Technical and safety successes of Hungary's lignite-mining operations at MÁTRA Power Plant

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1 Technical and safety successes of Hungary's lignite-mining operations at MÁTRA Power Plant Dr Joachim Witzel MÁTRAI ERŐMŰ ZRT. Mátrai Erőmű Zrt SEITE 1

2 Structure 1. MÁTRA Power Plant in Hungary 2. Developments in mining at MÁTRA Output Safety and environmental protection 3. Future mining developments 4. Conclusion Mátrai Erőmű Zrt PAGE 2

3 Electricity and coal production in Hungary, 2010 Domestic power supply, 2010 Nuclear 42% Wind, hydro 2% Other 8% Coal deposits and production Budapest Miskolc Gas 31% Coal 17% Lignite Pécs Szeged Installed capacity ~ 9,200 9,200 MW MW Mátrai Erőmű Zrt mill. mill. tt Gross power supply TWh Vértesi Erőmű Zrt. ~0.9 ~0.9 mill. mill. tt Including imports ~ % Production in mill. mill. tt Mátrai Erőmű Zrt SEITE 3

9,200 MW MW Mátrai Erőmű Zrt. 8.2 8.2 mill. mill. tt Gross power supply 42.7 42.7TWh Vértesi Erőmű Zrt. ~0.9 ~0.

4 MÁTRA 's Visonta power plant Generation: 6,300 GWh gross Equipment: Lignite 2 x 100 MW Lignite 1 x 220 MW Lignite 2 x 232 MW Gas 2 x 33 MW Input of some 10% of biomass Mátrai Erőmű Zrt PAGE 4

5 MÁTRA mining area in north-eastern Hungary 0 10 km Visonta power plant ~ 950 MW Bükkábrány opencast mine Visonta opencast mine Railway line Former mining fields Current mining operations Mining fields Mátrai Erőmű Zrt PAGE 5

opencast mine Railway line Former mining fields Current

6 Visonta and Bükkábrány lignite mines Visonta Coal production Overburden Ø overburden : coal ratio Ø calorific value Bucket-wheel excavators mill. mill. tt mill. mill. m³ m³ ~ 8 m³/t m³/t 6,800 6,800 kj/kg kj/kg 9 units units Bükkábrány Bucket-chain dredgers Spreaders 5 units units 7 units units Reliable lignite resources available for the long-term supply of the power plant Mátrai Erőmű Zrt PAGE 6

7 MÁTRA's continuous opencast mining equipment Mátrai Erőmű Zrt PAGE 7

8 Structure 1. MÁTRA Power Plant in Hungary 2. Developments in mining at MÁTRA Output Safety and environmental protection 3. Future mining developments 4. Conclusion Mátrai Erőmű Zrt PAGE 8

9 MÁTRA's mining activities: very successful trends in output and accident figures Own output (coal+overburden) in mill. (t+m³)/a Accidents in opencast mines (number per 1 mill. hours worked) ~ 40% ~ 80% Mátrai Erőmű Zrt PAGE 9

(t+m³)/a Accidents in opencast mines (number per 1 mill.

10 Positive output trend based on three crucial elements Retrofit Mátrafit Development projects > 5-year retrofit programme between 1998 and 2003 > Extensive modernization measures > Overall budget of 75 mill. Reliable basis for for dependable longterm coal coal productiotionat at a level level of of term some 8 mill. mill. t t p.a. p.a. > 5-year performance improvement programme between 2002 and 2007 > Increase in efficiency of processes and equipment Reduction in in mining costs to to retain competitiveness > Supporting projects for further development of equipment / processes > Examples: - support systems for equipment operators - new excavator Sustained and and continuous further improvement in in output and and cost cost levels Mátrai Erőmű Zrt PAGE 10

11 MT 14 compact bucket-wheel excavator sets new standards in MÁTRA's mining performance MT-9 MT-14 Δ (%) Theoretical excavation volume m³ loose /h 5,000 6, Planned annual output mill. m³ bank /y Service weight t 920 1, Driving power MW 2,000 3, Mátrai Erőmű Zrt PAGE 11

6,700 + 34 Planned annual output mill. m³ bank /y 8.

12 Aids for equipment operators to capture output and position data boost process efficiency Trend-data systems > Watching own output also relative to set output > Watching output of other equipment mining on same haulage route GPS-based support systems for operators > Slope and working level cut with GPS in exact agreement with operation schedule > High quality of working level cut, lower levelling outlays Mátrai Erőmű Zrt PAGE 12

route GPS-based support systems for operators > Slope and working level cut with GPS in exact agreement with

13 Output per employee doubled in 10 years Specific output per employee, in '000 (m³+t)/employee Own output, in mill. (m³+t)/a 80 Retrofit Mátrafit Projects MT % Mátrai Erőmű Zrt PAGE 13

(m³+t)/a 80 Retrofit Mátrafit Projects MT 14 80 60 60 40 +108%

14 Improvement in industrial safety based on three crucial elements Health protection > Prevention of workrelated diseases > Promoting healthier lifestyle (eg stopsmoking campaigns) > Medical care services offered Better personal well-being and and maintainace of of employability with with low low sick sick times Safety at work > SAFETY-FIRST campaign for avoiding accidents at work > Focus on both technical and behavioural aspects Lowering accident figures by by boosting industrial-safety awareness Incentive system > Involvement of all employees in an attractive moneypremium system > Taking account of aspects of industrial safety and health protection Staff Staff recognition and and motivation thanks to to direct monetary incentive Mátrai Erőmű Zrt PAGE 14

Focus on both technical and behavioural aspects Lowering accident figures by by boosting industrial-safety awareness Incentive system > Involvement of all employees in an attractive

15 Stimulus programme received very positively by employees Cornerstones of the stimulus programme > Annual premium disbursement with mediafriendly drawing of lots > Amount in the premium pot depends amongst others on industrial-safety savings > Preconditions for participating in draw: no suffering or causing of accident at work no breaching of industrial-safety rules no excessive sick times Mátrai Erőmű Zrt PAGE 15

on industrial-safety savings > Preconditions for participating in draw: no suffering or causing of

16 Focus of industrial safety programme on technology and behaviour Examples of technical measures > Replacing or facilitating manual work thanks to machines (eg auxiliary equipment for cleaning conveyor belts) > Continuous improvement in personal protection equipment Examples of behavioural measures > Regular workshops, training schemes and breefings SAFETY-FIRST > Thorough communication and processing of accidents and near-accidents > Integration of 'safety' as subject into regular discussions and events Mátrai Erőmű Zrt PAGE 16

Examples of behavioural measures > Regular workshops, training schemes and breefings SAFETY-FIRST > Thorough communication and

17 Accident frequency down > 80% in 10 years Accident trend (LTI), in accidents >1 day downtime per 1 mill. hours worked % Opencast mines, total Visonta mine Bükkábrány mine Mátrai Erőmű Zrt PAGE 17

hours worked 25 20 15 10-84% 5 0 2000 2001 2002 2003 2004 2005 2006

18 Protection of the environment and surroundings as elementary components of mining activity Recultivation / design of the post-mining landscape > Creation of 925 ha forestry and agricultural surfaces in last 15 years Protection from air pollution and noise > Deployment of lower-noise drives, sound-absorbing hoods, etc > Inclusion in planning (building embankments) Water management > Deployment of computer-based groundwater models to limit drainage amounts > Using the raised water (power plant, population) Mátrai Erőmű Zrt PAGE 18

of lower-noise drives, sound-absorbing hoods, etc > Inclusion in planning (building embankments) Water management > Deployment of

19 Structure 1. MÁTRA Power Plant in Hungary 2. Developments in mining at MÁTRA Output Safety and environmental protection 3. Future mining developments 4. Conclusion Mátrai Erőmű Zrt PAGE 19

20 Securing the future requires further development Concept for continuous improvement in mining R&D projects Experts Processing of comprehensive improvement projects or developments with basic-research character Medium- and long-term further development of components and processes by "experts" Improvement teams, working committees Weak-spot analysis Working out and implementing improvements for defined sets of items in teams Identifying weak spots with improvement potential based on systematic analyses Mátrai Kraftwerk G. AG SEITE 20

and processes by "experts" Improvement teams, working committees Weak-spot analysis Working out and implementing improvements for

21 Securing economic efficiency and competitiveness based on four main fields of action Plants > Identifying and remedying weak spots > New technologies and materials > Boosting output and lowering operating costs Environment > Further development esp. of standards for recultivation and for protection from pollution (noise/air) > Important element for ensuring acceptance Processes > Analysis and optimization of processes, specifically weak-spot analysis > Increasing utilisation and efficiency of own resources Industrial safety > Further enhancing of health protection and industrial safety standards > Permanent task, irrespective of successes posted Mátrai Kraftwerk G. AG SEITE 21

22 Structure 1. MÁTRA Power Plant in Hungary 2. Developments in mining at MÁTRA Output Safety and environmental protection 3. Future mining developments 4. Conclusion Mátrai Erőmű Zrt PAGE 22

23 Successes in recent years form basis for future developments Lignite mining at MÁTRA Power Plant looks back on very successful developments in recent years Specifically output and efficiency as well as industrial-safety and environmental standards were given a definite boost Thanks to these developments, it has been possible to solidify domestic lignite's position in Hungary's energy supply Lignite is available domestically in the long term and can be reliably mined at low, dependably calculable costs Lignite mining will be facing huge challenges, specifically due to the tightening CO 2 regime after 2013 Increases in output and efficiency as well as industrial safety and environmental protection remain ongoing tasks, therefore Mátrai Erőmű Zrt SEITE 23

24 Thank you very much for your attention! MÁTRAI ERŐMŰ ZRT. Mátrai Erőmű Zrt SEITE 24

LUSATIAN LIGNITE MODERN, COMPETITIVE AND SUSTAINABLE LIGNITE MINING. 1. Introduction and summary. Wolfgang Ketzmer*

Górnictwo i Geoinżynieria Rok 31 Zeszyt 2 2007 Wolfgang Ketzmer* LUSATIAN LIGNITE MODERN, COMPETITIVE AND SUSTAINABLE LIGNITE MINING 1. Introduction and summary Since May 2004, Vattenfall Europe Mining