ACARP Presentation Cutting A Smarter Metre Process optimisation techniques currently being utilised.

ACARP PresentationCutting A Smarter Metre

Process optimisation techniques currently being utilised

Sandvik Mining and Construction

Process Improvement – Measure

In order to improve processes you need a yardstick or a constant. With the MB it is reasonably obvious that you should use “Mesh Overlap Roof Bolt” to “Mesh Overlap Roof Bolt” as it is almost always one metre. What you do in that metre will affect greatly your panel advance rates.

Some of the easily recognisable areas for inefficiencies are listed below Cutting Techniques Loading and Haulage Techniques Bolting Techniques and Bolt Patterns (Roof and Rib) Mine Design and Coal Clearance Design People and Consistancy Machine and Road Maintenance



MINING SYSTEM PERFORMANCE

0.00

2.00

4.00

6.00

8.00

10.00

12.00

10 30 50 70 90 110 130

DISTANCE FROM SHUNT S1 (m)

ME

TR

ES

pe

r O

PE

RA

TIN

G H

OU

R

ABM-25

AB M- 20

Sh utt le Car

Shunt (S 1)

Boo t-end

Le

ng

th o

f Pilla

r

Dis

tan

ce

Sh

un

t - Fa

ce

D ista nce S hunt to Boot

AB M- 20

Boo t-e nd

O ve rdrive

Sh utt le Car

Sh unt (S 1)

TW O HEAD IN G PANEL LAYOUT

W idth of Pi ller

4 roof bolt, 2 rib bolt, mesh, 2 S/C only, 8t cars, 3m cut-out

Continuous Haulage

Self Drilling Bolt



The Operational Report is used to easily recognise your inefficiencies and should be used in conjunction with The Bolting Report in order to drill down on your process.



Reports from a Continuous Haulage MB


Process Improvement - Consistancy

With both these reports there is room for improvement, Ideally there is only one right way to cut a metre – The Fastest and Safest. In order to improve there is a need to look outside the square and

break down each step of the coaling process to identify bottle necks and either eliminate or manage them into your process

Traditional constraints on production are still valid ie. bolting , wheeling, and services but with the introduction of a continuous haulage product in conjunction with a MB other process improvements became apparent.

• surging / coal size

• horizon control

• transfer points



BM With Haulage. Identify Exceptions

Repeat Behaviours

Cycle variance / m



Why such a big difference?

What can be done to improve consistancy? With haulage you need to match your simultaneous tasks to the

slowest component in order maximise component life and minimise surging or peak loading

Horizon control can be difficult to maintain when operators are pushed and tired.

Floor conditions and outbye belts can suffer from overloaded belts and poor horizon control

One solution is Automation of the cutting process to control horizon and surging



Auto Cut Improvements Traditionally aimed at floor to roof

cutting in a predefined set of limits Focus on consistant machine set up

and operator interface at start of cut to enable a more consistant Roof to Floor methodology

• Consistant Horizon control

• Production can be slowed to match bolting to relieve belts and transfers

• Coal can be sized at the face to enhance output

• Free’s up an machine operator to assist with bolting activity

• Consistant cycle cutting time

• Lineal transducers in stab jacks



Shearing up can be a viable component of cutting cycle in order to control coal sizing, and flow depending upon hardness of material and sump depth, It can also be used as the final part of your cycle to prevent bogging and overloading of cutters

Must be used in conjunction with condition monitoring Increased load on cutter assembly



Digital Bolting Initial problems during

startup Feedback from operators

and MDG35.1 requirements led to refinments

Importance of focusing automation projects on flexibility and ease of use

Consistant cycle bolting time

Consistant bolt installation leads to better roof support and possibility for reduced bolt density



Bolts installed 3-5 minutes

Consistancy issues are related to consumable handling and tooling

Ability to put up primary roof support consistantly, while still having the flexibility to bolt manually and deal with adverse roof conditions

Maintenance and understanding of system


Process Improvement – Bolt Patterns

It is hard to measure your metre when you are forced to put up a centre bolt, With MB Operators See available coal so continue to cut thus only

use the last 50cm of sump

Ineffective bolting technique because you are lengthening the cycle time by adding this standalone process

Is it possible to maintain the same roof bolt density ie. 4 on the metre and 2 on the half, By just installing 6 in a row?

Consider other forms of bolting, QDS, SDB, Secondary support

overdrive then pre bolt intersections before they become intersections from QDS bolters to enable “tram through”


Process Improvement - Haulage

When installing haulage consider the following Pillar length Vs expected M/OH and shift duration ie.

• 8MOH over 12 hr shift = 96m production but

• 1 hr travel = 88m production

• 1 hr pull back to resupply and return to face = 80m

• Therefore maximum effective shift mining range is 80m if everything goes right

• Can we match mine design to mining range?

• Can we shorten pillars to allow side loading resupply and add 1hr production back to shift?

• Or double consumable storage to allow 2 shifts out of one supply = 140m range

How do you resupply your miner? pre-bolted intersections 60 degree cut throughs


Process Improvement – Storage For 90m Development we need to carry

270 + Roof Bolts, and chemicals 180 + Rib Bolts, and Chemicals 90 sheets roof mesh 180m rib mesh


Process Improvement – What Does 8MOH plus look like?


Process Improvement – Where Next?

Cutting faster when your bolting constrained can cause panel downtime

In order to allow machines to cut and bolt big metres simultaneously, more consideration has to be given to operator comfort

Focus on cyclic behaviours, find a place for consumables, the next metres bolts, drills, fit implements to machines for drill tip removal and cleaning etc…

Focus on mining and bolting patterns to optimise process efficiency

Support and maintain Autonomous Operations is dependant on supervisors and managers, It may take some getting used to but it will pay dividends

Focus on maintenance due to high cycle rates

ACARP Presentation Cutting A Smarter Metre Process optimisation techniques currently being utilised.

Documents

Transcript of ACARP Presentation Cutting A Smarter Metre Process optimisation techniques currently being utilised.