The document summarizes responses from three industry experts on challenges facing coal processing optimization: 1) Derek Scantlebury notes balancing return on investment while optimizing the entire production process from mining to shipping is challenging without scientifically comparing upgrade results. 2) Dr. Peter Koh explains increasing throughput requires higher pulp densities, causing viscosity issues, and computational fluid dynamics can help identify problem areas. 3) Jacques Dippenaar says identifying key faults allows focusing on strategic planning instead of reactive problem-solving and quantifying improvements requires cost and production data.

1. Key Topic Responses from
Industry Experts
Coal Processing Optimisation 2011
www.coalprocessing.com.au
P: 61 2 9229 1000 E: enquire@iqpc.com.au
@miningiq ‘Mining IQ’

2. With the demand for coal soaring over the past 12 months, the need for
optimising coal processing is at an all-time high as companies seek ways to
maintain and increase the highest levels of throughput.
As apart of Coal Processing Optimisation 2011, Mining IQ interviewed three key
note speakers to discuss issues facing the industry.
- Derek Scantlebury, CHPP Project Manager, Narrabri Coal Operations.
- Dr Peter Koh, Research Scientist, CSIRO Minerals Downunder Flagship
- Jacques Dippenaar, CHPP Manager, Sedgman
Mining IQ has collected a selection of their responses. For their full
interviews, please click here.

3. What are some challenges a
company might face when
increasing CHPP throughput
to meet demand?

4. Derek Scantlebury, CHPP Project Manager,
Narrabri Coal Operations:
“Finding the correct balance of ROI and following the entire flow
from the face of the Pit to the ship at the port. The question of
upgrade / repair/ replace often has many correct responses but
the realised gains will rarely be compared back to back in a
scientific manner. Therefore board opinions may need to be
politically changed.”

5. Dr. Peter Koh, Research Scientist for the CSIRO
Minerals down under Flagship:
- It is important to increase throughput of existing equipment which may require a
different approach compared to when we look at new equipment for additional
installation
- Most processes are based on volume flows, so the only way to increase
throughput is by increasing pulp density, which results in increased viscosity.
- There are problems associated with high viscosity pulps, which might have non-
Newtonian flow or yield stress properties.
- The particle-bubble attachment could be more difficult to achieve if viscosity is
high, although a detachment will improve with the viscous pulp.
- Computational fluid dynamics is a tool that can be used to help this area.

6. Jacques Dippenaar, CHPP Manager, Sedgman:
“In any processing plan there are always unplanned activities and when they do
occur it’s natural to take the ‘all hands on deck’ approach. This usually results in
the manager not having the party work on strategic planning activities which
means you’ll never get to that state where you take the next step forward in the
processing.
Any change made will have to be underpinned by a clear business case which will
have to have a cost-benefit analysis and a payback period. This requires that all
processes such as cost tracking analysis of potential gains. This data might not be
immediately evident and available to give a black and white answer.
The challenge lies in identifying those few critical items that will give a significant
benefit but then on the other hand quantifying this improvement and following with
the next steps.”

7. In terms of equipment optimisation,
why is it important to identify key
faults in the processing chain?

8. Derek Scantlebury, CHPP Project Manager, Narrabri
Coal Operations:
“From a project perspective the greatest challenge is
identifying the key variables that need to be optimised. The
most technically efficient solution may not be financially
viable- Cash flow is usually an issue.
Although a plant will produce significant value once
operational it will be constructed at the end of a period of 2-
3 years without significant income from the site.”

9. Dr. Peter Koh, Research Scientist for the CSIRO
Minerals down under Flagship:
- It’s important to identify what happens inside. Computational fluid dynamics is a
diagnostic tool which allows us to look inside the equipment. So you can find the
problem area in the equipment where problems could arise – like high shear, or
high turbulence, where particles will detach from bubbles, when they are already
attached.
- Computational fluid dynamics can be used to examine individual cell operation
to identify regions in the cell where particles are attaching to bubbles or where
they are detaching.
- This allows cell design and operations to be modified in such a way to
maximize attachment or to minimize detachment.

10. Jacques Dippenaar, CHPP Manager, Sedgman:
- The basic premise is that your constraint will always move within the process
and as such the bottlenecks will always be fully loaded.
- In the mining business the goal should be to have an external constraint rather
than internal and that should be things such as transporting coal to port. The only
way that this can be done is to have a continuous improvement approach to
running a processing plant. This can include taking plant data, turning it into
information and then using the information for decision making.
- If key problem areas are identified they can be rectified and given limited
resources just assigning a time line around achieving these goals.

11. Derek Scantlebury, Dr. Peter Koh and Jacques Dippenaar
will be presenting at IQPC’s Coal Processing Optimisation
Conference in March 2011.
For more information please visit www.coalprocessing.com.au.
Or call 61 02 9229 1000 or email enquire@iqpc.com.au.
Don’t forget – you can also follow us on twitter @miningiq or join our
‘MiningIQ’ LinkedIn Group.
If you would like to be involved in Coal Processing Optimisation 2011, or
other mining events please email Lauren Kelleher.