ACARP Australian Roadway Development Improvement Project OPERATORS’ WORKSHOPS March 2008.

ACARP

Australian Roadway Development

Improvement Project

OPERATORS’ WORKSHOPS

March 2008

Australian Coal Association Research ProgramAustralian Coal Association Research Program

ACARP Project C15005 2

SAFETY ASPECTS OF VENUE

As advised by venue


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


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


INTRODUCTION

Prerequisites for attendance:

A passion for roadway development, and

A willingness to participate in discussions and share experiences

ACARP

Australian Roadway Development Improvement Project

RESEARCH AND DEVELOPMENT STRATEGY

March 2008

Glen Lewis, Xstrata CoalBob Gordon, BHP BillitonGuy 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


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) 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


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

IntegratedPanel

Services

Improved Engineering Availability

Planning, Organisation and Process Control

People Behaviours and Skills

Project Management

of R&D Projects

High Capacity Roadway

DevelopmentSystem

Engagement of Corporate

Sector, OEMs, and

Mines


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


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


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


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


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 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 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


Will predominantly require operational improvement to apply existing technologies with some applied research required to integrate into a remotely supervised, high capacity mining system


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


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)


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


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



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


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


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


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])

ACARP

FUNDAMENTAL ANALYSIS OF DEVELOPMENT CYCLES AT XSTRATA

NSW MINES

Richard Porteous, Xstrata NSW


ACARP

IMPROVING ROADWAY DEVELOPMENT PERFORMANCE

AT ULAN

Ben Smith, Ulan


ACARP

MORNING TEA


ACARP

ROADWAY DEVELOPMENT AND THE INTRODUCTION OF HILTI SELF DRILLING

BOLTS AT BROADMEADOW

Matthew Jones, Broadmeadow


ACARP

SELF DRILLING BOLT UPDATE

Peter Gray, Ground Support Services


ACARP

THE NEWSTAN/MANDALONG MONORAIL SERVICES MANAGEMENT SYSTEM

Ray Coppins, Newstan/Mandalong Scott Jensen, Macquarie Manufacturing


ACARP

LUNCH


ACARP

EVOLUTION OF GATEROAD DEVELOPMENT IN THE PITTSBURGH

NO 8 SEAM (USA)

Brian Thompson, Joy Mining Machinery


ACARP

RESEARCH UPDATE - ALTERNATIVE SKIN REINFORCEMENT PROJECT

Chris Lukey and Jan Nemcik, UOW


ACARP

RESEARCH UPDATE – AUTOMATED BOLTING AND MESHING PROJECT

Stephen Van Duin, UOW


ACARP

AFTERNOON TEA


ACARP

ROADWAY DEVELOPMENT AT CRINUM

Martin Zgrajewski, Crinum


ACARP

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?


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


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


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


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 pre-treatment of faults and other geological anomalies


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


CM2010 CRITIQUE

What improvements could we make to the CM2010 Research and Development strategy?


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?


END OF WORKSHOP

Thank you!

Please join us for some for refreshments and further

networking!

ACARP Australian Roadway Development Improvement Project OPERATORS’ WORKSHOPS March 2008.

Documents

Transcript of ACARP Australian Roadway Development Improvement Project OPERATORS’ WORKSHOPS March 2008.