Remnant Coal Detection System

Abstract

This paper describes the development and successful implementation of a system designed to detect coal deposits remaining in coal train wagons after unloading (dumping). These undesirable coal deposits constitute both small residual amounts of “carryback”, but also larger “hang-ups” of significant volume that have failed to discharge. The system was originally developed simply to detect and record volumes of carryback, as part of an effort to characterise the extent of the problem for the coal transport industry, but was then enhanced to provide real-time feedback of large hang-ups so that they could be discharged prior to the wagons exiting the dump station. The paper describes the hardware and processing systems used in the system, including the different strategies employed to ensure a reliable detection system. The system has now been installed and operated in a production environment at three dump stations across two different coal terminals, and a case study of the results from one of these dump stations is presented. Automating remnant coal detection at dump stations provides short interval control to minimise potential hazards and downtime, and historical data that may be integrated into existing data platforms and analysed for productivity, environmental, and safety planning insights.

Application of lean and quality improvement methods for improving operational performance in coal supply chains: a case study

“…These incidents can have severe consequences, such as contaminating soil and water sources, damaging ecosystems and harming wildlife. To address the sticky coal problem during transportation, effective mitigation measures such as improved storage and containment methods, covering coal wagons and implementing strict monitoring and Traditionally, carry-back detection of sticky coal is detected using multiple closed circuity televisions and removal manually/automatic vibrators (Hargrave et al, 2010). A few mines have installed laser scanners that were developed by CSIRO.…”

“…A few mines have installed laser scanners that were developed by CSIRO. Although these scanners are good at detecting (Hargrave et al, 2010), they are not capable of removing the root cause of this sticky coal (Planner, 2016). Therefore, the approaches adopted in these case studies were limited to solutions such as a robotic coal wagon vibrator and scanners aimed at addressing only the downstream coal terminal issues and not the upstream root causes of sticky coal.…”

“…If that was unsuccessful, a mobile hand-held vibrating pad was placed against the wagon to try and dislodge the material. These solutions, for the most part, worked, but when the “remnant coal” would not drop after exiting the terminal, the KDD would then open and the material would fall onto the rail tracks and stop the train (Hargrave and McPhee, 2020). Terminal operators would then have to manually shovel the coal out from under the wagon to clear the rail track thus delaying placement by the stacker/reclaimer, for transfer of the coal stockpile (to customer specifications), via the chute conveyor, onto the ship loader and placed into the bulk ship compartment for shipping (CSIRO, 2021).…”

“…These incidents can have severe consequences, such as contaminating soil and water sources, damaging ecosystems and harming wildlife. To address the sticky coal problem during transportation, effective mitigation measures such as improved storage and containment methods, covering coal wagons and implementing strict monitoring and enforcement procedures (Hargrave et al. , 2010) are necessary to minimise the environmental and health impacts associated with coal transportation.…”

“…Traditionally, carry-back detection of sticky coal is detected using multiple closed circuity televisions and removal manually/automatic vibrators (Hargrave et al. , 2010).…”