Coal Recovery: PT Kaltim Prima Coal

COAL RECOVERY
Rudy Setiadi
Superintendent Production - Coal Mining Department
PT Kaltim Prima Coal
Session Outline
1. Introduction 3. What are the process
• What is Coal? that reduce coal
recovery?
2. Coal Recovery
Determination 4. What are the factors
• In situ model against actual coal that influence coal
mined recovery?
• ROM merge against actual coal
mined
• Survey data against actual coal 5. How to increase coal
mined
recovery?
6. Control and monitoring

Introduction
What is Coal?
• Coal is a complex bulk • Coals are formed under
commodity different geological
• Coal is a sedimentary conditions resulting in a
rock composed wide range of qualities
predominately of • Coal quality changes
organic material, with a within and between
greater or lesser seams in a single
amount of mineral pit/mine
matter • Coal quality changes
over the mine life
What is Coal?
CARBON
Thousands of
Organic HYDROGEN Organic and
Macerals
Inorganic
Compounds
3 forms of
Sulfur
- Organic
COAL 64
SULPHUR
- Pyritic trace
- Sulphate NITROGEN elements
OXYGEN
3 types of
Moisture
Up to
- Inherent
350 16
- Surface
million major
- Mineral elements
years old Hydrate
What is Coal?
• Peat
• Lignite
• Sub-Bituminous
• Bituminous
• Semi-Anthracite
• Anthracite
• Increase in Coal Rank

• Increase in Calorific Value
• Increase in Fix Carbon
• Decrease in Moisture
• Decrease in Reactivity
What is Coal?
Coal Recovery Determination
Coal Recovery - The percentage of total
tons of coal estimated to be recoverable
from a given area in relation to the total
tonnage estimated to be in the
demonstrated reserve base.
Coal recovery number indicates how
effectiveness of coal mined.
There are 3 methods to determine coal

recovery:
1. In situ model against actual coal mined
2. ROM merge against actual coal mined
3. Survey data against actual coal mined
In situ Model against Actual Coal Mined –
Geological model of coal log compared to truck
count (dispatch); coal reserve base
ROM Merge against Actual Coal Mined –
Determination including specified overburden
thickness above and below coal log that are
calculated as dilution
Survey Data against Actual Coal Mined – Based on
pick up survey actual roof and actual floor of coal
Insitu Model
Thickness
Interburden
4.00 Main Seam
Interburden
MSTD : Main Seam Top Dilution

OBTD : Over Burden Top Dilution
COTL : Coal Top Loss
COTD : Coal Top Dilution
COBD : Coal Bottom Dilution
COBL : Coal Bottom Loss
OBBD : Over Burden Bottom Dilution
MSBD : Main Seam Bottom Dilution
MSTD : Main Seam Top Dilution

OBTD : Over Burden Top Dilution
COTL : Coal Top Loss
COTD : Coal Top Dilution
COBD : Coal Bottom Dilution
COBL : Coal Bottom Loss
OBBD : Over Burden Bottom Dilution
MSBD : Main Seam Bottom Dilution
What are the process that reduce
coal recovery?
Over drilled – due to undulating drill pad and
inappropriate coal stratigraphy according to
geological model
coal recovery?
coal recovery?
Overburden Removal – coal losses due to
• Inappropriate digger allocation against coal
thickness
coal recovery?
• None and/or incorrect digging limit
coal recovery?
• Incomplete digging to final wall
coal recovery?
• Inappropriate coal exposing against target
elevation (target RL)
• Inappropriate dozer while coal exposing
coal recovery?
Loading Point Condition –
• Un spacious in multi seam pit; over dig issue
• Access through coal exposed
• Worse water management
coal recovery?
Coal Cleaned Up –
• In appropriate equipments
coal recovery?
Coal Mined –
• Inappropriate digger against coal thickness
• Inappropriate digger against haul trucks
• Overload while loading to haul trucks
coal recovery?
Coal mined –
• None and or incorrect coal edge limit; coal left
issue
coal recovery?
Coal Hauled –
• Undulating haul road
• Inappropriate super elevation
• Haul road grade > 8%
What are the factors that influence
coal recovery?
• Lack of survey data; coal roof and floor
• Unskilled operator
• Lack of control by Pit Geologist
• Lack of supervision by Coal Supervisor when coal
exposed, coal cleaned up and coal mined
• Over drilled
• Over dig when coal exposed
• Inappropriate equipment when cleaned up coal
roof
• Inappropriate digger against coal thickness
coal recovery?
• Inappropriate geological model on calculating
coal reserve
• Un spacious loading point
• Blasting area is so close against coal exposed
• Water management; drainage system
• Inappropriate coal edge limit
• Weather; flooding issue on loading point
coal recovery?
• Pilot hole to determine the depth of OB and the thickness of coal

• The distance of OB blasting and coal exposed ready to be mined are 50 m to avoid coal losses
because of re-cleaned up
• The drill pattern to the top of coal use stand off 4:1 (4 holes stopped 0.5-1.0 m above the roof and
1 hole touch the roof), over drilling OB causing contamination
coal recovery?
The distance of last row of drill 15 m to minimize
coal broken on the edges
How to Increase Coal Recovery?
Reserving –
• Review geological model based on mined out
limit
• Review coal density ( = W/V)
Drill and Blast –
• Commitment to Customer Supply Agreement
(CSA)
• Well prepared drill pad
• Accurate data of coal stratigraphy to avoid
over drilled
Overburden Removal –
• Appropriate digger and support equipments
when coal exposed
• Remains 0.5 meters above coal roof
• Appropriate digging limit
• Digging on final wall according to design
Loading Point –
• Good water management
• Trimming on final wall
Contour drain
Sump
Coal Cleaned Up –
• Appropriate equipments depend on coal
dipping and undulation (dozer or small
backhoe)
Coal Mined –
• Appropriate digger depend on coal thickness
(thin seam < 2 m, thick seam > 2 m)
• Target elevation (RL)
• Avoid overloading to haul truck
• Loading bottom coal
• Commitment to Customer Supply Agreement
(CSA)
Coal Mined –
• Appropriate coal edge limit
Coal Mined –
• Selection of coal working section
a b c d
Coal Mined – selection of coal working section
(a) Working section adjusted to include a coaly shale ply visually
indistinguishable from coal in the mine situation
(b) Working section adjusted to exclude a thin coal ply above a thick clay
band near the roof of the seam
(c) Working section including thin clay bands not readily separated from
coal at the mine face. The minimum thickness of such bands for
separate extraction, if scrapers or bulldozers are used, is usually around
15 cm
(d) Seam divided into two separate working sections by a thick non-coal
band. Bands between 15 and 50 cm thick may be extracted separately
as part of single seam operation. Bands greater than 50 cm thick
normally require multi-seam mining techniques, and must be evaluated
as additional overburden for the lower coal bed.
Coal Hauled –
• Haul road design 8%
• Appropriate super elevation
• Haul road maintenance
• Avoid give way or stop sign on ramp up haul
road
• Reduce haul truck speed in a bend haul road
Control and Monitoring
• SOP Coal Recovery
• CSA Coal Exposed
• CSA Coal Floor
• Coal Reconciliation
1. In situ model against actual coal mined
2. ROM merge against actual coal mined
3. Survey data against actual coal mined
Control and Monitoring
Thanks for your kind attention

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COAL RECOVERY

6. Control and monitoring

- Sulphate NITROGEN elements

• Increase in Coal Rank

There are 3 methods to determine coal

4.00 Main Seam

MSTD : Main Seam Top Dilution

MSTD : Main Seam Top Dilution

• Pilot hole to determine the depth of OB and the thickness of coal

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