United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Cincinnati OH 45268
Research and Development
EPA-600/S7-80-169 Dec. 1980
Project Summary
The Environmental Impact of
Coal Transfer & Terminal
Operations
L Pelham
U.S. Environmental Protection Agency
R- .*'on V, Library
'< , South Dearborn Street
Cii.cr.go, Illinois 60604
This EPA study was conducted to
assess current environmental impacts
and to define potential control tech-
nology that will minimize the pollution
resulting from coal transfer operations
and transfer terminal operations. This
document compares and evaluates
potential control technologies that
may be employed. Major sections are
as follows: (1) discussion of the major
differences between western coal and
lignites, and midwestern or eastern
coals; (2) description of coal transfer
operations and transfer terminal facil-
ities; (3) discussion of potential
environmental impacts associated
with transfer operations and terminal
facilities; and (4) review and assess-
ment of environmental controls that
are employed or available for control-
ling pollutant sources resulting from
coal transfer operations and facilities.
Environmental impacts can be
lessened by employing proper control
methods. Specific control methods
are applicable to each site and opera-
tion, and should be incorporated into
the early stages of planning and
design.
U.S. coal transportation methods
can be described in four major cate-
gories: railroads, barges, trucks, and
miscellaneous (i.e., tramways,
conveyors, and slurry pipelines).
A relatively new addition to coal
handling is the rail-to-barge or rail-to-
ship transfer (transshipment) facility.
Rail-to-barge facilities are used
increasingly for moving western coal
to points along the Mississippi River,
across the Gulf of Mexico, and to
foreign countries (i.e., across the
Great Lakes to Canada). A recent spin-
off of barge transport is the barge-to-
barge transfer method used for
conveying coal from one size barge to
a different barge or ship for transport.
Similarly, facilities have been
proposed to transport coal from slurry
pipelines to wet barges and to ocean-
going vessels. Such facilities do not
yet exist; but, they have been
proposed and the technology is
available.
Description of Facilities and
Operations
Western coal and lignite deposits are
located in the Northern Great Plains and
Rocky Mountain coal provinces. Since
these resources are remotely located,
they have not been given high priority
for development and use. Eastern coals
have been used instead because of their
convenient locations near consumers.
However, with the advent of the Clean
Air Act, it has become increasingly diffi-
cult to burn high sulfur-content
(Eastern) coals. Statistics have
indicated that, as an alternative energy
source, western coal and lignite ship-
ments will have to be increased in order
to meet mid-western and eastern
energy and clean air requirements.
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Transfer Operations and
Terminal Facilities
Transfer facilities are custom-
designed according to site-specific
requirements and conditions. These
conditions include, but are not limited
to, the following: the quantity and
quality of coal handled, the incoming
and outgoing modes of coal transporta-
tion, the physical size and shape of the
site, the function and orientation of the
site as a whole, meteorological condi-
tions of the site area, and economics.
Two major transfer points at
underground coal mine sites are: (1)
transfer from the device that brings coal
out of the mine to the mine site stockpile
and (2) transfer from the mine site
stockpile to the transport device that
carries the coal from the mine site.
Transfer facilities associated with
transfer operations usually include a
type of stockpile (e.g., open stockpile,
silo hoppers) and a loading system (e.g.,
loading tunnel).
Underground
Mine
Mine Site
Stockpile
Truck
Train
Conveyor
Tramway
Transfer operations involved in
surface mining include: (1) transfer
from the mining device to the onsite
transport device; (2) transfer from the
onsite transport device to the mine site
stockpile; and (3) transfer from the mine
site stockpile to the transport mode that
carries the coal from the mine.
Truck
Surface
Mine
Mine Site
Stockpile
Conveyor
Truck
Train
Conveyor
Tramway
Conveyors are used to move coal at
underground mines, in coal stockpile
and storage areas, and for loading and
unloading. Conveyors are also used to
move coal short distances, generally up
to about 15 kilometers (km) (10 miles).
Movement from mines to nearby
barge/ship loading facilities and from
mines to electric power generating
plants are just two examples of short
distance use of conveyors.
Conveyors have been proven techni-
cally feasible and have been considered
for long distance overland coal trans-
port and for uses requiring mobile
conveyors. Overland conveyors of
lengths greater than 322 km (200 miles)
have been proposed and should be used
instead of trucks, trains, or slurry
pipeline, because they are covered.
Mobile conveyors can now be designed
to follow mining equipment at surface
mine sites and replace onsite haulage
by truck. These mobile conveyors can
also be used to modify coal handling at
storage piles.
Trucks are commonly used to trans-
port coal from the point of excavation to
either tfie mine site stockpile or storage
area or, when economical, directly to
the end user's stockpile or storage area.
The coal is loaded on the truck either by
the shovel performing the digging or by
a front-end loader. They are also loaded
by feed from a n overhead bi n, by use of a
front-end loader, or by feed from a
conveyor.
Any practical method for coal trans-
portation can be employed. The unload-
ing system, and to some extent, the
stockpiling configuration, depends upon
the way the coal arrives at the site. A
typical barge unloading station includes
a system of unloading the barge, a
receiving bin with feeders, a conveyor or
facility for loading the transport, and a
method for moving the coal to the user's
stockpile or storage area. Major transfer
points at the barge loading facility are:
Train
Overland
Conveyor
Stockpile
Barge
Major transfer points at the barge-to-
barge terminal are:
Barge
Stockpile/
Storage
Barge
The Black Mesa pipeline is the only
commercial coal slurry pipeline current-
ly operating in the U.S. It transfers coal
from the Black Mesa coal field in
Arizona to the Mohave generating
station in Nevada. This- procedure
requires only one transfer point from
the transport device bringing coal from
the stockpile to the receiving bin or
hopper at the preparation plant.
Train
Conveyor
Coal
Truck Preparation
Plant
Pumping
Station
Pipeline
Most coals undergo some type of
preparation before delivery to the con-
sumer. The extent of preparation is
determined by the quality of the coal,
the mode and economics of transport
from the mine to the consumer, and the
requirements of the consumer. Five
transfer points are normally associated
with a coal preparation plant: (1) trans-
fer from incoming transport mode to
surge bins; (2) transfer from surge bins
to plant stockpile or storage area (usual-
ly screening and crushing of the coal is
also involved); (3) transfer from
stockpile to preparation plant; (4) trans-
fer from preparation plant to clean coal
stockpile and storage area; and (5)
transfer from clean coal storage to out-
going transport mode. The transfer
equipment/facilities normally involved
are surge bins, plant stockpile and
storage area, and clean coal stockpile
and storage area.
Train
Conveyor
Truck
Surge
Bin or
Surge
Feeder
Run of
Mine
Storage
Preparation
Plant
Conveyor
Train
Clean
Coal
Storage Barge
Truck
Stockpiles and quantities of coal
involved in the normal operations of the
site are sometimes referred to as active
storage or short-term storage
stockpiles. Storage refers to quantities
of coal held in reserve for times when
the quantity of coal available in stock-
piles is unable to meet demand. Storage
piles are usually much larger than
stockpiles and the turnover time of coal
held in storage may be significantly
greater. The greater size and average
age of the coal, generally, makes
storage more of a potential environ-
mental hazard.
The final mode of transporting coal is
a pneumatic pipeline. This represents
relatively new technology. Presently, it
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s used for transporting coal over rela-
'vely short distances. It is a pressurized
. ipeline into which coal is fed and
conveyed in a suspended state by
compressed air. The current, most
feasible application of pneumatic pipe-
lines appears to be the movement of
coal to and from a rail terminal. Pneu-
matic pipelines could be particularly
advantageous in the West because they
require no water. An above ground
Dneumatic system requires minimal
ground preparation and can be designed
o be portable.
Environmental Impacts
Various environmental impacts are
issociated with coal transfer operations
md transfer terminal facilities. These
nclude: loading, unloading, stockpiling
md storing, reclaiming, and other
iperations associated with coal
ransfer.
Loading, unloading, stacking, and
eclaiming coal can contribute to
ihanges in water quality due to the
nteraction of water with dust fallout
md coal spillage.
Coal stockpiles and storage areas
exposed to the environment are a poten-
>al source of water pollution. Coal
orage piles produce effluents during
id after precipitation resulting from
he drainage and runoff of water. Pre-
cipitation drains and leaches soluble
jollutants from the coal which may
affect aquatic life in nearby waterways.
'hese pollutants include organic sub-
stances (particularly humic substances
n lower rank coals), mineral matter
e.g., clays, alkaline earth carbonates,
sulfides and silica), and trace elements
i.e., trace amounts of nearly every
element found existing naturally in the
environment). The extent of physical
and chemical reactions between the
coal and the water depend upon their
characteristics and composition.
Slurry transportation of coal requires
large quantities of water, although
these amounts are less than would be
required for most minemouth utiliza-
tions of coal. Water from short pipelines
can be recycled and used in a water
make-up system. When the pipeline is
long, as is the case in the existing Black
Mesa pipeline and for most of the
facilities proposed for other locations,
adequate water resources must be
available. The quantity of water
required for slurry preparation depends
upon the volume of coal to be shipped
nd the water to coal ratio.
The extent to which the ambient air
quality will be affected by coal transfer
operations and terminal facilities will
depend on the equipment, storage, and
transportation facilities used at each
installation. Air emissions, common to
most transfer/terminal operations,
occur in the form of fugitive dusts from
open storage, from spillage during
transfer, and from traffic around the
facilities.
Fugitive dust (particulate matter)
emanates from open storage piles due
to weathering forces acting on the
surface of the pile. Gaseous materials
also emanate from coal storage piles
due to oxidation and the release of
pressure due to mining and
comminution.
Most loading and unloading
operations result in the release of coal
dust and particulates. The quantity of
particulate matter emitted from loading
and unloading operations depends on
the rate of flow of coal (design capacity),
coal size, moisture content of coal, and
the type of installation. If the transfer
operation employs silo storage systems
and enclosed conveyors, the particulate
emissions should be low from the facil-
ity. However, with open coal storage
piles, truck unloading, and the rotary
bucket reclaiming system, particulate
emissions may be significant. Particu-
late emissions will also be generated
from loaded vessels (trains, barges,
ships, etc.) waiting for shipment.
Fugitive dust emissions at slurry
preparation sites may result from coal
crushing and coal transfer operations.
These particulate emissions can be
effectively managed by providing
suitable enclosures.
Three basic sources of noise emanate
from coal transfer operations and
terminal facilities:
1. Vehicular movement and traffic
noise (e.g., trains, towboats, ships,
trucks).
2. Coal handling equipment (e.g.,
conveyors, crushers, bulldozers,
stackers, reclaimers).
3. Coal impact noise.
Aesthetic impacts occur during
construction, operation, and abandon-
ment of coal transfer unit operations
and transfer/terminal facilities. Vertical
equipment and coal storage piles
disrupt the horizon reducing the visual
attractiveness of not only the site but
the surrounding countryside as well.
Coal stockpiles, silos, and other storage
facilities are noticeable from significant
distances. Fugitive dust particles also
obscure the area because of the dark
color of coal.
Transfer operations that are part of
mining, utilization, and other coal hand-
ling facilities not used primarily for the
transfer of coal, represent minor land
use impacts because they are an
integral part of that facility.
Control Technology
Control techniques, discussed in
terms of the benefits on the
environment, are the use and quality
control of water, air quality control,
noise, and aesthetics and land use.
Coal slurry transportation depends
upon the availability of carrier fluid
(water) in sufficient quantities. Avail-
ability of a carrier fluid as a major
criteria for site selection may minimize
water resource impacts. Alternate
water supply sources should be investi-
gated at each site, either to supplement
or substitute available freshwater
supplies. Alternatives might include
surface water, groundwater, saline
water from deep wells, salt water from
the sea or lakes, municipal wastewater,
and industrial wastewater.
Control techniques available for
reducing the impact of wastewater
resulting from coal transfer operations
are: (1) techniques that are effective in
reducing runoff/leachate flow and
characteristics (source control), and (2)
techniques that are effective for
removing pollutants from runoff/
leachate wastes (collection and treat-
ment).
Most terminals handle and treat
wastes jointly, because the
wastewaters generated from coal pile
storage areas (runoff/leachate) and
from air pollution control devices (e.g.,
dust suppression, scrubbing, etc.) are
usually similar in characteristics.
Air pollutant control methods that can
be used during the operation of coal
transfer/terminal facilities are:
enclosed systems; water or chemical
sprays; surface coatings; dust
collections; containment equipment;
compaction; and barriers.
There are two basic approaches to
reduce or control noise levels generated
from any source: (1) shielding,
enclosing, or insulating the noise
source from the surrounding area and
(2) modifying the noise source through
vibration isolation or by structural
dampening. Modification of the noise
. S. GOVERNMENT PUNTING OFFICE: 1980-757-064/0203 Region No. 5-11
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source might also include equipment
replacement.
General and specific noise control
procedures are available. A major
alternative for controlling aesthetic and
land use impacts is the location of the
transfer/terminal facility. Site selection
criteria should include consideration of
landscaping and architecture (e.g.,
industrial site or park), which could
blend with the proposed structural and
non-structural features. Land use
impacts would be minimal if the area
considered for these facilities is already
zoned for industrial facilities.
Disturbances to terrestrial and aquatic
wildlife would also be dealt with on a
site-specific basis and require environ-
mental impact statements.
L Pelham is with Delon Hampton and Associates, Silver Spring. MD,
John Martin is the EPA Project Officer fsee below).
The complete report, entitled "The Environmental Impact of Coal Transfer and
Terminal Operations," (Order No. PB 81-104747; Cost: $8.00, subject to
change) will be available from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Industrial Environmental Research Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
Postage and
Fees Paid
Environmental
Protection
Agency
EPA 335
Official Business
Penalty for Private Use $300
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