gary gibson - acarp roadway development

Towards an Integrated Roadway

Development System (Generational Transformation in Roadway

Development)

Trends in Roadway Development?

Development Rates MPOH 2005-2014

“… A generational transformation in roadway development …”

Theme adopted by ACARP’s Roadway Development Task Group for the collaborative development of an Integrated Roadway Development System

WIP and currently under consideration by the RDTG and OEMs

My views and not necessarily those of ACARP and the Roadway Development Task Group

Towards an Integrated Development System

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

2020 Roadway Development R&D Strategy

The solution is an integrated development process that:

Mines, loads and transports product

Supports roof and ribs

Delivers and handles strata support and other consumables

Advances face services

Supports efficient (safe and ergonomic) human interaction with system

Provides an information system that allows effective management of the process

Facilitates effective maintenance

Minimises the total cost of development

Meets Australian mining requirements


Five core process elements of the integrated development system:

‘’Continuous’’ mining platform

Strata support installation system

‘’Continuous’’ coal haulage system

Face and panel services advancement/management

Integrated strata support materials resupply system


Sta

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Enabling Technologies and Systems

Key Process Elements

Improved Engineering Availability

People Behaviour and Skills

Planning, Organisation and Process Control

Pro

ject

Ma

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of

R&

D

Pro

ject

sOrganisational Competencies Implementation

Strategies

Strata Support Materials Handling

Self Steered Continuous

Miner

Automated Strata Support

Continuous Haulage

Face Services

Hig

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aci

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dw

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De

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Sy

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RDTG now recognises it has reached a watershed:

The continuing development of the core process elements and key enabling technologies is fundamental to improving roadway development performance

Realisation of these technologies and any substantive improvement in performance will however require development of a new integrated mining platform, and

Development of such a platform and the integration of these technologies is beyond the capacity of ACARP, an individual mining company, or OEM


RDTG has proposed a strategy to collaboratively develop an integrated roadway development system, involving mining companies, OEMs and researchers:

Industry workshop proposed for 24-26 November 2014 to develop industry support and consensus

Key members currently developing a business case for consideration at the workshop

Extensive simulation studies conducted to better understand the key drivers of and constraints to development performance


Developed by Dalin Cai at UOW as part of his PhD studies, with extensive input from industry mentors

Comprises roadway development and longwall extraction modelling capabilities

Extensive field testing against existing modelling and analysis regimes has validated Flexsim model

Over 300 scenarios modelled with most being subject to multiple iterations

Model run for 10 pillar cycle with KPI’s averaged over complete cycle

Flexsim Simulation Model

Configurable

Flexsim Model

By Developer

Development Sequence

Shift Schedule

Face Operation

3D View ...

Statistics tracking

Dynamic charts & graphs

Multi-objective Optimization

MTBF and MTTR

Panel Configuration

Machine Configuration

Excel or Other Databases

Export or import data

By Model User or Analyst

Flexsim Simulation Model

Simulation Scenarios

Parameter Options 1 2 3 4 5 6

No of Entries 2 2 3

Pillar Length (m) 4 40 100 150 200

Entry Centres (m) 12 37

Miner Type 4 1 Miner-Bolter

1 Bolter-Miner

2 Miner-Bolters

2 Bolter-Miners

Cut & Load Cycle 4 1.9 min /0.5 m

1.2 min /0.5 m

3.8 min /1.0 m

2.4 min /1.0 m

Support Type

8

Haulage System

6 1SC 2SC 4FCT Premron CHS

1 Slow SC

2 Slow SC

Periodic and Random Delays

7

KPI’s 5 Days/10 Pillars Panel

Advance

Days/1 Km Panel Advance

Metres/ Day

Panel Metres/5

Day Week

Panel Metres/7

Day Week

Support Types

1 Pass 2 Pass 3 Pass 3 Pass and Limited Tendons

(30 m/pillar)

3 Pass and Full

Tendons

Standard 2 min Mesh + 6 min Bolt

2 min Mesh + 5 min Bolt + 5 min Bolt

2 min Mesh + 5 min Bolt + 5 min Bolt + 4 min Bolt

2 min Mesh + 5 min Bolt + 5 min Bolt + 8 min Tendon

2 min Mesh + 5 min Bolt + 5 min Bolt + 8 min Tendon

Fast 1.6 min Mesh + 4 min Bolt

1.6 min Mesh + 4 min Bolt + 4 min Bolt

Very Fast 1.2 min Mesh + 3 min Bolt

1.2 min Mesh + 3 min Bolt + 3min Bolt

Process Delays

► 21 hour panel advance (standard) plus 15 hour and 10 hour options

► Flit CM between roadways (CM Only) – 1 m/min for CM

► Flit CM between roadways (CM and CHS or CM and Monorail) - 30 min + 5 m/min

► Resupply and stonedusting (CM and PCHS) – 50 min each 25 metres

► Resupply and stonedusting (4FCT) – 50 min each 25 metres plus withdrawal of 4FCT at 10 m/min

Periodic Delays

► Typically non-scheduled time, planned maintenance, SOS and PASS meetings – hours per week

Random Delays

► Typically unplanned maintenance and operating delays, external idle time, excess travel time – hours per 100 m Panel Advance

Process, Periodic and Random Delays

Periodic and Random Delays Periodic Delays

(h/week) Random Delays (h/100 m Panel

Advance)

Without Delays 0 0

Delay Case 1 – 7 Day Operation 42 50


Delay Case 3 – 5 Day Operation 82.5 41


Delay Case 2 – 80% Random Delays 42 30.4

Delay Case 2 – 80% Random Delays 32.8 38

Delay Case 2 – 80% Random and Periodic Delays

32.8 30.4

PANEL ADVANCE M/WEEK 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260

MINER-BOLTER

100m Cut Through Centres

3P+F 1SC

3P+F 2SC

3P+F 4FCT

3P+F PCHS

3P+L 1SC

3P+L 2SC

3P+L 4FCT

3P+L PCHS

3P 1SC

3P 2SC

3P 4FCT

3P PCHS

2P 1SC

2P 2SC

2P 4FCT

2P PCHS

2P 1SC-X.1

2P 2SC-X.1

2P 4FCT-X.1

2P PCHS-X.1

2P 1SC-X.2

2P 2SC-X.2

2P 4FCT-X.2

2P PCHS-X.2

140.9

140.9

141.0

144.2

159.1

159.1

159.2

163.3

162.0

162.0

162.1

166.3

190.3

190.3

190.5

196.4

212.2

212.7

212.9

220.3

227.2

239.1

241.3

250.8

80.8

80.8

80.8

82.2

88.4

88.4

88.5

90.1

89.6

89.6

89.7

91.4

100.6

100.6

100.6

102.8

108.4

108.6

108.6

111.1

113.4

117.3

118.0

121.0

Miner Bolter (100m) - 1


MINER-BOLTER


1P 1SC

1P 2SC

1P 4FCT

1P PCHS

1P 1SC-X.1

1P 2SC-X.1

1P 4FCT-X.1

1P PCHS-X.1

1P 1SC-X.2

1P 2SC-X.2

1P 4FCT-X.2

1P PCHS-X.2

1P 1SC 15hr PA

1P 2SC 15hr PA

1P 4FCT 15hr PA

1P PCHS 15hr PA

1P 1SC 10hr PA

1P 2SC 10hr PA

1P 4FCT 10hr PA

1P PCHS 10hr PA

209.1

209.6

209.8

217.0

221.4

226.8

227.4

235.8

228.0

242.9

248.2

258.2

225.9

226.6

226.8

235.2

242.2

243.0

243.3

252.9

107.3

107.5

107.6

110.0

111.5

113.3

113.5

116.3

113.7

118.5

120.2

123.2

113.0

113.2

113.3

116.1

118.3

118.5

118.6

121.6

Miner Bolter (100m) - 2


BOLTER-MINER


3P+F 1SC

3P+F 2SC

3P+F 4FCT

3P+F PCHS

3P+L 1SC

3P+L 2SC

3P+L 4FCT

3P+L PCHS

3P 1SC

3P 2SC

3P 4FCT

3P PCHS

2P 1SC

2P 2SC

2P 4FCT

2P PCHS

2P 1SC-X.1

2P 2SC-X.1

2P 4FCT-X.1

2P PCHS-X.1

2P 1SC-X.2

2P 2SC-X.2

2P 4FCT-X.2

2P PCHS-X.2

125.5

125.5

125.6

128.1

139.7

139.7

139.8

142.9

141.9

141.9

142.0

145.2

163.2

163.2

163.3

167.6

179.3

179.3

179.5

184.7

198.8

199.1

199.2

205.7

73.9

73.9

73.9

75.1

80.2

80.2

80.3

81.6

81.2

81.2

81.2

82.6

90.1

90.1

90.1

91.9

96.4

96.4

96.5

98.5

103.7

103.8

103.8

106.1

2P 4FCT-Scenario5

2.1 P 4FCT-Scenario5


2P PCHS-Scenario5

2.1 P PCHS-Scenario5


102.2

110.4

120.1

104.4

113.0

123.2

194.8

218.2

248.1

200.9

225.9

258.1

Bolter Miner (100m) - 1

1P 4FCT-Scenario5



1P PCHS-Scenario5



116.7

123.7

130.6

119.6

127.0

134.3

237.3

260.0

283.7

246.5

271.0

296.9

PANEL ADVANCE M/WEEK 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300

BOLTER-MINER


1P 1SC

1P 2SC

1P 4FCT

1P PCHS

1P 1SC-X.1

1P 2SC-X.1

1P 4FCT-X.1

1P PCHS-X.1

1P 1SC-X.2

1P 2SC-X.2

1P 4FCT-X.2

1P PCHS-X.2

1P 1SC 15hr PA

1P 2SC 15hr PA

1P 4FCT 15hr PA

1P PCHS 15hr PA

1P 1SC 10hr PA

1P 2SC 10hr PA

1P 4FCT 10hr PA

1P PCHS 10hr PA

177.6

184.1

192.2

198.2

190.0

197.5

206.8

213.8

204.3

213.0

223.9

232.0

189.6

197.0

206.4

213.3

201.0

209.3

219.9

227.7

95.8

98.2

101.3

103.4

100.5

103.2

106.5

108.9

105.6

108.7

112.4

115.0

100.3

103.0

106.4

108.8

104.4

107.4

111.0

113.6

Bolter Miner (100m) - 2

The Bolter-Miner configuration typically shows a 7-14% improvement in development rates over a Miner-Bolter in all scenarios modelled due to the ability to concurrently cut, load and support

Key Findings and Conclusions

Typical Periodic and Random Delay profiles effectively halve weekly development rates

► there appears to be 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)


Weekly Operating Time – Bolter-Miner

operation time

28%

weekend

29%

Periodic delay

time

24%

Random delay

time

19%

1P 1SC

1P 1BM with 1SC

Delay Case 3 – 5 Day Operation Delay Case 3 – 5 Day Operation

28%

32%

1P 1BM with 1SC

Weekly Operating Time – Bolter-Miner

Delay Case 2 – 7 Day Operation

Process is essentially support constrained throughout “normal” range of support installation times modelled, including 1, 2 and 3 Pass support modes

► although Premron CHS shows a potential 2-3% improvement above other haulage options in “normal” support modes

Improving support cycle times for both 1 and 2 Pass support modes reduces support constraint and allows potential of a CHS to begin to be realised - 3-8% improvement with a Premron CHS and up to 6% with 4FCT (the gains from continuous haulage also continue as over)

► the extent of support constraint evident in the development process warrants a major R&D focus to pursue alternative support regimes and automation of the installation process

Even though support constrained rates are highly sensitive to SC wheeling speeds (ie; floor conditions, operators) and discharge times - Slow SC options reduce rates by 7-13% in 1 Pass support mode


As Compared with 1.9min/0.5m cut

Impact of Cutting Cycle

The Premron CHS is shown to increase development rates by 3-8% against a standard SC or 9-21% against Slow SC options (with full 1.0 m cut out further increasing rates)

Withdrawal of the 4FCT for strata support resupply and stonedusting at routine intervals erodes potential to improve rates (1-6% against a standard SC)


CHS Versus SC - Bolter Miner

Adoption of monorail services management systems shown to increase development rates by 2-3% due to improved flit speeds, and further 11-12% due to reduced panel advance times (12 hours)

► Integration of the services management functions into the CHS options has potential to further improve development rates (subject to reduced panel advance times)

Reducing the panel advance time from the standard 21 hours to 15 hours or 10 hours has the potential to improve development rates by 5% and 10% respectively

Adoption of 150m cut through centres typically improves average weekly development rates by 7%


To achieve 150m of panel development per week in a 2 heading configuration to support a 7-8 Mtpa longwall with a single gateroad development unit would require:

► 7 day operation, 100 m centres, 10 hour Panel Advance AND

► Reducing Periodic and Random Delays by 20% AND

► Reducing support cycle times (Fast 1 Pass – 1.6 + 4.0 min or Fast 2 Pass – 1.6 + 4.0 min + 4.0 min ) AND

► 3.8 min /1.0m cut

► CHS


Is it Possible?

Beltana Super Unit

Towards an Integrated Roadway

Development System

What is the future of underground mining?

Now (Baseline)

Longwall performance constrained by current development practices, equipment, and a Batch Production system

Future (End State)

Longwall mines require a radically new step-change in roadway development technology and equipment to achieve Continuous Production

Capital efficient extraction systems required to optimise exploitation of thinner seams and/or smaller deposits

Interim (Mid-state)

Pilot and embed step-change solutions to achieve a Semi-Continuous, Non-Integrated Development System and ultimately Continuous Production


2014 2020 2017

TRANSITION A TRANSITION B Baseline End State Mid-State

BASELINE Batch

MID-STATE Semi-continuous Non Integrated

END STATE Continuous Integrated

Towards a generational transformation in roadway

development

What are the key Roadway Development elements to change?

1. Coal Haulage To continuously convey product from the face to the panel conveyor

2. Excavation and Support To enable concurrent excavation and installation of primary support on a continuous basis

3. Strata Support Materials Handling and Resupply To enable resupply of materials without impacting production

4. Face Services Eliminate manual handling and advance face services on a continuous basis

5. System Integration and Automation To enable autonomous operation of the system to reduce the exposure of personnel to

hazards in the immediate face area


2014 2020 2017


BASELINE Batch




development

What is the Roadmap Approach?

Pilot and embed step-change solutions to ultimately achieve continuous Production (End State) through 2 transitions

Transition A (2014-2017) • Priority on Continuous Haulage, automation of Primary and Secondary

(Long Tendon) Support, and application of information and communication technologies (ICT) to improve uptime

Transition B (2017-2020) • Priority on fundamental redesign of mining platform to integrate

Excavation, Support and Materials Resupply functions


2014 2020 2017

TRANSITION A

TRANSITION B

Baseline End State Mid-State

BASELINE Batch




development

Key

Ele

me

nts

Maj

or

Solu

tio

ns

Current Equipment & Processes

CHS Develop, demonstrate and implement CHS

Strata Support

Develop and demonstrate automated primary and secondary support installation and handling systems

ICT Develop and adopt integrated monitoring and reporting system

New Equipment & Processes

Mining Platform

Design, Prototype, Implement

Materials Resupply & Services

Develop, Prototype, Implement

System Integration

Integrated autonomous operation


2014 2020 2017


BASELINE Batch



ROADMAP: Towards a generational transformation in roadway development

Key

Ele

me

nts

Current Equipment & Processes

CHS Develop, demonstrate and implement CHS

Strata Support

Develop and demonstrate automated primary and secondary support installation and handling systems

New Equipment & Processes

Mining Platform

Design, Prototype, Implement

Materials Resupply & Services

Develop, Prototype, Implement

System Integration

Integrated autonomous operation

VISION Secondary extraction with continuous high volume production and high safety by 2020

MISSION Step-change in roadway development production and safety – more predictable, reliable, controllable, efficient, profitable

APPROACH Pilot and embed step-change solutions

(Design, Trial, Implement) (Design, Trial, Implement, Optimise)

Constrained by inherent equipment design and lack of system integration

Step change in system design and integration

Remove haulage constraints and improve support capabilities

Production Highly constrained by support and haulage functions

Costs High Operating

Efficiency Unreliable, inability to optimise

Technology Slow and reluctant adopters

Production Doubling of development rates

Costs 25% reduction in Operating

Efficiency Improved reliability and sustainability

Technology Embed emerging technologies

Production Single gateroad development unit supporting high capacity extraction system

Costs Further 25% reduction in Operating

Efficiency Reliable and predictable with sustained system effectiveness

Technology Embed integrated technologies and systems

What are the key mining optimisation factors?

1. How can mine/panel designs be varied to enable longwalls to operate more effectively, at lower cost, and with improved safety?

2. How can mine/panel designs be varied to enable longwalls to operate effectively, at lower cost, and with improved safety in thinner and/or less extensive (smaller) deposits?

3. What mine/panel designs and mining methods need to be developed and adopted to enable thinner and/or less extensive (smaller) deposits to be exploited at longwall comparable productivity, cost and safety levels?


2014 2020 2017


BASELINE Longwall Mining >2.6 m

MID-STATE Mine Design and Process

Simulation

END STATE Optimised Exploitation of

Reserves