Mike Mosser Energy Efficiency


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  • Mike Mosser Energy Efficiency

    1. 1. Energy-Efficient Technology for Mining Mike Mosser National Energy Technology Laboratory U.S. Department of Energy August 23, 2007
    2. 2. Outline <ul><li>DOE Mining R&D Program Snapshot </li></ul><ul><li>Utah / DOE R&D partners </li></ul><ul><li>Energy-Efficient Mining Technologies Available </li></ul><ul><li>U.S. Mining Energy Bandwidth </li></ul><ul><li>Need for further mining R&D </li></ul>
    3. 3. Mining Program Objectives <ul><li>Objectives: </li></ul><ul><ul><li>Increasing Energy Efficiency in Mining </li></ul></ul><ul><ul><ul><li>Reduce mining energy requirements </li></ul></ul></ul><ul><ul><ul><li>Invest in mining technology needs </li></ul></ul></ul><ul><ul><ul><li>Reduce environmental impact (e.g. Reduce greenhouse gases and other emissions) </li></ul></ul></ul><ul><ul><ul><li>Reduce mining operation costs </li></ul></ul></ul><ul><ul><ul><li>Improve worker health and safety </li></ul></ul></ul><ul><ul><ul><li>Improve productivity </li></ul></ul></ul><ul><li>Mission: To strengthen America's energy security, environmental quality, and economic vitality in public-private partnerships with the mining industry pertaining to coal, metals and industrial minerals. </li></ul>
    4. 4. Analytical and Roadmap R&D Documents <ul><li>Mining Industry Vision (1998) </li></ul><ul><li>Targeted Roadmaps </li></ul><ul><ul><li>Crosscutting Technologies Roadmap (1999) </li></ul></ul><ul><ul><li>Mineral Processing Technologies Roadmap (2000) </li></ul></ul><ul><ul><li>Exploration and Mining Technologies Roadmap (2002) </li></ul></ul><ul><li>Energy and Environmental Profile of the </li></ul><ul><li>U.S. Mining Industry (2002) </li></ul><ul><li>Mining Industry Energy Bandwidth Study (2007) </li></ul>Exploration and Mining Technology Roadmap Mineral Processing Technology Roadmap
    5. 5. Snapshot of the Mining Portfolio <ul><li>47 Cost shared projects </li></ul><ul><li>146 Industry partners </li></ul><ul><li>19 University partners </li></ul><ul><li>56% Cost share </li></ul><ul><li>$27.3 Million DOE funds </li></ul><ul><li>$34.8 Million Cost share </li></ul><ul><li>6 “R&D 100 Awards” </li></ul><ul><li>16 patents </li></ul><ul><li>7 projects commercialized, and 8 expected to be commercialized in less than 2 years . </li></ul><ul><li>Cumulative Energy Savings by 2020 = 841 TBtu or $5.04 B </li></ul>
    6. 6. Mining Project Industrial Partners <ul><li>Utah Partners : </li></ul><ul><li>CONSOL </li></ul><ul><li>Joy Mining Machinery </li></ul><ul><li>Kennecott Utah Copper </li></ul><ul><li>SUFCO </li></ul><ul><li>University of Utah </li></ul><ul><li>Utah Engineering Experiment Station </li></ul>
    7. 7. Radio Imaging Methods (RIM) <ul><li>Description : </li></ul><ul><li>Forward imaging with confirmation will reduce the risk of interrupting production because of adverse geologic conditions, allow drilling in targeted areas, and the ability to extract cleaner coal. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>Reduce energy use 2.7 TBtu/yr by 2020. </li></ul></ul><ul><ul><li>$3.59 M savings by 2020. </li></ul></ul><ul><ul><li>7% energy savings. </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>Commercialized In-Mine RIM-IV, Down-Hole RIM-IV, and RIM-based risk reductions to the coal mining industry. </li></ul></ul><ul><ul><li>RIM Surveys conducted at 40 US mines includes 200 surveys, 60 World Wide mines includes 300 surveys </li></ul></ul><ul><ul><li>RIM Surveys conducted in Utah at Sufco, Skyline (Arch Western Coal); Genwal Mine and West Ridge Mine (Andelex Resources). </li></ul></ul><ul><ul><li>Horizon Sensor applied to Sufco Mine. </li></ul></ul>
    8. 8. Advanced Drillstring Radar Navigation for Horizontal Directional Drilling <ul><li>Description : </li></ul><ul><li>Create, demonstrate and validate a functional drill-string assembly outfitted with a commercial version of Drill-String Radar. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>31 trillion Btu saved by 2020 </li></ul></ul><ul><ul><li>$178 million saved by 2020 </li></ul></ul><ul><ul><li>10% reduction in drill energy for undulating coal beds </li></ul></ul><ul><ul><li>Ave. 20% reduction in energy for ventilation </li></ul></ul><ul><ul><li>10% reduction in mining energy due to better anomaly detection and confirmation </li></ul></ul><ul><ul><li>Ave. 60% coal mine methane recovery for fuel source. </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>DSR and LAR prototype testing at Sufco Mine </li></ul></ul><ul><ul><li>HS and DeltaEM Gradiometer testing at Emery Mine (Consol). The DeltaEM technology was a part of that MSHA void-detection program. (void detection – Horizon sensor) </li></ul></ul><ul><ul><li>DSR and DTS field tests at Deer Creek Mine (Pacificorp). </li></ul></ul>
    9. 9. Effective Conveyor Belt Inspection System <ul><li>Description : </li></ul><ul><li>A low-cost automated belt inspection system (real-time detection) that will decrease the frequency of unexpected belt failures and increase overall belt availability. Detects vulcanized splices in underground conveyor belts, in real-time. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>$3.5 M/yr savings in 2020 </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>16 early systems in daily use at 7 different mines, including San Juan Mine, NM, 20 Mile Mine, CO, and Dugout Canyone Mine, CO., Robinson Run, WV, Blacksville # 2, WV, Bailey/Enlow Fork Mine PA, Loverage Mine, WV, McElroy Mine, WV </li></ul></ul><ul><ul><li>Total inspected belt length exceeded the 3 million mile mark in late 2006, and has guided the replacement of countless splices reducing unscheduled belt downtime. </li></ul></ul>Current Belt Inspection System
    10. 10. Development of a Novel Dry Coal Processing Technology <ul><li>Description : </li></ul><ul><li>Employ a novel, dry deshaling technology near the extraction point of surface mining operations in order to improve energy efficiency/economics of transporting and processing coal. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>Ability to remove high-density rock in an amount equal to 37.4% of the total coal. </li></ul></ul><ul><ul><li>Installation at a Kentucky mine site projected to save $5.5 M/yr. </li></ul></ul><ul><ul><li>Sulfur and Mercury content was reduced by 40-65% at a mine site in the Gulf Coast. </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>Eriez Manufacturing, working in conjunction with University of Kentucky, has recently sold a commercial unit of its FGX separator, a pneumatic table concentrator, to a Gulf Coast Lignite mining operation. The mining operation does not wish to be named at this time. The purchase order was for a 240 ton per hour unit at a cost of $768,000. </li></ul></ul>
    11. 11. Improving Energy Efficiency in SAG Mills <ul><li>Description : </li></ul><ul><li>Use of advanced SAG mill simulation software to determine charge motion inside the mill. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>2-11% reduction in SAG mill energy use </li></ul></ul><ul><ul><li>15-17% in energy use by grinding </li></ul></ul><ul><ul><li>100% for unscheduled downtime </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>SAG mill simulation and design optimization were successful for Cortez Gold, where an estimated $1.5 million will be saved annually through reduced operating costs and unscheduled mill shut-downs. </li></ul></ul>
    12. 12. GranuFlow Process in Coal Prep Plants <ul><li>Description : </li></ul><ul><li>CQ Inc. of Homer City, PA has been performing tests to utilize the Granuflow process in coal preparation plants. Granuflow uses a bitumen emulsion to displace water from fine coal, agglomerating the coal prior to dewatering and thereby improving coal recovery in coal preparation facilities. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>Ability to recover coal fines (currently 2 Billion is impounded annually + 50 M tons added each year) </li></ul></ul><ul><ul><li>The process can add more than $1 million in annual profits for operators producing metallurgical coal, and add between $600,000 and $3 million for coal market values ranging from $50 to $100 per ton. </li></ul></ul><ul><ul><li>$7.1 M/yr savings in 2020 </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>Three full-scale demonstrations in Pennsylvania and Alabama recently confirmed previous test results and established operating parameters for future commercialization. </li></ul></ul>
    13. 13. Smart Screens for Mining <ul><li>Description : </li></ul><ul><li>Controls the flow and confines the energy to the screen panel rather than shaking the entire support structure. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>The motors reduce weight by 80% and energy by 50 to 95%. </li></ul></ul><ul><ul><li>$79.3 M/yr savings in 2020. </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>To date 44 units have been installed at three iron ore plants in Minnesota, Minntac, Keetac and Ispat. </li></ul></ul><ul><ul><li>Two units have been sold and are in operation in a Russian plant. One unit was sold to a Mexican plant and eight more sales are pending. </li></ul></ul><ul><ul><li>Twelve units were sold and commissioned in South Africa and one unit was provided to a test facility in Canada. </li></ul></ul><ul><ul><li>This technology has applications in mining, oil field services, food processing, pharmaceutical, and defense industry. </li></ul></ul>
    14. 14. Wireless Communications <ul><li>Description : </li></ul><ul><li>Wireless through-the-earth communications have not been research since the mid-1970’s. There are technical barriers associated with through the earth – two-way voice communications which need to be developed for underground mining in order to improve mine productivity, reduce energy consumption, improve mine safety and provide a personal communication system which all employees can utilize. </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>Technical barriers must be achieved to apply through the earth communication that penetrates up to 1200-1400 ft. of overburden and has voice to voice function. </li></ul></ul><ul><ul><li>Improvement in safety and health, and productivity. </li></ul></ul><ul><li>Commercialization: </li></ul><ul><ul><li>The Mine Safety Health Administration (MSHA) recently selected the 7 premier through-the-earth communication systems to demonstrate at a CONSOL mine, in which case the Transtek and Los Alamos National Laboratory projects were selected. </li></ul></ul><ul><ul><li>Transtek was the only wireless system to perform successfully and was able to communicate voice-to-voice up to 270 ft from the surface. Los Alamos National Laboratory is also working on a through-the-earth communication system which has recently been licensed to Vital Alert, and is continuing on its commercialization path. </li></ul></ul>
    15. 15. Why Mining? Sources: EIA 2001, 1998 Manufacturing Energy Consumption Survey; U.S. DOE 2002, Energy and Environmental Profile of the U.S. Mining Industry Energy Consumption (Trillion Btu) Petroleum Chemicals Paper Primary Metals Food Processing Nonmetallic Minerals Tobacco/Beverages Furniture Leather Machinery and Computers Wood Transportation Fabricated Metals Textiles/Apparel Plastics/ Rubber Electrical Printing Miscellaneous 1 10 100 1000 10 100 1000 10000 Energy Intensity (Thousand Btu/$ GDP) Energy-Intensive Industries Industrial Energy Intensity vs. Energy Consumption MINING
    16. 16. Mining Energy Bandwidth Source: Mining Energy Bandwidth Study (Draft 2007)
    17. 17. Energy Saving Opportunity in U.S. Mining Industry (Mining Focus Area) Source: Mining Energy Bandwidth Study (Draft 2007)
    18. 18. Energy Saving Opportunity in U.S. Mining Industry (Mining Process Equipment) Source: Mining Energy Bandwidth Study (Draft 2007)
    19. 19. Accessing Mining R&D Related Information <ul><li>DOE OSTI Site </li></ul><ul><ul><li>Final Reports </li></ul></ul><ul><li>Portfolio Articles in Trade Journals </li></ul><ul><ul><li>Mining Engineering </li></ul></ul><ul><ul><li>Coal Age </li></ul></ul><ul><li>Portfolio Presentations </li></ul><ul><ul><li>SME Annual Meeting </li></ul></ul><ul><li>Industry Associations </li></ul><ul><ul><li>NMA </li></ul></ul><ul><ul><li>SME </li></ul></ul><ul><li>Website </li></ul><ul><ul><li>Mining Resources Site </li></ul></ul><ul><ul><ul><li>http://www.eere.energy.gov/industry/mining/resources </li></ul></ul></ul><ul><ul><li>Includes real-time information on: </li></ul></ul><ul><ul><ul><li>Partners </li></ul></ul></ul><ul><ul><ul><li>Status </li></ul></ul></ul><ul><ul><ul><li>Photo library </li></ul></ul></ul><ul><li>Commercialization </li></ul><ul><li>Outreach </li></ul><ul><li>Contacts </li></ul><ul><li>Contacts : </li></ul><ul><li>Elliott Levine - (DOE-HQ) </li></ul><ul><li>Mike Mosser - NETL </li></ul><ul><li>Joe Renk - NETL </li></ul><ul><li>Roy Tiley - BCS </li></ul><ul><li>Majeed Aziz - BCS </li></ul>
    20. 20. Mining IOF Budget History NOTE: FY2007 House Mark is $1 million.
    21. 21. The Continued Need for Mining R&D <ul><li>Decrease production costs (e.g. reducing energy consumption) </li></ul><ul><li>Enhance productivity of workers and equipment safely </li></ul><ul><li>Open up new reserves (increasing geologic challenges) </li></ul><ul><li>Extend life of existing ore bodies </li></ul><ul><li>Respond to new government regulations on improving safety performance </li></ul><ul><li>Provide increased supply for a growing global appetite </li></ul><ul><ul><li>Developing world slowly moving from exporting their commodities to consuming them. </li></ul></ul><ul><li>Reduce Climate Change </li></ul><ul><li>** Important to improve industry/academia/government relationship in order to compete against foreign competition. </li></ul>
    22. 22. Contact Us NETL www.netl.doe.gov EERE/ITP www.eere.energy.gov/industry/mining/ Mike Mosser 304-285-4723 [email_address] Elliott Levine 202-586-1476 [email_address] Joe Renk 412-386-6406 [email_address]
    23. 23. <ul><li>EXTRA SLIDES </li></ul>
    24. 24. Crosscutting Roadmap
    25. 25. Crosscutting Roadmap (contd.)
    26. 26. Crosscutting Roadmap (contd.)
    27. 27. Energy Saving Opportunity in U.S. Mining Industry Source: Mining Energy Bandwidth Study (Draft 2007) 0 50 100 150 200 250 300 350 400 Energy Savings Opportunity (Trillion Btu/Year) separations grinding crushing electric diesel ventilation dewatering drilling digging blasting Coal Minerals Metals Extraction 126 TBtu Materials Handling 119 TBtu Beneficiation & Processing 420 TBtu
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