Remnant Coal Detection System

This paper describes the development and successful implementation of a system designed to detect coal deposits remaining in coal train wagons after unloading (dumping). These undesirable coal deposits constitute both small residual amounts of “carryback”, but also larger “hang-ups” of significant volume that have failed to discharge. The system was originally developed simply to detect and record volumes of carryback, as part of an effort to characterise the extent of the problem for the coal transport industry, but was then enhanced to provide real-time feedback of large hang-ups so that they could be discharged prior to the wagons exiting the dump station. The paper describes the hardware and processing systems used in the system, including the different strategies employed to ensure a reliable detection system. The system has now been installed and operated in a production environment at three dump stations across two different coal terminals, and a case study of the results from one of these dump stations is presented. Automating remnant coal detection at dump stations provides short interval control to minimise potential hazards and downtime, and historical data that may be integrated into existing data platforms and analysed for productivity, environmental, and safety planning insights.