Coal Age Serving the Needs of the Coal Mining Industry
October 06, 2008
Comprehensive Pump Book Available
The reference publication Optimizing Pumping Systems: A Guide to Improved Efficiency, Reliability, and Profitability is now available from the North Americabased Hydraulic Institute. The 250-page book, according to the publisher, is the most definitive guidebook to date on how to optimize pumping systems for maximum energy efficiency. Based on the collaborative efforts of industry experts, the compendium explains how optimizing both existing and new pumping systems, and purchasing based on lifecycle cost, can lead to increased profitability through a reduction in unnecessary, expensive energy consumption and maintenance costs. The guide covers a range of topics including: pump fundamentals, pump and system interaction, calculating cost of ownership, improving the performance of existing pump systems, optimizing new designs, and pumping system economics—opportunities to improve lifecycle performance. Also included: a 13-page glossary of terms along with case studies and a detailed matrix of useful tools for optimizing pumping systems. Optimizing Pumping Systems is $195/single copy, with discounts available for larger quantities. For more information, visit the company’s Web site. www.pumps.org
MSHA Refers Issues Relating to Crandall Canyon Mine to U.S. Attorney for District of Utah
The Mine Safety and Health Administration (MSHA) recently acknowledged that it has made a criminal referral of issues relating to the Crandall Canyon mine to the United States attorney for the District of Utah in a motion filed with the federal Mine Safety and Health Review Commission.
The criminal referral arises out of the same facts, events, and conditions that led to MSHA’s issuance of civil citations and orders on July 24, 2008. At that time, MSHA fined the operator of the Crandall Canyon mine $1,340,000 for alleged violations that directly contributed to the deaths of six miners last year. Agapito Associates Inc., a mining engineering consultant, was fined $220,000 for an allegedly faulty analysis of the mine’s design.
"Through its investigation of the tragic accidents last year at Crandall Canyon, MSHA determined that the operator and its engineering consultants demonstrated reckless disregard for safety," said Richard E. Stickler, acting assistant secretary of labor for MSHA. "MSHA has referred this case for possible criminal charges."
The United States attorney for the District of Utah requested that the secretary of labor seek a stay of all civil proceedings, including all discovery in all civil proceedings, in response to this criminal referral. The requested stay is necessary to avoid potential interference with the criminal enforcement process, which could arise from a contemporaneous related civil enforcement proceeding.
The new Caterpillar 785D Mining Truck incorporates new features to boost performance and reliability, reduce engine emissions, and enhance safety. The improvements also focus on component commonality to keep parts stocking and maintenance simple. The 785D builds on more than 20 years of proven performance for the 785 model. The 785D target payload ranges from 142 to 155 tons depending on the specific configuration. The range enables new trucks to integrate well with fleets of earlier 785s.
Using the latest technology, the Cat 3512C HD engine maintains fuel efficiency, delivers 1,348 net horsepower, and is compliant with U.S. EPA Tier II emissions standards. The engine is capable at altitudes up to 14,000 ft with no derate. With the change to a high displacement engine, engine life is extended.
Caterpillar also introduces the X body with the 785D. The X body provides mine specific options (e.g. liners, rail caps, sideboards, etc.) for new sites and contractors. The new body also provides greater volume—111 cubic yards (cu yd) vs. 102 cu yd for the dual slope body. Additional body choices are Mine Specific Body (MSD II), gateless coal body, and dual slope. The canopy of each of the bodies extends farther over the cab for greater protection. Additionally, the 785D has improved catwalks and a factory installed 600-mm diagonal stairway.
A number of changes extend reliability and durability: a new pump drive system provides continuous rear axle filtration. Benefits include cleaner oil, less downtime, and improved component life. Extended life disc brakes may achieve up to double the wear life of standard brakes and are resistant to glazing. The result is consistent braking power and reduced maintenance. New air intake and filters have a new seal, which provides easier servicing and lower maintenance costs. The Cat mechanical drive power train and power shift transmission provide superior operating efficiency and control on steep grades, in poor underfoot conditions and on haul roads with high rolling resistance. The 785D retains the Caterpillar mechanical power train that has enabled 785 models to achieve high productivity and reliability in challenging mining conditions around the world. www.cat.com
The Crow Tribe recently struck a deal with an Australian company toward building a $7 billion plant to convert coal into liquid fuels, which would be among the first such projects in the nation, The Associated Press reported.
Capping months of negotiations, the Crow Legislature ratified a 50-year development agreement with Australian-American Energy Co., a subsidiary of Australian Energy Co.
The Many Stars coal-to-liquids plant initially would produce 50,000 barrels a day of diesel and other fuels. Construction would begin in several years and coal for the project would come from a mine yet to be developed by the tribe on the reservation, Crow leaders said.
The Illinois Basin is forecast to experience a tremendous resurgence of interest similar to that experienced in the 1970s, much in part due to the developing scrubber and export market and renewed interest in coal gasification and coal-to-liquids, according to Wood Mackenzie subsidiary, Hill & Associates, in its latest comprehensive review of coal production in the region.
"If markets develop, the Basin’s production is poised to expand more than two-fold in the next 10 years," said John Hanou, vice president, Hill & Associates. "Given the Basin’s tremendous reserve of low-cost, medium and high-sulfur coal, existing producers are all planning expansions, in addition, many newcomers also are entering the market with plans to develop a multitude of mines."
The Illinois Basin’s turn-around has been long-coming. The region suffered great losses due to Phases I and II of the Clean Air Act Amendments of 1990, when utilities switched to low-sulfur Powder River Basin coal to meet the new mandates. By 2000, production had declined to 89 million tons from 145 million tons in 1989. In 2007, production rebounded somewhat to 97 million tons, due to shortages in the eastern U.S and new scrubbing at several power plants.
"Basin production capacity will probably expand to 103-104 million tons in 2008," said Hanou. "Based on our 10-year analysis, we have identified enough projects to suggest that Illinois Basin production could expand to more than 250 million tons per year by 2017 with an upside potential to produce more than 350 million tons, assuming demand is present."
The Illinois Basin contains a tremendous underground reserve base, which is five to 10 times larger than the Pittsburgh No. 8 seam reserve base in Northern Appalachia. As the surface reserves deplete and as demand increases, these reserves will likely be developed in the next 10 years.
The top three producers currently (Peabody, Alliance, and Murray) control 57% of the market; however, by 2011, we estimate that this will fall to about 42%. Peabody is likely to retain its lead in 2011, but if The Cline Group is successful in developing the mines that the company has proposed, Cline will likely become the largest producer in the Illinois Basin post 2011.
Hill & Associates' latest review of the Illinois Basin is published in the Coal Supply Service. This update encompasses Indiana, Illinois, and West Kentucky and includes mine-specific data on coal reserves, quality, production costs, and capacity at active, idled, and proposed mines. In total, more than 240 mines and reserves are analyzed.
WEG has announced a program for ordering custom designed AC induction motors for a wide range of horsepower, voltage and speed ratings. Customization can include special shafts, special sealing or ventilation, special insulation requirements, and other factors, allowing an industrial user to exactly replace a motor used in an existing machine or facility.
"Until now, customers with an old nonstandard size motor were faced with a challenge–either modify a piece of machinery to accept a new standard size motor or continue to rewind the existing motor even as its performance continued to decline," explained Gerardo Elias, Marketing Manager. "Our new Custom motor program will enable these users to exactly replace or even upgrade an existing motor within the physical limits of their machinery or process."
Elias noted that WEG had a long tradition for building custom motors. "For example, our motor experts designed and installed the world’s largest induction motor at the Collahuasi mine in northern Chile to drive long conveyor belts removing copper ore and overburden. This motor weighed 15,000 kg and delivered 2,788 HP with an efficiency of 97.5%. And while not every custom motor will be this large, we are committed to meeting our customers needs going forward." www.wegelectric.com
The Czech government will give 800 million crowns every year to the regions affected by coal mining and energy production from coal, Czech News Agency reported. The money will come from the dividends the state receives from the CEZ power utility. The largest sum, or 450 million crowns per year, will go to the Usti region. Regional authorities will receive the money that should be used for the revitalization of the landscape affected by coal mining. The aim is to revitalize the landscape so that people can live in it again. The current law orders mining companies to give money to the repair of environmental damage, but the sums were too low and the revitalization often had to be covered from local budgets. The cabinet also approved the plan to give 3 billion crowns to the coal-mining area of northwest Bohemia that are to go for land revitalization. In this way, the government will meet the promise made in 2001 to earmark 15 billion crowns to the Usti and Karlovy Vary regions. Until now, the state has distributed 11 billion to the two coal-mining regions. Coal mining has affected some 350 km2 in the Usti region.
Custom bar rail liners made of a long-wearing polyurethane compound are now available from W.S. Tyler. Tyrethane Bar Rail Liners are designed to protect tension poly screens and extend the service life of traditional wire mesh screens. They have 20 to 30 times greater service life of inexpensive rubber liners. Tyrethane Bar Rail Liners are used to support all metal media options, including perforated plate, wire, and other metal screens. This translates into less down time and lower production costs. Tyrethane Bar Rail Liners are easy to install and are available in 4 ft, 5 ft, and 6ft lengths, for a variety of steel bar widths. The liners can be used on any OEM vibrating screens. W.S. Tyler offers Tyrethane Bar Rail Liners at no charge when purchasing the company’s Ty-Max Tension Polyurethane Screen Panels. W.S. Tyler offers a complete line of polyurethane screening products, including panels, liners, and accessories. www.wstyler.com
ArcelorMittal Acquires Mines in Central Appalachia
ArcelorMittal, the world’s largest steel company, has signed an agreement to acquire Mid Vol Coal Group which operates mines in Southern West Virginia and Southwestern Virginia. “This acquisition further increases our upstream self sufficiency in a primary raw material during a time when metallurgical coking cola demand on a global scale remains strong,” said Aditya Mittal, CEO, ArcelorMittal. Mid Vol produced 1.5 million tons of high-quality metallurgical coal last year. The company has more than 85 million tons of recoverable coal reserves in Central Appalachia. Plans are to double coal production levels at Mid Vol mines under permits already approved. In 2007, ArcelorMittal produced 116 million tons of steel, or about 10% of the world’s total production.
HAWE Hydraulics, a leading supplier of sophisticated controls to the mobile and industrial markets, offers its PSL proportional directional spool valve, ideal for constant delivery pump systems. Adhering to the load-sensing principle, these spool valves serve to control the direction of motion while delivering infinite speed control for hydraulic consumers regardless of load type and weight. With the option of a valve bank or manifold mounting design and several available actuation types, the PSL is well-suited for a wide array of mobile hydraulic applications. www.hawehydraulics.com
