Bma Bucket Efficiency Case Study(09!06!2009)
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Australia Energy Excellence Programme BHP Billiton Mitsubishi Alliance (BMA) is Australia’s largest metallurgical coal miner and exporter. BMA operates nine large mines and the Hay Point Coal Export Terminal in Central Queensland, Australia. BMA is centred on long- term sustainability to provide a platform for growth; meaning that while the company grows in economic importance, it simultaneous ly progresses its sustainability performance – socially and environmentally. WCI Case Study | November 2008 To achieve a sustainable platform for growth, BMA has introduced an Energy Excellence Programme (EEx), based on the Federal Energy Efciency Opportunity legislation for large energy-using corporations with an annual energy usage above 0.5 petajoules a year (8 PJ/y). Six BMA sites (except Hay Point Terminal and South Walker Creek and Poitrel Mines because of their lower energy consumption) trigger these legislative requirements with a total energy usage of 15.8 P J/y. BMA is required to a ssess 80% of its total energy use within the ve year assessment cycle. Through steering committees and site ownership of the EEx Programme, BMA has identied a number of projects to reduce energy consumption. One of these initiatives - dragline bucket efciency - is already showing signicant results, with energy reductions of 20% when lling the bucket. Estimated electricity savings of around 630 megawatt hours (MWh) have been achieved, equal to turning off power to approximately 500 homes for one year. What is a Dragline Bucket? Dragline excavation systems are used in surface mining, where they remove overburden above coal. A dragline bucket system consists of a large bucket that is suspended from a boom (a large truss-like structure) with wire ropes. The bucket is manoeuvred by a number of ropes and chains. The hoist rope, powered by large diesel or electric motors, supports the bucket and hoist-coupler assembly from the boom. The dragrope is used to draw the bucket assembly horizontally. In a typical cycle of excavation, the bucket is positioned above the material to be excavated. The bucket is lowered and the dragrope is drawn so that the bucket is dragged along the surface of the material. The bucket is then lifted by using the hoist rope. A swing operation is performed to move the bucket to the place where the material is to be dumped. The dragrope is then released causing the bucket to tilt and empty. www.worldcoal.org case study
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AustraliaEnergy Excellence Programme
BHP Billiton Mitsubishi Alliance (BMA) is Australia’s largest
metallurgical coal miner and exporter. BMA operates ninelarge mines and the Hay Point Coal Export Terminal inCentral Queensland, Australia.
BMA is centred on long-term sustainability to
provide a platform forgrowth; meaning that whilethe company grows ineconomic importance, itsimultaneously progressesits sustainabilityperformance – socially andenvironmentally.
WCI Case Study | November 2008
To achieve a sustainable platform forgrowth, BMA has introduced an Energy
Excellence Programme (EEx), based onthe Federal Energy Efciency Opportunitylegislation for large energy-usingcorporations with an annual energy usageabove 0.5 petajoules a year (8 PJ/y).
Six BMA sites (except Hay Point Terminaland South Walker Creek and PoitrelMines because of their lower energyconsumption) trigger these legislativerequirements with a total energy usage of15.8 PJ/y. BMA is required to assess 80%of its total energy use within the ve yearassessment cycle.
Through steering committees and siteownership of the EEx Programme, BMAhas identied a number of projects toreduce energy consumption. One of theseinitiatives - dragline bucket efciency - isalready showing signicant results, withenergy reductions of 20% when lling thebucket.
Estimated electricity savings of around630 megawatt hours (MWh) have beenachieved, equal to turning off power toapproximately 500 homes for one year.
What is aDragline
Bucket?Dragline excavation systems are usedin surface mining, where they removeoverburden above coal. A dragline bucketsystem consists of a large bucket that issuspended from a boom (a large truss-likestructure) with wire ropes. The bucket ismanoeuvred by a number of ropes andchains. The hoist rope, powered by largediesel or electric motors, supports thebucket and hoist-coupler assembly fromthe boom. The dragrope is used to drawthe bucket assembly horizontally.
In a typical cycle of excavation, the bucketis positioned above the material to beexcavated. The bucket is lowered and thedragrope is drawn so that the bucket isdragged along the surface of the material.The bucket is then lifted by using the hoistrope. A swing operation is performed tomove the bucket to the place where thematerial is to be dumped. The dragropeis then released causing the bucket to tilt
and empty.
www.worldcoal.org
case
study
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2 WCI Case Study | November 2008
DraglineFleet Upgrade
StudyThe project stemmed from BMA’s draglineeet upgrade study which aimed toincrease the payload (or weight) capacityof each bucket by 25%. Studies wereconducted by South Walker Creek Mine,in partnership with Central Queensland
Mining Supplies, and included a seriesof tests and full design specications tocalculate the total weight the boom cancarry.
To increase the new bucket’s payloadcapacity by 25% to the desired 125% ofthe dragline’s ‘rated suspended load’,the shape of the bucket was altered toobtain the optimal relationship betweenbucket mass, height and width for llingefciency. A bigger and wider bucketwould usually mean the dragline suspendsa heavier payload and uses more energy.However, it was a key goal of this projectthat although the bucket’s load wouldincrease, the energy required to ll thebucket would stay the same or actually bereduced.
Following the studies, designs wereapproved for the development ofa lightweight bucket, with a morestreamlined design to improve the removalof spoil when in operation. The redesignedbucket and rigging weighs 62 tonnes andcan carry up to 109 tonnes per load. Nowin full operation at South Walker CreekMine, the energy required to ll the buckethas reduced by 20%. Similar bucketefciency designs are being replicated
at BMA Blackwater, Peak Downs andGoonyella Riverside Mines
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For further information on BHP Billiton Mitsubishi Alliance visit: www.bmacoal.com
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South Walker Creek Mine’s energy efcient dragline bucket
