Emissions Management

For
Coal Handling
Neptune Bulk Terminals Emissions Management

Contents
Emissions Management for Coal Handling ............................................................................2

1) Audit of Loaded Coal Trains On Arrival....................................................................2

2) Assessment of Risk Prior to Unloading Trains .........................................................3
3) Management While Unloading Trains .....................................................................4
4) Management of empty coal Cars Departing the NBT Site ......................................5
5) Management of Conveyed Coal ..............................................................................7
6) Management of Coal in Stockpile ............................................................................9
7) Management When Reclaiming Coal from Stockpile to Vessel ..............................13
8) Management of Vessel Emissions ...........................................................................13
9) Management of Site ................................................................................................13

Appendix 1 .............................................................................................................................16

Appendix 2 .............................................................................................................................22

1|Page
Neptune Bulk Terminals Emissions Management

Emissions Management for Coal Handling

Neptune Bulk Terminals (NBT) is a participant in the logistics and supply chain for the export of
metallurgical coal from British Columbia and North East Alberta. With respect to emissions, NBT
has a key role in auditing the performance of certain aspects of the supply chain. This includes
ensuring that we demonstrate excellence, continuously improve our performance and actively
seek and invest in technology and training that allows NBT specifically, and the entire supply
chain generally, to perform better than or at the requirements of the respective emissions
permits.

NBT’s Environmental Management, Quality Management, Safety Management systems and

Emergency Management Response Plan provide the tools to audit performance, identify and
prioritize action items, respond to system failures and internal and external concerns, and to
manage emergencies related to emissions created through operational activities involved in the
handling of coal. This Emissions Management document outlines the current emission controls
relating to the coal handling system. The key NBT activities with respect to emissions
management are:

1) Audit of loaded coal trains on arrival

2) Assessment of risk prior to unloading trains
3) Management while unloading trains
4) Management of empty coal cars departing the NBT site
5) Management of conveyed coal
6) Management of coal in stockpile
7) Management when reclaiming coal from stockpile to vessel
8) Management of vessel emissions
9) Management of site

1) Audit of Loaded Trains On Arrival

The top of every coal car of every train entering the NBT site is recorded by a camera. The
recordings for twenty-five trains, five trains from each TECK mine, are inspected by an
independent third party each month. The third party provides an analysis of the volume of coal
in the car to confirm loading was below the sill height and the appropriate profile in the car was
achieved to prevent wind loss. The third party also provides an analysis of the performance of
the crusting agent which is applied at each mine load out and again near Kamloops, BC.

2|Page
Neptune Bulk Terminals Emissions Management

Figure 1 – Coal car properly profiled; loaded below sill with intact crust.

The third party analysis is provided to TECK Logistics each month and shared with each source
mine, re-enforcing successful outcomes and addressing any issues with regards to car loading
or the application of the crusting agent. On arrival, and at unload point, at NBT all coal trains
are inspected for the integrity of the crust and the height of the coal in the car by terminal staff
and operators. Discrepancies are reported to the TECK Logistics group for action by the
originating mine.

2) Assessment of Emissions Risk Prior to Unloading Trains

The NBT operating group reviews all available information provided at the time of the train
loading and establishes an unloading plan for each train to stockpile or direct loading to vessel.
Considerations in the plan include safety, emissions control and mitigation, noise control and
mitigation, productivity and cost control. The required control tools are determined on the
basis of this assessment; these include, pre-unloading car water addition, dumper scrubbing
system, water systems at the coal dumper, water addition on conveyors, spray systems on
stackers, spray pole systems, ground water cannons, crusting agent systems for stockpile and
empty cars and on-site weather stations. Having determined which tools are required these are
verified to be available for use prior to unloading.

For the purposes of managing emissions, the coal loaded to each train is sampled for its
moisture content. The mine provides the moisture content of the coal to NBT within 24 hours
of departure of the train from the mine. If the moisture of the coal is not in the target range,
and presents a risk of creating dust when unloading at NBT, each railcar has water added at a
3|Page
Neptune Bulk Terminals Emissions Management

prescribed, measured rate 100m ahead of the NBT unloading station which is referred to as the
“dumper”. Trains can be travelled under this spray system multiple times should this be
required to achieve a desired moisture level.

3) Management of Emissions While Unloading Trains

The rotary coal car dumper is an enclosed building with an air collection and wet scrubbing
system. The system runs continuously while rail cars are unloading, creating a negative
pressure in the unloading building. All collected air is then forced through a wet scrubber
which removes particulate; the air is then released via a single stack. The collection system has
complete redundant fan and motor to allow continued operations in the event of a mechanical
failure. In accordance with the air emissions permit, emissions from this stack are audited and
measured by third parties and by trained NBT personnel on an ongoing basis. Water from the
scrubbing system is treated to remove collected particulate.

Figure 2- Wet scrubber at coal dumper.

The wet scrubber is connected to the NBT industrial technology system Rockwell Software
Supervisory Edition (RSSE) which allows for continuous monitoring and recording of its
operational, mechanical and electrical status. NBT personnel are trained to observe and report
any occurrences of unusual emissions from the stack point or the dumper building as part of
their standard work routine. An NBT employee is stationed at the dumper at all times while
unloading is occurring. Manual spray systems are available should any coal dust be observed to
escape the building. These are rarely used.

4|Page
Neptune Bulk Terminals Emissions Management

Figure 3 - Scrubber Screen RSSE

The two or three locomotives that remain attached to the train through the unloading process
are in idle mode and not under load, greatly reducing emissions. NBT trains are moved using an
electrically driven car indexer. NBT personnel are trained to observe for and report any unusual
performance issues including: emissions, noise, fluid leaks or damage as the idling locomotives
move through the coal dumper.

4) Management of Emissions for Empty Coal Cars Departing the NBT Site
Once a car has been rotated and unloaded in the dumper, then returned to the upright
position, it is weighed to ensure that no significant amount of coal remains in the car and will
be carried back to the mine, potentially releasing dust from the car as it travels. Should the car
weight exceed the set point, it is visually inspected for the cause of the carry back and if it is
coal, the car is unloaded until all the material has left the car.

All cars are visually inspected as they leave the coal dumper and a photo recording of each car
interior is captured and stored.

5|Page
Neptune Bulk Terminals Emissions Management

The exterior unloading side and top sill of

each car is washed prior to leaving the NBT
site to ensure no residual coal or coal fines
leave on the car after it is unloaded. This
water is collected and treated to remove
any coal.

Currently, Neptune is implementing, as a

trial program, a binding agent spray system
for empty coal cars before they are returned
to the mine. Once emptied, coal cars have a
bio-degradable, environmentally-friendly
binding agent sprayed into the interior,
similar to the product used to crust the
loaded cars when departing the mine. This
binding agent ensures no coal can leave the
car on the return journey.

Figure 4- Car washing system cleans residual coal The performance of the binding agent is
from sills of coal car after dumping. monitored through the random use of on-
board cameras and portable particulate meters. This system is being further enhanced by being
linked to a weather station to ensure optimal application of the binder to the temperature and
humidity at the time of unloading.

Figure 5- Binder being applied to empty coal car.

6|Page
Neptune Bulk Terminals Emissions Management

5) Management of Emissions for Conveyed Coal

The NBT conveyors are designed and operated with ample room to prevent coal from coming
close to the edge of the conveyor and adjust to the distribution of coal on the conveyor to
prevent spillage. The enclosed transfer chutes permit coal to move from one conveyor to
another without generating dust. The chutes are designed to optimize the flow of the coal,
minimize the entrainment of air in the coal flow which prevents dust from being lifted out of
the product and to have no spillage by centering the transferred coal on the next conveyor
belt. Transfers are designed with internal water spray systems to permit “self” cleaning and
prevent plugging which could cause spillage and dust emissions.

Four additional controls are also employed to mitigate coal dust emissions from conveyed coal:

a) Scrapers: Scrapers are used to remove residue from the conveyor belt and are situated near
the head pulley of a conveyor as the coal is discharged to the next system. All conveyors
have been fitted with secondary scrapers to back up the work of the first. This prevents
particulate from falling from the return side of the belt and becoming air borne.
Tension in the scraper mounting mechanism allows the scraper to self-adjust to
compensate for wear. Scraper blades are regularly replaced as a part of the planned
maintenance program.

b) Conveyor Belt Misalignment Correction: From time to time, a conveyor belt may move out
of alignment. This is known as ‘side travel’. If the side travel becomes excessive, minor
temporary spillage of coal product could occur on site. All the conveyors are fitted with
automatic side-travel correction devices which lead the belt back on to its designed track.
In the event that the side travel overcomes these tracking devices, there are side travel
sensor switches which detect excessive movement which automatically shut the conveyor
down triggering further investigation by the maintenance department.

c) Spillage Protection: Each Conveyor has plugged chute detectors, spill detectors and rip
detectors, any of which will shut-down the conveyor if they are tripped. The plugged chute
detectors are of a tilt switch design which trip as soon as coal in the chute backs-up to the
point that the switch is displaced from a vertical position. The sill detectors are a balance
device deployed at the head-end of a conveyor and provide a back-up to the tilt switches.
All conveyors are electrically interlocked together. This ensures that if any one conveyor is
stopped then all the following conveyors in the sequence also stop in order to prevent
over-load and spillage. Belt rip detectors provide an early warning of objects penetrating
the belt which may cause damage to the belt and spillage to occur.

7|Page
Neptune Bulk Terminals Emissions Management

d) Skirts: Each conveyor transfer is equipped with a set of skirts where the product feeds onto
the next belt. This ensures the product centres onto the belt and prevents spillage.

There is constant observation of the stockyard, conveyors, stacking and reclaiming equipment
by onsite employees, supervision and cameras recording the performance of the system during
the conveying of coal from the dumper to stockpile to direct to vessels. If emissions are
observed during the conveying of coal to stockpile or while loading a vessel, additional water is
added at a prescribed, measured rate from a weir located above the conveyor prior to entering
the stockyard, at the stacking point, at the incline of the conveying system leaving the stockyard
and at both ship loaders.

Planned water addition also occurs at these points based on field data collected from the coal
when it has been in stockpile. If the moisture level is below the known safe reclaim point,
water is added to ensure no dust occurs during handling.

Figure 6 - Binder applied to stockpiled coal.

A second system is installed on the first conveyor from the dumper which adds a binder, similar
to the crusting agent added at the load point and to the interior of the empty coal cars as they
leave site. The binder is added to coal being stockpiled if it will be on site for periods of weather
conditions where the temperature is below zero degrees or above 25 degrees Celsius, or in the
case of water restrictions.

8|Page
Neptune Bulk Terminals Emissions Management

Figure 7 - No dust while stockpiling at below zero temperatures. Note ice in foreground.

The standard operating procedure dictates the stacking equipment operate as close to the pile
as safely practical which minimizes drop height and reduces the entrainment of air in the
product flow which can produce dust. Water addition at the point of stacking occurs as routine
operating procedure which ensures that any dust entrained in the coal flow from the stacker to
the stockpile is contained and “knocked down”.

The standard operating procedure dictates the reclaim equipment operates with its bucket in
the pile. During routine operation, a fine mist of water is added as the coal is reclaimed to
ensure no dust escapes when the coal arrives at the first reclaim belt.

6) Management of Coal in Stockpile

The coal stock yard has a capacity for up to 600,000 metric tonnes (MT) in the summer months
and approximately 550,000 MT in the winter months. This volume difference is a result of the
safe height the coal can stacked at and not slough. In wet winter conditions, there is a greater
risk of pile slough.

In both warm and cold dry conditions, the Neptune site is manned 24 hours a day with
personnel dedicated to ensuring optimum conditions and system performance are occurring in
the coal stockpile storage area. The Neptune site is manned for stockpile management on
required days normally prohibited from operation under the Collective Agreement. This
includes twelve 8-hour Union Meeting nights per year, New Year’s Day, Labour Day and
Christmas Day.

NBT prevents dust from leaving the coal stock yard through the use of:

A. Coal moisture content as described in the previous five sections.

9|Page
Neptune Bulk Terminals Emissions Management

B. Stockpile configuration; Neptune limits the number of stockpiles reducing the number
of exposed surfaces. The stockpiles are constructed longitudinally NE to SW on either
side of the stacking/reclaim berm way. This provides for limited exposure of surface
areas to the prevailing winds. (See image next page)

Figure 8 - Neptune Coal Stockpile viewing North.

C. Stockpile height and profile: wherever possible, Neptune limits the height of the
stockpile and ensures the piles are either stacked flat or flattened through the use of
mobile equipment, which prevents excess turbulence from occurring in the air flow.

D. Moisture addition to pile surfaces which prevents particles from becoming air borne.

NBT has five independent methods of water application to ensure the surface of the stockpiled
coal does not dry out and that redundant wetting capacity is in place should one system suffer
a failure.
a) The primary water application system is the fourteen stockpile spray poles located
around the perimeter and in the interiors of the stockpile. These poles have both
misting and individual water cannons on the top of the pole.

10 | P a g e
Neptune Bulk Terminals Emissions Management

Figure 9- RSSE Spray Pole Overview

The high mast misting spray bars poles have both a manual and automatic
capability. The automatic program is based on an algorithm which works from data
from three on-site weather stations which measure wind direction, humidity and
temperature. The computer program uses the algorithm to turn water on to the high
mast misting spray bars and ensure maximum application of water to the stockpiles
as required by the weather conditions occurring. Greater detail technical detail is
provided in Appendix 1 and 2 of this document with regards to the Spray Pole Dust
Control Automation.

The water cannons on the spray poles are manually operated through the RSSE
system and are used for moisture addition as well as wetting the tops and upper
sides of stockpiled coal.

b) The two stacker reclaimers are used to apply water to the surface of the stockpiles
from the center of the stock yard to their maximum reach. The two machines can
cover the entire length of the stock yard in approximately 45 minutes if operated
individually and in 30 minutes if operating simultaneously while applying the
required amount of water in the form of a mist to ensure the pile surfaces remain
wetted. There is a clear process in and demonstrated history of using these
machines for pile wetting in priority to stockpiling or reclaiming coal should the
weather and stockpile conditions require this step. These units can operate in wind
speeds of up to 40 km/h above which they must be shut down for safety reasons.

11 | P a g e
Neptune Bulk Terminals Emissions Management

c) The fourteen spray poles have manually operated water cannons at the base which
can provide a water spray over 70% of the maximum pile surfaces and the exterior
base of the entire stock yard.

d) There is access to water the entire length of the berm which runs through the centre
of the coal stock yard and down the entire length. A number of specialized water
cannons have been built and are used to provide coverage to 70% of the stockpile
surfaces from the interior of the stockpiles. This provides a substantial overlap to the
water cannons described in point three above and allows for 100% pile coverage
between the two means of pile wetting.

Figure 10 - showing reach of portable water cannons.

e) There is one water truck on the Neptune site equipped with a turret style water
cannon on its front bumper. This unit can travel the length of the centre berm or
around the base of the coal stockpiles as required. It provides coverage to isolated
spots or in areas where individual water cannon maybe temporarily out of service.

The five methods of pile wetting provide a combination of abilities such that should any two
methods be out of service full stockpile coverage can be maintained at all times.

As with all environmental control systems at NBT, maintenance of these systems is a priority.

12 | P a g e
Neptune Bulk Terminals Emissions Management

7) Management When Reclaiming Coal from Stockpile to Vessel

In addition to the ability to increase the moisture content of the coal prior to and during ship
loading, the conveyors and ship loaders have specific enhancements to assist in controlling coal
dust and potential emissions. These include spill trays, tail pulley curtains and water addition in
the ship loader loading spouts.

The yard conveyors travel from the stockpile area to a surge bin, an elevation gain of
approximately 30 meters. Catchment trays have been installed under these conveyors at the
elevated point to ensure no material falls from the conveyors or the return side of the belts and
becomes air borne.

These trays have an automatic wash feature which ensures material build up is minimal and the
collected material is kept wet. The two coal ship loaders have a similar collection system but,
rather than a tray, a secondary conveyor belt has been installed under the primary conveying
system on the ship loader shuttle. These secondary conveyors catch any material that could fall
from the primary conveyor for vessel loading and the return side of the primary belt as well.
This prevents material from becoming air borne, and this material is collected and returned to
stockpile.

Both coal ship loader spouts have water addition points to permit wetting of the coal should
there be dust occurring at the vessel hatch. The ship loaders are manned at all times during
vessel loading and operators are trained to look for, report, and mitigate dust occurring during
vessel loading.

8) Management of Vessel Emissions

As a member of Green Marine, NBT actively encourages all vessels visiting the terminal to
participate in the PMV initiative to have marine vessels use the highest quality lowest impact
fuels available.

On arrival, all vessel personnel meet with terminal staff and, as part of the loading agreement,
sign the requirement not to operate the main vessel engines. Ship loader operators and
foreman report any breaches of this agreement in a timely manner. Neptune has the power
and distribution system to supply bulk vessels with shore-based power should bulk vessels with
this capability become available.

9) Management of Site
In addition to the detailed management processes described above, there are site processes
which assist in the management of emissions: site cleanliness, spills, mobile equipment, air
quality monitoring, training and awareness.

13 | P a g e
Neptune Bulk Terminals Emissions Management

Site cleanliness is managed through the operations group. By site design, the coal system (the
rail track, unloading system, stockpiles, loading systems and ship loading) is contained as a
separate unit. All water in this area drains to the coal water management plant.

Spills of coal on site are uncommon and are cleaned up at the time they occur. Spillage can
only occur adjacent to or amongst operating equipment and presents a trip/slip and fall hazard
to employees, in addition to the possibility of allowing coal to become air borne. All spilled
material is collected and returned to stockpile.

All required maintenance services have been positioned to service the coal system such that
mobile equipment does not have to leave the stockpile area. Access into the storage area is
limited to a single road way, thus reducing traffic. A number of speed bumps and water swales
are in place to ensure light vehicle traffic is not tracking coal out of the coal area. Road ways are
routinely washed using the water truck and power swept throughout the year.

All mobile equipment is purchased to meet or exceed current emission standards. NBT has
been aggressive in ensuring it is a leader in the port community with respect to meeting
California Tier 3 standards or better for all its large and small mobile equipment.

Figure 10- Onsite air monitoring and particulate measurement.

Neptune has onsite air monitoring and particulate measurement devices that exceed permit
requirements. Operations and maintenance personnel are included in the investigation process,
follow up and corrective actions required should these devices indicate any recording near
permit exceedance levels.

14 | P a g e
Neptune Bulk Terminals Emissions Management

There is ongoing training and education of all employees with regards to safety and the
environment, including emissions.

15 | P a g e
Neptune Bulk Terminals Emissions Management

APPENDIX 1
Neptune Bulk Terminals Limited
Spray Pole Dust Control Automation
Quick Reference – Part 1

16 | P a g e
QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Neptune Bulk Terminals Limited

Spray Pole Dust Control Automation

Quick Reference – Part 1

Version: 1.0

Date: Nov 27, 2013

Nov 27th, 2013 Page 0

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Contents
1. System Overview ....................................................................................................... 2
1.1. RSView Screens .............................................................................................. 2
1.2. Weather Monitoring Stations ............................................................................ 2
1.3. Dust Control Program ...................................................................................... 2
Weather Station 1 Calculated K Value: .......................................................................... 3
Group 1 Mist Times ........................................................................................................ 3

Nov 27th, 2013 Page 1

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

1. System Overview
The spray pole dust control system is a distributed control system which allows
centralized supervisory manual and automatic control of the spray poles.

Coal storage dust control is provided by spray poles positioned around the stockpiles.
The spray poles provide two types of moisture addition. One is a fixed array of misters
connected to a horizontal manifold sitting a top the spray pole. The second is a single
nozzle or turret which directs a spray similar to a fire hose. Both types of sprays are
used to prevent the piles from drying out.

The turrets operate with manual intervention locally at the spray poles or remotely via
the supervisory HMI system. The fixed misters are able to run in manual or full auto
mode. The full auto mode turns the misters on and off using a weather based algorithm
and RSView timer setpoints. Three site weather stations provide data to the system.

1.1. RSView Screens

RSView supervisory control system screens are used to control the spray pole system.
On and off timers can be altered, automatic weather setpoints can be adjusted and the
entire system can be monitored remotely.

1.2. Weather Monitoring Stations

There are three weather stations located around the coal system; the maintenance
building, coal dumper and Tower # 32.

Humidity, temperature, wind speed and direction are used to determine which mists are
going to be used to control the main PLC program.

1.3. Dust Control Program

The automated math algorithm output has been named the K factor. This control
scheme attempts to estimate coal moisture. Users have the ability to set K parameters
for each pole. The K factor control scheme uses weather station data:

 Wind speed
 Wind direction
 Humidity
 Temperature
 Rain fall (interlock only to prevent overwatering)

Nov 27th, 2013 Page 2

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Weather Station 1 Calculated K Value:

K=SQRT{ [(Temperature^2)*Wind Speed]/Humidity}

 Temperature: in Fahrenheit
 Wind Speed: in Mph
 Humidity: in percent
 Compare this computed value to the Normal and Extreme K value settings for
each Spray Pole for specified wind directions

Example, where:

 Temperature: 68 F
 Wind Speed: 10Mph
 Humidity: 70%

K = SQRT {[(68^2)*10] / 70} = 25

Group 1 Mist Times

If Weather station 1 calculated K value is greater or equal to weather station 1 normal K

value set point, Group 1 mist time:

 Group 1 Mist On Time (sec) = Group 1 Manual Mist On Time (from RSView –
e.g. 15 seconds) + 2(sec)*( K calculated-K normal weather station 1 setpoint)

Example, where:

 K normal setpoint = 18
 K calculated = 25
 Mist On Time setting (sec) = 15

Group 1 Mist On Time (sec) = 15 + [2 * (25 – 18)] = 29

*** End of Document ***

Nov 27th, 2013 Page 3

Neptune Emissions Management

APPENDIX 2
Neptune Bulk Terminals Limited
Spray Pole Dust Control Automation
Quick Reference – Part 2

Nov 27th, 2013 Page 22

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Neptune Bulk Terminals Limited

Spray Pole Dust Control Automation

Quick Reference – Part 2

Version: 1.0

Date: Nov 27, 2013

Nov 27th, 2013 Page 0

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Contents
1. System Overview ....................................................................................................... 2
1.1. RSView Screens .............................................................................................. 2
1.2. Weather Monitoring Stations ............................................................................ 2
1.3. Dust Control Program ...................................................................................... 2
Weather Station 1 Calculated K Value: .......................................................................... 3
Group 1 Mist Times ........................................................................................................ 3
Accumulated Rainfall ..................................................................................................... 4
Humidity ......................................................................................................................... 4
Temperature .................................................................................................................... 4
Wind Speed ..................................................................................................................... 4
Wind Direction ............................................................................................................... 4
Auto Mist Times ............................................................................................................. 6

Nov 27th, 2013 Page 1

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

2. System Overview
The spray pole dust control system is a distributed control system which allows
centralized supervisory manual and automatic control of the spray poles.

Coal storage dust control is provided by spray poles positioned around the stockpiles.
The spray poles provide two types of moisture addition. One is a fixed array of misters
connected to a horizontal manifold sitting a top the spray pole. The second is a single
nozzle or turret which directs a spray similar to a fire hose. Both types of sprays are
used to prevent the piles from drying out.

The turrets operate with manual intervention locally at the spray poles or remotely via
the supervisory HMI system. The fixed misters are able to run in manual or full auto
mode. The full auto mode turns the misters on and off using a weather based algorithm
and RSView timer setpoints. Three site weather stations provide data to the system.

2.1. RSView Screens

RSView supervisory control system screens are used to control the spray pole system.
On and off timers can be altered, automatic weather setpoints can be adjusted and the
entire system can be monitored remotely.

2.2. Weather Monitoring Stations

There are three weather stations located around the coal system; the maintenance
building, coal dumper and Tower # 32.

Humidity, temperature, wind speed and direction are used to determine which mists are
going to be used to control the main PLC program.

2.3. Dust Control Program

The automated math algorithm output has been named the K factor. This control
scheme attempts to estimate coal moisture. Users have the ability to set K parameters
for each pole. The K factor control scheme uses weather station data:

 Wind speed
 Wind direction
 Humidity
 Temperature
 Rain fall (interlock only to prevent overwatering)

Nov 27th, 2013 Page 2

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Weather Station 1 Calculated K Value:

K=SQRT{ [(Temperature^2)*Wind Speed]/Humidity}

 Temperature: in Fahrenheit
 Wind Speed: in Mph
 Humidity: in percent
 Compare this computed value to the Normal and Extreme K value settings for
each Spray Pole for specified wind directions

Example, where:

 Temperature: 68 F
 Wind Speed: 10Mph
 Humidity: 70%

K = SQRT {[(68^2)*10] / 70} = 25

Group 1 Mist Times

If Weather station 1 calculated K value is greater or equal to weather station 1 normal K

value set point, Group 1 mist time:

 Group 1 Mist On Time (sec) = Group 1 Manual Mist On Time (from RSView –
e.g. 15 seconds) + 2(sec)*( K calculated-K normal weather station 1 setpoint)

Example, where:

 K normal setpoint = 18
 K calculated = 25
 Mist On Time setting (sec) = 15

Group 1 Mist On Time (sec) = 15 + [2 * (25 – 18)] = 29

Nov 27th, 2013 Page 3

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Accumulated Rainfall

Accumulated rainfall is currently recorded using the weather station. This data is used to
lock out automatic mister operation if it has recently rained. This is done to prevent water
being unnecessarily added to the piles. Rainfall is recorded in mm.

Humidity
Relative humidity is used in the automated control of the Misters. This data is recorded
in percent. This value is used in the K value calculation. It is assumed that rainy
conditions result in increased humidity.

Temperature
Temperature is used for the Mister Auto mode control. This value is used in the K value
calculation. The K value calculation uses temperature in Fahrenheit units. All references
to other temperature readings in the RSView system are in Celsius.

Wind Speed

Wind speed is a key input for automated control. Windy conditions are utilized to carry
the water to the coal piles effectively.

Wind speed is used in the K factor approach. Wind speed is recorded in mph. Extreme
wind conditions are defined as speeds above 35 mph, when ship loading is stopped.
Filtered average speeds are used in order to reduce solenoid valve fluctuations in short
gusts of wind or breaks in the wind.

Look up tables are used to configure mist control for individual poles. Look up tables are
a mechanism that is used to configure and control the system. Each mister has its own
look up table that determines the K value for pole operation based on wind direction.
Each look up table is a matrix of rows and columns representing wind direction
quadrants and wind speed levels respectively. At each intersection we define whether
the mister is on or off.

Misters are automatically turned on when the calculated K value exceeds the value of
the look up table.

Wind Direction

The wind direction is utilized to place water onto the piles effectively. The user has the
ability to select wind directions for each pole. This enables misting for that pole when
certain conditions are met using the K factor approach.

Wind direction is presented using look up tables for each pole. An RSView screen allows
the user to enable misting for a pole based on wind direction at a preset K value.

For poles located at the north end of the coal piles, these sprays function to trap coal

Nov 27th, 2013 Page 4

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

dust as a last defence. For this reason, two K factor thresholds are provided. The first is
defined as normal wind conditions and the second as extreme.

Screenshot from RSView: Look up table for Spray Pole ‘B’

Nov 27th, 2013 Page 5

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Auto Mist Times

Auto mist times are derived from the manual mist times for each group. When conditions
produce a calculated K value (shown in RSView as “Current K Value”) which is less than
the normal K set point, the manual mist timers are used for poles within that grouping
regardless of wind direction.

For values between the normal and extreme K set points, poles mist based on wind
direction that is set in RSview for each pole. The current manual mist times for each
group apply to each group as follows:

Two seconds are added to the Mist on time for each calculated K value above the
Normal K set point. The Mist off time is a slope calculation done in the Control PLC. It
uses the Mist off time as entered for the manual mist off times for each group. The Auto
mist off time is formed by subtracting time away until the mist off time is zero when the
Extreme K set point is reached.

Ex.

Manual Mist On time = 45s, K normal = 25, Current K value = 30s.

Auto Mist On time = 45s + (30-25)*2s = 45+10 = 55 seconds

A slope calculation is used to determine the mist off time. The line is calculated from the
Normal K value which represents the manual Mist Off value and the line crosses at the
Extreme K set point. This turns the mist on fully and remains on until the current K value
drops below the Extreme set point.

The user can fine tune the Auto system by selecting a manual mist on and off time and
choosing appropriate K set points after some experimenting. Spacing out the Extreme K
set point results in a less aggressive mist cycle that delivers less water as apposed to a
closer spaced set up.

Note the slope is calculated using the weather station #1 data. The slope calculation
applies to all poles regardless off additional weather stations.

Nov 27th, 2013 Page 6

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Screenshot from RSView: Timer adjustments.

Nov 27th, 2013 Page 7

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

Typical K values
Typical Mister Operation within the K value range. The following illustration assumes a K
normal value of 20 and an Extreme value of 30.

Low Moderate Extreme

Mister On
based a slope
calculated
Manual time Mister
timer On
Utilized Continuously
K>Extreme
set point

0 20 30 40 50 60
K Value

Some K values are included for reference under set conditions.

K value with temperature varying

Variable Temperature
Rel H = 70%
Wind Speed = 7 mph
35

30

25
K

20

15

10

0
-10 -5 0 5 10 15 20 25 30 35 40
Temperature (C)

Nov 27th, 2013 Page 8

QCA Systems Limited Spray Pole Dust Control Automation Reference Manual

K Value Wind Speed Variable

Variable Wind Speed

Rel H = 70%
Temp = 20 C

50

40

30
K

20

10

0
0 5 10 15 20 25 30
Wind Speed (mph)

K Value Relative Humidity Varying

Varying Rel Humidity

Wind Speed = 7 mph
Temp = 20 C

300
250
200
K

150
100
50
0
0 20 40 60 80 100 120
Relative Humidity (%)

*** End of Document ***

Nov 27th, 2013 Page 9