Transcript ACARP - underground COAL

ACARP
Australian Coal Association Research Program
Australian Roadway Development
Improvement Project
OPERATORS’ WORKSHOPS
March 2008
SAFETY ASPECTS OF VENUE
 As advised by venue
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OBJECTIVE AND FORMAT
Provide a forum for roadway development
operators to:
 Learn of emerging best practice and roadway
development initiatives
 Learn of developments in equipment and
technology
 Network with peers, and share their experience
and learnings (and not just their successes)
 Identify areas for targeted research
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FORMAT

5 presentations by operators detailing current operational practices
together with one presentation giving an international perspective on
roadway development

A number of research and technology updates by researchers

The presentations each comprise a 20-25 minute presentation with a
15-20 minute open forum for discussion and sharing of experiences
and learnings

The research and technology updates each comprise a 20 minute
presentation and a 10 minute open forum for discussion

Conclude with a review to capture key findings, identify opportunities
to improve the workshop process, and to identify presentations for
future workshops

Workshop report with copies of presentations to be provided to all
participants
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INTRODUCTION
Prerequisites for attendance:

A passion for roadway development, and

A willingness to participate in discussions and share experiences
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ACARP
Australian Coal Association Research Program
Australian Roadway Development
Improvement Project
RESEARCH AND DEVELOPMENT STRATEGY
March 2008
Glen Lewis, Xstrata Coal
Bob Gordon, BHP Billiton
Guy Mitchell, BMA Coal
ROADWAY DEVELOPMENT R&D STRATEGY - 04/07
 Following the March 2007 Roadway Development Workshops the
RDTG developed a Roadway Development R&D strategy based
upon input given by participants at those Workshops
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ROADWAY DEVELOPMENT R&D STRATEGY - 04/07
 Immediate (1 year project)
 “project management” systems for roadway development (including
maintenance)
 “fundamentals of roadway development” handbook
 process model for development
 management structure, style and skills;
 functional specification for “CM 2010”
 Medium term (2-4 years) - “CM 2010 project” (similar to LW project)

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components that can be retrofitted to current generation machines
automated bolting system
alternate skin reinforcement and rib confinement
services
 Longer term (+5 years) - “continuous mining system”
 integrated system incorporating cutting, loading, conveying, support,
and logistics flowing on from CM 2010 project
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KEY ELEMENTS - CM2010 R&D STRATEGY

Later in 2007 we attempted to develop a model which demonstrated
the relationship between key elements of the CM2010 R&D strategy
as it became known as
Remotely
Supervised
Continuous
Miner
Automated
Installation
of Roof and
Rib Support
Continuous
Haulage
Integrated
Panel
Services
Improved Engineering Availability
Project
Management
of R&D
Projects
Engagement
of Corporate
Sector,
OEMs, and
Mines
High Capacity
Roadway
Development
System
People Behaviours and Skills
Planning, Organisation and Process Control
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ACARP FUNDING 2008

Pleasing to advise that a number of roadway development related
R&D projects have been funded by ACARP commencing 2008
following recommendations made by the RDTG, including
development of:

A polymer based alternative skin reinforcement and confinement
system - to eliminate the installation of steel mesh and, in conjunction
with SDB, allow operators to be removed from the immediate face
area while improving roadway development performance

An automated system for installing SDB and mesh, including an
integrated logistics and materials handling system from the supplier to
the face - to similarly remove operators from the immediate face and
improve roadway development performance

A simulation model to enable the limitations of current development
processes to be understood, and to evaluate potential roadway
development technologies and practices before committing scarce
resources to pursue development and/or conduct field trials

A handbook to capture the industry’s current “body of knowledge” of
roadway development practice for future generations
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CM2010 R&D STRATEGY - MARCH 2008
 The RDTG has continued to develop the CM2010 R&D
strategy to provide the framework for an integrated
approach to developing a new generation high capacity
roadway development system
 Now like to share the strategy with you and invite your
review and critique
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KEY STRATEGIES – CM2010
 Develop “self-steering” technologies and systems that enables mining
equipment to mine roadways in accordance with predetermined
survey controls and to maintain both azimuth, horizon and grade
control within a variable seam horizon, and to totally automate the
cutting and loading cycle (including mining breakaways) thus
enabling equipment to be remotely supervised
 Will require a combination of fundamental and applied research building
upon Highwall Mining and Longwall Automation technologies
 CSIRO Queensland Centre for Advanced Technologies has
demonstrated capabilities
 Key R&D element over next 2-3 years
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KEY STRATEGIES – CM2010
 Develop technologies and systems that enables face services to be
extended within the 3 minute cut, load support cycle and without
direct operator involvement
 One monorail system currently being reinstalled at Mandalong with
recent orders placed for 2 new monorail systems
 Expected to be largely driven by mine sites, with support from and
feedback to RDTG
 Will predominantly require operational improvement to apply existing
technologies with some applied research required to automate
installation of monorails and integrate into a remotely supervised, high
capacity mining system
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KEY STRATEGIES – CM2010
 Develop systems that enables the automated installation of
conventional resin anchored bolts and self drilling bolts, and to feed
bolts and mesh to the installation hardware without direct operator
involvement
 Will require a combination of fundamental and applied research
 UOW recently awarded ACARP funding to pursue this initiative
 Joy have prototype carousel bolter and Sandvik have operational
carousel bolters (metaliferous sector) that could provide basic
equipment platform, whilst CSIRO has developed a range of
technologies for the ACBM that could potentially be applied
 Key R&D element over next 2-3 years
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KEY STRATEGIES – CM2010
 Develop alternative skin reinforcement and confinement technologies
and systems that eliminates the installation of roof and rib mesh and
provides an enhanced roof and skin reinforcement medium
 Will require a combination of fundamental and applied research
 UOW recently awarded ACARP funding to pursue this initiative
 Initial research shows considerable promise (refer Chris Lukey’s
presentation)
 Key R&D element over next 1-2 years
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KEY STRATEGIES – CM2010
 Demonstrate, adapt and refine continuous haulage technologies and
systems currently being used overseas for use in Australian longwall
mines, and subsequently combine suitable coal clearance
technologies into an integrated, remotely supervised high capacity
mining system
 Two continuous haulage systems currently being installed or
commissioned in Australian mines, with a third system expected to be
ordered mid 2008
 Expected to be largely driven by mine sites, with support from and
feedback to RDTG
 Will predominantly require operational improvement to apply existing
technologies with some applied research required to integrate into a
remotely supervised, high capacity mining system
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KEY STRATEGIES – CM2010
 Develop technologies and systems that enables panel services to be
advanced on a continuous basis in parallel with mining operations or
alternatively, within scheduled maintenance windows
 Expected to be largely driven by mine sites, with support from and
feedback to RDTG
 May require some applied research to develop extensible conveyors
and integrate major services (H/T power reticulation, transformers, etc)
into a services management system
 May also require some applied research to develop more efficient mine
compliant services (eg; pipework)
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KEY STRATEGIES – CM2010
 Develop mine logistics systems that enables mining and maintenance
supplies and consumables to be delivered to the immediate mining
area at a rate consistent with a 3 minute cut, load support cycle.
 Logistics systems should similarly enable materials and equipment
required for panel infrastructure and services to be delivered to the
mining area at a rate consistent with a 200 m per day advance rate
 Expected to be largely driven by the yet to be determined design of the
primary mining equipment, and mine specific parameters
 Therefore expected to be driven by mine sites, with support from and
feedback to RDTG
 May require some applied research to develop a mechanised,
extensible supply system, and for overall system integration
 Expected to draw upon logistics systems expertise from other industries
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KEY STRATEGIES – CM2010
 Develop technologies and systems that enables high speed haulage
roadways to be constructed and maintained without impacting the
continuity of face operations
 Expected to draw upon roadway and pavement construction and
maintenance expertise from other industries
 Expected to be largely driven by mine sites, with support from and
feedback to RDTG
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KEY STRATEGIES – CM2010
 Develop strategies to improve engineering availability of equipment
and enable equipment to operate at design rates (10 MPOH) for 20 or
more hours per day
 Expected to be largely driven by mine sites with strong support from
OEM sector
 Industry wide coordination will be necessary to improve overall
engineering competency standards across the industry and to ensure
industry wide standards are developed and adopted. Hence anticipate
continuing support from and feedback to RDTG
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KEY STRATEGIES – CM2010
 Develop pre-mining systems, including gas drainage, seam
dewatering, and the detection and pre-treatment of faults and other
geological anomalies, to enable a safe, compliant and productive
mining environment to be maintained
 Expected to include a combination of fundamental and applied
research, together with a major operational improvement component at
a mine site level
 CSIRO Queensland Centre for Advanced Technologies and CRC
Mining have demonstrated research capabilities in this field
 Anticipate that specialist service providers (eg; drilling contractors) will
also have significant input into developing industry wide capabilities
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KEY STRATEGIES – CM2010
 Develop hazard management and safety compliance systems to
enable sustained high performance levels to be achieved, including
gas content testing, the detection and location of geological
structures, and the management of variable strata conditions
 Expected to include a combination of fundamental and applied
research, together with a major operational improvement component at
a mine site level
 CSIRO Queensland Centre for Advanced Technologies and CRC
Mining have demonstrated research capabilities
 Anticipate that specialist service providers (eg; geotechnical
consultants) will also have significant input into developing industry wide
capabilities
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CM2010 CRITIQUE
 Later today we will invite your feedback and critique on
the CM2010 project including
 What improvements could we make to the CM2010 Research
and Development strategy?
 Any champions interested in being involved at a R&D, OEM or
mine site level?
 We would also ask that you take the CM2010 Research
and Development strategy document back to site,
whether it be a mine, workshop or laboratory, and to
share it with your colleagues and give feedback directly
to the RDTG via Gary Gibson ([email protected])
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ACARP
Australian Coal Association Research Program
FUNDAMENTAL ANALYSIS OF
DEVELOPMENT CYCLES AT XSTRATA
NSW MINES
Richard Porteous, Xstrata NSW
ACARP
Australian Coal Association Research Program
IMPROVING ROADWAY
DEVELOPMENT PERFORMANCE AT
ULAN
Ben Smith, Ulan
ACARP
Australian Coal Association Research Program
MORNING TEA
ACARP
Australian Coal Association Research Program
ROADWAY DEVELOPMENT AND THE
INTRODUCTION OF HILTI SELF DRILLING BOLTS
AT BROADMEADOW
Matthew Jones, Broadmeadow
ACARP
Australian Coal Association Research Program
SELF DRILLING BOLT UPDATE
Peter Gray, Ground Support Services
ACARP
Australian Coal Association Research Program
THE NEWSTAN/MANDALONG MONORAIL
SERVICES MANAGEMENT SYSTEM
Ray Coppins, Newstan/Mandalong
Scott Jensen, Macquarie Manufacturing
ACARP
Australian Coal Association Research Program
LUNCH
ACARP
Australian Coal Association Research Program
EVOLUTION OF GATEROAD
DEVELOPMENT IN THE PITTSBURGH
NO 8 SEAM (USA)
Brian Thompson, Joy Mining
Machinery
ACARP
Australian Coal Association Research Program
RESEARCH UPDATE - ALTERNATIVE
SKIN REINFORCEMENT PROJECT
Chris Lukey and Jan Nemcik, UOW
ACARP
Australian Coal Association Research Program
RESEARCH UPDATE – AUTOMATED
BOLTING AND MESHING PROJECT
Stephen Van Duin, UOW
ACARP
Australian Coal Association Research Program
AFTERNOON TEA
ACARP
Australian Coal Association Research Program
ROADWAY DEVELOPMENT AT
CRINUM
Martin Zgrajewski, Crinum
ACARP
Australian Coal Association Research Program
FUTURE DIRECTIONS
– CM2010 PROJECT
Glen Lewis, Xstrata Coal
Bob Gordon, Centennial Coal
Guy Mitchell, BMA Coal
CM2010 CRITIQUE
 What improvements could we make to the CM2010
Research and Development strategy?
 Any champions interested in being involved at a R&D,
OEM or mine site level?
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VISION - CM2010
An integrated, remotely supervised high capacity roadway
development mining system that enables 15 Mtpa longwall
mines to be established and sustained with a single mining
unit.
The system will also enable mining to be safely undertaken
under adverse or extreme mining conditions, thus opening
up access to reserves previously considered unminable
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MEASURES - CM2010
 A sustained performance rate of 10 metres per operating
hour (MPOH) for 20 hours per day, based on installing
primary support of 6 roof and 2 rib bolts per metre
advance together with roof and rib confinement measures
(mesh)
 Improved health and safety through reduced exposure to
hazards in the immediate face area
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GOALS - CM2010
•
By end 2010, demonstrate key enabling component technologies that will
form the basis of an integrated high capacity mining system, eg; remote
operation of the continuous miner, automated self drilling bolts and mesh
installation, continuous haulage, integrated panel services
•
By end 2010, establish programs that enable the key organisational and
technical competencies required to support a high capacity mining system to
be developed throughout the industry, eg; improved engineering availability,
people behaviour and skills, and planning, organisation and process control
•
By end 2011, improve industry roadway development performance to current
industry best practice levels of 5 MPOH for 12 or more hours per day
•
By end 2012, demonstrate an integrated, remotely supervised high capacity
roadway development system
•
Progressively reduce the physical demands on personnel engaged in the
development process and reduce their exposure to workplace hazards
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KEY OBJECTIVES - CM2010

A high capacity roadway mining and support system capable of 1 metre
roadway advance cycles in 3 minutes, with all functions of the system
remotely supervised without personnel in the immediate face area

A coal clearance system that enables the mining and support system to
achieve the target cycle times, without impacting the ability to service and
support that (mining and support) system

A panel advance system that enables services to be advanced without
impacting operation of the mining, support and coal clearance systems

A mine logistics system that ensures on-time delivery of mining and
maintenance supplies and consumables, and panel infrastructure and
services. The system also includes the construction and maintenance of
roadways to facilitate the rapid distribution of personnel, materials, and
equipment

Pre-mining systems that remove potential impediments to high performance
levels, including gas drainage, seam dewatering, and the location and pretreatment of faults and other geological anomalies
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KEY OBJECTIVES - CM2010

Mine design systems that optimise the high capacity roadway development
system,

Significant improvements in engineering availability and reliability levels
through improved equipment specification, design, pre-manufacture
simulation and equipment manufacture, and improved operating and
maintenance standards

Development of people’s behaviour and skills to better lead, communicate,
plan, supervise, operate and maintain technologically complex systems and
equipment

Hazard management and safety compliance systems that enable sustained
high performance levels to be achieved

Process management tools that enable sustained performance levels of 200
m per day of roadway development to be achieved
•
Development of mining and ancillary equipment that reduces the exposure of
personnel to work place hazards, eliminates manual handling, and improves
ergonomics
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CM2010 CRITIQUE
 What improvements could we make to the CM2010
Research and Development strategy?
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WORKSHOP CRITIQUE
 What improvements could we make to the
structure and format of the Workshop:
 Suitability of location, venue and facilities?
 Timing (eg; day of week, and actual times)
 What issues should be the subject of future
workshops?
 Any volunteer presenters?
 Anything else?
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END OF WORKSHOP
Thank you!
Please join us for some for
refreshments and further
networking!
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