EYNEZ EAST UG COAL MINERisk Management Program

Hacı KARAKUŞ

HSEC Manager – Demir Export A.Ş.

December 2014

DEMİR EXPORT – FERNAS JV

Eynez East Coal Mine Introduction

Risk Assesment Methodology

Major Hazards

High Risk Areas

Risk Treatment Plan

Conclusion

Contents

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• Eynez East UG Coal Mine is located in the vicinity of Eynez village,

35 km South of Soma; 106 km North of Manisa City.

• Eynez East is on the TKI concession of Soma Basin.

• Demir Export – Fernas JV (DEF) to all required surface and

underground facilities to produce 2.5 million tonnes per year over

16 years of mine life.

• Coal seam is 22-29 thick, brown coal (lignite)

East Eynez Coal Mine

Introduction

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East Eynez Coal Project was tendered out by Turkish Coal Enterprises (TKI)

in 2011.

DEF started field work in May 2012.

Project Schedule:

2012-2015 : Mine Development Period

2015-2016 : Start-up and ramp up period (1.5 Mtpa)

2016-2030 : Full production (2.5 Mtpa)

Selected Mining Method:

Longwall Top Coal Caving for safety and production capacity

Introduction

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45 exploration drillholes were done by MTA for TKI. In addition DEF have done 8

more drillholes to develop 3D resource model for mine design and planning

purposes.

Eynez

Village

Pillar (to

protect Village)

Open Pit

Mine (TKI)

Drillholes

Locations

New drillholes were drilled;

• To improve coal reserve

• To validate the formations

• Collect geotechnical data

• Collect data for gas content

• Detailed mine plan

Introduction

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Main Gallery

Ventilation Gallery

Production Panels

Coal Blocks

Infrastructure

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Fully mechanized longwall top coal caving mining

method (LTCC)

Infrastructure

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Coal and Personnel Transportation

• Coal will be transported to surface through belt conveyors. All belt conveyors convey to

international coal mining standards ,1200 mm wide and flame proof. Main haulage belt is steeel

supported while others are solid woven belts.

• People who work in the mine and equipments mainly transported to work areas through mono rail

system.

Infrastructure

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Linear Development

• 13 production panels will be mined out over life of mine, for all panels total

maingate and tailgate roadways will reach 45.000 meters through LoM.

• Advance of the ventilation drift is 1716 m, by mid of Nov. 2014

• Advance of the main haulage drift is 1580 m, by mid of Nov. 2014

Infrastructure

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Longwall Top Coal Caving Method:

Each coal level is divided into

two sections (upper and lower

excavation section)

The lower section is 3,5 m

high and secured by the

hydraulic support system, coal

is produced by shearer.

The upper section 5 to 10 m in

height, is exposed to dynamic

stress conditions due to

crumbling of the coal layer.

To sum up, 70% of Coal

production will be provided by

free-falling and 30% by

shearing.

Mining Method

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WHY LTCC?

Mine Safety

• Lower face heights result in improved face control, smaller and less

expensive equipment and improved spontaneous combustion control in thick

seams, through removal of the majority of top coal from the goaf.

Resource Recovery and Mine Financial performance

• The LTCC method enables extracting up to 90% of seams in the thick coal

seams.

Operating Cost

• Since only 30% of coal is cut and the rest is free caving coal, operating cost

for LTCC is typically lower than classical longwall operation.

Mining Method

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Production equipment

• Shearer

• Hydraulic Shield Support

• Front AFC (armoured face conveyor)

• Rear AFC

Hydraulic Shield Support

Longwall Equipment

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Haulage and Transport Equipment

• Conveyors

• Armored Chain Conveyor

• Belt Conveyor

• Monorail

• Diesel Monorail

• Shunting Trolley

Belt Conveyor Chain Conveyor Monorail

Equipment

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Face/drift Development Equipment

• Roadheader

• Tunnel heading and loading machine

Roadheader Tunnel Heading and Loading Machine

Equipment

• The site team have carried out a Broad Brush Risk Review (BBRR)

for Eynez East Underground Coal Mine. The key objectives of the

BBRR are to :

1. Identify the groups of major hazards those require detailed risk

assesment by using bow tie analysis method.

2. Confirm the qualitative risk priority and

3. Provide a list of hazards that engineering and safety personel can review

to ensure there are currently policies, procedures and strategies in place

to control these hazards.

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Risk Assessment

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• The Bow Tie method is used extensively in hazardous industries

• Forms the basis of the risk assessment

• Focus is on:

• What can go wrong and why? Causes/Threats/Hazards

• How do we prevent it? Preventative Controls

• If we do lose control, how do we limit the effects Reactive Controls

• A Bow Tie model is developed for all the identified “major hazards” which includes

specific hazards for the Eynez East Underground mine under Enyez Village

Risk Assessment

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Loss of Control

Preventative Controls

ReactiveControls

Outcomes

Near Miss

Minor Loss

Major Loss

Catastrophic

Causes/ Threats

Hazard 1

Hazard 2

Hazard 3

Hazard 4

Hazard 5

The focus is on the hazards and controls

Risk Assessment

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Gas About to

Ignite

Preventative Controls

ReactiveControls

Outcomes

Near Miss

Minor Loss

Major Loss

Catastrophic

Causes/ Threats

Gas

Electrical Equipment

Failure

Gas Drainage

Auto shut down of

equipment

Withdraw personnel

Gas monitors

Ex Rated Equipment

Equipment maintenance

Everyone has responsibilities for the controlsnot just Safety people

Emergency Response

Risk Assessment

✓ By its definition, major hazards have the potential, if not controlled

effectively, to result in catastrophic outcomes therefore all are considered

high risk (high consequence even if the likelihood is very low) and

therefore all require detailed analysis to develop risk treatment plans to

reduce the risk to ALARP (As Low As Reasonably Practicably).

✓ Team workshops were then conducted on the high risk areas,

✓ Major Hazard = those hazards which have very high consequence (eg)

multiple fatalities or significant loss (immediate or over time)

✓ 22 major hazard groups were identified.

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Risk Assessment

The top 10 Major Hazard groups were identified for review process are:

1. Spontaneous Combustion

2. Strata Instability

3. Gas Explosion

4. Entanglement, Conveyors, Caught in and Struck By Equipment

5. Inrush / Inundation

6. Emergency Response

7. Electricity

8. Carbon Monoxide (CO) / Gas Asphyxiation / Atmospheric Contaminants

9. Underground fire

10. Airblast

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Introduction

• The residual risk of spon com, gas explosion, and strata failure are still

high because the level of consequence is still extreme should an

unwanted event occur. Risk level can be reduced through the effective

implementation, monitoring and review of the risk treatment plan.

Managing the controls at all times is critical during operation.

• The Risk Treatment Plan (RTP) for spon com, strata and gas explosion

was the starting point only and it is reviewed and updated by technical

specialists with more information obtained and analyzed. The plan is

based on the input from the team members with the information and

understanding of the risks at the time. This may require review and change

in the future if required.

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Risk Assessment

• Strata instability / failure :

• The team identified and defined 15 hazards that need careful consideration by

technical personnel and specific controls. Additional recommendations were made

to improve the adequacy of the current and planned controls. Critical controls

included development of ;

• Strata Control Management Plan,

• Cave Management Plan,

• Subsidence Management Plan, and

• An effective mine design,

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Risk Assessment

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Eynez

Village

Pillar (to protect

Village)

• Mining affects on Eynez Village

• Subsidence and strata affects

• Vibration

• Water loss or impact on water quality

Risk Assessment

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Open Pit Mine

(TKI)

• Mining near to or underneath an operational open cut mine

• Water inrush if flooded

• Blasting

• Pillar and strata issues

Risk Assessment

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• Mining next to old underground workings

• Water inrush if flooded

• Pillar and strata issues

Risk Assessment

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• Mining through faults

• Pathways for water and gas

• Pillar and strata issues

• Longwall operations difficult (eg) slow advance which leads to

deteriorating strata conditions in gate/tail roads

Risk Assessment

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• Mining in thick seam and use of LTCC

• Caving issues (eg) mudrush (fines and water in goaf / cave zone)

• Pillar and strata issues

• Longwall operations difficult

• Spon com

Risk Assessment

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• Gas – high gas concentrations

• Gas explosion

• Effects on strata instability (eg) coal outbursts

• Asphyxiation

• Lower coal seam interconnectivity and through faults

• Fire

• Carbon Monoxide

• Effects on ventilation flows

• Spontaneous Combustion

• The coal has a high propensity for spon com

• Goafs

• CO inflows to other areas

Risk Assessment

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Additional controls were developed throughout the hazard identification section of the risk

assessment with a focus on the hierarchy of controls as depicted in the figure below.

Hierarchy of Controls

1. Eliminate the Hazard

2. Substitute / Minimise

3. Engineering Control

▪ Redesign

▪ Enclose

▪ Isolate

4. System Controls

▪ Safe Work Procedures

▪ Training

▪ Warning Devices

5. PPE (last line of defence)

Risk Assessment

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• At Eynez East Coal Mine three major hazard groups were identified.

• DEF internal control procedures and applications are developed.

• DEF Team suitably being trained.

• DEF Management Commitment, DE vision covers these major risks

• DE Safety Management Plan and applications covers the risks.

• Outside Services and Studies for Spon Com, Strata and Gas explosion

• Purchasing fit for purpose systems to reduce the impact of risks.

• Continuous training, monitoring and auditing.

• Reporting all incidents and accidents.

• Proactive HS applications.

Conclusions

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THANK YOU