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Longwall 2014
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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
2020 Roadway Development R&D Strategy
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
2020 Roadway Development R&D Strategy
Sta
ke
ho
lde
r E
ng
ag
em
en
t
Enabling Technologies and Systems
Key Process Elements
Improved Engineering Availability
People Behaviour and Skills
Planning, Organisation and Process Control
Pro
ject
Ma
na
ge
me
nt
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
h C
ap
aci
ty R
oa
dw
ay
De
ve
lop
me
nt
Sy
ste
m
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
2020 Roadway Development R&D Strategy
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
Towards an Integrated Development System
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 2 – 7 Day Operation 41 38
Delay Case 3 – 5 Day Operation 82.5 41
Delay Case 4 – 7 Day Operation 35 90
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
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
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
PANEL ADVANCE M/WEEK 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260
BOLTER-MINER
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
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
2.2 P 4FCT-Scenario5
2P PCHS-Scenario5
2.1 P PCHS-Scenario5
2.2 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
1.1 P 4FCT-Scenario5
1.2 P 4FCT-Scenario5
1P PCHS-Scenario5
1.1 P PCHS-Scenario5
1.2 P 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
100m Cut Through Centres
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)
Key Findings and Conclusions
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
Key Findings and Conclusions
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)
Key Findings and Conclusions
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%
Key Findings and Conclusions
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
Key Findings and Conclusions
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
Towards an Integrated Development System
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
Towards an Integrated Development System
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 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
Towards an Integrated Development System
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
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
Towards an Integrated Development System
2014 2020 2017
TRANSITION A TRANSITION B Baseline End State Mid-State
BASELINE Batch
MID-STATE Semi-continuous Non Integrated
END STATE Continuous Integrated
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?
Towards an Integrated Development System
2014 2020 2017
TRANSITION A TRANSITION B Baseline End State Mid-State
BASELINE Longwall Mining >2.6 m
MID-STATE Mine Design and Process
Simulation
END STATE Optimised Exploitation of
Reserves