Mining quality coal requires high quality equipment

Atlas Copco turbocompressors at Dalkia Industry CZ

Dalkia
Industry CZ
Mining quality coal requires
high quality equipment
In 2005, when it came time to replace
the turbo compressor at the ČSA
mine, employees of OKD simply had to
formulate their requirements.
They wanted equipment with the lowest
operating and service cost, and at the
same time a supplier they could rely on
long-term.
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Extracting violently explosive
methane and at the same time
providing oxygen for miners
working up to a kilometre below
ground. For OKD, machines from
Atlas Copco were up to the job.
Thanks to 20 turbocompressors,
Dalkia Industry CZ, a.s. annually
produces 2.4 billion cubic metres
of compressed air for the miners
there. What‘s more, waste heat
that develops during compressed
air production is used to heat
water for employee use.
Six years, 20 new
turbocompressors
Dalkia Industry CZ already has previous
experience with Atlas Copco machines,
thanks to the ČSA mine, where the
collaboration started six years ago.
Currently a total of 20 Atlas Copco
turbocompressors assist OKD miners.
In the end, it was necessary to replace
the equipment at all active mines. The
final six compressors were ceremonially
put into operation at the ČSM mine
in summer 2011. In most cases, this
involved replacing the original ČKD
turbocompressors, some of which had
been operating for more than 50 years.
Compared to the new, technologically
advanced equipment, they were obsolete
and took a lot of energy to run. This made
the large investment for new machines
necessary. Besides greater safety, the
modern turbo compressors also gave
Dalkia Industry CZ an advanced control
system with the lowest possible stress on
the environment.
However, the main benefit is low energy
consumption and automatic operation.
„It‘s enough to inspect the machines
once or twice a shift, which takes about
15 minutes. The old equipment required
constant attention,“ explains Martin
Mikula, manager of major projects at
Dalkia Industry CZ. That alone meant that
the new turbocompressors saved a lot of
money, he says. „Generally, the return on
investment at a given location takes less
than two years,“ he adds.

A compressor is a machine that

compresses gases and steam.
Compressors can be volumetric or
dynamic.
A dynamic turbocompressor is
a device that compresses gases and
steam by converting kinetic energy
to pressure energy. The kinetic
energy is delivered by impeller and
changes to pressure energy in the
compressor‘s diffuser.

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It delivers air, removes methane
and even heats water
„For work in mine shafts, compressed
air is absolutely key for operational and
safety reasons.
Every black coal deposit contains
dangerous methane. It is violently
explosive and also lighter than air.
When tunnelling passages that air can‘t
get through, ventilation pipes with fans
are needed to exhaust not only used air,
but some methane at the same time. And
compressed air is the safest propulsion
medium for fans, thus keeping the
explosion hazard to a minimum. Besides
fans, in mine operation other equipment
is run by compressed air, such as
drilling machines, transport gates, pick
hammers, hand tools and much more.
The mines even use waste heat from
production of compressed air to heat the
water used in the miner‘s showers.

Atmospheric
air

Input power Output energy

electrical energy hot water

Compressed
air

When reusing energy recovery, all 20 machines can produce up to

87 million kWh of heat per year. That‘s enough, for example, to heat
about 2,700 family homes.

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One turbocompressor can heat
up to 13 m3/h by an unbelievable
30°C more.
Thus up to 45 percent of the
energy consumed for producing
compressed air can be reused.
Installation didn‘t shut down
operation
Not only was the process of replacing
20 machines in the four north Moravian
mines gradual, it also wasn‘t easy.
Hundreds of hours of preparation and
the involvement of dozens of people
required perfect coordination.
In the end, it was possible to install
the new turbocompressors without
limiting the mines‘ operation. OKD never
had to shut down mining operations
because of us. We always adapted to
the possibility of operation, and the most
demanding tasks were done during
downtimes planned for other technical
reasons,“ says Jan Stařičný of Atlas
Copco. However, some operations, like
connecting pipes or high voltage could
not be done during full operation.
Of course, the mine employees didn‘t
even notice most of the replacement
work. „The shafts had always been
equipped with a large number of
turbocompressors, of which at least one
was a standby. So, in relative peace, we
were able to dismantle some equipment
and install new machines in its place,“
Stařičný adds.
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Continuous monitoring

All new stations are equipped

with continuous remote
monitoring through a central
Atlas Copco server, which
eases access to operating
information. Actual service
is done just as in other
operations, based on hours
worked. The basic period is
8,000 operating hours.
Of course, for turbocompressors in 24,000 operating hours. Under OKD‘s
particular, the first somewhat more conditions, that means about three
extensive service is recommended after years of operation.

Service support is needed

Service is performed by technicians

with appropriate qualifications and
many years of experience. „In the
Moravia region, we now take care
of 28 turbocompressors, so we have
employees who specialize exclusively
in these specific installations, control
and monitoring,“ says Tomáš Příhoda,
Atlas Copco head of service.

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„From a quite simple installation at the
Karviná-ČSA mine, we worked together
on sophisticated installations at the
Paskov and ČSM locations. The investor‘s
employees played an indispensable
role in this development. They gradually
increased and more and more deeply
specified their requirements for each part
of the installation,“ he adds.
It is absolutely indispensable that every
compressor station is supported by
a professional service organization.
The money spent would be wasted
if observing regular service intervals
and the manufacturer-recommended
procedures were not observed, and
if original replacement parts were
not used. Regular service ensures
quick return on investment, a reliable
compressed air supply, low operating
cost and long equipment life.
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All mines needed a change
The first turbocompressor, replaced
at the Karviná-ČSA mine in 2005,
launched a multi-year collaboration
between Atlas Copco and Dalkia
Industry CZ. At the time, this involved
trial replacement of obsolete ČKD
brand turbocompressors. „During
several months of operation, the
new ZH 10000 machines convinced
everybody that replacing the old
machines was really effective and had
economic significance,“ remembers
Stařičný.
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Therefore, the very next year, Dalkia
Industry CZ decided to replace
10 more turbocompressors. Atlas
Copco again won the tender. At
the Karviná-Lazy mine, three more
ZH 10000 turbocompressors were
installed, including an external
cooling tower, a plate heat exchanger
and several pumps. The delivery
also included a replacement diesel
generator and four screw compressors
for mining machines.
However, the two companies anticipated
that the hardest task would be replacing
the equipment at the Karviná-ČSA mine.
„In this first series, the compressor
station here was the most elaborate, the
most complicated and at the same time
the most demanding. Three ZH 15000
turbocompressors were delivered
and installed with a complete cooling
system, double plate heat exchangers
The Darkov mine needed another four
ZH 15000 turbocompressors. All but
one were machines with hot air output
(for cleaning capability during operation),
with double pumps (operating and
backup), and especially a system for using
waste heat for warming utility water,“
Stařičný explains. He says that one of
the characteristics of this installation
was the need to dismantle all three
turbocompressors into smaller units, move
them through an installation hole at the site
and reassemble the turbocompressors.
without after-coolers. The original
after-coolers are used to heat utility
water.
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The other mines waited until 2011
for their new equipment. The
Paskov mine awaited two ZH 15000
turbocompressors, each using 1,250 kW,
and one ZH 15000 requiring 900 kW.
Delivery also included systems with
energy recovery for heating utility
water.
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The ČSM mine was the last to get
its modernized equipment. Atlas
Copco delivered six ZH 15000
turbocompressors, each using
1,250 kW. Again, all compressors will
preheat utility water. The ceremonial
start-up of the last station took place
in August 2011, and thus ended the
replacement of all compressed air
sources at all of OKD‘s active mines.
Water cooling system
All Atlas Copco turbocompressors
serving the north Moravian miners have
a water-cooled design. For just one of
the Paskov mine locations Chlebovice,
Atlas Copco also provided two dry
Alfa Laval coolers, each with a 630 kW
capacity. „There was no cooling tower
available here, and in this case not even
Complete monitoring
At each site there are control systems
Atlas Copco ES 130 T that, as needed,
regulate the turbocompressors,
control the IGV regulation valve,
alternate operation of individual
water for cooling,“ Stařičný explains,
adding that at the other sites the original
atmospheric cooling towers were used
for preparing water for cooling.
„Only at the Karviná-Lazy mine did we
also install a closed cooling tower with
a spraying system. And at one of the
Karviná-ČSA sites, it was necessary to
install a traditional micro cooling tower
with an open cooling circuit,“ he adds.
turbocompressors and monitor the
entire compressor station.
And backup turbocompressors are
a given at all sites. At all sites, most
of the turbocompressors were ČKD or
Škoda models.
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All-in-one delivery
All turbocompressors that now
supply compressed air in north
Moravia have been chosen
with the demands of the mining
industry in mind. The main
requirement is sufficiently large,
stable output, pressure of 4 to
4.5 bar and undried air, no hotter
than 60°C.
The amount of compressed air
OKD needs depends on the size
of the mining field, the number of
work sites, the number of „stories“,
and the amount of coal extracted.
„The smallest amount is now at
the Karviná-Lazy mine, where we
deliver about 20,000 to 24,000 m3/h.
On the other hand, at the ČSM mine,
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the installed compressors‘ output is
90,000 m3/h,“ Mikula says.
All ZH 10000 and ZH 15000
turbocompressors are water-cooled,
two-stage centrifugal air compressors.
Atlas Copco delivers them as a complete
unique package with all components,
internal pipe systems and connections.
They include a horizontally-split gearbox
with two compression stages, a high
efficiency electric motor with lubrication
and a cooling and regulation system. All
of the mentioned equipment is installed
in a complete and integrated package
and ready for immediate operation.
The innovative Atlas Copco ZH line
turbocompressor — an industrial
solution featuring plug & run type
centrifugal compressors — is ready for
immediate operation.
Main part of a ZH turbocompressor

Inlet guide Electrical

vanes Modulating cabinet
blow-off
Controls valve Compressor
and actuator core

Blow-off Oil
silencer demister

Inlet silencer
& filter Motor

Cooling
water
manifold
Canopy

Oil tank
and
ancillaries
Intercooler
Frame
aftercooler

Oil
cooler

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 Dalkia
Industry CZ
Dalkia is one of the most important energy groups in the Czech Republic. It has
operated there since 1991 and has gradually positioned itself as a leading producer
and distributor of heat and electrical energy for the Czech market. Currently, the Dalkia
group in the Czech Republic employs almost 2,500 and consists of eight companies:
Dalkia Czech Republic, Dalkia Kolín, Dalkia Mariánské Lázně, Olterm&TD Olomouc,
AmpluServis, and since 2010 also Dalkia Industry CZ (originally called NWR Energy)
including their two companies Dalkia Commodities CZ (originally CZECH-KARBON) and
Dalkia Powerline (formerly NWR Energetyka Polska).

For Dalkia itself, Dalkia Industry CZ serves as a worldwide standard in the mining
industry, because it delivers and distributes electrical energy and produces hot water
and compressed air for coal extraction in mines belonging to OKD, the largest mining
company in the Czech Republic. Other clients of Dalkia Industry CZ include public
sector entities.

Dalkia got acquainted with Atlas Copco technology immediately upon entering the
Czech market. It bought a number of heating plants that had been using Atlas Copco
compressors since the 1990s. Five of them served at the Ostrava and Olomouc
production sources, which belong to Dalkia Czech Republic.

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Atlas Copco is an industrial group with world-leading positions in compressors,
expanders and air treatment systems, construction and mining equipment, power
tools and assembly systems. With innovative products and services, Atlas Copco
delivers solutions for sustainable productivity. The company was founded in
1873, is based in Stockholm, Sweden, and has a global reach spanning more than
170 countries. Atlas Copco’s Compressor Technique business area provides industrial
compressors, gas and process compressors and expanders, air and gas treatment
equipment and air management systems. It has a global service network and
offers specialty rental services. Compressor Technique innovates for sustainable
productivity in the manufacturing, oil and gas, and process industries. Principal
product development and manufacturing units are located in Belgium, Germany, the
United States, China and India.

Oil-free Air is a division within Atlas Copco‘s Compressor Technique business area. It
develops, manufactures, and markets worldwide oil-free and oil-injected air and gas
compressors combined with air and gas treatment systems. The division focuses on
sustainable solutions for all kind of industries where the gas quality is critical to the
production processes. The divisional headquarters is located in Shanghai, China, and
the production centers are in Antwerp, Belgium; Wuxi, China; Pune, India and São
Paulo, Brazil.

In the Czech Republic, Atlas Copco offers all compressed air users a complete
product line, repair and maintenance services, and rental services, through
a broad network of business partners and service technicians. The company is
headquartered in Prague, with branches in Brno and Ostrava.

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Thank you!
This publication is dedicated to everyone who contributed to the
Atlas Copco compressor project at Dalkia Industry CZ. Although
technological progress may march on, there is still no replacement for
human work. It is people‘s determination, commitment, diligence and
enthusiasm that move us forward and help us reach our company‘s
goal of sustainable development.

Special thanks also go out to our subcontractors, who significantly contributed

to installing the new stations at OKD. Only thanks to their flawless cooperation
could all projects be properly realized. Key subcontractors included IPT and
AUTEL-montáže. Further significant contributors were partners like MONT
Karviná, Autel, DISAM RT and VKS Havířov.

Published by Atlas Copco s.r.o. The photographs and text

can be printed and otherwise distributed only with the
www.atlascopco.cz written consent of Atlas Copco.