CAIndiaC2012_Covers_CA India 11/16/12 3:14 PM Page 1 CAIndiaC2012_Covers_CA India 11/16/12 2:23 PM Page 3 The problem? Pump hoses were getting chewed up at Barrick Gold’s Lawler operations near Kalgoorlie, Australia. Sometimes failing after just ten days on the job. Fact is, the hoses weren’t tough enough to handle the abrasive sulphides. Then they turned to Weir Minerals for something that was. Hoses with Linatex® latex lining. Now they’re going 12, 16, even 18 months without maintenance. Linatex® latex liners simply outwork and outlast anything that they had tried before. Turning rubber into gold. A job-report from Barrick Gold And turning gold into profi t. no hose “patch jobs” and increased R&D. For a real world. It adds up to over $700,000 savings safety. And big cost savings. Linatex® liners are a product of the Weir per year in production costs for “The long life, the monitoring Minerals Advanced Research Center in Barrick. Plus, the exclusive Wear capability and the quality of the Malaysia. It’s where we simulate the Indicator Technology has turned hoses set them apart from the rest,” toughest mineral processing conditions maintenance from a reactive process says Maintenance Planner Dave on the planet. And build products accordingly. Linatex® liners are 95% into a totally predictive one. Long. Material Matters.™ And at latex for superior resistance to cutting, It’s a built-in early warning system, Barrick Gold’s Lawler plant, what tearing and abrasion. And when they featuring a wireless transmitter that matters most is Linatex® liners from do start to show wear, they even tell sends wear information to a remote Weir Minerals. For them, it’s the you about it. In advance. With a built-in wear indicator. Material Matters™. In receiver, ensuring fewer shut downs, gold standard. everything we do. And it all starts at our Advanced Research Center. To learn more about this story and other Weir Minerals products, visit whatismaterialmatters.com Copyright © 2012, Weir Slurry Group, Inc.. All rights reserved. LINATEX is a registered trademark of Linatex Ltd; MATERIAL MATTERS and the M2 Material Matters logo are trademarks of Weir Minerals Europe Ltd; WEIR is a registered trademark of Weir Engineering Services Ltd. Aspects of the Wear Indicator Technology described in this publication are protected by patents pending and registered. CAIndia_pg1_India_pg01 11/16/12 2:51 PM Page 1 News Briefs 20122012 COALCOAL AGEAGE IndiaIndia WWW.COALAGE.COM News Briefs CIL constrained by red tape and poor infrastructure................................4 NTPC increases total installed capacity .........................................................5 Features The Benefits of Slurry Pump System Optimization Improved energy efficiency and reliability enhance the bottom line .........6 Coal Handling System.................................................................8 The Growing Popularity of Sustainable Mine Reclamation..............................................10 Couragous Leadership..............................................................12 Mining Equipment and Technology Best of Germany 2012 A Supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal Age Chinese Edition, Best of Germany 2012 Coal Age Russian Edition, Coal Age India, A Supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal Age Chinese Edition, Coal Age Russian Edition, Coal Age India, Coal Age Asia and The ASIA Miner .........................13 Coal Age Indonesia and The ASIA Miner In Co-operation With VDMA Product News...................................46 COAL AGE INDIA 2012 1 2-3 CAIndia_India_pg02-03 11/16/12 3:12 PM Page 2 Editor’s Note Preparing for the Future By Steve Fiscor, Editor-in-Chief www.mining-media.com Mining Media International In some ways the situation with the U.S. and Indian elec- Editorial Office 11555 Central Parkway, Suite 401 trical infrastructure is similar and in other ways it’s a Jacksonville, Florida 32224 U.S.A. world apart. Both countries rely on coal and have mas- Phone: +1.904.721.2925 sive reserves. American mines are highly productive and Fax: +1.904.721.2930 the Indian mines are hoping to achieve that status. Coal Editor-In-Chief – Steve Fiscor, is shipped by rail long distances to the power plants. [email protected] Production in both countries is being restrained. India Western Field Editor – Russ Carter, has infrastructure issues while coal in the U.S. faces stiff [email protected] competition from inexpensive natural gas and resistance Steve Fiscor/Editor-in-Chief due to environmental activism. The coal-fired power European Editor – Simon Walker, [email protected] plants in the U.S. have ultra-high availability rates and healthy stockpiles; India’s power sector, as we saw this summer is unreliable and Latin American Editor – Oscar Martinez, stocks are running short. [email protected] As this edition of Coal Age India goes to press, India is worried that massive Associate Editor – Gina M. Tverdak-Slattery, blackouts will reoccur with the slightest disruption in supply. According to the [email protected] Central Electricity Authority, 35 power plants have reached a “super critical” stage. The CEA classifies super critical situations as those plants with less than a Graphic Designer – Francesca Peeples, [email protected] four-day coal supply. Eventually India will work through these problems, as peo- ple demand a more secure energy supply. The positive message is that coal demand is high and will only continue to grow. Each year, Mining Media produces several regional editions by repurposing Mining Media International technical information from Engineering & Mining Journal (E&MJ) and Coal Age, Corporate Office the two leading mining trade journals. E&MJ covers the metal mining and miner- 8751 East Hampden, Suite B1 Denver, Colorado 80231 U.S.A. al processing business worldwide. It has about 20,000 readers who are mostly Phone: +1.303.283.0640 mine engineers, metallurgists and geologists. Coal Age covers the U.S. coal min- Fax: +1.303.283.0641 ing and processing sector. It has more than 16,000 readers who are mostly mine President/Publisher – Peter Johnson, engineers, mine managers and prep plant managers. [email protected] This edition of Coal Age India includes a special section, the Best of Germany, which was produced in cooperation with the German Engineering Federation U.S. & Canada Sales Manager – Victor Matteucci, [email protected] (VDMA). Many of the mines in Germany have closed, but the region still makes some of the best mining equipment, and it exports its expertise to mining regions Scandinavia, UK and European Sales around the world. In this special section, VDMA members talk about how they are Manager – Colm Barry, [email protected] improving equipment and technology. German Sales Manager – Gerd Strasmann, Monthly, Coal Age and E&MJ offers readers ideas on how to operate mines [email protected] and plants more safely and efficiently. Society has made some huge strides, but we are still far from perfect. I watch sadly as the U.S. abandons coal and regu- Ad Traffic Manager – Erica Freeman, [email protected] lates itself out of the mining business. Similar to the Germans, we have a great mining heritage. They say those that do not learn history are destined to repeat the mistakes. Hopefully you can learn from our experience and avoid repeating our mistakes. COPYRIGHT 2012: Coal Age. ALL RIGHTS RESERVED. Our goal is to inform India’s mine and prep plant managers about many of the new developments taking place. If one reader gets an idea from reading this This publication was printed by: Starling Media magazine that makes a mine safer or saves time or money, then we consider this Kolkata, India. exercise in trade publishing a success. Enjoy this edition of Coal Age India. Phone: +91-98300 53601 Thank you. E-mail: [email protected] 2012 COALCOAL AGEAGE Steve Fiscor, Editor-in-Chief, E&MJ/Coal Age IndiaIndia 2 COAL AGE INDIA 2012 2-3 CAIndia_India_pg02-03 11/16/12 3:12 PM Page 3 Reliability. Experience that works for you. To maximize equipment reliability, Liebherr combines manufacturing expertise with superior monitoring and diagnostic capabilities to pro- vide customers with high quality equipment and services. Liebherr Mining Equipment Newport News Co. 4100 Chestnut Avenue Newport News, VA 23607 Phone: (757) 245-5251 E-mail: [email protected] www.liebherr.com The Group 4-5 CAIndia_News_News Briefs 11/16/12 2:14 PM Page 4 News Briefs CIL constrained by red tape and poor infrastructure During November 2012, Coal India Ltd. During October, as many as 19 thermal (CIL), one of the world’s largest coal produc- plants in India were reportedly reaching the ers, reported it will unlikely be able to “super critical category” for having coal increase coal deliveries significantly for at stock for less than four days and 11 thermal least three years due to bureaucratic red tape plants figure in the “critical category” with and a lack of transport infrastructure. This is coal stock availability for less than a week. not good news for India’s power sector, A report issued by the Operation which is also suffering availability problems. Monitoring Division of the Central Electricity At the end of July, two days of consectuive Authority (CEA) on September 4 said that out Soon after taking control, Rao said the immediate priority was Narsing Rao took over as chairman of the CIL during April to increase coal production and step up the coal supply. Now he 2012. Prior to the top post at CIL, he was chariman of Singareni Collieries Co. Ltd. (SCCL). says he can raise production, but without adequate rail serv- The latest figures by Punjab State Power ice, stockpiles will only build at the mines. Corp. Ltd. (PSPCL) reveal Bathinda thermal plant has coal stock for 22 days (for three units, one is non-operational at present), blackouts left more than 600 million people of 89 thermal plants, monitored by the CEA, against the normal requirement of 30 days.