Advances in stonedusting

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 I will talk about and show footage relating to

 the basics about Stonedust

 methane and coal dust explosions

 why previous wet dusting attempts failed

 ACARP project C16014 - Advances in wet slurry dusting

 how the slurry additive process works

 and look at the equipment involved in the process

 Some information within this presentation is well known by the

coal industry. It has been included to provide a summary of
how various elements interact.

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 Stone dust
 Stone dust or calcium carbonate is used in underground coal mines as
a primary inerting agent, in the prevention of coal dust explosions.

 The application of dry stone dust creates large quantities of airborne

dust along the ventilation circuit, requiring the extraction of inbye
personnel.

 In a methane explosion, a pressure pulse travels through the

immediate area of the mine.

 This wave raises any dust into suspension, both coal and stonedust.

 Areas treated with adequate quantities of stone dust, will render the
dust cloud inert and a coal dust explosion will not occur.

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 Methane
 The ignition of methane in an underground mine is not common
but does occur.

 Friction sparks from continuous miner and shearer drum picks

have provided ignition sources for methane gas.

 Other potential sources are cable flashes, belt friction, heating

and open fires.

 Given the right conditions a methane explosion itself is most

explosive at 9% general body and has deadly consequences.

 The following footage is a weaker explosion that compares to a

typical 10 metre overdrive allowed to accumulate a methane
concentration of only 7.5%.

 If an ignition source is present………….

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7.5% Methane
Explosion

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7.5% Methane
Explosion

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7.5% Methane
Explosion

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 Coal dust
 Minimising the make of coal dust and reducing float dust is an
ongoing challenge for all coal operations.

 Areas that were stone dusted once, if left unmaintained,

accumulate coal dust deposits providing fuel for an explosion to
propagate.

 Only 4-5mm of dry dust will be lifted in a weak methane

explosion. The more float dust accumulated, the less of the
underlying stone dust will be lifted.

 We saw that a methane explosion creates a fire ball that travels

behind the shock wave and hits the dust cloud.

 Insufficient quantities of stonedust in suspension will allow the

coal dust to ignite will obvious catastrophic consequences.

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Coal dust explosion
1 kg

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Coal dust explosion
75kg

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Coal dust explosion
75kg

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 Wet stone dusting
 Wet dusting was always viewed as an opportunity to help
overcome reductions in cutting times due to stoppages caused
by stone dusting.

 The onset of 7 day operations compounded the problem and

attempts were made to apply stone dust as a slurry.

 This allowed crews to continue production while wet dusting

was carried out in the ventilation intakes of the panels.

 Wet dusting is a process of creating a stone dust / water slurry

and pumping it onto the mines walls.

 The intent was to replicate the conventional dry dusting without

the need to withdraw inbye personnel.

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Wet stone dusting

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 Why wet dusting does
not work
 The application of wet dusting was proven however the final
product failed to provide adequate inerting qualities.

 When stone dust comes in contact with water the particles

partly dissolve.

 As the slurry dries, the dissolved solution moves between the

stonedust particles forming a bonding bridge that locks the
particles together.

 This is referred to as “The Caking Effect”.

 This caking reduces the amount of stone dust raised into

suspension, creating enough doubt on its effectiveness as an
inerting agent.

 Inspectors in NSW and Qld rightfully issued directives

restricting the use of slurry dusting
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 ACARP project C16014
 Australian Coal Association Research Program (ACARP) contracted
Mining Attachments to research and develop a wet slurry treatment
process that could overcome the caking effect.

 Applied Australia were requested to engineer an additive that would

work but had to be end user friendly.

 In 2006 the additive was ready to be trialled and tested on large scale.

 The 3 stage project spanned over two years.

 Surface full scale spray trials
 Underground spraying trials
 Full scale explosion testing

 Industry monitors were required to assess each stage objectives were

achieved, before advancing onto the next.

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 Airo-Dust™ Additive
 Airo-Dust™ Additive has been designed with the primary focus of
providing a safe product for use in the underground mining
environment
 The MSDS outlines all the health and safety requirements.
 Non-combustible
 Operators wear standard PPE
 Classified Non-dangerous goods
 Warnings in regards to skin, eyes, inhalation and ingestion are
similar to those of concentrated household dishwashing
detergent
 pH of the additive is between 6-8 (water 7.0 neutral)

 The required dosage of 10 litres of additive is required to treat one

tonne of stone dust.

Airo-Dust™ Additive is a trademark of Illinois Tool Works Inc.

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Surface full scale
trials

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 Surface full scale
trials
 Samples were taken during the surface spraying trials and sent
for particle size distribution.

 Results showed little change to the original particle sizes,

supporting the anti caking ability of the process.

 A simulated explosion demonstrated that the treated wet dust

could be put into suspension.

 The project moved to Cook Colliery, one of many operations

that supported the project.

 Mining Attachments fit for purpose equipment was mobilised

onsite and the first underground trials began.

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Underground Trials

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 Underground Trials
 The experience gathered from the 6 months of trials allowed
the necessary time to refine the process with dedicated
personnel allowed to focus on achieving the projects aims.

 Industry monitors evaluated the underground trials, operating

the equipment and viewing other areas of the mine previously
dusted using the new slurry additive process.

 The project then moved into the final stages of conducting full
scale explosion testing by third parties.

 The new slurry additive process was named Airo-Dust.

 The CSIR explosion testing facility in Kloppersbos South Africa,

hosted comparative Dry v’s Airo-Dust testing, facilitated by
Skillpro Services.

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 Explosion Testing
 The testing facility comprises of a 200m steel pipe tunnel that
has a methane mixing station and ignition centre one end and
the other end is open.

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Explosion
Testing
 Trays were prepared
prior to testing.

 Prior to each test

explosion, trays were
weighed and secured
into the tunnel.

 After the blast the loss

of stone dust from each
tray was recorded.

 High and low speed

video footage captured
each blast.

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Explosion Testing

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 Explosion Testing
 On average 40% more stonedust was lifted from the Airo-Dust
trays compared to the stonedust lifted from the Dry dust trays.
4000

3500
Loss of stone dust (g)

3000

2500

2000
3462

3315
3218

3035
2855
1500

2300
2075

1845
1810
1754

1755
1000

1485

1420
500

820
0
6 10 11 12 13 14
Dry stone dust trays 3462 1754 1755 2075 1810 1845 820
Slurry additive process trays 3218 2855 1485 3035 2300 3315 1420
Explosion test number

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 Explosion Testing
 On average the depth of dust lifted by the explosions also
varied.
4-5mm in the case of the Dry dust trays
in most cases the Airo-Dust trays were empty (30mm)

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 Explosion Testing
 Full details of this project including all the results from the
explosion and underground testing can be obtained on line by
visiting

www.acarp.com.au Project number C16014

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 How the Airo-Dusting
process works
 Stonedust slurry is made by mixing two parts stonedust with 1
part water.

 The Airo-Dust additive is dosed into the pump out line which
provides a protection barrier around the stone dust particles,
minimising the caking effect.

 Air is entrained into the line to create a foam. The product is

highly vesicular, trapping millions of tiny air pockets or voids in
the product as it dries.

 From the explosion testing it was evident that a methane

pressure wave is able to penetrate these voids, smashing
through the surface and raising the stonedust into suspension.

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 How the Airo-Dusting
process works
 The equipment consists of a mixing tank and paddle, slurry
pumps, additive pumps and the foam generation equipment.

 The system is non adjustable making the process less

complicated and simple to use.

 The additive is accurately dosed into the pump out line and
delivers a steady stream of shaving cream like slurry to either a
hand held nossel or machine spray bars.

 Existing equipment can be modified or new custom made Airo-

Dusters can be supplied.

 The Airo-Dust additive is supplied and serviced Australia wide

by ITW’s Applied Australia or nominated overseas agent.

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Equipment

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Equipment

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 Getting started
 A copy of the final ACARP report has been sent to
both NSW and Queensland inspectors for review.

 The NSW DPI have assembled a review committee

to firstly review the ACARP report and secondly
participate in the initial underground trials in NSW.

 This will allow the Airo-Dusting process to be viewed

from both a technical and practical perspective.

 Operations can now make application to the NSW

DPI to use the Airo-Dusting process underground.

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 Current participating
sites
 Grasstree Mine
 1 x existing wet duster modified into an Airo-Duster
 2 x new Airo-dusters

 Greenside Colliery (South Africa)

 1 x new Airo-Duster

 North Goonyella
 1 x Hire Airo-Duster

 Centennial Coal (Mandalong, Clarence, Springvale)

 DPI application pending

 Vale (Integra Coal)

 DPI application pending

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Airo-Dusting

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