Remnant Coal Detection System

Chad Hargrave,Paul Mcphee

doi:10.3390/resources9040045

Chad Hargrave, Paul Mcphee

Open Access

https://doi.org/10.3390/resources9040045

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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.

Highlights

To maintain efficiency and maximise productivity, unloading dump stations at coal terminals must discharge all coal in the incoming wagons, if possible, without stopping the train, and certainly before a given wagon passes by the last unloading pit
Two aspects of the basic carryback data have been selected for analysis: the total carryback detected per wagon, as well as the KDD carryback per wagon, which refers to occurrences of carryback where the coal is located over a wagon door
Based on an average train frequency of 4.5 trains per day through the dump station, this equated to a total of approximately 61,000 tonnes per year of total carryback, including approximately 8400 tonnes per year of KDD carryback

Summary

Introduction

To maintain efficiency and maximise productivity, unloading dump stations at coal terminals must discharge all coal in the incoming wagons, if possible, without stopping the train, and certainly before a given wagon passes by the last unloading pit. Even if the coal hang-up is seen after the wagon has passed beyond the final pit, a costly exercise in reversing the train will ensue that will cost the dump station productive time. Carryback is responsible for reducing wagon capacity for future loading, causing cross contamination of coal types, increasing coal dust pollution in population centres near train lines, and, in some cases, causing derailments due to spillage of remnant coal onto the tracks [2,3]. The first requirement for effective control of carryback is a reliable and accurate system that can detect and quantify the level of post-dump remnant coal in coal wagons

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