gary gibson - acarp. gary gibson & associates - towards an integrated roadway development system
Post on 13-Apr-2017
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Introduction
Key learnings - 2014:
incremental approach to roadway development R&D could not deliver the step change improvement in development performance required
fundamental reconfiguration of the mining platform was necessary if we were to address key constraints within the development process, and develop a totally integrated system
the scale of such an initiative was beyond ACARP, any single mining company, or OEM
the necessity to engage the industry generally, as well as key stakeholders and OEMs specifically, if we were to contemplate such a step-change development
Introduction
Industry Workshop – Towards and Integrated Roadway Development System:
review the barriers to improved development performance
examine the role of emerging technologies
identify key R&D requirements
explore opportunities for the collaborative development of a safe, efficient and highly productive roadway development system
Industry survey - Functional Requirements of an Integrated Roadway Development System
Introduction
Survey findings - Functional Requirements of an Integrated Roadway Development System
Opportunities for addressing key constraints within the development process
Current and prospective roadway development related R&D
The views contained herein are mine and not necessarily those of ACARP and the Roadway Development Task Group
Cut
Convey
Support
Extend services
Resupply
What - Integrated Roadway Development?
Continuously
Consistently, reliably and repeatedly
Safely
Minimal manual handling
Cost effectively
Deliver a step change improvement in development performance
Why - Integrated Roadway Development?
Longwall continuity
15,000-30,000 tpd longwall production (average 25,000 tpd)
$0.5-0.7M longwall revenue/day (NSW)
$2-3.7M/day longwall revenue/day (QLD)
Longwall capacity
1% Δ of 25,000 tpd = additional 50,000 tpa (or more)
Development costs
24-60% total mine operating costs (average 40-45%)
$7.5-40M/annum/development unit (average $20M/unit)
Improved safety
Reported injuries in roadway development 3 times greater than in longwall
How - Integrated Roadway Development?
2007 CM2010 R&D Strategy
Estimated $30M or more to progress an incremental R&D approach, with ACARP funding some $8-10M
ACARP has since committed almost $16M to roadway development R&D, with just 4 projects consuming $12M
Integrated development system beyond capacity of ACARP, individual OEM or mining company - collaborative approach necessary
The first collaboration – industry survey to establish the Functional Requirements
Identify industry needs, requirements, and priorities
Develop industry consensus
Quantify costs and potential gains
Establish R&D priorities
Industry Survey – Functional Requirements
Survey jointly developed by Joy Global, Sandvik and ACARP’s Roadway Development Task Group
Distributed to all longwall mines and emerging projects in NSW and QLD
Responses received from 15 mines and 4 emerging projects
Survey topics included:
Mining Parameters Coal Haulage
Performance Requirements Strata Support
Geological Information Mine Logistics
Mining Regulations Panel Conveyor and Advancement
Operating Targets Process Costs and Savings
Continuous Miners Future State
Industry Survey – Key Longwall Parameters
NSW QLD
Target ROM Production
Range 3-8 Mtpa, average 5.0-6.5 Mtpa
All mines >6 Mtpa, most 7-10 Mtpa range2 new projects 14-15 Mtpa
Longwall Block Length
Typically 2.5-4.0 km, newer mine 6.5 km
Typically 2.5-3.5 km, newer mine 6.0 kmNew projects typically 6 km
Longwall Face Width Range 160-400m, average 320-340m
Existing mines typically 300-320m, new projects 350-400m
Longwall Retreat Length
Typically 2,350-4,000 m/annum, average 3,300-3,500 m/annumMine with 160m wide face -5,000-6,000 m/annum
Typically 4,000-5,000m/annum, average 4,400 m/annumNew 7Mtpa project – one block/annum
Development Metres Gates: typically 15-20 km/annum (12-25 km/annum) Mains: typically 4 km/annum (3.8-12 km/annum)
Typically 6-9 km per development unitOverall mine totals range from 15-30 km/annum
Industry Survey – Development Parameters
NSW QLD
Roadway Width Typically 4.8-5.5m wide Typically 5.2-5.6m, newer mines planning for 5.8-6.0m
Seam Gradients Typically 1:30-1:20 Typically 1:15-1:12
Pillar Length Typically 125-130m (100-150m) Typically 120-130m (100-130m)
Roof Bolt Length Best: 1.8-2.4m (4-6 bolts/m)Worst : 2.1-2.4m (6-8 bolts/m)
Best: 1.8m (4-8 bolts/m)Worst: 1.8m (6-8 bolts/m)
Rib Bolt Length Typical: 1.2-1.8m (0-3 bolts/m/r)Worst: 1.5-1.8 (3 bolts/m/rib)
Typical: 1.5-1.8m (0-3 bolts/m/r)Worst: 1.5-1.8 (3-5 bolts/m/rib)
Long Tendons 40%, range 5-100% 30-40%, range 5-100%
Crew Size Typically 2-4 Operators Typically 5-6 Operators
1.0m Cycle Time Typically 27-35 min, (20-50 min) Typically 20-25 min, (14-60 min)
900 Breakaway Typically 16-18 hr, (10-24 hr) Typically 8-10 hr, (3-10 hr)
Development Rates 1.15-2.5 MPOH 2.2-3.6 MPOH
Cutting Time (7 day) 70-80 hr/week 63-90 hr/week, typically 80 hr
Industry Survey – Geological Information
Majority of mines were mining seams of 4.0m or more thickness with these mines typically mining roadways 3.2 -3.7m high
Only 2 mines reported mining seam thickness of 3.1 m or less, with 2.6-2.7m being identified as the practical minimum roadway height
Mines generally projected steepening grades over next 5-10 years with 7 mines reporting grades increasing from 1:12 to 1:6
Gradients of 1:9 to 1:8 generally considered maximum practical working grade, although three mines considered gradients of 1:6 to 1:4 as practical operating limits
Almost half of mines noted that ground conditions might preclude the use of mechanical temporary roof support systems
Industry Survey – Mining Parameters
Typically 2 entry gateroads with 3 entries adopted for longwall ventilation/gas management
Single entry gateroads generally not supported although under active consideration at one new project
Longwall ventilation requirements, longwall equipment transportation and geotechnical factors key determinants in regards to roadway widths
Move to 150m pillars in some NSW mines may be result of crew sizing (2-4 operators) – not haulage constrained but support constrained with smaller crews
Flat roof generally preferred if conditions allow although rounding of roof/rib corner or arching of roof expected to improve strata control
Industry Survey – Performance Requirements
2 development units supporting one longwall was seen as optimum, although some mines were projecting 4 and 5 development units
Development rates generally expected to increase over time driven by:
increased longwall productivity
need to reduce overall development costs
increased depth and support requirements
mining of geographically challenged reserves with shorter, narrower longwalls
General support for development of specialised gateroad development and specialised mains development equipment
Industry Survey – Performance Requirements
What are the key “missing” enabling technologies required for an efficient roadway development system?
Improved bolting systems including SDB
Automated bolting systems including removal of mesh handling
Automated cutting and support systems
Improved cable bolting and post-grouting systems
Materials management and delivery, including automated materials handling
Continuous haulage
CM navigation and horizon control systems
Rapid panel extension
Better ventilation systems for gas control
Improved communications and decision support systems, particularly at the operator level in order to support employee engagement
Industry Survey – Operating Targets & Delays
Target cutting time in NSW ranged from 70-80 hr/week, and 63-90 hr/week in QLD (and typically 80 hr/week)
9 mines reported Panel Advance in top 2 Operating Delays, with 7 others reporting Conveyor Delays in top 5 delays
6 NSW mines reported Strata Support in top 5 with 2 others reporting Secondary Support – no QLD mines reported Strata Support in top 5
Other top 5 delays included Flitting CM (6), Supplying CM (6), Ventilation Extension (6), Prep or Process Work (4)
Planned maintenance in 7 day operations ranged from 8-26 hr/week, and typically 12-18 hrs
9 mines reported Bolting Rigs in top 5 Engineering Delays, with 7 mines also reporting Hosing or Hydraulics Delays in top 5 Engineering Delays
Industry Survey – Strata Support
Average number of bolts installed typically half of best performance levels achieved – average typically 150-360 bolts per shift, including 10-12 Megabolts or 8m tendons
Factors needing action to improve bolting cycle times:
Speed of drilling and handling of roof and rib mesh
Automation of the drilling and installation process, removal of meshing requirements
Reduction of material handling to resupply face
Limitations of human speed and capabilities – operator fatigue
SDB, spin to stall resin, torque-tension cable bolts
Improved positioning of rigs
Reducing extent of bolting required through other means – ie; changing roadway shape
Industry Survey – Mining Regulations
Good ventilation system design considered essential to meet ventilation standards - last C/T quantities of 20-50 m3/sec required in NSW, 30-50 m3/sec in QLD
8 of 9 QLD mines/projects (and 1 NSW mine) noted heat management was an issue, with 2 QLD mines noting use of bulk air coolers
Good to strong support for adoption on monorail mounted services management systems - a number of practical issues were identified
Potential adoption of higher voltages (>1100V) on continuous miners and other face equipment was generally not supported
Industry Survey – Mine Logistics
Distance from surface to face (and return) and type of material handling system – LHD’s and trailers are too slow and move small amounts at one time
Poor floor conditions and/or floor heave extending travel time and reducing overall availability and access to the working faces
Heat management/ventilation constraints in long gateroads/DPM management limiting number of vehicles in operation (or removal of diesels from underground due to concerns re DPM)
Industry Survey – Future State
What an optimised gateroad development system should look like in 5-10 years (ie; one that meets safety and production requirements)?
Continuous cutting and supporting cycles – hence continuous coal clearance
Mechanised supply handling system - non manual material handling system
Automated mesh and support installation
Self-installing roof bolts and cables
Refined strata support designs, targeted to increased CM coal cutting time
Monorail services management - cable management system
Real time monitoring of face functions
Reduced exposure of personnel
2 headings
Industry Survey – Future State
What enabling technologies are key to achieving increased roadway development rates in the future?
Simpler more efficient bolting systems with elimination of mesh
Refined strata support designs to reduce the amount of primary support installed or increase the speed at which it is installed
Continuous coal clearance
Automation of key controls ie; cutting sequence and drilling, and remove manual handling
Reliable accurate proximity detection
Cost effective SDB
CM navigation systems
Real time monitoring - real information - overall system reliability
Wireless technology
Miniaturisation of CM components to increase storage space
Panel advance – integrated monorail systems
Industry Survey – Future State
What enabling technologies are key to addressing existing safety concerns/hazards?
Ergonomics for operators
Automated processes – remove or reduce manual handling, reduce human errors or interactions with machinery, reduce exposure to crush potential, reduce exposure to fluid power systems and dust
Safe method for putting mesh sheets up
Continuous haulage or automation of SC
Increased use of monorails, and self-advancing systems
Improved ventilation systems and ergonomic protection
Simpler more efficient bolting systems with the elimination of mesh
Remove manual handling - particularly vent tubes and long tendon bolts
Management of diesel particulates
Travel road management/maintenance - controlling water make
Industry Survey – Future State
What priorities and timeframes should be assigned to the development of these key “safety” related enabling technologies?
Automated bolting and materials resupply – within 2 years
Continuous haulage – within 2 years
Automated bolting and reduced manual handling – within 5 years.
Diesel particulates – within 2 years
Removing manual handling identified as a high priority
Other identified priorities noted include:
• Personal proximity detection
• Cost effective SDB
• CM navigation – self steering
• Real time monitoring
• Automation of SC
“Priority should be given to automation to standardise results and reduce manual requirements - should be focused on optimisation of the coal cutting process from cutting, to support installation and coal haulage”
Most mines are significantly support constrained
Typical Delay profiles effectively halve weekly development rates
Support Constraints and Delays
Opportunities – Support, CHS and Delays
Enabling capability of CHS - ability to complete full cut outs
Focus on improving Support Systems and reducing Delays
The Opportunities
Bolting and Support Constraints
Eminently possible to automated the strata support process – to a point
• UOW has demonstrated how bolts and mesh can be manipulated
• Automated carousel bolting systems have been developed and are used in other sectors
The Opportunities
Bolting and Support Constraints
How can we determine when we have installed adequate support?
What is the optimum roadway shape from a ground control perspective? – how can this shape be incorporated into CM design?
What is the optimum timing, location , density and type of installed support - can support installation be distributed along or behind CM?
Can CM be reconfigured to free up space for fitment of additional roof bolting capacity and/or materials handling and storage? – how will adoption of CHS assist?
Can CM be reconfigured to free up space for fitment of additional rib bolting capacity and/or better accommodate longer rib bolts?
What technologies need to be developed to facilitate mechanisation/ automation of long tendon installation?
“Out of the box” support methods, technologies, and consumables?
The Opportunities
Continuous Haulage
Can CMs be reconfigured to produce a controlled and sized product flow that obviates need for a hopper/sizer between the CM and CHS?
How can the functionality of the hopper/sizer be extended ie; secondary support installation platform, strata support materials storage)?
The Opportunities
Continuous Haulage
Can CMs be reconfigured to produce a controlled and sized product flow that obviates need for a hopper/sizer between the CM and CHS?
How can the functionality of the hopper/sizer be extended ie; secondary support installation platform, strata support materials storage)?
Process Monitoring and System Integration
Significant potential to improve development rates by better managing available time through improved process monitoring and reporting (ie; achieving longwall standards of process monitoring, reporting and control)
Enhanced levels of system integration will be required to achieve the potential development rates from best practice development systems
Will require application of state-of-the-art communication technologies and decision support systems to roadway development
The Opportunities
What’s ACARP Doing – Strata Support?
Review of Roof Support Options for Next Generation CM – awarded as part of 2015 ACARP funding
Self Drilling Bolt Automation (OKA) - shortlisted 2015 ACARP funding
Spin and Push Cable Bolt Feeder (Tornado) - shortlisted 2015 ACARP funding
C17018: Automated Bolt and Mesh Handling System (UOW) –demonstrated December 2012
C20041: Alternative Skin Confinement System - ToughSkin (UOW/BASF) – expect to submit for preliminary regulatory testing (LOBA) December 2015
What’s ACARP Doing – CHS?
C24023: Continuous Haulage System for Gateroad Development (Premron)
Stage 1: 24m long Prototype System – demonstrated December 2013
Stage 2: 50m long Mine Functional System – demonstrated December 2014
Stage 3: 150m long Mine Compliant/Mine Functional System – scheduled to be demonstrated March/April 2016
Stage 4: Underground Trial of 180m long Mine Compliant/Mine Functional System commencing July 2016 - shortlisted 2015 ACARP funding
C23018: Continuous Haulage System for Gateroad Development (Scott Technology)
Stage 1: FRAS Conveyor and 50m Prototype Demonstration
What’s ACARP Doing – Next Gen CM?
Ground Support Functional Specification for Next Generation CM –shortlisted 2015 ACARP funding
C23015: CM Navigation System (CSIRO)
Currently being fitted to MB650 for underground trials 4Q 2015
Second system being factory fitted to an MB650 for delivery 2Q 2016
Continuing Engagement with OEMs
RDTG’s vision is to ensure a sustainable Australian underground coal mining industry:
Remove exposure of persons to hazards associated with the roadway development process
Optimize development system efficiency and productivity
Supports overall mine productivity
Thank you!
Integrated Roadway Development System
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