European Coal Exploitation Technologies State of the Art and RTD Needs Industrial Technologies June 2012 Concert Hall, Aarhus, Denmark presented by Franco Cozzani – Deputy Head of Unit, EC Research Fund for Coal and Steel on behalf of Jürgen Czwalinna – Chair, Euracoal Technical Research Committee

Aarhus June Figure 2 EU coal production and imports, 2010 (Mt) Coal’s economic importance grew with enlargement

Aarhus June Figure 3 Power generation in selected EU countries, 2008 source: Eurostat - Annual Energy Statistics 2008 (data accessed 06/2010) (Peat and oil shale included in other/hydro) Coal accounts for >50% in some Member States

Aarhus June Figure 4 gas hydropower and other energies nuclear coal Forecast: EU Commission 2008 baseline scenario million GWh oil 29% 35% % Share of coal based electricity generation in the EU-27 could even rise Power generation in EU 27

Aarhus June Figure 5 World hard coal production 1990 – 2010 Source: VDKI

Aarhus June Figure 6 Admittedly European deposits are more challenging than elsewhere in the world (deep, hot, laterally extended workplaces) However, thanks to RFCS funded research the European Mining industry and related technology suppliers master these challenges and As a consequence European mining technology has a world leading position – something research politicies are repeatedly calling for with the Framework Programmes! And inevitably, the geological situation worldwide is developing into a similar direction, i.e others will face the same problems! Assists in application of safe and environmentally friendly coal production and use in emerging countries like China and India European coal mining situation – problem or chance?

Aarhus June Figure 7 3D-modelling now standard for mine planning and support management Significant safety and productivity improvements less roof falls, less downtimes, simplified support, record production) Increased productivity and safety in the face - roadway junction  New automated, universal 3D-modelling tools  Support management systems (SMS)  SMS logical tree covering all underground coal mine types (arched, rectangular, multi-slice) Benefit State of the art - PROSAFECOAL SMS

Aarhus June Figure 8 Advanced drivage and intelligent roadheading systems Increased lifetime Reduced number of failures and downtimes Increased driving efficiency Increased precision of roadway profile cut Increased work safety Cost reduction  “Intelligent”, fully automated, self- controlled system for road headers  Applicable to a variety of specimen, manufactured by several companies in different countries Benefit State of the art - ADRIS

Aarhus June Figure 9 Optimization and automation of longwall and drivage equipment  Automated shearer loader  3D-modelling of cutting drums  drum design analysis software  Machinery monitoring and visualization system  Maintainability assessment software package Performance nearly doubled Shearer efficiency improved by 60% Maintenance and repair effort significantly reduced Cutting tool abrasion reduced Downtime reduction & machine lifetime extended Time and money savings at drum design and testing Benefit State of the art - NEMAEQ

Aarhus June Figure 10 Three driving forces for R&D effort Geology Enhancing performance efficiency & reliability Intelligent & sustainable post- mining activities

Aarhus June Figure 11 Growing depths causes Higher temperature  mine climate  ventilation & air conditioning issues Higher rock pressure  rock mechanic challenges & support issues Higher risk of rock and gas outbursts Need for more precise geological information Longer distances cause Safety & rescue issues Transportation issues 1) Geology

Aarhus June Figure 12 by Higher  Performance  Efficiency  Reliability Automation Condition monitoring Sensors System optimisation Improved exploitation of existing machines through higher “intelligence” and system integration Open and compatible monitoring and automation systems instead of individual solutions 2) Performance, efficiency & reliability

Aarhus June Figure 13  Obtaining knowledge of the status of old mine workings by improvements in geophysical analysis  Long- term stability and behaviour of mine workings  Energy- efficient long- term post- mining activities (pumping, monitoring, …  Environmentally friendly mine closure and brownfield recultivation  Pumped- storage hydroelecricity or compressed- air power storage in shafts, mineworkings or spoil heaps – to balance eratic wind power generation  Efficient use of CH 4 vented from abandoned shafts and mines  Investigation of sites for CO 2 storage in coal basins Mastering the mining legacy Sustainable and smart follow- up use 3) Intelligent and sustainable post mining activities

Thank you for your attention Industrial Technologies June 2012 Concert Hall, Aarhus, Denmark presented by Franco Cozzani – Deputy Head of Unit, EC Research Fund for Coal and Steel on behalf of Jürgen Czwalinna – Chair, Euracoal Technical Research Committee

Aarhus June Figure 15 Arguments for indigenous coal production and respective RTD Coal represents 80 % of EU fossil fuel reserves; Security of energy supply for citizens through reduction of reliance on imports; Coal mining and value chain create wealth in the EU; EU’s coal industry is leading in health and safety and environmental protection; Base for mining technology development and transfer

Aarhus June Figure 16 RFCS and FP7- different but complementary Different origin of assets RFCS –Budgetwise „Dwarf against FP Goliath“ –Incremental R&D, application orientated –Industry driven –Rapid implementation of results FP –Disruptive breakthrough innovations –Wide scope of themes –Broad range of funding instruments (e.g. IP, CSA, NoE, …)

Aarhus June Figure 17 Coal related funding topics in FP 7 NMP : Catalysts and sustainable processes to produce liquid fuels from coal and natural gas ENERGY : Optimisation of IGCC technologies for use with high ash content coal Topic ENERGY : Advanced Gas Turbines for Solid Fuel Gasification Processes Topic ENERGY : Solid fuel gasification development – improvement of gasifier technologies NMP :New environmentally friendly approaches in minerals processing (expected)

Aarhus June Figure 18 Common Issues with an international dimension: 1.Information deficiencies and poor situational awareness 2.Poor communicatios infrastructure resilience 3.Location and status of workforce 4.Delays in rescue initiation 5.Secondary explosion risks 6.Impacts of heat and humidity How do we safely increase the ´penetration distance`envelope limitations imposed on rescuers due to heat and humidity? How do we access inbye refuges in severe conditions? What are the respective roles for hydration, active-passive cooling and core body temperature monitoring? How do we assess secondary explosion risk and possible ´windows of opportunity`in order to commit rescue teams? How do we advance the state of escape respiratory protection, exploiting the best features of SCSRs and FSRs? EGRESS issues and strategies in the case of ‘incidents’ (safe havens, personal physical conditions of ‘evacuees’ with regard to mine climate and longer distances advanced sensors for fire detection and ‘control’ ( conveyors, spontaneous combustion Safety, rescue & mine emergency support

Aarhus June Figure 19 Safe & efficient sublevel caving through a monitoring and control system  Based on results of several RFCS (and ECSC) projects (e.g. EPCWCMS, RAINOW)  Environmental control, CH 4 and CO monitoring, ventilation control, safety interlocks  High speed tx to surface, UCR-AV, remote controls, Digicom, new cabling, bluetooth Safe and flexible operation Suited to the particular requirements in sublevel caving mine types (complex ventilation system, single entry faces, multiple levels, frequent changes and re-configurations) Applicable and promoted outside Europe Benefit State of the art - RELIA

Aarhus June Figure 20 Improving performance, reliability, safety and environmental aspects of mining transport systems  Software tools for designers and users, improving safety in underground mine transportation systems  “Knowledge repository” on internet platform including design guidelines, safety criteria, legal acts, regulations, standards and manufacturer’s documentation More efficient design process Improved quality of transportation route designs Means of transport and route configurations are better selected Improved work safety due to minimized accident probability Benefit State of the art - Mintos