor and Mono Pump. A quick analysis has been done; a detailed analysis will be carried out soon. A An innovative passive suspension system has been Revibe model D energy harvester has been tested on patented and successfully tested in lab-based mine site 1. experiments recreating vertical vibration exposures from several different types of commercial vehicles and PhD recruitment is underway, and the student is in a field-based experiment evaluating an on-road truck expected to join the team in late August. COVID-19 application. The design was found to reduce whole-body restrictions have delayed progress slightly. vibration exposures by 50% compared to conventional, commercially available mechanical and air-suspension seats. Based on these preliminary results, the seat suspension design appears to have the potential to substantially reduce operator exposure to whole-body vibration.
This technology will be utilised along with data collected in previous projects, to develop a prototype seat tuned Figure 1. Using the vibration data collector with STM32 to the specific vibration attenuation requirements of development kit (left) to collect vibration data from a dozers and conduct an independent evaluation of the jumbo box (middle) and a mono pump (right). performance of the seat in real mine operation utilising the technology developed in project C26026.
Hardware involving a miniature accelerometer located in the seat and on the vehicle floor, and utilising a Raspberry Pi microcomputer has been sent to site for dozer instrumentation. The analysis software is in place.
A prototype seat base tuned to the specific vibration attenuation requirements of dozers has been developed. Fabrication to replicate a site dozer seat is in progress.
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C33036 the fabrication and assembly of the test rigs. Shortages Radar Tyre Monitor System in the supply of electronic components used in the data acquisition systems also impacted the schedule. CSIRO Significant efforts were made to mitigate these delays, including implementing redesigns to the test rigs to Value: $132,382 accommodate available manufacturing processes and Report Expected: September 2022 the inhouse design and fabrication of 50+ custom built Industry Monitor/s: Brendan Wilkins machine vision cameras. Rob Fraser Tim Gray The supply and fabrication of all hardware components ACARP Contact: Cam Davidson is now largely complete. Final assembly and commissioning of the test rigs is currently underway. It is This project is currently on hold, while CSIRO recruits a forecast that fatigue testing will now commence in the replacement project leader. third week of August.
C33044 Mining and the Community Design and Evaluation of a Passive Structural Fatigue Gauge C28046 Broader Contribution of Coal Sector Employment EngAnalysis to Indigenous Individuals, Families and Charl Pieterse Communities Ian Stevenson
John Vazey Myuma
Michael Limerick Value: $169,055
Report Expected: March 2022 Value: $199,472 Industry Monitor/s: Brendan Wilkins Report Expected: January 2022 Peter Walsh Industry Monitor/s: Anthony Galante Tim Gray Hayden Leary Weylon Malek Weylon Malek ACARP Contact: David Drakeley ACARP Contact: Patrick Tyrrell
The primary objective of this project is to assess the The project aims to investigate the impact and feasibility of a passive fatigue sensor to serve as a cost contribution that employment of Indigenous persons by effective alternative to detailed strain gauge testing coal companies has made to the life circumstances of regimes and fatigue analyses. To investigate this those individuals and their families and communities – in question, EngAnalysis set-out to deliver the following terms of not only material wellbeing, but other social and scope of work: economic dimensions, including health, education, • Conduct a literature review of existing passive fatigue emotional wellbeing, levels of social capital and even measurement techniques. cultural resilience. • To develop several (up to six) passive fatigue gauge designs and arrange for the manufacture of 100 units COVID-19 restrictions on accessing sites in the Bowen of each. Basin have continued to cause delays to fieldwork, as the • To design and manufacture a fatigue testing project is based on face to face interviews with apparatus suitable for safely and rapidly evaluating Indigenous workers. In the meantime, the research team large numbers of gauge samples simultaneously. has been able to interview four Brisbane-based • Conduct a series of fatigue tests aimed at determining Indigenous participants, taking the total number of the statistical performance of each fatigue gauge interviews to seven. The research team continues to design. Gauge designs are to be evaluated based on liaise with its industry partners with a view to arranging their conformance to their intended S-N curve and interviews with Indigenous workers employed at Bowen their repeatability. Basin coal operations.
Good progress has been made with the completion of the literature review, the design and manufacture of the first 300 fatigue gauges and completing a detailed design of a custom fatigue testing rig.
In this quarter, we set out to arrange for the fabrication and assembly of two fatigue testing machines and commence testing on the first of three round 1 fatigue gauge designs. Unfortunately, progress during this quarter has been slower than expected due to delays in Page 53 ACARP Current Projects Report August 2021 Open Cut Projects
Health and Safety C26026 Continuous Monitoring of Whole Body Vibration C25026 and Jolts and Jars Associated with Operating Reducing Risk Taking Among Australian Coal Earth Moving Equipment
Miners University of Queensland
Robin Burgess-Limerick University of Newcastle
Anna Giacomini Value: $328,704 Mark Rubin Report Expected: January 2022
Industry Monitor/s: Ellen Roots Value: $302,235 Shane Apps Report Expected: October 2021 Troy O'Reilly Industry Monitor/s: Doug Kennedy ACARP Contact: Patrick Tyrrell ACARP Contact: Patrick Tyrrell
The project objectives are to: This multi phased project aims to investigate the cause of • Develop, demonstrate, and evaluate iOS and server risk taking behaviour in Australian coal mines (Phase 1) software to allow continuous monitoring and analysis as well as develop and deliver a practical intervention to of earth-moving equipment operator vibration reduce dangerous risk-taking (Phase 2). Both open cut exposures using off-the-shelf hardware; and underground mines will be involved. The aim is to • Utilise this system to obtain an enhanced improve safety outcomes through reducing risk taking and, consequently, accidents and injuries. The project understanding of the sources of elevated whole body will test the effectiveness of the intervention and vibration and impact loads associated with haul truck develop a tool to enable industry users to assess the and dozer operation at a surface coal mine; and to • effectiveness of the intervention over time. Make the software freely available for adoption by other sites. The research team is currently focused on participant recruitment and data collection for Phase 2 of the Hardware involving a miniature accelerometer located in project. As of the start of August 2021, we have secured the seat and on the vehicle floor, and utilising a participation (signed consent) from an additional four Raspberry Pi microcomputer has been designed and underground mines and are working closely with the software coded. Data inspection and analysis software respective sites to commence data collection as soon as has been completed. possible. A previously committed underground mine that needed to pause participation due to COVID is also re- Data are now being obtained from accelerometers commencing data collection in the first week of August. mounted in both floor and seat of trucks at a central We are in regular contact with this mine to support the Queensland coal mine. Hardware has been fabricated to on-site data collection activities. The inclusion of these allow all equipment on site to be instrumented. This is in five additional sites in our research sample will the process of being installed. The hardware will also be significantly enhance our response rate as we look to utilised in a subsequent project to assess an innovative build on the 273 completed surveys which have been suspension seat for use in dozers. The company have received to date. requested hardware to install on an additional 25 trucks at a different site. We have signed consent from a further three mines (one open cut and two underground) who are yet to C29001 commence participation. We are working with these Case Study of Human Centred Design of New sites to negotiate timeframes and finalise planning Technology in Mining activities. We continue our recruitment efforts to engage additional sites for participation in the current data University of Queensland collection round. Given the recent addition of Robin Burgess-Limerick underground sites to our sample, we are concentrating these efforts on sourcing additional open-cut mines to Value: $133,198 aid in balancing our sample across the mining sectors. Report Expected: September 2021 Industry Monitor/s: Brad Lucke Tony Egan ACARP Contact: Cam Davidson
The objective of the extension part of this project is to document the human centred design process employed by Glencore and Wabtec throughout the development of the collision advisory system and develop a case study suitable for dissemination to industry.
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Background documentation provided by Glencore has C33005 been reviewed. Research Ethics approval has been Human Factors Aspects of Tyre Handling obtained for subsequent interviews with both Glencore Equipment Design and Operation Examined and Wabtec staff during a site visit planned as part of the within an EMESRT Control Framework Approach project. The site visit has been postponed until travel is possible. A presentation regarding the findings so far will University of Queensland be made to at “Mine automation and emerging Mike Boyle technologies health and safety partnership” meeting Nathan Cables organised by NIOSH in August. Robin Burgess-Limerick Sara Pazell C29021 Assessing the Impact of Consecutive Night Shifts Value: $241,424 on Night-time Alertness and Daytime Sleep Report Expected: December 2021 Industry Monitor/s: Craig Mason Central Queensland University Iain Curran Greg Roach Matt Clements Tim Gray Value: $254,604 Tony Egan Report Expected: October 2021 ACARP Contact: David Drakeley Industry Monitor/s: Craig Hagan ACARP Contact: Patrick Tyrrell Objectives of this extension stage of this project are to: • Develop the information architecture for rapid The objective of this project is to test an almost synthesis of task design and functional operating universally held orthodoxy – that the best way to requirements of tyre handling within the EMESRT minimise the fatigue risk associated with night work is to Control Framework approach; limit the number of consecutive night shifts to a • Populate the database with data obtained with focus maximum of four in a row. The alternative point of view on the high consequence, fatal events associated is that if the body clock can at least partially adapt to with tyre handling; night work after four consecutive shifts, then it may be • Add additional information to the database gathered better from a fatigue risk management perspective to from the EMESRT Tyres and Rims Technical Working work more night shifts while in an adapted state, ie work Group; tyre handling service providers; and analysis longer, but fewer, blocks of night shifts. of Fingermark video data; • Validate and verify the utility of the resulting register The project includes a laboratory based shift work of Required Operating States; Credible Failure Modes simulation study with 24 participants randomly assigned and Business Inputs at mine site(s); and to to one of two groups: Night Shift – 7 x 12-hour night • Determine the implications of the data gathered for shifts; or Control – 7 x 12-hour day shifts. The study is equipment functional specifications, training, and being conducted at our accommodation suites in other business inputs. Adelaide. The accommodation suites are set up like serviced apartments to house a total of four research The information architecture is under development. A participants concurrently, each with their own private workshop with the EMESRT tyres and rims working group bedroom, lounge room and bathroom. During data to review progress is scheduled for August. collection, participants reside in our accommodation suites 24 hours per day for a 10 day period.
In the past three months, eleven participants completed the protocol, which means we have now completed data collection for the whole project. In total, 24 participants completed the 10 day protocol as planned – eleven in the Control Condition and thirteen in the Night Shift Condition. For all participants who completed the protocol, we obtained daily assessments of body clock time, cognitive function and quantity/quality of sleep. We are now processing and analysing the data in preparation for a final report.
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C33007 and site staff (alert triggers only). SICK sensors have been EYECUE - Real Time Safety Monitor and Alert purchased by SW development team and proof of System for Tyre Handling concept bi-directional communication has been achieved. Fingermark Mike Boyle Product hardening work has also taken place on the Nathan Cables dashboard and refinement of the representation of the Robin Burgess-Limerick SW ‘brain’ view. It is currently in its second iteration as a 2D ‘top down’ view. There may be additional Value: $577,800 2D refinements – but ultimate goal is to have a 3D or near Report Expected: November 2021 3D representation of the work area eventually. Industry Monitor/s: Craig Mason Iain Curran Next Step – Linked to Objective 2 above – working groups Matt Clements will provide alert/alarm continuums – escalation paths Tim Gray and appropriate mechanism for alerts, alarms, then cut Tony Egan off. Could be visual, audible, sensory prior to mechanical ACARP Contact: David Drakeley cut off necessary triggers.
The purpose of the first phase of the tyre monitoring Objective 4 - Incorporate key findings from UQ ACARP project was to prove that using Computer Vision (CV), project C33005 – ongoing. Machine Learning (ML) and Artificial Intelligence (AI) can As above – EYECUE team is linked closely with Sara and improve worker safety in real-time when workers are Robin’s work and in weekly contact. engaged in changing, removing, servicing, and refitting large vehicle tyres in a mining workshop environment. C33008 This trial has also highlighted the applicability of the Relevance and Applicability of Inhalable Dust and technology to other mining use cases. The phases Current Issues with AS3640 completed to date are as follows. University of Queensland Objective 1 – Install a 2nd trial site at Glencore site in New Guldidar Kizil South Wales Hsin Wei Wu Has been slowed down due to COVID-19 implications – Mehmet Kizil but Nathan Cables has completed the required paperwork for the installation to be completed for the Value: $244,833 ACARP and Glencore site team. Report Expected: March 2022 Industry Monitor/s: Andrew Lau Next step – W/C 17 August 2021 – Nathan will initiate site Bharath Belle staff meetings and obtain site drawings/layout and Brad Lucke pictures so that installation planning can take place. Kevin Rowe • Will involve GC site, IT and security teams (need to Sharif Burra agree on network and HW approval requirements Tony Egan for site); ACARP Contact: Patrick Tyrrell • MST Global will do the installation – same as Trial site 1 – if approved by GC team. The aim of this project is to investigate the relevance and applicability of inhalable dust monitoring program Objective 2 - Encode the safety control framework rules implemented by Australian coal mining industry at the as application logic within the system. present, identify any issues with AS3640 - Workplace Requirements to be provided by ACARP and EMERST atmospheres - method for sampling and gravimetric groups is now in progress. Sara Pazell (C33005) determination of inhalable dust, and examine the reason presented an update at the EMERST monthly meeting behind the suspension of inhalable dust person exposure 9/8/21 – work in progress. limits in the U.S. • Initial feedback received on framework approach from Tony Egan, Craig Mason and Sara Pazell. The scope of the study will be focused on: • Investigating the relevance of inhalable dust Next Step – Await industry definition of behavioural particulates and its adverse health effects associated slippage and what kind of alerts and alarms may be with exposure of these particulates to CMW; appropriate. SW changes pending on outcomes of • Validating the applicability of the inhalable dust working groups. monitoring program currently implemented by Australian coal mining industry; Objective 3 - Demonstrate real-time alerting of breaches • Identifying any issues with AS3640 (Workplace to the SOP using the system. atmospheres - method for sampling and gravimetric Alerts and alarms have been generated – coming from determination of inhalable dust); and SW triggers of preliminary breaches as defined by team
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• Examining the suspension of inhalable dust person Population of the EMESRT control framework with exposure limits in U.S. required operating states and credible failure modes with data from project C28034 and other previous work Current status: has commenced. • The collected references are being reviewed and compiled into a report while searching for more Site access to conduct a detailed human factors task references related to inhalable coal dust. analysis, and facilitation of a workshop with a diverse • The developed questionnaire survey has been group of personnel experienced in the maintenance reviewed and modified based on the industry tasks associated with a Caterpillar D11 bulldozer have feedback and currently being transformed into an been confirmed. Both activities have been delayed due online survey. Soon it will be released to the industry to current COVID-19 restrictions. to gauge the applicability of inhalable dust monitoring programs employed in coal mining Overburden Removal operations in Australia. • The survey results will be compiled and analysed to C26035 determine the status of the industry’s inhalable coal dust program, monitoring instruments used and any Dynacut Fundamental Development: Phase 2 other related issues or concerns. Mining3 Erik Isokangas C34001 Isaac Dzakpata Human Factors Design for Diversity within an Paul Lever EMESRT Control Framework Value: $1,134,493 University of Queensland Report Expected: February 2022 Danellie Lynas Industry Monitor/s: Andrew Lau Robin Burgess-Limerick ACARP Contact: Patrick Tyrrell
Value: $66,974 A draft report is with the industry monitor(s) for review. Report Expected: November 2021 Industry Monitor/s: Bianca Matthews C27063 Iain Curran SATS Automated Mission Planning Matt Clements Tony Egan University of Queensland ACARP Contact: Patrick Tyrrell Peter Beasley Ross McAree The project complements project C28034 Mining equipment human factors design for workforce diversity, Value: $346,046 completed in 2020 in conjunction with EMESRT. The Report Expected: October 2021 outcome of C28034 was the identification of 14 Credible Industry Monitor/s: Brian Neilsen Failures Modes with respect to worker diversity Shaun Booth associated with surface coal mining equipment. EMESRT ACARP Contact: Cam Davidson is planning further engagement in 2021 with equipment manufacturers on these issues and has The Caterpillar Semi-Autonomous Tractor System (SATS) requested the outcomes of this project to assist in the facilitates autonomous execution of production engagement process. bulldozing in strip mining applications. The system is capable of performing several variants of production The objectives of the project are to: bulldozing: Push-To-Edge, Tip-Head and Pivot-Push. • Provide equipment designers with access to an EMESRT control framework structure with required To autonomously perform production bulldozing, the operating states and credible failure modes drawn current SATS system must be provided with missions that from existing EMESRT design philosophies, the are designed by an operator at a remote work-station. examples gathered in project C28034 and other Missions are the ‘packages’ of work that the bulldozer previous work. completes autonomously with one operator overseeing • Provide a detailed case study of how human factors several bulldozers, each completing its own sequence of task analysis may be used within an EMESRT control missions. framework to focus on the credible failure modes highlighted by EMERST design philosophies and The project aims towards the increased utilisation of identify opportunities for improving equipment available production time by planning missions design and business inputs to both reduce serious autonomously and choreographing dozers to deliver injury risks associated with equipment maintenance automated tactical planning capability. The technology and barriers to worker diversity. that performs this choreography is known as STAMP. The system underwent successful remote trials at Page 57 ACARP Current Projects Report August 2021 Open Cut Projects
Caterpillar’s Tucson Proving Ground in late 2020. These trials we conducted in lieu of being able to undertake planned field trials because of site availability during the COVID-19 pandemic. The team were very happy with the performance of STAMP in these trials, whilst gaining insights to improve the technology.
In the previous quarter the project completed a site trial that compare the performance of SATS-dozer mining with manned-dozer mining. A program to compare SATS operation with and without STAMP operating was progressively scheduled in June, July and August but each was postponed because of COVID-19 related restrictions. The next potential opportunity is September, and there are sanguine hopes that the trial can take place. As a contingency the research team have undertaken a risk assessment for a remotely run trial and this proposal to do this has been put to the trial site.
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C27064 COAL PREPARATION Dry Beneficiation Using FGX and X-Ray Sorters
Dewatering A&B Mylec Glenn Sherritt
C27016 Value: $112,000 Eriez HydroFloat in Plant Evaluation Report Expected: September 2021
Industry Monitor/s: none Eriez Magnetics ACARP Contact: Nerrida Scott Darren Mathewson Liam Davis The main objective of the project is to determine the performance of single and combined dry-processing Value: $155,600 technologies, treating a coal sample sourced from a local Report Expected: September 2021 coal resource. In addition, the project will undertake Industry Monitor/s: Clinton Vanderkruk order of magnitude estimates for the impacts upon Han Hooi resource value for such processes. Luke Dimech ACARP Contact: Nerrida Scott The overall outcome is to assess the merits of this unique combination of technologies as a processing option for The Eriez HydroFloat is a small footprint, high capacity, those Australian coal mine sites where either wet coarse particle flotation technology capable of processing is an unpalatable option or an in-pit recovering coal from a fine (eg -2.0 +0.3 mm) material processing option improves the overall resource stream using both density and surface chemistry economics through reduced haulage of rejects. Dry properties of the feed. This hybrid technology combines processing, at a suitable throughput and metallurgical the capacity and throughput of a density separator, with efficiency may also assist some projects in cold climate the selectivity of flotation. areas or remote locations which are being considered by Australian mining houses. The low capital cost profile The yields from 19 tests on the TBS feed stream at the and quick site establishment of an FGX plus XSS-T first site were very high at an average of 97.1% (ad) at the operation is likely to be a better capital fit for junior to low product ashes with an average of 8.8% (ad). The mid-tier mining houses seeking to establish a cash flow tailings ashes were high at an average of 75.4% (ad) and from their resource. the combustibles recoveries were extremely high at an average of 99.2% (ad). As expected, the greatest The following lists some of the key project milestones variation in yield was in the +1.4 mm size fraction, which and status to date: ranged from 79 to 96.3% (averaged 89.4%) (ad). The yield • A 3-tonne sample of ROM coal has been collected; of the other size factions was >95% (ad) on all but one • Mining location, working section, bore core data and occasion (ie for one size fraction for one test). The feed, predicted product qualities and yields for the product and reject samples from eight tests were float- collected sample have been collated; sunk. • The bulk sample was then transported to ALS
Maitland for initial crushing and sizing; The Whiten equation was curve fitted and showed • FGX test work including sizing and float-sink of cutpoints between 1.80 and 2.40 RD with overall Eps of product, middlings and reject has been completed; between 0.10 and 0.22. Due to the higher than expected • cutpoints, there is often only one, or zero, float-sink The samples for the FGX middlings test procedure fraction above the calculated cutpoint, so the curve-fit is were then progressed through the XSS-T sorting significantly overestimating the cutpoint and the Ep. process in individual and combined size fractions; • Being the very first Australian HydroFloat trial, it was also The product and reject samples from the middlings expected that some results would be sub-optimal. test procedure have undergone float/sink testing at Nevertheless, the overall Ep of 0.10 is thought to be ALS to complete the program; and superior to any other technology when fed with a feed • A final report is being compiled. top:bottom size ratio of >16:1 (ie 2.0 mm/0.125 mm).
Testing at a second site was delayed due to COVID-19 restrictions and then operational circuit changes. An alternate site is sought.
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C28052 revealed a thin layer of the slimes in the upper crust of Application of Agglomeration to Minimise the filter cake. Moisture and Maximise Yield If a conventional flotation product is subjected to the University of Newcastle novel agglomeration it should be possible to reject the Kevin Galvin ultrafine slimes from the product, in turn forming a basis for reducing the product moisture. This has now been Value: $146,342 quantified. It should be noted however that such a state Report Expected: August 2021 can also be formed using the Reflux Flotation Cell. For Industry Monitor/s: Clinton Vanderkruk this reason, recent work involved applying the Kevin Rowe agglomeration to the clean coal product, completely free Luke Dimech of ultrafine slimes, to examine the genuine impact of the Penny Walker agglomeration. ACARP Contact: Nerrida Scott The above systematic approach has provided clear The objective of this project is to investigate a new evidence on the precise reductions in product moisture application of a novel agglomeration technology to that can be achieved using the novel emulsion binder. It improve the dewatering of fine coal flotation product. is clear the limitations in the reduction are due to the Laboratory based studies will be conducted to determine very fine coal particles present in the RFC product, which the yield, ash, and moisture benefits of the technology is slimes free, and that further gains would be possible by versus the oil consumption to establish the technical and deliberately limiting the final particle recovery. economic viability of the approach. The novel fine coal agglomeration technology, applied at reduced binder The final report has been submitted to the industry levels, is expected to cause partial agglomeration of the monitors for review. ultrafine coal, reducing the losses of ultrafine coal in a screen bowl centrifuge. The partial agglomeration will C28056 also reduce the final moisture content, ensuring the Surface Alloying of Centrifuge Baskets and Sieve extra yield does not result in excessive moisture. It is also Bends Screen Surfaces to Increase the Service anticipated that there will be further reduction in the Lifetime product ash. CSIRO Strong progress has been made on this project to build Mike O'Brien the ground-work for quantifying any improvement that arises from the application of the novel binder Value: $131,644 agglomeration. The initial work was focussed on Report Expected: February 2022 distinguishing the basic components of the flotation Industry Monitor/s: Luke Dimech product into firstly (i) a portion of clean coal product Rahul Patel containing no slimes and (ii) varying portions derived Rebecca Fleming from the -38 micron portion of the tailings. The Reflux ACARP Contact: Nerrida Scott Flotation Cell provided a simple way to generate an ultra- clean flotation product. The ultra-clean flotation product The project will produce treated wedge wire surfaces was separated into different size portions covering (i) the which will be tested for wear properties against full RFC product (ii) +38 micron (iii) +45 micron etc. The untreated stainless steel wedge wire. The effect of overall clean coal RFC product was then modified by flexing on the continuity of the alloying will also be introducing different portions of the tailings to simulate investigated. The wedge wire will be tested for abrasive different conventional flotation products. This initial wear properties using a nozzle and sand blaster adapted work has shown that the final moisture content is a very for this type of test work. Sufficient treated wedge wire strong, and almost unique function of the Sauter mean, will be produced to build a pilot scale basket for the pilot and shows that one way to target a lower product centrifuge and sieve bend. moisture is to introduce sharp desliming or size classification. Moistures well below 20% were achieved The objective of this project is to investigate use of the by simply removing some of the finest coal. This CSIRO developed laser technique to produce a hardened approach was only effective when the product was surface on stainless steel wedge wire for use as screening slimes-free. media for sieve bends and centrifuge baskets in order to extend the wear of these surfaces. It is anticipated that Other work has also shown that relatively small portions the life of the screen medium would have to be doubled of entrained slimes included with the clean RFC product for the technique to be of practical use. can result in excessive moistures, above 30%. Interestingly, the rate of filtration was reduced almost Outcomes from a successful project will provide the coal exponentially by this material. This means that for a fixed producer with information on the value of using this type filtration capacity, high moistures may be produced due of technology to enable the extended use of centrifuge to incomplete filtration. Observation of the cake baskets and sieve bends well beyond their current
Page 60 ACARP Current Projects Report August 2021 Coal Preparation Projects lifetime. This will benefit the producer by reducing the C29059 maintenance costs, reducing the plant down time and Control System to Improve Ultrafine Coal Tailings reducing the risk of injuries during maintenance. Dewatering
CSIRO Manufacturing have been carrying out University of Queensland optimisation test work on stainless steel surfaces to Anh Nguyen determine the best conditions for the wedge wire surface alloying. Test pieces from a wedge wire Value: $174,230 manufacturer have been acquired and alloying of a small Report Expected: January 2023 fine coal basket will take place in the near future. Delays Industry Monitor/s: Han Hooi have occurred due to COVID-19 restrictions. Luke Dimech Majid Ejtemaei C28062 ACARP Contact: Nerrida Scott Improving Operation and Control of Centrifugal Dewatering Using a Novel Online Tool The objectives of this project are to: • Increase the performance of dewatering devices with University of Queensland a better control system to obtain required cake Liguang Wang moisture, cake yield stress, and centrate turbidity with any feed type. Value: $157,400 • Establish an empirical model for controlling the Report Expected: September 2021 centrifugal dewatering machine. Industry Monitor/s: Josh Kowalczuk • Design a closed-loop control system for the ACARP Contact: Nerrida Scott dewatering machine to adjust the operational parameters of the device to achieve desired moisture The objectives of this project are to: content and turbidity with varying feed type based on • Develop and evaluate an online tool for monitoring the monitoring of cake moisture, cake yield stress, the solids content and particle size distribution of the and centrate turbidity. feed and discharge of centrifuges; and to • Improve the operation and control of centrifugal This quarter, we kept focusing on making the control box dewatering for ultrafine coals. and improving the empirical model for the solid bowl centrifuge (SBC). The University of Queensland workshop The system of the prototype unit of the solid content and specialists have been working on the control box, which particle size distribution monitoring tool has been is expectedly completed in this August. Upon completion upgraded in the last quarter. The prototype unit is now of the box, it will be installed to the electrical board of able to automatically dilute the sample slurry, capture the SBC, tested, and used to calibrate and validate the the image, and clean the system. The team also improved empirical models, which allows for automatically the algorithm enabling simultaneous detection of the controlling the quality of the discharged water centrate. solids content and the particle size distribution. A new While awaiting the completion of the box, the team has image analysis approach was developed and been working on improving the automatic generation of implemented with the algorithm. We are currently PID control parameters. A program was designed to refining the algorithm to speed up the analysis as the import collected experimental data, and then current one typically takes 15 minutes to analyse one automatically generate an empirical model and the slurry sample (= 25 pictures). desired control parameters.
In the following quarter, the team will: C29060 • Extensively test the upgraded prototype unit; and Tailings Management - Dewatering Flume Site • Continue to improve the algorithm to shorten the Trials analysis time while maintaining high accuracy. University of Newcastle Craig Wheeler
Value: $242,500 Report Expected: March 2022 Industry Monitor/s: Kevin Rowe Peter Shumack ACARP Contact: Nerrida Scott
The objective of this project is to further refine and conduct site trails of a dewatering flume developed in C27067. The aim of the flume is to increase the solids content of the tailings entering the tailings dam and recover water before it is deposited in the tailings dam. Page 61 ACARP Current Projects Report August 2021 Coal Preparation Projects
The recovered water would be recycled back to the CHPP C33039 as process water, thus limiting the volume of water Efficient Reagents for Disposal of Coal Tailings – stored in the tailings dam and reduce, or eliminate, the Phase 2: Pilot Scale Studies use of secondary flocculant in the tailings dam. University of Queensland Extensive trials with the pilot-scale rig have been Anh Nguyen conducted and progress made in measurement and in refining the design. It has been found that solids Value: $180,000 concentration is highly influential on performance of the Report Expected: September 2022 system, with reductions in solids concentration resulting Industry Monitor/s: Han Hooi in significant increase in performance. This observation Luke Dimech has explained previous results and has also once again Tom Wilson allowed the use of 10 mm plate spacing for increased ACARP Contact: Nerrida Scott performance. The objective of this project is to deliver further progress Testing is ongoing and focus will be on further and developments of projects C27065 and C28054. In quantifying the influence of solids concentration, testing phase I, we developed a new technique to screen lower solids concentrations without flocculant and suitable chemicals for disposal by measuring the sample optimising flow patterns by varying the positions of the yield stress, strength via the peak force, and stickiness via dividing plates. Findings from the testing are being the tack energy. In phase II, we will focus on extending translated towards the full scale site design, which is pilot-scale testing to a belt press filter - BPF (and progressing through the conceptual design stage. continuing the work with solid bowl centrifugation - SBC) and collaborating with chemical suppliers on designing, C29062 testing, and screening new, efficient reagents for Process for Separating and Dewatering Fine disposal of coal tailings. They will help to achieve efficient Particles handleability and disposal stability. The knowledge gained from this project will help developing simple on- University of Queensland site tools to assess the consistency of tailings that are Liguang Wang suitable for stable disposal and to support decision making on the allocation of the current tailing stream. Value: $177,400 Report Expected: November 2021 In addition to the samples of the previous phase of the Industry Monitor/s: Michael Carnell project, extra samples were organised and waiting for ACARP Contact: Nerrida Scott delivery from the other two of the mine sites to UQ. Also, additional chemicals were purchased and received from The objectives of this project are to: the suppliers (from two more suppliers, totaling four • Develop a proof-of-concept technology based on different suppliers for the project). Chemical screening acoustic particle manipulation for beneficiation of using the developed testing method is in progress, ultrafine and fine coals; and to finishing with one mine site sample which is composing • Demonstrate and evaluate the effectiveness of this of column settling in conjunction with a lab-scale press novel beneficiation process for raw coals over a broad filter. A pilot-scale belt press filter was selected based on particle size range. a suggestion of monitors and paperwork are finalising for the hiring. In the next phase of this project, chemical The particle separator based on acoustic particle screening is continuing, and a lab-scale press filter will be manipulation has been assembled and some tests for this conducted to select the most suitable chemicals for pilot- separator have been done. A series of experiments were scale trials (SBC/BFP) and continue to develop the bucket carried out at a fixed ultrasonic frequency, with various rheometers for fine-coarse rejects. sizes of coal particles (-38, 38-45, 45-75, 75-150, +150 µm), and at a low solid concentration. Local tap water was used as the carrier fluid. Results show that it is possible to use the current device to manipulate the motion of particles in water.
In the following quarter, the technique will be tested against silica particles, which represent the gangue minerals, and the mixture of silica and coal particles at various mass ratios to investigate its effectiveness in particle separation. The effect of ultrasound amplitude will also be studied.
Page 62 ACARP Current Projects Report August 2021 Coal Preparation Projects
C33050 tailings dams to drier and safer options. A viable Dewatering Efficiency of Fine Flotation alternative to tailings storage in dams is Dry Stack Tailings Concentrates by De-Aerating Froth Products - (DTS) technology. Plant Demonstration This project proposes a new approach to developing a technology that can reduce the tailings moisture content University of Queensland Yongjun Peng to the level required for dry stacking, at a reduced operational and capital cost – the use of Hybrid Microwave Technology. This approach makes use of a Value: $627,923 combination of microwave treatment with conventional Report Expected: March 2023 methods, such as centrifuging. This method could bridge Industry Monitor/s: Andrea Crawford Frank Mercuri the moisture content gap between conventionally Naresh Racha dewatered material and Dry Stack Tailing requirements.
ACARP Contact: Nerrida Scott The project aims to deliver the development of a small- The objectives of this project are to: scale continuous microwave system that would evaluate the feasibility of a continuous process, and measure the • Develop large demonstration scale mechanical and energy requirements to achieve different product vacuum deaerators which are fully automated and moisture content. Finally, it will provide a concept for a can run continuously in plants; microwave-assisted dewatering process for future • Identify optimum operating conditions and control research studies. strategies through continuous plant trials;
• Evaluate and optimise equipment stability, wear, The project has recently started and has organised two maintenance requirement and operational costs; and coal tailings samples from a Queensland coal site. The • Identify equipment size and key parameters for samples include a thickener underflow material and a future full-scale operation in plants. product from a centrifuge dewatering process and had
recently arrived for testing. Initial characterisation of the UQ researchers and process engineer from DADI samples will be undertaken in the next couple of months Engineering have visited two participating coal including analysis for mineral content, bound and preparation plants to discuss the project plan and unbound water, particle size distribution and dielectric schedule with plant engineers. Key information required properties. Once completed, dewatering tests using for designing and installing the deaerators have been conventional and microwave processes will be identified, including plant operation conditions, plant undertaken as a benchmark to compare with the hybrid dimensions, location of the installation, power microwave process proposed in this project. connection and site safety standards for manufacturing the deaerators. C33053
UQ researchers are working with DADI engineering to Improving Centrifugal Dewatering via Modelling design the two demo-scale froth deaerators. The draft and Analysis design is expected to be completed in November. The design will be reviewed by plant, industry monitors and University of Queensland registered professional engineers before starting the Liguang Wang manufacturing. Value: $149,400 C33051 Report Expected: January 2023 Clinton Vanderkruk Hybrid Microwave Technology for Dry Stacked Industry Monitor/s: Josh Kowalczuk Tailings Applications ACARP Contact: Nerrida Scott
University of Queensland The objectives of this project are to: Christian Antonio • Develop a capability for modelling and simulating
dewatering and size classification of full-scale screen Value: $121,335 bowl centrifuge; Report Expected: September 2022 • Validate the model through pilot-scale trials, Industry Monitor/s: Frank Mercuri followed by full-scale trials if feasible; and to Kevin Rowe • Provide a guide to flowsheet design and industrial Naresh Racha operation of centrifugal dewatering. ACARP Contact: Nerrida Scott
The project has just commenced. To date no results have One of the most pressing challenges facing the coal been produced. In the following quarter, we will start the industry today is the increasing frequency of catastrophic modelling work on the centrifugal dewatering process. tailings dam collapses. Such events are known to cause significant environmental damage as well as loss of life. There is a strong industry push to move away from wet Page 63 ACARP Current Projects Report August 2021 Coal Preparation Projects
Environmental Improvement Mine site 2 field trial site has been prepared ready for tailings to be deposited. 115m3 of tailings is currently
being collected to incorporate at two different C28059 concentrations in preparation for a September planting. Impact of Water Quality in CHPPs This trial Will target two tailings ratios and a control with two amendments for three target plant species. Basacon Services Bruce Atkinson
Value: $111,414 Report Expected: August 2021 Industry Monitor/s: Kevin Rowe ACARP Contact: Nerrida Scott
A draft report is with the industry monitor(s) for review.
C29042 Tailings to Topsoil
University of Newcastle Ken Williams Figure: Mine site 2 field trial site preparation Value: $350,000 Report Expected: May 2022 Initial plant growth assessment in the glass house and Industry Monitor/s: Bill Baxter field 1 trial site indicates that a 25% tailings addition Luke Dimech increase plant growth when compared to the control soil. Patrick Tyrrell The filed trial 1 site also shows that tailings addition Paul O’Loughlin moderates moisture variations. Phillip Enderby ACARP Contact: Nerrida Scott Fine Coal Collection of tailings samples is continuing with six New South Wales mine sites and six Queensland mines sites C23045 being assessed. To date 49 tailings samples have been Full Scale Trial of the Reflux Flotation Cell collected from across New South Wales and Queensland. Ten of the 12 mines have supplied tailings for initial University of Newcastle characterisation and ex-situ trials. 32 of the 48 tailings Kevin Galvin chosen for this project have been collected. Value: $294,820 Characterisation has been conducted for 38 tailings to Report Expected: January 2022 date. Tailings constituent properties are currently Industry Monitor/s: Clinton Vanderkruk undergoing assessment and include clay content, Kevin Rowe salinity, pH, sodicity, sulphur content, particle sizing, Luke Dimech Cation Exchange Capacity (CEC), Acid extractable Penny Walker elements. Tailings have been selected for ex-situ glass ACARP Contact: Nerrida Scott house trials with key characteristics under investigation. The objective of this project is to investigate the In-situ field trials -Mine site 1 field trial has been performance of the Reflux Flotation Cell (RFC) at full established with regular growth measurement taken. In scale. This will be a two stage study investigated at a addition, soil moisture is collected and logged on-site volumetric throughput of up to 1000 m3/h. A key focus of every 15 minutes. the study is on the physics that underpin the scale-up performance of the technology, in terms of delivering “Fast Flotation”, and “Desliming Flotation”. The existence of a system of inclined channels increases the segregation rate of the bubbles from the downwards tailing flow. This mechanism produces a significant gas- hold-up, a concentrated bubbly zone, ideal for counter current washing to achieve clean product. A further objective is to assess the potential for process control of the technology, and hence assess the reliability over extended campaigns.
Figure: Mine 1 field site (1 block of 3 replicants)
Page 64 ACARP Current Projects Report August 2021 Coal Preparation Projects
Early experiments involved a two-stage system, however later work showed that a single stage operation was more effective. Thus, the project was developed as a single stage rougher/cleaner process, with high throughput and extreme cleaning. Laboratory scale work confirmed the approach, leading to the design and installation of the facility.
Following commissioning of the facility the Reflux Flotation cell was operated in accordance with the parameters established in the laboratory, with the application of wash water to create a positive bias flux. The Sauter mean of the feed was extremely fine at approximately 5mm, although the coal itself was coarser. It is noted that although some minor process control issues needed to be addressed, and the wash water rate Several candidate froth and pulp sensors were tested to the unit was temporarily limited, experiments still during this deployment and many were found to be proceeded. inappropriate for the challenging environment of coal
flotation. One of these was the CSIRO InterFloat™ Feed rates of up to 230 m3/h were applied, with wash (above), which was not able to measure the froth depth water rates of 60 m3/h, generating strong separations to a sufficient resolution for use in the envisioned control between the feed, product, and reject. This rate is strategy. The performance data collected during the visit, arguably three to four times the rate to a conventional however, was of good quality and mass-balanced well. cell for this feed. The performance of the full-scale Using this data, preliminary statistical models were system was very strong, with product ashes and yields in- developed to relate Jameson cell performance and line with the tree curve. Operating at about 2 cm/s feed operational parameters. flux with an average feed ash of 60.9%, the RFC achieved an average product ash of 12.6%, and reject ash of 81.8%. A second site visit at the same coal processing plant was This level of performance was maintained over many planned for 2020 with the objective of testing a range of hours throughout the day. alternative sensors and to collect a more comprehensive
dataset of Jameson cell operation. UQ personnel were C27021 deployed to site in mid-October but unfortunately the Model Informed Control Strategy for Coal visit had to be cut short due to plant instability problems, Flotation but not before UQ had tested all of their new sensors and collected a small dataset on the effect of frother dosage University of Queensland on flotation froth behaviour and performance. Kym Runge A third site deployment scheduled for early 2021 to Value: $199,571 collect a larger dataset had to be cancelled due to Report Expected: January 2022 ongoing plant instability. Instead, the decision was made Industry Monitor/s: Clinton Vanderkruk to complete the project based on the data collected in Majid Ejtemaei 2019 and 2020 only. Work is ongoing to complete the ACARP Contact: Nerrida Scott analysis of this data.
The objective of this project is to develop a model- C27026 informed control strategy for coal flotation. The project Ultralow Ash Coal by 3D Binder Flotation involves the application of AMIRA P9 flotation models developed for metalliferous flotation informed by University of Newcastle measurements performed using various sensors and a Kevin Galvin froth vision system.
Value: $152,020 In 2019, UQ and CSIRO researchers spent six weeks on a Report Expected: June 2021 coal processing plant in Queensland. During that time, Industry Monitor/s: Kevin Rowe they installed a number of sensors on a Jameson cell to ACARP Contact: Nerrida Scott monitor its behaviour in response to changes in operating conditions, particularly the supplied air rate. At The objective of this project is to investigate the potential the same time, they undertook a comprehensive to produce a coal-water mixture fuel, ideally less than 1 sampling campaign to measure the performance of the wt% ash, through liberation by grinding, followed by Jameson cell under the same conditions. beneficiation via a novel agglomeration method referred
to as 3D Flotation. Different levels of grinding will be used to achieve increasingly lower ash product. The final clean coal product will be further investigated in terms of its Page 65 ACARP Current Projects Report August 2021 Coal Preparation Projects size distribution, rheology and stability to quantify its C28050 suitability for transport, storage, and utilisation. Thus this Developing a Frother Decision Tree for Australian study is a precursor to a larger scale trial using an engine Coal Flotation Plants system to generate electricity. University of Queensland Following earlier problems associated with using iron- Yongjun Peng based grinding media, we moved to a ceramic milling arrangement. We also chose to use a binder that Value: $168,666 contained no salt. A coarser feed was sourced from New Report Expected: January 2022 South Wales, offering prospects for a lower ash through Industry Monitor/s: Luke Dimech liberation. A clean coal product was generated and then Mathew Merryweather subjected to significant grinding and liberation. The new ACARP Contact: Nerrida Scott product released significant levels of brown/grey waste. Initial results indicated the stage 1 product ash to be far The objectives of this project are to: higher than expected at 19% ash. Thus, the strong • Understand frother-saline water-coal interactions; liberation only reduced the ash to 14%. • Develop a frother decision tree based on coal properties and water properties; and to Surprisingly, the fine grinding continued to produce poor • Guide plant engineers to identify the best frother for quality results, contrary to expectations, with only their coal preparation plants. modest reductions in the ash observed. We suspected that the mineral matter was being crushed and During the quarter, the characterisation of different effectively smeared into the surface of the coal macerals, frothers in three-phase (air-water-solid) system using and that the fine coal formed was similarly being four coal samples collected from the participating plants contaminated by the ultrafine mineral matter. The point and the corresponding process water used in the plant is that this technology will “grab” any particle that have been completed to determine their CCC (frother contains almost any level of hydrophobicity, so the critical coalescence concentration) and DFS (dynamic results are suggesting that high ash particles froth stability index) values. Flotation tests were then contaminated by the fine coal are being recovered. With conducted with these coal samples using mechanical this hypothesis in mind, new experiments were flotation cell to correlate flotation combustible recovery conducted for the purpose of cleaning and dispersing the and product ash content with the CCC and DFS values. It particles, ahead of the agglomeration. A teepol was found that the presence of coal particles changes dispersant was added, while ultrasonic cleaning was frother characteristics in terms of both bubble size applied to the ground material. Moreover, the emulsion reduction and froth stability. The flotation results have binder that was added was reduced to ideally target the indicated a relationship between flotation performance most hydrophobic of the particles. The product ash was and CCC/DFS. Based on these understanding, a frother still only 6.2%. It is suspected that the coals being used decision tree has been developed to establish the are less than ideal, so others will be sourced. relationships of frother characteristics (CCC and DFS) and
coal flotation performance (combustible recovery to This work has so far demonstrated that the infer frother power and product ash content to infer agglomeration can be used to efficiently recover and frother selectivity) as a function of water classification concentrate a fine coal tailings stream to achieve a low criteria and coal classification criteria. In addition, further product ash. However, further grinding of the flotation tests have been conducted with Jameson Cell to concentrate product followed by application of the novel investigate the influence of the cell type on the frothing agglomeration does not yield a further reduction in the properties of these frothers and flotation performance. product ash. In order to assess whether this result was due to the coals selected for the study, an alternative In the next stage, the Microcel flotation column will be series of experiments was conducted. Product generated set up and further flotation tests with these frothers will from the Reflux Flotation Cell (RFC) was subjected to fine be conducted. The flotation data with Jameson Cell and grinding to achieve liberation. This material was then Microcel flotation column will help understand the subjected to (i) agglomeration to achieve product influence of the type of flotation cell on the frothing upgrade and (ii) flotation using the RFC. The original properties of frothers and flotation performance. These tailings stream generated a product ash of 7% following data will also be used to further validate and improve the application of the RFC. The ground product then frother decision tree. The frother decision tree will help achieved a product ash of 2.5% following application of guide plant engineers to fast identify the best frother for the RFC and 7% following the agglomeration. Clearly, the their coal preparation plants. coal used is capable of delivering liberation and reduction in the ash. This work has been repeated using multiple stages, using the RFC to achieve the cleaning to determine the lowest possible ash. The experimental program has been completed, and the draft final report has been submitted to the industry monitors for review.
Page 66 ACARP Current Projects Report August 2021 Coal Preparation Projects
C28051 C28054 Reducing Diesel Consumption while Improving Effect of Chemicals on Stabilising Tailings Fine Coal Flotation Through Controlled Diesel Disposals of Coarse and Fine Coal Rejects Emulsification in Saline Water University of Queensland University of Queensland Anh Nguyen Yongjun Peng Value: $150,000 Value: $153,450 Report Expected: August 2021 Report Expected: August 2021 Industry Monitor/s: Andrea Crawford Industry Monitor/s: Luke Dimech Han Hooi ACARP Contact: Nerrida Scott ACARP Contact: Nerrida Scott
A draft report is with the industry monitor(s) for review. A draft report is with the industry monitor(s) for review.
C28053 C28055 New Approach to Simultaneously Improving Review of the Current Australian Standards for Flotation and Subsequent Froth Breakdown Coal Flotation Testing: Phase 2 - Development of the Guideline Handbook University of Queensland Liguang Wang University of New South Wales Seher Ata Value: $192,600 Report Expected: October 2021 Value: $295,750 Industry Monitor/s: Clinton Vanderkruk Report Expected: June 2022 Luke Dimech Industry Monitor/s: Peter Shumack ACARP Contact: Nerrida Scott ACARP Contact: Nerrida Scott
The objectives of this project are to: The project builds on Phase 1, which had the primary • Develop and assess a new approach to improving the objective of reviewing the types and applications of test flotation efficiency of fine coals while keeping fast procedures that are currently being practiced. The breakdown of the discharged froth; objective of this Phase 2 project is to set out the • Prove the new approach on an industrial scale; and to recommended practices for coal flotation testing in the • Provide a fundamental understanding of this new form of a guideline document. The main objective is to approach. develop guidelines in the form of a Handbook that would enable practitioners to translate best evidence into best Additional coal flotation tests were carried out at practice. laboratory scale with saline water in the absence of organic chemicals (ie frother and collector) to investigate The work in Phase 1 showed significant variations in both the potential of applying this technique in a wider range combustible yield and ash in the tests done by various of applications. It was found that the improvement in commercial laboratories and research institutions using flotation performance was not on the par with the identical samples. Phase 2 work deals with identifying previous tests with addition of a frother. This finding potential factors leading to these variations. The could be attributed to the lower stability of the froth potential factors focused on are cell hydrodynamics, generated with saline water compared to that generated reagent dosage, solid % and fine loss during testing. The with a common frother solution. effect of cell hydrodynamic on the variation of the results have been studied using different impeller types (flat and An in-plant trial has been planned with the participating standard). Both impellors have been found to produce site to test the proposed technique using a 0.5-m similar results. With fine loss, tests have been carried out diameter column. The trial is expected to be commenced to investigate the impact of using flocculant/coagulant in in the following quarter. reducing fine particle loss during filtration. A significant reduction in flotation loss has been found when using a The final report has been drafted, pending the plant trial suitable flocculant. Work is currently underway to test results. contribution of reagent dosage and solid % to the variation in the test results observed in Phase 1.
Page 67 ACARP Current Projects Report August 2021 Coal Preparation Projects
C28057 from the individual size fractions, and the composite has Fine Coal Dewatering Test been crushed, subdivided and ground to – 1 mm for a routine raw sample CGA. CSIRO Mike O'Brien The specific objective is to determine whether the CGA data mathematically re-combined from analysis of the Value: $169,260 individual size fractions ‘at top-size’ retains the same Report Expected: November 2021 correlation to a ground raw sample CGA as if the raw Industry Monitor/s: Han Hooi sample had first been crushed, subdivided and ground to Luke Dimech – 1 mm. Michael Carnell ACARP Contact: Nerrida Scott In addition, a single lump of coal will be analysed by CGA as progressive slices, and compared to its bulk The objective of this project is to provide the industry composition after grinding to minus 1 mm. with a validated test method that will give an accurate estimate of the dewatering potential of tailings, fine coal The coal grain analysis remains in progress. Conducting and ultra fine coal. The method will establish a CGA on particles larger than 8 mm has created challenges benchmark for the final product moistures based on the that were not foreseen due to: coal type and the size distribution of the coal/tailings in • The prevalence of cracks and fissures in larger fine coal centrifuges, screen and solid bowl centrifuges at particles which are not experienced in smaller g-forces up to 3,200 g. This project may ultimately lead particles; to the establishment of an Australian Standard similar to • Difficulties in procuring satisfactory images of that of the coarse coal dewatering standard adopted in singular flat particle surfaces compared to routine 2016. images of thousands of much smaller particles; and • Software processing time. CSIRO has developed a method which has been successfully used over the last five years to provide an This has led to several software changes to the ParIS estimate of these dewatering properties. While the system, and dramatically slowed project progress. It is researchers believe this method to provide a good currently anticipated that the CGA work will be estimate of the dewatering properties and the limited completed during late 2021. feedback from producers has shown that this to be true, no real validation work has been carried out to C29055 determine the accuracy and confidence limits of the test Froth Flotation of 4mm Feed Coal Particles method. University of Newcastle A new holder has been constructed which allows for the Graeme Jameson two phases of separation in a solid bowl centrifuge. The holder can be spun to separate the water and solids and Value: $198,000 is then turned at 90 degrees to provide an angle bed for Report Expected: April 2022 the second decanting stage. Results are currently being Industry Monitor/s: Frank Mercuri produced. In parallel with this work the data from the ACARP Contact: Nerrida Scott laboratory work used to simulate a screen bowl and a fine coal centrifuge are being collated and reviewed. No report received.
C28060 C29061 Measuring and Correlating CGA Data at Particle Improving Flotation Recovery and Throughput Topsize with a Combined Method
Basacon Services University of Queensland Bruce Atkinson Liguang Wang
Value: $55,444 Value: $199,000 Report Expected: November 2021 Report Expected: January 2022 Industry Monitor/s: Chris Urzaa Industry Monitor/s: Kevin Rowe Tim Manton ACARP Contact: Nerrida Scott ACARP Contact: Nerrida Scott The objectives of this project are to: This project involved sizing a coal sample into separate • Develop and assess a method combining the use of size fractions (-31.5 +16, -16 +8, -8 +4, -4 +2 -2 +1 and - oscillatory air supply and vibrators for further 1mm) to allow CGA to be determined on each size improving the flotation recovery and throughput; and fraction individually, in the as-received sample state. In • Prove the new method on an industrial scale. addition, a composite sample was carefully prepared Page 68 ACARP Current Projects Report August 2021 Coal Preparation Projects
The oscillatory air conversion device was upgraded. A Finalised laboratory test methods have been produced series of two-phase tests were carried out and the and feedback/quotations for work scope are imminent. pressure profile of the oscillatory airflow was recorded to characterise the upgraded device. The device in the The outcomes of this project will be testing of each current version helped generate smaller bubbles attrition apparatus with attained bore core/in-pit site compared to steady air supply. The attainable frequency samples, and comparison of outcomes with both current range of this device was broadened. The operation time methods of processing and CHPP actual outcomes (pre- was also greatly increased. Several pilot-scale coking coal plant/estimated in-plant). Methods for use of such will flotation tests were also carried out. Results showed that be produced for application to routine unbroken coal the apparent flotation rate constant obtained with predictive samples (borecores and strip samples). oscillatory airflow at a certain frequency was significantly increased. C33055 Optical Profiling of Coal and Mineral Particles in In the following quarters, more pilot-scale flotation tests the Ultrafine Circuit for Online Analysis will be carried out to study the influence of the device’s configuration on the effectiveness of oscillatory airflow University of Newcastle and obtain the scale-up information. Rohan Stanger
C29065 Value: $157,387 Wash Plant Fines Testing Methods Enhancement Report Expected: May 2022 Industry Monitor/s: Clinton Vanderkruk McMahon Coal Quality Resources Jason Schumacher Chris McMahon Michael Carnell ACARP Contact: Nerrida Scott Value: $197,330 Report Expected: November 2022 A new microscope camera for acquiring videos of particle Industry Monitor/s: Frank Mercuri below 150um has been purchased and we are currently ACARP Contact: Nerrida Scott in the process of working through a scope of work with industry partners Restech to describe the software This project seeks to better determine predictive size upgrades required. The next work component will be to distribution on small samples by testing multiple integrate the new camera with the existing software. enhanced attrition apparatus and methods. C33058 Originally a new “attrition” apparatus was to be Full Scale Studies of Diesel Emulsification by designed, manufactured and trialled on “unbroken” coal Ultrasonication for Fine Coal Flotation (from strip samples and/or borecores supplied) and compared against plant feed/in-plant samples and University of Queensland standard laboratory drum tumbling test outcomes. CHPP Anh Nguyen operations data and operator expertise in relation to predictive/actual size distributions will also will be Value: $180,000 sought, documented and used in the planning and Report Expected: September 2022 evaluation stages. Industry Monitor/s: Clinton Vanderkruk Frank Mercuri On further consultation with industry and examination of Luke Dimech potential for building such an attrition apparatus, the ACARP Contact: Nerrida Scott process has evolved to test existing laboratory attrition processes in elevated time allotments, and the gauging The objectives of this project are to: of increased attrition effects compared with CHPP • Examine the adaptability and feasibility of outcomes. incorporating a full-scale ultrasonic unit into the
flotation process of an Australian coal preparation The attrition apparatus now being evaluated include plant. Prove the superiority of ultrasonic additional drop shatter, dry and wet tumbling, sieving emulsification to other mechanical methods. and use of a coke testing “Micum” tumbling drum. • Scan effective surface-active agents for diesel Individual and compounding effects (fines generation dispersion using the ultrasonicator. Examine the increase) will be examined. compatibility of the utilised reagents with frothers
and saline process water. Two potential coal sources have been confirmed with • Optimise the fraction of diesel, surfactants, and water sampling at both now in advanced planning stages, and to produce stable oil-in-water emulsions, which de for execution in the current quarter, with immediate improve the flotation of low-rank fine coal. commencement of laboratory testing. • Optimise the operational parameters of the
ultrasonic device including the ultrasound amplitude, reaction time, and the addition point. Page 69 ACARP Current Projects Report August 2021 Coal Preparation Projects
Progress to date Sampling at all four sites has been completed. Nine buckets of fine coal sample from Caval Ridge CHPP Preliminary analysis for the ash-by sizing results for the were received and characterised. The purchased LC3 samples show very high combustibles recoveries for ultrasonicator was tested, set up and applied for batch the entire -2.4 +0.125 mm size range with an Organic emulsification experiments using 16.7 %w/w diesel in Efficiency of 94.5% for the feed with a size ratio of water. Relatively stable diesel-in-water emulsions were 19.2 (ie 2.4/0.125). obtained with the droplet diameter between 1 and 10 µm, which is good for fine coal flotation. The device C33056 amplitude was optimised at 75 %. However, a fraction of Modelling and Control of Classifying Cyclones used diesel was not able to be emulsified due to the intense-but-local effect of ultrasound. A rig for QCC Resources continuous emulsification experiments was also set up Ausenco Services and used to carry out the test work using a special Andrew Swanson flowcell to enhance the emulsification. Diesel-in-water emulsions were continuously produced with good Value: $227,080 stability. The project investigators will further redesign Report Expected: May 2022 the emulsification process to improve the stability of Industry Monitor/s: Michael Carnell obtained emulsions and carry out the coal flotation Naresh Racha TM experiments using a pilot-scale microcel column at UQ ACARP Contact: Nerrida Scott before moving to the onsite test work. The objectives of this project are: Gravity Separation • Interpretation and evaluation of CGA data will allow the modelling of cyclone performance to be further C29064 developed to better understand behaviours of finer particles both in terms of size and density. Modern Coal Spiral Plant Performance Evaluation • New data from small diameter cyclones will allow the
utilisation of these cyclones in fine coal treatment to Quality Process Solutions be better appraised. Darren Mathewson • The use of CGA as a technology to investigate cyclone
performance and operation will be assessed. Value: $187,900 • By examining cyclone performance, along with a Report Expected: January 2022 review of on-line measurement techniques and a Industry Monitor/s: Andrea Crawford range of sample testing methodologies, it is hoped Michael Carnell that improved approaches to managing cyclone ACARP Contact: Nerrida Scott operational efficiencies will be identified.
• Although several designs of hindered bed separators If justified, the scope for a detailed large-scale (HBSs) have increasingly been used in the coal industry, evaluation will be developed. Spirals offer a number of advantages such as simplicity, reliability and lower capital and operating cost. Due to Agreements for the pilot plant and sampling analysis are the relatively narrow effective operating size range of being finalised. Sample collection is scheduled to occur in HBSs, there are often issues with carry-over of high ash August and the pilot plant work will follow from this. slimes and/or a loss of low-ash coarse coal. Process Control New spiral profiles are currently available. The industry would prefer supplier-independent Spiral bank C26013 performance data, and at lower cut points. The current Effect of Flotation Water Chemistry on Coal ACARP Spirals data is outdated and severely flawed eg it Chemistry, Fluidity and Coke Quality is for trough designs that have been superseded, or for cases where solids loading was excessive, or both. University of New South Wales Consequently, the reported Eps were extremely poor Noel Lambert and uncompetitive when compared to those for HBSs. Seher Ata Therefore, flawed design and investment decisions are likely to have been made, and will likely continue to be Value: $337,986 made. It is widely reported in the literature that as spiral Report Expected: June 2022 solid loading increases, both cut point and Ep increase. Industry Monitor/s: Clinton Vanderkruk Therefore, lower cut points are expected to be Rebecca Fleming achievable from any spiral if the feed solids loading is ACARP Contact: Nerrida Scott decreased.
The aim of the project is to evaluate the potential benefit This project will provide the industry with accurate data of washing a flotation product filter cake using clean on the new Minerals Deposits LC3 and LD7 and Multotec water to remove impurities (salts) and the consequence SX4 spirals. Page 70 ACARP Current Projects Report August 2021 Coal Preparation Projects of this practice on the fluidity of coal. In the first instance, Collaborators from Monash recently prepared the first dewater of coal products is being investigated. series of candidate polymers and sent these to Newcastle to canvas the potential for hydrophobising the clay An experimental setup is currently being developed for particles to support either agglomeration or flotation and measuring filtration kinetics. The setup consists in in turn dewatering. A systematic program involving placing a flask on a plate with a load cell. The flask is flocculation, and batch settling was undertaken to connected to a Buchner funnel. The device measures the quantify the potential for dewatering a range of mass of water over time. It is being trialled for suspensions, covering a broad range of doses. Some of reproducibility to evaluate the filtering of water under the reagents performed well in terms of achieving rapid various conditions. This experiment will provide settling and clarification, however, these failed to deliver information on the effect of salts and flocculants on the the necessary hydrophobicity. Hence, the flotation and dewatering properties of the filtration cake. agglomeration of the flocculated suspensions was not successful. C28073 Novel Processing to Reduce the Cost of An alternative feed was then used in a series of Generating Dry Stackable Tailings experiments, involving a coal tailings sample. A fine coal product was formed in stage 1. The stage 1 reject stream University of Newcastle was then flocculated using the RAFT agent to examine Kevin Galvin whether additional yield could be produced via a second stage of agglomeration. Despite the application of a Value: $141,342 reagent with a longer chain length, the stage 2 reject Report Expected: September 2021 particles were not recovered. It is concluded that the Industry Monitor/s: Andrea Crawford RAFT agent does not deliver the necessary Clinton Vanderkruk hydrophobicity. Kevin Rowe Penny Walker In June we secured five new RAFT polymers (~1 g each) ACARP Contact: Nerrida Scott from Monash University containing a short chain of poly(acrylic acid) and different units of hydrophobic An entirely new approach to processing tailings will be monomers. Multiple approaches were again taken to investigated at a laboratory scale, the ultimate goal being investigate their efficacy. These were also ineffective in to achieve dry‐stackable tailings. Hydrophobic forming hydrophobic flocs, so requested and received aggregation using cationic surfactants and or polymers new polymers at the end of July. We still need to assess will be used to form hydrophobic flocs that can be either the latest polymers. agglomerated or floated using ultrafast separations. This process, combined with more standard dewatering C33052 technology, should concentrate and dewater the Smart Conveyor Belts for Structural Health clay/siliceous minerals to achieve a moisture sufficient Monitoring and Weigh-In-Motion for dry‐stacking. Imagine Intelligent Materials The formation of dry‐stackable tailings is a capital and Phil Aitchison energy intensive operation primarily because the flocs used in thickening are hydrophilic, hence there is strong Value: $305,440 water retention in the thickener underflow. This project Report Expected: September 2021 seeks to reduce the capital and operating cost by Industry Monitor/s: Nicholas Roberts producing hydrophobic flocs, and then applying new Peter Shumack ultrafast beneficiation technologies to extract the ACARP Contact: Nerrida Scott hydrophobic solids from the water, and in turn dewater. This approach will deliver real‐time management of coal Smart conveyor belts allow real-time monitoring of the tailings, limiting the volume of the tailings waste, and structural health of the belt, the strain it is under, aims to reduce the costs of tailings management. damage to the belt and the weight on the belt. Imagine has previously built sensing systems for mining and Preliminary experiments have been conducted at the construction based on large area graphene sensors, University of Newcastle. Here well-defined suspensions including smart floors for buildings, people counting of clay have been used in agglomeration experiments mats and leak location systems. These sensors are using CTAB to promote hydrophobicity as a function of incorporated into existing materials without changing pH. Other experiments have included standard their mechanical properties and use edge-based flocculants such as the anionic polyacrylamides. We are monitoring to allow sensing where sensing has not also pursuing other approaches, using SMO as a previously been practical or economic. collector. The goal is to capture the clay material rapidly through agglomeration from suspension so that strong The objective of this project is to demonstrate a proof- compressive forces can readily be applied to squeeze of-concept smart belt and determine the technical steps water from the pulp. to a commercial product.
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The challenge in adapting Imagine’s stationary sensing technology to moving belts used in mining are primarily % Minus 1 to OS as a % of Feed around attaining sufficient signal sensitivity and 20 resolution and engineering the sensing electronics and materials to be robust enough to operate reliably in a 15 continuously moving and harsh environment. 10 5 Model data Model Progress: 0 • Initial tests of the sensing conveyor have been 0 5 10 15 20 successfully conducted; and Measured • A project extension (of one month) has been
approved, the delay is due to COVID-19 delaying Figure 4. Multiple regression model data for the percent hands-on work. of the minus 1mm reporting to the oversize versus the measured data. General C26011 C26010 CSIRO Instruments at Multiple Plants Multi-sloped Screening Efficiency with Changing Strokes, Frequencies, Feed Solids and Feed Rates - CSIRO Pilot Plant Study Mike O'Brien
Value: $427,798 CSIRO Report Expected: September 2021 Mike O'Brien Industry Monitor/s: Rebecca Fleming
ACARP Contact: Nerrida Scott Value: $140,025
Report Expected: September 2021 To maintain the momentum of industry access to the Industry Monitor/s: Clinton Vanderkruk CSIRO technology, the project will manufacture and ACARP Contact: Nerrida Scott install CSIRO density monitors into DMC circuits at
approximately six plants covering a range of mining This project aims to provide the industry with usable data companies, plant designs and coal types so that from a pilot scale multi-sloped screen that can be used to operating conditions from each plant and the dense maximise screening efficiency while providing the lowest medium conditions can be monitored by the plant possible forces on the screen, screen components and operators to optimise the DMC circuit providing screen structures. immediate benefits to the plant. This information will
also be used to further CSIRO research and knowledge on The project experimental work is complete and the improving the efficiency of DMC circuits. The exact report is completed and is now under internal review. number of participating plants will be subject to industry The qualitative effects of increasing the control variables pressures influencing the feasibility of their committing of Hz, Stoke, Feed Solids, Feed rate (t/h/m2), near size to the project. material and the g-force on the response variables are shown in Figure 1. Models were produced using multiple New sensors have been developed to fit under the sieve regression analysis for each of the response variables, as bend drain discharge chute. These sensors have been an example the model for % minus 1mm to oversize is designed to allow time for any entrained air to be shown in Figure 2. removed from the medium sample prior to entry into the
sensor body. Figure 1 shows a drawing of the under-sieve bend discharge chute unit and Figure 2 shows this unit in place at the site. Four of these units have been installed and are awaiting approval to energise.
Figure 3. Qualitative effects of increasing the control variables on the response variables.
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The instruments are all housed in stainless steel cabinets and communicate wirelessly between each other and the main wireless modem in the control box. Figure 4 is a schematic of the installations. The main control box also communicates back to CSIRO via a wireless 4g connection.
Figure 5. Drawings of the new sensors for under sieve bend discharge.
C26016 Benefits of Online Thickener Underflow Rheology Measurements
Clean Process Technologies Alexander Everitt Noel Lambert
Value: $251,000 Report Expected: January 2022 Industry Monitor/s: Michael Carnell ACARP Contact: Nerrida Scott
This aim of this project is to find how useful are the Figure 6. Sensors mounted under one of discharge chutes rheology measurements generated by the Thickener at site. Underflow Monitor (TUM).
A new sensor was also installed for the measurement of The TUM is currently able to generate information the feed density. This sensor was manufactured from 50 regarding the rheology of coal thickener underflow (as mm ID pipe and installed so that the medium flowed well as solids concentration m/m and v/v, slurry density upward through the system. This configuration shown in and particle density), but the usefulness of this the drawing in Figure 3 and installed in Figure 4 will information is not well understood. prevent blockages.
It is the purpose of this project to determine if and how these rheology measurements can be applied to standard thickener operations, paste thickener operations, secondary thickening operations, belt filter presses and other mechanical dewatering devices to see if online rheology measurement of tailings thickener underflow can be used to: • Optimise thickener operation; • Optimise paste thickener operation; • Reduce flocculant consumption to belt filter operations; • Reduce flocculant consumption in secondary flocculation; and to • Provide a means for maintaining more consistent operation of all the above systems.
During this period the installation of the TUM was completed at Mine Site B. Unfortunately, no further work was able to be conducted as, shortly after the installation, access to site was restricted due to COVID- 19 restrictions. CPT is maintaining open communication Figure 7. 50 mm pipe section with internal electrodes used for the feed medium.
Page 73 ACARP Current Projects Report August 2021 Coal Preparation Projects with site contacts and will be notified as to when site • an optimisation tool for extending the access can recommence. estimated fatigue life of a structural element based on its risk rating and its failure Work to be undertaken next quarter: probability; • Compile and analyse data and submit draft report for • a set of algorithms to identify the sensor status, review. condition and noise levels in order to define real-time reliability of the sensed data; C27050 • an alerts module for each frequency of analysis Detection of Non-Ferrous Broken Pick Tips and based on the results of the structural and risk Clay Balls in the DMC algorithms; • a comparison module to provide a tracking tool CSIRO of the asset among structural events and asset Mike O'Brien evolution through time; • a 3D visualisation of the asset in a programming Value: $61,280 language highly functional with the Report Expected: August 2021 implemented algorithms and the user- Industry Monitor/s: Clinton Vanderkruk interaction controls. ACARP Contact: Nerrida Scott Current work: A draft report is with the industry monitor(s) for review. • The experimentation phase will be deployed by September; C28061 • Waiting for non-operational time when the Quantitative Based Structural Integrity equipment is in maintenance to start the first part of Evaluations Using Modal Parameters Estimation the sensing campaign which includes the gathering of the modal response of the structure with any load. Mincka Engineering This will allow the calibration of structural response Fidel Gonzalez characterisation algorithms; • Significant improvements of the user interface with Value: $363,651 the integration of the 3D component and the Report Expected: September 2021 functional layout. Industry Monitor/s: Kevin Rowe Peter Shumack Phillip Enderby ACARP Contact: Nerrida Scott
The objectives of the project are to: • Develop a technique for reliable, cost effective and objective structural condition assessments of mining infrastructure used in coal mining; • Eliminate the subjectivity and conservative structural
condition assessments; and to Figure 1. 3D visualisation of the asset • Enable data driven decision making and increased the reliability of structural condition assessments.
Work to date: • Implementation of a set of identification algorithms to separate the changes of natural frequency of vibration from ambient effects, transient mass inside the bins effect, and stiffness in joints and members.; • Development of: Figure 2. Tracking tool for the comparison of two stress • an algorithm to perform risk assessments of the events structure, based on a stochastic modelling approach from an Australian Standard; • an algorithm for fatigue remaining life estimation, based on the stresses of the components and the probability of failure; • a set of structural KPIs to provide a better understanding of the potential failure mechanisms and its effect on the global response of the structure;
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C29054 C29056 Developing Operator Friendly Coal Oxidation Quantitative Based Protection Coating Measurement Assessment using Digital Imaging and Artificial Intelligence University of Queensland Yongjun Peng Mincka Engineering Fidel Gonzalez Value: $156,762 Report Expected: December 2021 Value: $335,100 Industry Monitor/s: Han Hooi Report Expected: December 2021 ACARP Contact: Nerrida Scott Industry Monitor/s: Jeci Guintu Peter Shumack The objectives of this project are to: Phillip Enderby • Develop a coal oxidation measurement kit which can ACARP Contact: Nerrida Scott be easily used by plant operators to fast measure coal surface oxidation in plant; The objectives of the project are to: • Develop a model to directly predict the mixing of • Automatically evaluate surface conditions and diesel with polar collector based on the measured quantify affected areas in length squared; degree of coal surface oxidation; and to • Enable data based decision making and increase the • Demonstrate a systematic approach to optimise reliability of corrosion condition assessments; flotation performance when tailings and oxidised • Lead to a reduction in turnaround time between coals are processed. inspections and repairs by virtue of faster assessment responses; The development of the new operator friendly coal • Capture paint condition degradation (rusting, oxidation measurement system has been completed. flaking, and blistering) with hyperspectral, infrared, Laboratory tests have shown that the new system can RGB and thermal cameras; generate accurate and repeatable results in a much • Train a machine learning algorithm to perform shorter time and therefore can replace the traditional automatic classification of the surface condition method. under recognised standards; and to • Overlay the hyperspectral, Infrared and RGB The new coal oxidation measurement system will be signatures to automatically obtain a classification of further tested in a coal preparation plant. The testing the paint condition under recognised standards. plan has been discussed with plant engineers. UQ researchers are completing required inductions at this Work to date: stage. Test work on site is expected to start in • Almost 6,000 categorised failures images from September. During the plant test, flotation feed samples structural inspections conducted in the years 2014 will be collected and measured by the new system and and 2018 have been pre-processed. This amount of the previous system at the same time. The two systems input data allows developing a robust and accurate will be compared in terms of measurement time, results system; accuracy/repeatability, safety and environment hazard. • A machine learning algorithm model has been Further optimisation will be conducted if required to selected and tuned for paint condition degradation make it more operator friendly. categorisation (type and level of degradation); • The algorithm training has been done using the pre- Laboratory testing of different polar collectors have also processed images; been conducted on coal samples with different degrees • The trained algorithm has been tested and validated. of oxidation. It was found that the application of polar It was found that the algorithm does not reach the collectors together with diesel is beneficial for the desired accuracy. flotation of oxidised coals, and the optimum ratio of polar collector to diesel is dependent on the degree of Current work: coal oxidation. More polar collector is required for coal • Tuning the hyperparameters of the algorithm and with a higher degree of oxidation. A plant trial of the train it again to improve its performance; polar collector together with the new oxidation • Evaluate other algorithm models that could reach a measurement system is planned. The optimum dosage of better performance. polar collector will be identified based on the measured degree of coal oxidation.
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C29057 Value Added Products from Coal Tailings
Western Sydney University Zhong Tao
Value: $212,540 Report Expected: April 2022 Industry Monitor/s: Luke Dimech ACARP Contact: Nerrida Scott
This project aims to develop new tailings management solutions by using coal tailings to produce road base/sub- base and stemming materials as well as agricultural soil Figure 1. Cylinder samples soaked in water. conditioners that are of immediate application for use on a mining lease area of a productive mine. A key objective is to assess whether these products are able to generate a revenue stream or result in a significant cost saving for the mine.
Further material characterisation was conducted to measure the ash contents of coal tailings from four mine sites. It is found that the ash contents are similar for samples from mine sites 1, 3 and 4 (ranging between 64 to 69%), whereas samples from mine site 2 have an ash content of 47%. The results indicate that the coal tailings from mine site 2 have a high amount of residual coal, which are suitable for making soil conditioners. Ongoing optimisation of mix design for making aggregates has been conducted using tailings from site 1. Cylinder Figure 2. Pelletised aggregates. samples were prepared and compacted using a California Bearing Ratio (CBR) test machine at an optimum moisture content. It was found that the ambient-cured cylinders can reach a compressive strength of 3.7 MPa at seven days when 3% slag and 2% sodium silicate are added. The cylinders showed very good integrity even soaking in water for four days (Figure 1). Pellets were further made using a pelletising machine based on the same mix design (Figure 2), and the 14-day compressive strengths of ambient-cured pellets (6.6-12.1 mm in diameter) ranged from 0.3 to 1.6 MPa. Further CBR tests will be conducted to check suitability of the pellets for use of road base/sub-base and stemming materials.
Efforts have also been made in making tailings-based soil conditioners to be used for mine site rehabilitation. It was found that seed germination could be improved for using site 3 tailings. This is consistent with the previous tests using tailings from sites 1 and 2. It is also found that chicken manure can be added to not only provide essential nutrients but also adjust pH of tailings. Ongoing research is being conducted to find out the optimised amounts of chicken manure and iron sulphate to be included in tailings-based soil conditioners.
Once the lockdown in Sydney is lifted, we will catch up the schedule to finalise the mix design of tailings-based aggregates and soil conditioners and start to characterise the pellet products (eg leaching behaviour). Engagement with relevant industry contacts from sample donor companies is being actively pursued for their input and advice regarding this research work.
Page 76 ACARP Current Projects Report August 2021 Technical Market Support Projects TECHNICAL MARKET Future Technologies
SUPPORT C33060 Sustainable Cokemaking and Ironmaking Technologies: Current Trends and Future Major Projects Research Needs
C27001 University of Newcastle Maritime Regulation Project Arash Tahmasebi
Goodwin Port Solutions Value: $71,500 Ash Goodwin Report Expected: April 2022 Industry Monitor/s: Kim Hockings Value: $4,169,012 Nick Andriopoulos Report Expected: July 2022 Stephen Brant Industry Monitor/s: Maritime Regulation ACARP Contact: Ashley Conroy Task Group ACARP Contact: Anne Mabardi The project involves a technical review of the current status and understanding of sustainable and low carbon The project includes research to investigate issues cokemaking and ironmaking technologies. Specific relating to the accuracy, repeatability and reliability of objectives are to: the IMSBC Code corrosivity test. ACARP work is closely • Review the development status, future outlook, and linked with a Global Industry Alliance, addressing similar challenges facing ironmaking technologies regarding issues from an international perspective for other feedstock quality requirements and impacts; cargoes. Initial research is now complete for coal and • Identify research opportunities to support Australian other cargoes and has been peer-reviewed. Findings and coal producers in responding to the changing market recommendations were reported to the IMO in demands; September 2018, resulting in a guidance note • Improve the understanding of efficiency, emissions, “MSC.1/Circ.1600 – Interim guidance for conducting the process parameters, and feedstock requirements of refined MHB (CR) corrosivity test” being issued by the low-carbon ironmaking technologies; IMO in January 2019. • Identify the coal and coke quality parameters and develop valid criteria that influence sustainable AMSA subsequently issued Exemption 5739, allowing cokemaking and ironmaking processes. Australian shippers of solid bulk cargoes to use the Refined MHB(CR) Corrosivity Test. Progress during the quarter: • The parallel review of 1) low carbon cokemaking and The second aspect of the project relates to issues 2) sustainable ironmaking technologies continued concerning the accuracy, repeatability and reliability this quarter; when testing coal cargoes for self-heating potential. • Journal publications, reports, conference Experimental work continues towards the confirmation proceedings, and case studies relevant to green of a refined testing method. cokemaking and ironmaking have been compiled and
are under review; AMSA has issued a Certificate of approval AP5620, • Progress was made in reviewing alternative raw allowing coals meeting specified criteria to be classified materials (eg biomass, waste plastics) to partially as MHB. substitute metallurgical coal in cokemaking. We
attempt to compile a database to summarise the The Exemption and Certificate of approval are available literature results on the properties of coals (rank, to download via the AMSA website: maceral composition, fluidity, etc) used in blending https://www.amsa.gov.au/vessels-operators/cargoes- with biomass; and-dangerous-goods/exemptions-and-determinations- • Review of current and emerging coke oven gas cargoes). utilisation is ongoing, as are the properties of coke
oven gas for re-purposing;
• The review of low-carbon ironmaking technologies
focused on current and emerging strategies for
reducing energy intensity and CO2 emission from
BF/BOF ironmaking;
• We reviewed the impact of hydrogen injection into the blast furnace and its implications for coke reactivity and gasification kinetics. Review of models used to explain coke reactivity under increased steam content is currently underway;
Page 77 ACARP Current Projects Report August 2021 Technical Market Support Projects
• Review work in the next quarter will involve Metallurgical Coal developing a database to summarise the properties
of coals used for blending with biomass and waste plastic and the quality of resulting coke. C27031 Evolution of the Pore Structure in Coke and In the next quarter, we will review literature data on the Implications on Coke Strength impact of altered reaction environment in low-carbon blast furnace processes on coke degradation mechanism. University of Queensland Karen Steel C33067 Merrick Mahoney Review of the Pilot Scale Coal Combustion Research Facilities Required to Meet the Value: $108,050 Report Expected: December 2021 Demands of Contemporary and Emerging Power Industry Monitor/s: Kim Hockings Generating Technology Sean Flanagan ACARP Contact: Ashley Conroy Ashley Conroy A draft report is with the industry monitor(s) for review. Value: $61,000 Report Expected: November 2021 C27053 Industry Monitor/s: Caroline Lang Method to Compare Chemistry vs Structure Greg Wickman ACARP Contact: Anne Mabardi Effects of Fusible Inertinite in Coke Making
This project is focused on the combustion of coal in HELE CSIRO (high efficiency, low emissions) boilers. Its objectives are Chad Hargrave to describe HELE boilers and the possible impact of coal Karryn Warren properties on their operation, and in so doing, identify Merrick Mahoney thermal coal research requirements and priorities associated with HELE power generation. The required Value: $173,196 capabilities of state-of-the-art thermal coal research Report Expected: September 2021 facilities will also be assessed, and the extent to which Industry Monitor/s: Chris Urzaa the existing ALS facility meets, or can be adapted to Tim Manton meet, those requirements. ACARP Contact: Ashley Conroy
The draft report is currently being prepared addressing The objective of this project is to demystify coking the objectives above. A meeting has been held with ALS behaviour of some coals that have similar ranks and and operating data pertaining to the combustion test maceral composition but behave differently during coke facility has been obtained, to assess its capability to making. The revised project scope aims to determine the replicate HELE conditions. There has also been relationship between reflectance, chemistry and communication with technical staff at a Japanese fusibility for the different macerals and try to answer the ultrasupercritical power station regarding their following questions: experiences in operating a HELE plant. • Is there a link between the fusibility of inertinite and its chemistry/reflectance? In the next quarter, the literature survey and drafting of • Is there a chemical difference between vitrinite and the report will continue, with a view to submitting the inertinite structures with the same reflectance? draft report around the end of October. • Are there differences in aliphatic/aromatic ratios and oxygen functional groups of maceral structures with a range of reflectance values? • Do these ratios determine the level of reactivity/fusibility of the maceral?
The data analysis of the individual project components (CGA, region of interest, and FTIR data) is now complete, and the consolidation of results for comparative analysis has commenced. In the next quarter this comparative analysis will be completed in order to answer the key project research questions. Based on these completed comparative results, the final project report will be drafted and circulated to the project monitors.
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C28066 (ii) coal grain analysis (CGA) and maceral composition Influence of Coal Blending on Coke Nanoporosity analysis, and (iii) Gieseler, dilatation and CSN tests. and CO2 Reactivity In the last quarter, fractographic analysis of the small- CSIRO scale cokes was carried out. Examination of these results Mihaela Grigore and linking to coal grind characteristics and thermoplastic properties is underway. In addition, CGA Value: $151,824 was carried out on each grind sample and the prepared Report Expected: September 2021 reserves from each of the laboratory carbonising tests. Industry Monitor/s: Kim Hockings Nick Andriopoulos In the next quarter, we expect to link coke strength Sean Flanagan (fractographic analysis) data to the CGA analysis and the ACARP Contact: Ashley Conroy results from the laboratory carbonising tests conducted on each grind sample. The aim of this project component Project C26039 found that closed nanoporosity occur in is to ascertain if the characteristics of the different grind large proportions in cokes, and almost all pores less than samples are carried through into the Gieseler and 5 nm are closed. Also, closed porosity in cokes becomes dilatation test sizings, and if there are differences, whether CGA can provide further information. increasingly accessible to the reactant gas (CO2) during gasification. Blending coals may have a significant influence on the coke nanopore structure, since Preparation of the draft report for this project is interaction between coals during carbonisation was underway and will be submitted in the next quarter. observed in previous studies. C29040 The aims of this project are to determine the effect of Direct Imaging of CO2 Penetration in Cokes Pre coal blending on the amount of open and closed and Post Reaction nanoporosity in cokes and gasification rate. The effect of coking conditions on the amount of open and closed CSIRO nanoporosity will be also investigated. Sherry Mayo
The draft report is being compiled.. Value: $104,463 Report Expected: January 2022 C28071 Industry Monitor/s: Graeme Harris Improving Understandings of IMDC-RMDC Steve Lempereur Interfaces ACARP Contact: Ashley Conroy
University of Newcastle No report received. Hannah Lomas C29066 Value: $161,076 Evaluation of Australian PCI Coals Under Industry Report Expected: September 2021 Scale Blast Furnace Conditions using a 3D Industry Monitor/s: Kim Hockings Computer Modelling - Stage 3 Under Overseas Morgan Blake Blast Furnaces Conditions Stephen Brant ACARP Contact: Ashley Conroy University of New South Wales Yansong Shen This project has investigated the principal mechanisms involved in determining the microtextural interface Value: $150,000 properties of metallurgical cokes by: Report Expected: August 2021 • Using an inertinite analogue to elucidate the Industry Monitor/s: Cameron Tasker influence of particular inertinite attributes; and Chris Urzaa • Examining the impact of maceral associations on Kim Hockings laboratory carbonising tests as a step towards Morgan Blake improving predictions of coking performance from ACARP Contact: Ashley Conroy these tests. This project follows on from two previous projects which Previously, five grind samples were prepared using one modelled the PCI behaviour of single coals and binary of the parent coals as the major component. For each coal blends respectively, under Bluescope Steel’s blast sample, the grinds of the vitrinite-rich and inertinite-rich furnace and PCI conditions. The overarching objective of components were adjusted separately before this project is to evaluate Australian PCI coals under recombining to produce samples with different grain overseas industry-scale blast furnace conditions composition for the same overall composition. Each (specifically those found in the Chinese blast furnaces sample was subdivided for (i) small-scale coking tests, Page 79 ACARP Current Projects Report August 2021 Technical Market Support Projects and Indian blast furnaces) using an improved 3D C29068 computer model. In-Situ Study of the Permeability of the Plastic Layers of Australian Coking Coals Using an The first version of the final report was sent to industry Advanced Permeability Test Apparatus monitors in early April. The final report has been revised for several rounds based on the comments from industry University of Newcastle monitors in May- June. For example, one more discussion Soonho Lee section has been added, more detailed descriptions and data of different overseas blast furnaces have been Value: $154,000 added, some statements have been rephrased or Report Expected: October 2021 explained, and more simulation results have been added Industry Monitor/s: Cameron Tasker and compared based on different overseas blast Nick Andriopoulos furnaces. The PCI simulators of Chinese and Indian blast ACARP Contact: Ashley Conroy furnace conditions have also been improved based on the feedback. This project aims to carry out comprehensive research on the plastic layer permeability in various aspects by A revised final report was returned to monitors in July developing two advanced permeability measuring and will be submitted for publication shortly after the techniques. confirmation from the industry monitors are received. We have selected different sets of samples varying in C29067 coal rank, fluidity and vitrinite content (MMVR: 0.97- Oxidation Rate in Reducing Coking Propensity of 1.53, vitrinite contents: 54.9-70.1, Gieseler maximum Individual Maceral Grains Residing Naturally in fluidity: 66-770dpm) to see the impacts of those Lump Coal using FTIR Microscopy properties on the plastic layer permeability. All of the given samples have been tested using both of the University of Newcastle advanced permeability rig and the in-situ permeability Quang Anh Tran rig.
Value: $99,800 To take a deeper look at the impacts of the measured Report Expected: October 2021 permeability on the microstructures inside the plastic Industry Monitor/s: Graeme Harris layers, we have prepared the plastic layer samples and Steve Lempereur scanned them using Synchrotron micro-CT with Teneal Groves resolution on the scale of a few microns. GeoDict, 3D ACARP Contact: Ashley Conroy microstructure analysis software, has been used to obtain several structural parameters such as porosity, This project employs μFTIR technique to investigate the pore connectivity, pore number; size distribution. In change in chemical properties of individual maceral addition, the scanned samples have been collected from grains residing on coal lumps during oxidation. Two aging Synchrotron and prepared for IR microspectroscopy techniques, natural and artificial, are employed in this analysis to measure spatial distribution of functional project. While the natural oxidation of sample is groups across the plastic layers. Ultimately, the chemical conducted at room temperature, the artificial condition structure transitions will be aligned with the stores samples at 60°C. A third experimental program, microstructure data to investigate the impacts of the the accelerated oxidation program, was conducted in the variations in permeability and microstructures in the last quarter to investigate the change in μFTIR spectra of plastic layers on the mass transport between the plastic coal samples under oxidation temperatures varying layers and their adjacent layers. between 70°C and 120°C.
The experimental component of this project has been completed and a draft report is being prepared.
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C29070 C29071 Effect of Coke Properties on High Temperature Source of Variability of Reactivity of Coke in the Strength and Hot Metal Reactivity Under Blast NSC Test (CSR Test) Furnace Conditions CSIRO University of New South Wales Lauren Williamson Pramod Koshy Value: $144,760 Value: $369,000 Report Expected: December 2021 Report Expected: April 2022 Industry Monitor/s: Chris Urzaa Industry Monitor/s: Jay Zheng Jeremy Byrnes Nick Andriopoulos Nick Andriopoulos Stephen Brant ACARP Contact: Ashley Conroy ACARP Contact: Ashley Conroy The main objective of this project is to determine if the This collaborative project between UNSW, ANSTO, UoN, variability in reactivity of the coke particles used in the and UoW focussed on the impact of blast furnace CSR test is due to the crushing procedure used to prepare conditions, specifically the high-temperatures and the sample or inherent variability in coke at the gasification conditions on the strength development and 20mm size. associated microstructural, microtextural, and mineralogical and corrosion characteristics of single-coal The following activities have been completed: and blended cokes. Through the work, the project aims • Four cokes have been produced; to a) compare high-temperature and room temperature • CSR testing for the coke analogue and two of the four mechanical strengths of two single-coal cokes and two cokes; blends derived from these cokes, all from a pilot oven, b) • All four Coke samples mounted and polished for gain understanding of key factors affecting carbon microscopy. dissolution into hot metal in the presence of slag under BF conditions, and c) form associations between strength In the next quarter the following activities are planned development and reactions with metal/slag with the • CSR Testing of the final two cokes; mineralogical, microstructural, and fracture • Automated image analysis of the four cokes; and characteristics of the coke and ultimately with coal blend • Mounting, polishing and imaging of reacted coke properties. particles.
Coke blends (C1 and C2) and two single-coal cokes (H and C29072 D) were prepared in the pilot oven at CSIRO. These cokes Effect of Parent Coal Origin on Coke Quality by were cored and gasified under blast furnace simulating Studying Structural and Textural Differences conditions. Room temperature and high-temperature Between Cokes made from Similar Australian and strengths were determined. Extent of gasification was compared for the cokes after gasification and testing at Northern Hemisphere Coals different temperatures (figure below). Coke H from high rank coal showed highest extent of graphitisation CSIRO followed by binary blend Coke C1 (with high proportion Eugene Donskoi of high rank coal). Select samples after high temperature and room temperature mechanical testing were Value: $97,195 provided to UoN for fractography and microtextural Report Expected: December 2021 analysis. Select samples of the single coal cokes were Industry Monitor/s: Nick Andriopoulos provided to the UoW for dynamic corrosion tests in hot ACARP Contact: Ashley Conroy metal. Extensive delays are expected owing COVID-19 restrictions limiting lab access in all three universities. The main objectives of this project are to: • Confirm greater fusibility of inertinites in Australian coals compared to Northern Hemisphere coals; • Understand the difference in fusibility between vitrinites in Australian and Northern Hemisphere coals; • Reveal systematic differences between coke structures and textures for cokes made from Australian and Northern Hemisphere coals of similar maceral composition and rank; and to • Achieve a more integrated understanding of difference in formation of coke structure/texture from Northern Hemisphere and Australian coals, how
Page 81 ACARP Current Projects Report August 2021 Technical Market Support Projects
it is connected with parent coal composition and how tribological testing of coke samples was completed such differences affect the resulting coke quality. earlier this year. Samples of each coke underwent tribological testing at room temperature, 950°C in an At current stage 19 coke samples made from single coal, inert atmosphere, and 950°C in a carbon dioxide and 22 industrial coke samples, all of them made from atmosphere. Northern hemisphere coals, were obtained. Matching with coke samples from Southern hemisphere for cokes In the last quarter, quantification of the tribological test made from single coal has been performed (six pairs results was carried out. This included (i) analysis of the made from low rank coal and six from medium and high coefficient of friction over the duration of the tribological rank coals). All polished blocks have been already test, and (ii) quantification of the wear severity and prepared – eight blocks per coke. All blocks have been mechanisms as a function of coke microtexture using imaged (more than 50,000 elementary images per coke), SEM image analysis. image quality control on all images has been performed, image analysis of all coke sets (six or more blocks) have The next steps will be to investigate whether the been performed and currently data processing and quantified data from SEM analysis can be used in report writing are in progress. combination with micro-CT image analysis (by comparing pre- and post-tribology 3D rendered images) to measure C29073 the relative abrasion resistance of the RMDC and IMDC Correlating the Distribution of Multiscale (i) in a given coke and (ii) relative to cokes from other Structural Features with Coke Quality Indicators single coals. We would then assess the potential to by Combining Advanced Datamining Approaches develop a wear coefficient tool to rank coke abrasion resistance as a function of its microtextural composition with 3D Visualisation and key coal properties.
University of Newcastle Interestingly, the difference in COF and wear severity Keith Nesbitt results for two of cokes of similar parent coal rank but
different maceral composition (and from different Value: $89,680 basins) as a function of temperature and gas composition Report Expected: August 2021 were markedly different. To better understand the Industry Monitor/s: Graeme Harris reasons for these differences, the anisotropy of the Lauren North microtextural constituents pre- and post-heat treatment ACARP Contact: Ashley Conroy to 950°C in inert and CO2 gas atmospheres will be
compared, allowing abrasion resistance from tribological A draft report is with the industry monitor(s) for review. testing to be linked to the degree of microtextural
anisotropy. C29074 High Temperature Tribological Testing of Coke In addition, the COF and wear severity results will be Coupled with 3D Visualisation to Enhance compared with industry measures of abrasion, eg ASTM Understanding of Coke Breakage and Link to Hardness and I600. However, it should be noted that these Parent Coals drum tests do not clearly dissociate strength from abrasion. In addition, we will examine if there is a University of Newcastle relationship between abrasion resistance values and the Hannah Lomas duration of the drum test.
Value: $161,029 C29075 Report Expected: December 2021 Fine Particles from Coal Industry Monitor/s: Kim Hockings Morgan Blake University of Newcastle Stephen Brant Liza Elliot ACARP Contact: Ashley Conroy Value: $188,700 The main aim of this project is to facilitate understanding Report Expected: July 2022 of the relevance of tribological testing to recognise Industry Monitor/s: Brenda Hutchinson factors that influence coke abrasion resistance at both Chris Urzaa room and elevated temperatures as a function of key Jane Lawson coal properties including rank, petrographic composition ACARP Contact: Ashley Conroy and measure. Atmospheric fine particles, commonly referred to as Three pilot oven cokes covering a range of rank, PM10 and PM2.5, ie particles less than 10 µm and 2.5 µm petrographic composition and two Australian coal respectively, has been shown to be a significant hazard measures (Moranbah and Illawarra) were selected for to public health. Historically, power stations have been a this project, each of which was studied in the previous significant source of fine particles, often becoming the project C27017. Micro-CT imaging followed by Page 82 ACARP Current Projects Report August 2021 Technical Market Support Projects target of criticism on medical and environmental C29076 grounds. As ESP’s are known to have poor collection of Understanding of the Mechanism of Chemical particles between 0.1 and 10 µm, this criticism may be Interaction Between Vitrinite and Inertinite justified. Fabric filters, if well maintained, generally don’t have this limitation and have very good capture University of Newcastle efficiencies of fine particles. Knowledge of a coals Wei Xie expected formation of fine particles would assist with the preferential placement of coals within the market; Value: $149,500 ensuring coals that produce a heavy load of fine particles Report Expected: September 2021 during combustion in boilers are not utilised where ESPs Industry Monitor/s: Kim Hockings are installed, as these units are not capable of completely Sean Flanagan collecting these particles. ACARP Contact: Ashley Conroy
The proposed program aims to develop a suitable This project attempts to obtain fundamentally technique for the measurement of fine particles understand of the chemical interaction between vitrinite produced by coal. A drop tube furnace will be used to and inertinite. The objectives are to (1) investigate combust selected coal samples. These furnaces have the chemical interactions between volatiles released from closest laboratory combustion conditions to a power vitrinite and inertinite on altering the thermo-plasticity station boiler, with similar heating rates, producing ash of coal coking; (2) evaluate the chemical structure with similar morphologies. Collecting the ash produced alteration of inertinite during coking with and without in the drop tube furnace in a cyclone and cascade volatiles and condensable tar released from vitrinite; (3) impactor allows particle sizes down to 0.1 µm to be clarify how volatiles and condensable tar from vitrinite collected. interact with inertinite to alter coking of inertinite. To achieve the goals, we use Reflux Classifier (RC) for TIMA chemistry and mineral association results will then concentrating inertinite particles, 0.3-0.5 mm, Computer be utilised to link the mineral species in the coal to the Aided Thermal Analysis (CATA) for swelling and particles within the ash. This is a first step in the process permeability; Dynamic Elemental Thermal Analysis that will eventually allow the entire particle size (DETA) for volatile (C, H) release, Attenuated total distribution of the ash from a given coal to be predicted reflectance-Fourier-transform infrared spectroscopy from the TIMA analysis. This will eventually allow a coals (ATR-FTIR) for identifying structure features of inertinite predicted fine particle formation to be predicted prior to and coal tar, Thermogravimetric analysis (TGA) for coal any detrimental outcomes occur by simply completing a tar boiling point and Pearson Petrography for fused TIMA analysis and utilising an ash formation model. carbon and structures.
Four coals will be used in this study; Each have been The project requires three coal samples. In the past sourced and crushed. Coal Grain Analysis of two of the quarter, we completed the CATA and DETA tests for feed coals have been completed and analysis of the other maceral concentrates from the third coal as this coal two coals is in progress. Pyrolysis and combustion sample had been delayed. The FTIR analysis for macerals experiments in the drop tube furnace of the coals have and the coking products from the third coal is currently been completed. TIMA analysis of the coals, and cyclone delayed. Next quarter, we are expecting to complete the chars from the pyrolysis experiments and ash from the FTIR analysis for these samples at chemistry department combustion experiments have been completed and and complete the fused carbon analysis for the prepared mining of the resulting data is underway. TIMA appears coke buttons while we are preparing the draft report. to “break-up” large porous char particles and there appears to be no way of resolving this problem meaning C29077 the analysis of the types of char formed during pyrolysis Effects of Ash Minerals on Coke Reactivity at High will now be dependent on Char Grain Analysis, which is in progress. Temperatures
Whilst SEM analysis of the combustion ash and char University of Wollongong cascade impactor samples produce good quality particle Brian Monaghan size distributions, a Zetasizer has been found that Pramod Koshy provides very similar particle size distributions in a timelier manner. However, separation of filter cake to Value: $414,733 produce particle size distributions is difficult and this Report Expected: May 2022 work is ongoing. Industry Monitor/s: Jay Zheng Jeremy Byrnes Limited access to the Scanning Electron Microscope due Kim Hockings to mechanical failures has delayed analysis of cascade ACARP Contact: Ashley Conroy impactor trays and filter chemistries. A draft report is with the industry monitor(s) for review.
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C29078 mechanisms of the transformation of cross-linking High Resolution Micro CT 3D Assessment of Coke structures during the coking process. Gasification C33062 University of Wollongong Evaluation of Australian PCI Coals in the Co- Brian Monaghan Injection of Hydrogen and Coal into Blast Furnaces using a 3D Computer Model Value: $64,590 Report Expected: August 2021 University of New South Wales Industry Monitor/s: Nick Andriopoulos Yansong Shen Tim Manton ACARP Contact: Ashley Conroy Value: $150,000 Report Expected: May 2022 A draft report is with the industry monitor(s) for review. Industry Monitor/s: Cameron Tasker Chris Urzaa C33059 Morgan Blake Transformation of Cross Linking Structures in the Peter Austin Plastic Layers During Coking of Australian Coals ACARP Contact: Ashley Conroy and its Role in Coke Formation This project seeks to use a 3-dimensional CFD model to University of Newcastle evaluate the performance of PCI coals when hydrogen is Soonho Lee co-injected with the coal into ironmaking blast furnaces (BF) at a low hydrogen rate. Of particular interest are to Value: $144,800 assess the impacts of hydrogen/coal co-injection on the Report Expected: October 2022 combustion behaviour in the raceway for a range of Industry Monitor/s: Kim Hockings Australian PCI coals including oxygen balance and coal Morgan Blake burnout under different co-injection conditions like coal Nick Andriopoulos type and rate, and on the other hand, to identify the ACARP Contact: Ashley Conroy requirements on potential Australian PCI coals when different hydrogen/coal co-injections are employed. This project mainly aims to study the underlying mechanisms of the transformation of cross-linking During the quarter: structures from the plastic layers to coke/semi-cokes • CI Shen gave an online presentation about the project during coking of Australian coking coals and its impacts outline, plan and details. The coal selection, BF on coke quality. It also investigates the effect of various operating conditions, other injectants, and maximum coal properties such as coal rank, vitrinite content and hydrogen injection rate were discussed. coal fluidity, on the transformation of the crosslinking • BSL data: Following up the discussion between the structures. project team and industry monitors, it was suggested to invite BSL and use BSL BF data in this project. In Coking coals covering a reasonable range of rank, fluidity early March, CI Shen had an online meeting and and maceral content have been obtained from the several email rounds with Peter Austin (guest ACARP coal bank in conjunction with the project industry monitor) and obtain the approval of the use monitors. The plastic layer samples for the given samples of BSL’s data. John Mathieson and Sheng Chew will have been prepared by using the plastic layer sampling provide help. technique equipped in the 4kg coke oven facility. The • Coal selection: Following up the discussion between plastic layer samples include the characteristic layered the project team and industry monitors, it was structures such as loose coal, plastic layer and coke/semi- suggested that the PCI coals that were used in the coke. The sub-samples from the layered structure from previous PCI project will be used in this project as each sample have been extracted for X-ray there would be existing baseline model data for those photoelectron spectroscopy (XPS), high-resolution coals, which can be used as the reference point from transmission electron microscopy (HR TEM) and carbon- which the co-injection of hydrogen could be 13 nuclear magnetic resonance (13C NMR) analyses to evaluated. observe transformation of C-bearing and O-bearing • Co-injection scheme design: Significant effort has crosslinking structures from the plastic layers to been made to develop a new Heat and Mass Balance coke/semi-coke regions. In addition, the parent samples (HMB) model for the scheme design of the innovative have been preheated from 300 to 700°C at 50°C intervals co-injection of hydrogen and coal. One confidential for electron spin resonance (ESR) analysis to observe the report of 5 BF data has been received and has been changes in radicals from the thermoplastic to post- applied for the HMB model calibration. Following up thermoplastic range. The results will be used to interpret on the discussion between the project team and the transformation of cross-linking structures observed industry monitors, the injection rate of hydrogen is from the various analytical techniques mentioned above, preliminarily determined and will be further studied which will deepen an understanding of underlying to set up a base line for the subsequent simulations. Page 84 ACARP Current Projects Report August 2021 Technical Market Support Projects
C33063 C33064 Micro-CT Based Characterisation of the IMDC- Influence of Inertinite and Volatile Release RMDC Interfacial Interaction in Blends of Characteristics on Viscosity Development and Australian and International Coals Fusibility During Coking
University of Newcastle University of Queensland David Jenkins Karen Steel
Value: $175,000 Value: $105,800 Report Expected: May 2022 Report Expected: April 2022 Industry Monitor/s: Graeme Harris Industry Monitor/s: Graeme Harris Kim Hockings Morgan Blake ACARP Contact: Ashley Conroy Nick Andriopoulos ACARP Contact: Ashley Conroy The project objectives are to: • Use high resolution micro-CT imaging to obtain We have previously observed various interactions quantitative measures of the IMDC-RMDC interfacial occurring that provide a strong indication that both interaction; volatile release and inertinite porosity influence viscosity • Use IR microscopy to characterise the inertinite development. In this project we are focusing our particles; attention on these two things and will test the following • Investigate the IMDC-RMDC interaction for a range of hypothesis. Australian and international coals; and to • Identify the key properties of Australian coals that The pore properties within inertinites are variable and contribute to good IMDC-RMDC interaction. also vary during pyrolysis/carbonisation. The changes in pore properties influence: retention of volatiles and Progress during the quarter include: therefore liquid within the inertinite, allowing the • Selection of ten coals (five Australian, five inertinite to deform and fuse; adsorption of volatiles international) in conjunction with Tata. Coal samples from neighbouring vitrinite, thereby reducing the have been delivered to Newcastle; amount of liquid generated by the vitrinite and reducing • Commencement of maceral separation at UQ. About expansion. 70% of maceral separation has been completed; • Preparation for IR microscopy of individual inertinites To date, we have received two of the four coals chosen at UoN. Activity has included design and construction and have started SAXS experiments. We have prepared of sample holders and inert atmosphere capability; thin wafers (0.9 - 1 mm) and established regions of • Design of graphite crucibles for coking of samples. interest. For example, the wafer shown below has a large These have been constructed and are in the process lens of inertinite, which appears to be semifusinite of being delivered; and around the outer edge with a centre portion being • Application for merit-based access to the IMBL at fusinite with mineral infilling the cell lumina. For SAXS, a Australian Synchrotron, for micro-CT imaging. vertical slice passing through the centre of the lens was Outcome of application should be known within two chosen and profiles were taken at locations spaced 0.5 weeks, with imaging to be schedule for the last mm apart down this vertical slice. We are examining the quarter of 2021. SAXS data to establish pore size distributions. We have also prepared a wafer that is parallel to the bedding CVID-19 restrictions will severely limit our ability to plane to see the extent that pores are anisotropic. progress this project. The project team is meeting regularly to investigate means of ameliorating the effect Further into this project we will be coking the wafers and of lockdowns on project progress. repeating SAXS analysis along the same vertical slice. We will also carry out maceral separation and thermogravimetric analysis to study the volatile release behaviour for various vitrinite and inertinite combinations.
Page 85 ACARP Current Projects Report August 2021 Technical Market Support Projects
In the past quarter we revised the working program and coal selection with the discussion with the industry monitors. With these changes, we have agreed that this project will target on the raw coals rather than the product coals. The coal samples will not be crushed, the study will include all different sizes of fractions, 0.15-2, 2- 4, 4-8, 8-16, 16-32, 32-50, and 50+ mm particles from the raw coals. Next quarter, we are expecting to receive the raw coal samples and start the analysis.
C33071
Fig 1: Top, left: Photograph of thin wafer of coal Use of Vitrinite Reflectance Categories on Coke (polished). Top, right: Microscopic image of thin wafer Strength Prediction of Bi-Modal and Multimodal revealing lens of semifusinite-fusinite. Bottom: Close-up Coal Blends of semifusinite-fusinite lens. University of Newcastle C33066 Arash Tahmasebi Washability and Distribution of Sulphur and Trace $138,400 Elements for Different Sizes and Densities of Value: Report Expected: July 2022 Product Coals Industry Monitor/s: Cameron Tasker
Kim Hockings University of Newcastle Nick Andriopoulos Wei Xie Stephen Brant
ACARP Contact: Ashley Conroy $128,550 Value: April 2022 Report Expected: The project aims to examine the in-situ coking behaviour Caroline Lang Industry Monitor/s: and the use of Vitrinite Distribution Category (VDC) Jane Lawson parameter in predicting coke quality from blends of Shaun Booth dissimilar coals. Specific objectives are to: ACARP Contact: Ashley Conroy • Explore the potential of the VDC approach, as an
alternate classification method, in improving the This project will focus on investigating if sulphur and prediction of quality of cokes made from coal with bi- trace elements contents from Australian coals vary with modal and multi-modal vitrinite reflectance different coal particle sizes and densities, and to what distributions. extent. • Investigate the carrying capacity of Australian
premium coking coals in blends with non-coking and The objectives are to: weakly-coking coals. • Quantify total sulphur, including organic and • Determine whether the introduction of VDCs inorganic sulphur contents, for different size and provides meaningful insight into blending decisions, density fractions of raw coals; particularly in coals with significantly different plastic • Quantify trace elements contents of different size ranges. and density fractions of raw coals. • Better understand the relationship between fluidity • Identify which fractions of raw coals should be and vitrinite reflectance distribution of bi-modal coal specifically targeted in coal preparation for reducing blends and the potential impacts on CSR. sulphur and trace elements contents.
Progress during the quarter: To achieve the objectives, total sulphur content, • Five out of six requested coals have been received inorganic sulphur, mainly sulphide and sulphate will be from the ACARP coal bank. analysed based on Australian Standards (ISO 19579 and • Five single coals and four coal blends (blends 7-10) ISO 157:1996). The difference between total sulphur and were prepared from the supplied coals and sent for inorganic sulphur is considered organic sulphur. Trace Gieseler fluidity and dilatation measurements. The element contents, including As, B, Hg, Cd, F, Mo, Pb, Se, objective is to determine the extent to which the Zn, etc. will be analysed by X-ray Fluorescence plastic range of blend components overlap. spectrometry (XRF) and Inductively coupled plasma - • optical emission spectrometry (ICP-OES) at the University The vitrinite reflectance distribution of the single and of Newcastle. Also, for some selected samples, blend coal samples were obtained by petrography morphology distributions of sulphur and trace elements analysis. Modelling analysis of reflectance on coal particle surface will be characterised by Scanning distribution of samples for assigning the VDC Electron Microscopy / Energy Dispersive X-Ray categories will be conducted in the next quarter. • Spectroscopy (SEM-EDS) and the mineral compositions We completed the thermogravimetric analysis (TGA) will also be analysed by X-ray powder diffraction (XRD). of the available nine single and blend samples in July. TGA data processing is scheduled for the next quarter Page 86 ACARP Current Projects Report August 2021 Technical Market Support Projects
to examine thermal decomposition behavior, C33061 synergistic effects between blend components, and Optimisation of Co-Firing Selected Australian carbonisation kinetics analysis. Thermal Coals with Biomass and International • Maintenance of the 4kg coke oven was conducted in Coals this quarter. New heating elements have been fitted to the coke oven, allowing the wall temperature CSIRO reach 1200 °C consistently. This modification Joe Perkins increased the middle charge temperature to 950 °C, a 100 °C improvement from previous configuration. Value: $122,660 New reactors were manufactured, allowing a 7kg coal Report Expected: October 2022 charge to the oven for coke sample preparation in the Industry Monitor/s: Graeme Harris project for CSR/CRI tests. Greg Wickman ACARP Contact: Ashley Conroy The in-situ coking tests on the remaining seven samples (three single coals and four blends) will be carried out in The project is a follow on from project C27047 and is the next two quarters, as scheduled in the proposal. Two aimed at extending the analytical capability developed in single coals were tested in the previous quarter. C27047 by developing a similar link between parent biomass particles and the optical properties of their Thermal Coal daughter combustion chars. This new capability would be applied to the analysis of coal/biomass blends and the C28067 combustion chars. Characterisation of Complex Coal Blends, and The project aims to: Methodology to Investigate Thermal Coals Based • In consultation with the project monitors, construct on Compositional Analysis and analyse co-firing scenarios with relevant thermal
coals (Australian and international) and biomass fuels CSIRO currently being utilised by Australian thermal coal Priyanthi Hapugoda customers in Japan and Korea.
• Further develop CSIRO’s CGA ParIS software to Value: $104,008 ascertain the combustion potential of Australian and Report Expected: September 2021 international coals when blended with other solid Industry Monitor/s: Graeme Harris fuels such as biomass. Use the information from this Greg Wickman test program to develop a coal/biomass char model Stephen Brant modelling which could predict the combustion ACARP Contact: Ashley Conroy performance without relying of drop tube furnace
experiments. A draft report is with the industry monitor(s) for review. • Assess the mineralogy and ash chemistry of chars
formed from Australian and international coals when C28072 blended with other solid fuels such as biomass. Mineral Redistribution from PF Coal to Ash in • Clearly identify and validate co-firing opportunities of Commercial Power Stations Australian thermal coals, and thereby provide recommendations to industry to enhance University of Newcastle marketability and enable power generators to make Rohan Stanger informed decisions concerning fuel choice prior to purchase. Value: $153,270 • Further develop the focused research collaboration Report Expected: May 2021 between CSIRO and researchers from the University Industry Monitor/s: Morgan Blake of Nottingham which was first established during Shaun Booth ACARP project C27047 and involved the sharing of ACARP Contact: Ashley Conroy both facilities and knowledge.
A draft report is with the industry monitor(s) for review.
Page 87 ACARP Current Projects Report August 2021 Technical Market Support Projects
At the time of writing, this project has entered month five C26003 (Gantt Chart). Due to COVID-19 restrictions and delays Management of SA and ISO Coal Technical associated with adding new coals to the coal bank, the Committees Work Programs project is approximately one month behind schedule. Carbon Connections Consulting The coal and biomass samples are now with the Barry Isherwood researchers at University of Nottingham where initial characterisation of the parent fuels will be commencing Value: $283,550 shortly. After these initial characterisation results are Report Expected: December 2022 received, meetings with industry monitors and UoN Industry Monitor/s: Graeme Harris researchers will be held to devise suitable blending Kevin Rowe strategies. Kim Hockings ACARP Contact: Anne Mabardi General This project is a continuation of ACARP support for the C25053 management of and input into both Australian and ISO Coal Sampling, Preparation and Analysis Standards. Coal Sample Bank
The main Committee MN/1 Coal and Coke, as well as the CSIRO Subcommittees MN/1/1 Coal Analysis and MN/1/2 Coal Lauren Williamson Preparation held Zoom video meetings in July.
Value: $458,451 COVID-19 restrictions have resulted in a number of Report Expected: November 2024 disruptions to the work programs of the Committee and Industry Monitor/s: Technical Market Subcommittees of both TC27 and MN/1. The effects on Support Committee MN/1 and its SC’s have not been as problematic as it has ACARP Contact: Ashley Conroy been for TC 27 and its SC’s. Although Zoom
videoconferencing for meetings can work well within The main objective of this project is to operate the Australia, the same process cannot be utilised as easily ACARP Sample Bank which makes coal and coke samples for international meetings for many reasons including available to researchers; and to enhance the systematic eight time zones involved, a week of day long meetings, provision of the samples for ACARP funded projects. language barriers, lack of one-on-one discussions and
lobbying, communication platforms etc. The inability to To date, 59 coal samples have been delivered, stored at - be able to hold the planned biennial meeting last month, 18°C and their details recorded in a database, there are and with no line of sight as to when a face-to-face also 32 cokes stored. Of the 59 samples stored coal meeting may be held, is now starting to have an adverse quality data has been provided by coal producers for effect. 53 of the samples.
The Conveners’ Policy Manual prepared by SC5 is still Requests for coal and or coke samples have been being further refined for use across all of TC27 SC’s. The received from the researchers for projects C33061, manual contains valuable information on language, C33064, C33066 and C33071. Ten coals and eight cokes terminology, and how to plan, conduct and interpret an have been added to the coal bank so far this year with ILS. The Manual specifically needs to consider how to further coals being sourced from coal producers to handle the production of a Technical Specification refresh depleted samples and or meet the requirements “Standard” which is more of a Guide, often without ILS of projects commencing in 2021. The coal bank has also data and thus less rigorous in its application. Additional provided support by providing sample identifiers to work will be required for some Standards which can be researchers where bulk /mine site samples have been more subjective, rather than objective in measurements required (C33070). such as Petrography Standards, and where some
qualifications of results is usually allowed in reporting. Coal and/or Coke samples have been supplied to the following projects in the 2021 calendar year: C29066, For discussion at the next ISO meeting is to address an C29067, C29068, C29075, C29076, C29077, C33061, issue whereby all the ballot comments received at ISO C33064, C33066 and C33071. Systematic Reviews are summarised and then either
accepted or rejected by the WG Convenor before any
document progresses. This puts a lot of power into the
hands of one person and the process adopted in recent
years is for all comments to be discussed at a face-to-face
meeting (ie the biennial TC27 SC5 meeting), where there
is the opportunity to discuss and possibly reverse or
amend any decisions made. However, with the TC27 SC5
Page 88 ACARP Current Projects Report August 2021 Technical Market Support Projects meeting having been delayed by at least a year, this has • Next meeting: July 2022 (TBA) not been possible. MN-001-01 (Coal analysis) —Mirror Committee for A further issue is that trade between Australia and China ISO/TC27/SC3 and SC5 is currently disrupted by politics and this has • Chairman: Barry Isherwood unfortunately resulted in the inability to have ILS samples • Last meeting: 15 July 2021 (Zoom meeting) from Australia distributed to Chinese labs. This has • Next meeting: 18 November 2021 (Zoom meeting) delayed at least one project, the development of an ISO • Meeting objective: Review ISO/TC27/SC5 and SC3 Standard for the Sapoznhikov Plastometer which is based documents including systematic reviews and finalise on a Chinese Standard and considering that this test has Australian mirror Committee position on ISO ballot been incorporated into some coal sales/purchase (and comments). agreements with China, it is essential to have Chinese labs involved in any ILS program. MN-001-02 (Coal Preparation) —Mirror Committee for ISO/TC27/SC1 and SC4 At the recent MN/1 meeting, the concept of adopting or • Chairman: Dave Osborne co-badging an ISO Standard as an AS/ISO version was • Last meeting: 14 July 2021 (Zoom meeting) again discussed. This was last discussed in 2014, when it • Next meeting: 8 December 2021 (Zoom meeting) was decided that this was not necessary. The long- • Meeting objective: Review of ISO/TC27/SC1 and SC4 standing practice for most coal analysis Standards has documents including systematic reviews and finalise been to develop a robust AS version, input this into ISO Australian mirror Committee position on ISO ballot and when the ISO version is published to then withdraw (and comments). Review update on national the AS version. This then means that within Australia, Standards and projects. there is no AS version and the ISO must be used both domestically and internationally. This has not created MN-001-05 (Coal Mining and Geology) any real issues to date and has avoided any numbering • Chairman: Walter Pickel problems. However, there is an alternative model • No meeting planned, subcommittee has no work whereby the ISO is adopted (co-badged) as an AS “cover” program. version which is simply the ISO version directly referenced in as AS/ISO publication. However, the AS and MN-001-06 (Determination of Gas Content) ISO numbering may not be able to be identical in all • No Chair cases, which could create confusion). It has been • No meeting planned, subcommittee has no work suggested that this system has advantages in some program since publication of AS 3980-2016. domestic contracts (eg coal sales, equipment manufacture) where users may prefer to reference an AS Standard rather than ISO. C28069 How Inertinite Concentrates in Blends Affect Coke Further discussion is required by industry and it is Strength proposed that the issue be taken up with ACARP Committees for guidance. University of Newcastle Wei Xie C26037 Australian Participation in Development of ISO Value: $99,500 Report Expected: May 2021 Methods for Sampling, Analysis and Coal Industry Monitor/s: Jay Zheng Preparation and National Technical Committee Sean Flanagan Support ACARP Contact: Ashley Conroy
Standards Australia A draft report is with the industry monitor(s) for review. Abbey Dorian
Value: $312,170 Report Expected: February 2022 Industry Monitor/s: Graeme Harris Kevin Rowe Kim Hockings ACARP Contact: Anne Mabardi
SA support for Australian Mirror Committee—Schedule of meetings: • MN-001 (Coal and Coke)—Mirror Committee for ISO/TC27 • Chairman: Barry Isherwood • Last meeting: 15 July 2021 (Zoom meeting) Page 89 ACARP Current Projects Report August 2021 Technical Market Support Projects
C33065 repeatability. Testing of five different coal types will be Digital Petrographic Atlas of Australian Coals - undertaken by three different Australian entities. Maintaining the Knowledge Outcomes of the round robin will inform an update of the standard AS4156.6 through Standards Australia, coal University of Queensland preparation working-group MN001-02. Joan Esterle Update: Value: $197,537 • Planning of procurement and schedule of coal Report Expected: July 2023 sampling and delivery was arranged in May; Industry Monitor/s: Graeme Harris • Coal 1 was received in June; Jay Zheng • Coal 1 was homogenised and dispatched to all Sean Flanagan laboratories at the end of June; ACARP Contact: Ashley Conroy • The updated sample preparation and testing procedure was issued to all laboratories at the start This project will create a Digital Petrographic Atlas of of July; Australian Coals, their maceral and mineral composition • Two of the laboratories have commenced testing of at different ranks, linked into our current understanding Coal 1; of basin scale variation in rank, type and grade, • The third laboratory has been impacted by the highlighting case studies that assist with conceptual COVID-19 shutdown and has not yet been able to minescale models for understanding and predicting coal commence testing; quality variation. In addition to the atlas, a library of • Supply of Coal 2 for homogenisation is expected in scanned petrographic images of product coals from the latter half of August. different basins and formations, illustrating the variation in rank, grade and type will be developed. The atlas and library can be used for reference; coal market and training purposes by the coal industry, service laboratories and academics; and as round robin samples with microscope emulation software.
To date, no such atlas and library exists in the public domain for Australian coals.
Whereas the atlas should reflect the breadth of coal deposits and their petrographic variability, it is difficult to source, prepare, scan, analyse and illustrate all available coals. Therefore the digital library and illustrations may focus on commercially traded product coals in the first instance, working collaboratively with other ACARP projects, for example Project C25053 Coal Sample Bank, agencies and commercial labs where able. A draft outline for the contents of the atlas has been prepared and under discussion with the industry monitors.
C33070 Update of Coal Dustiness and Dust Extinction Moisture Standard AS4156.6
University of Newcastle Dusan Ilic
Value: $150,000 Report Expected: May 2022 Industry Monitor/s: Brenda Hutchinson Jane Lawson Kevin Rowe ACARP Contact: Ashley Conroy
Following completion of two previous projects, C23054 and C26007, a revised sample preparation and testing method has been specified. The current project involves a laboratory testing round robin to confirm the precision of the modified method, notably, reproducibility and
Page 90 ACARP Current Projects Report August 2021 Mine Site Greenhouse Gas Mitigation Projects
C28078 MINE SITE GREENHOUSE Technical Development Unit (TDU) for Catalytic Conversion of VAM GAS MITIGATION University of Newcastle C28076 Michael Stockenhuber Selective Absorption of Methane by Ionic Liquids (SAMIL) - Phase 2: Demonstration in Packed Bed Value: $646,080 Reactors Report Expected: March 2022 Industry Monitor/s: Bharath Belle University of Newcastle Jim Sandford Andrew Maddocks Trevor Stay Behdad Moghtaderi ACARP Contact: Patrick Tyrrell
Value: $463,020 Methane emissions from VAM (ventilation air methane) Report Expected: March 2022 are one of the largest greenhouse emissions associated Industry Monitor/s: Ben Klaassen with mining. Due to the high greenhouse potential of Bharath Belle methane (23 times that of carbon dioxide), it is often Jim Sandford combusted to significantly reduce environmental ACARP Contact: Patrick Tyrrell impacts associated with its emission. VAM presents significant difficulties in processing, namely methane The selective absorption of ventilation air methane concentrations below the lower flammability limit. (VAM) in ionic liquids has the potential to be a step- Catalytic oxidation offers a possible technology to change in VAM abatement technology. The absorption mitigate these emissions, with the current system process would occur at ambient temperatures, which is addressing two of the main causes for catalyst significantly less than the autoignition temperature of deactivation, surface carbonaceous species deposition lean methane/air mixtures. Operating at temperatures and stable surface hydroxyl groups, to extend catalyst less than the autoignition temperature of VAM activity. completely eliminates the safety concerns related to a mine fire or explosion caused by connecting a ventilation A scaled Technical Development Unit (TDU) has been shaft to a VAM abatement plant. designed, with a long-term study being performed to determine the stable temperature required to maintain The primary aims of this project are to demonstrate the high levels of conversion. The current test has exceeded continuous operation of a bench-scale pilot-plant 2500 hours of operation, where it is predicted that involving both absorption and desorption and temperatures lower than current alternative understand the mine site integration challenges of the technologies will be sufficient to maintain high levels of ionic liquid process. The research will focus on methane oxidation. As part of the development of the determining: TDU, it is vital to monitor the pressure of the system to • The capture efficiency of the absorption process. ensure inherent safe operation. A system to measure • The energy requirements for the desorption process pressure drop across the catalyst bed has been and assess these requirements against the quantity of developed to be installed in the TDU to ensure the scaled methane captured and desorbed. unit is able to meet requirements. • The scale-up rules for the process and estimate the size of the process equipment required for a typical C29069 mine site; and Low Cost Catalyst Materials for Effective VAM • Mine site integration by modelling the process as it Catalytic Oxidation would occur on a mine site using APSEN+. CSIRO Ionic liquid for the pilot-plant has been received from a Yonggang Jin supplier in Europe. The modelling and design of the pilot- plant was completed in Q2 2021. Construction and Value: $178,380 commissioning of the pilot-plant is ongoing and is Report Expected: January 2022 expected to be completed in August. Industry Monitor/s: Ben Klaassen Bharath Belle Bianca Matthews Trevor Stay ACARP Contact: Patrick Tyrrell
Catalytic oxidation is an effective way to remarkably lower the temperature of VAM thermal oxidation. The main objective of the project is to develop new low-cost high-performance catalyst materials for VAM catalytic
Page 91 ACARP Current Projects Report August 2021 Mine Site Greenhouse Gas Mitigation Projects oxidation, which will lead to opportunities for lowering • Tensile strength testing was carried out on the the cost of catalytic VAM mitigation and speeding up its shortlisted fabrics (Figure 1). development. • The construction of the first RAINBOES module model was completed and mounted on the flame During the quarter work focused on testing of catalytic propagation tube (Figure 2). durability of several candidate catalysts under vapour- • Preliminary computer simulation study on the airbag bearing conditions. The results showed exceptional inflating mechanism is in progress. stability of metal oxides catalysts with the simulated wet VAM, exhibiting high catalytic activity over 90% CH4 The modification of small scale flame propagation tube is conversion around 500oC for an extended testing period in progress. of more than 200 hours. The influences of catalyst structures on their catalytic performance were studied on the fresh and spent catalysts with a variety of characterisation techniques including XRD, SEM, H2-TPR, CH4-TPR and O2-TPD. The selected high-performance metal oxides catalysts will be further tested with varied VAM concentrations and flow rates. The density functional theory (DFT) calculations are being undertaken to reveal the mechanism of methane oxidation over metal oxides catalysts, key energy barriers for elementary reactions and the interaction of water vapour with catalytic CH4 oxidation. The combined DFT study has provided an important means to aid catalyst design and development.
C33068 Airbag Inspired Explosion Suppression System for Mitigation of VAM Explosions
University of Newcastle Behdad Moghtaderi
Value: $286,678 Report Expected: April 2022 Industry Monitor/s: Bharath Belle David Webb Donna Dryden Jim Sandford ACARP Contact: Patrick Tyrrell
The principal vision in this project is to advance the development of a Rapid Action Inflating Nitrogen Bag Obstruction Explosion Suppression (RAINBOES) concept as an effective and ultra-fast suppression system for gas explosions. To fulfil this vision, the project aims at proving the concept through a combined theoretical and experimental approach. Theoretical studies will involve both analytical assessments and CFD modelling aimed at gaining a deeper understanding of the fundamental science that governs the operation of RAINBOES and its key components. The experimental studies include prototype development followed by small-scale assessment and concept validation.
With reference to the project structure plan, several essential and key tasks of phase one have been achieved in this quarter, as follows: • A compressive study was carried out to identify appropriate material/fabric for fabrication of the airbag. Over 30 different fabrics were studied; and some fabrics were identified as meeting the key criteria required for airbag fabrication.
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