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ABSTRACT
Advancements in quality control at the mine site, and throughout the entire quality chain from production to
consumption, have been made in technology and automation. These have improved sample collection and
analysis processes. However, the basic purpose of quality and quantity monitoring, control and verification, which
is ultimately to provide information for risk management, has not changed.
• If calorific value is the main parameter be used and documented, and the OLA
to be measured, does the dry ash-free data collection must be in accordance
calorific value remain fairly consistent? with the manufacturer’s procedures.
During sample collection the actual coal
SGS provides a guide for planning the source, seam mineralogy, etc. should
calibration test procedure, verifying the be recorded and compared with the
calibration itself and conducting an OLA optimal or design conditions. In general,
performance test. The source document calibration samples are collected after a
is ASTM D6543. Key elements are the period of time established in conjunction
reference methods for sampling, sample with OLA manufacturer. During this initial
preparation and analysis, which must period, the manufacturer confirms that
be established and used consistently, the OLA and related software are fully
Double-roll crusher outside One additional key aspect is that the operational.
laboratory used for routine quality
ago did not have the same impact as assurance should also be used for VERIFICATION TESTING
the innovations in mechanical sampling calibration. Once the calibration parametes are
during this period. This is because initially instlaled in the analyser, verification
the use of the OLA was extremely During normal use, an OLA can be samples are collected in the same
limited, due to a lack of standardization compared to various routine samples, manner as outlined above, in order to
of the calibration process, which such as shift samples or other samples confirm that the calibration paramters
is essential for an OLA to produce collected by the sampling system. are correct. Once the verification
meaningful results. OLA instrumentation These routine samples can be used to is complete, the OLA is ready for
has improved over the years as have the construct control charts that provide performance testing.
calibration procedures. OLAs are now an indication of the status of the OLA
routinely installed and operated at mines, calibration. However, when needed, the PERFORMANCE TESTING
washing plants, load-out facilities and one hour reference method is used to Performance test samples are collected
elsewhere, but specifically as process make calibration adjustments. in the same manner as the calibration
control devices. and verification samples. One of the
ONE HOUR REFERENCE recommended methods for performance
The following questions should be asked METHOD testing (in ASTM D65443) is the Grubbs
to determine if an OLA is suitable for a test, which requires the collection of
particular installation: CALIBRATION TESTING 60 test sets. This test also required an
• Do the economics of the process The coal flow, moisture variations and independent sample to be collected from
control at this site justify the cost of an other conditions that can have an effect the coal flow, which can be extracted
OLA? on the coal stream or coal characteristics from one of the reject streams within the
• What are the parameters that can be must be reviewed. The number of mechanical sampling system.
controlled? For example, ash or sulphur. seams, coal types or blends to be used
• If blending is a goal, are the feeders in the test must be established, and DATA EVALUATION
responsive and scales installed for the widest range of ash and sulphur Calibration data must be reviewed and
each blend source, as well as the final values must be selected. The mechanical calibration parameters established by the
product stream? sampling system should be inspected manufacturer. The manufacturer must
• Which parameters are for contract and its bias test data must be reviewed. also review verification data. However,
purposes, but do not have to be Additionally, the suitability of the onsite the performance test data should be
analysed in real-time? sample preparation facilities must be calculated and reviewed independently.
• What degree of accuracy is needed for evaluated and corrective action taken if
the process control? necessary. REFERENCE BLOCK TESTING
Corollaries to the process control The one hour sample collaction period A routine evaluation method for OLA
accuracy include the following: must be synchronised with the OLA utilises ‘reference blocks’. This eliminates
• Is it well known that the calorific value, computer clock. This should take into the effect of comparison to routine
volatile matter and sulphur dioxide are consideration the lag time for the sample analysis or the reference
not directly measured, but calculated mechanical sampling system to process sampling and analysis method. The
from other elements? the sample (the one hour collection reference blocks, provided by the
• Are the limitations of microwave period must be a full hour of coal flow). manufacturer, are comparative tools
technology for moisture determination The sampling system should be set that are placed in the analyser’s path
understood, particularly regarding to collect at least the sample mass (between the source and detector). The
inherent moisture changes or specified in the standard during one hour analyser is set up to interrogate the block
differences? test periods. All of the proper protocols with a ‘raw’ calibration, which does not
for sample preparation and analysis must change when it is re-calibrated.
SGS MINERALS SERVICES TECHNICAL BULLETIN 2003-10 3
The interrogation period is usually • ASTM D6518: Standard Practice Conceptually, a bias test on a coal
four hours or as directed by the OLA for Bias Testing a Mechanical Coal mechanical sampling system is a simple
manufacturer. or as directed by the OLA Sampling System. comparison of the material extracted
manufacturer. It is advisable to read the by an MSS to the material from which
calibration blocks before and after source It is impossible to design an effective it was extracted. However, in practice
refreshment to provide a temporary mechanical sampling system (MSS) the bias test is complicated by the
analyser calibration adjustment prior to without knowing detailed information existence of various statistical models,
its updating via the reference method. about the characteristics of the material experimental designs, and interpretive
The objective of reference block testing to be put through the system and techniques. However, in this instance
is to determine whether the analyser where the system is to be installed. it is inappropriae to itemise the various
is stable with respect to the last block The following points are some general options available for bias testing
reading and/or historical information. rudimentary requirements for the design programmes. During a bias test, the
The reference blocks are not used to of MSS: samples collected by the mechanical
calibrate the analyser. Optimal use of the • Apertures of cutters, chutes, etc. must sampling system are compared to
reference block should be verified with be at least 2.5 times the top-size of the reference samples, which are typically
the OLA manufacturer. material. collected from a stopped conveyor belt
• There must not be any choke points (‘stopped-belt’ samples).
PERFORMANCE OF within the system. The construction
MECHANICAL SAMPLING
SYSTEMS
and demonstrate that the device is the mechanical samplying system is This is the reason the weight (mass) of
consistent from day to day. A common operating in the same manner as during the sample produced by the mechanical
method for monitoring and controlling its last bias test. Conventional wisdom sampling system for every 1000 t of
the MSS performance on an ongoing indicated that if there are no changes to coal should be routinely determined and
basis is the critical inspection together the extraction ratio, then it is reasonable plotted on SPC charts. This promotes
with statistical process conrol (SPC) to assume that there is no fundamental the continual real-time monitoring of the
charts. change in the operating or bias condition MSS performance.
of the MSS. Individual and moving range
Since there are many different types SPC charts are used for this purpose. CONCLUSION
and designs of mechanical sampling Where there is a deviation beyond a pre-
systems, which utilize a variety of determined action limit, an investigation Clearly, there have been advancements
different components, it is not possible in to the cause of the excursion is in technology, automation and
to provide a critical inspection procedure conducted. standardization involved with coal quality
that will be universally appropriate. monitoring, control and verification.
However, the following general Plotting and monitoring individual and These improvements have been
requirements are offered: moving range SPC charts charts allows significant and provide better information
• An experienced inspector must be the control of the two fundamental on which to base risk management
perform the critical inspection. characteristics of any process decisions.
• There must be a report that records distribution; its centre and its range.
each critical inspection.
• Corrective action (or preventice action)
requests must be prepared when
problems are encountered.
• Maintenance requests must also be
part of the critical inspection report.
• All corrective, preventive or
maintenance requests must be
followed-up to ensure compliance.