ROADWAY DEVELOPMENT IMPROVEMENT PROJECT

1
ROADWAY DEVELOPMENT IMPROVEMENT PROJECT

• CM2010 Update
• Greg Pawley, Xstrata Coal
• Bob Gordon, BHP Billiton Illawarra Coal
• Guy Mitchell, BMA Coal
• August/September 2010

2
CM2010 Update

• CM2010 RD Strategic Review
• Current Projects
• New Projects Under Consideration

3
CM2010 RD Strategic Review

• Strategic review conducted in July 2010 with
  objective of reconfirming and/or amending the
  CM2010 Vision, Goals, Measures and Strategies in
  the context of developments to date, and
  potential RD achievements over the next 3 years

4
Review Inputs

• Existing CM2010 Vision, Goals, Measures and
  Strategies
• Review of current research initiatives including
  both ACARP funded projects and direct industry
  funded initiatives (mines and OEMs)
• Fundamental Analysis of Roadway Development
  System Richard Porteous excellent analysis of
  contributing factors to roadway development
  performance
• Roadway Development Technology Audit report of
  the Audit completed earlier this year across
  mines, OEMs and suppliers
• CM2010 Technology Gap Analysis as completed by
  RDTG

5
Fundamental Analysis of Roadway Development

• Richard Porteous 2008 study across Xstratas 11
  mines illustrated that adoption of current and
  emerging technologies has the potential to
  achieve significantly improved development rates
• Study based on standard bolting cycle of 6 roof
  and 4 rib bolts per metre, with base case of a
  miner-bolter and 1 SC (bolting constrained
  system)
• Study examines effect of various refinements to
  the system
• Adoption of a bolter-miner with concurrent
  cutting and bolting
• Employment of a second shuttle car throughout
  pillar cycle
• Adoption of self drilling bolts
• Utilisation of a continuous haulage system
• Projected that a rate of 8.5MPOH could be
  achieved with these measures
• Fully details of report available at
  www.undergroundcoal.com.au

6
2010 Technology Audit

• Recommended that the RDTG maintains general
  thrust of CM2010 and review RD priorities in
  regards to
• The development of remote bolting technologies
  including
• Self drilling bolts
• Bolt, washer and mesh storage/handling
• Remotely controlled/automated bolting rigs and
  manipulators
• Associated sensing and monitoring systems
• The development of CM self steering technologies
  including
• Remote sensing, seam profiling, and video
  monitoring
• Machine navigation and steering
• Communication protocols
• Machine supervisory/auto-reporting systems
  (including development of black box data
  logging system)

7
2010 Technology Audit

• Recommendations regarding general thrust of
  CM2010 (cont)
• Addressing issues associated with on-board
  ventilation systems
• Development of SC guidance (automation) systems
• Addressing issues associated with management of
  face services, by either continuous haulage or
  monorail systems, including development of self
  advancing system in later instance
• Developing strategies to address equipment
  certification and regulatory issues, including
  adoption of EMERST design philosophies
• Also recommended that mines continue to undertake
  operational research to optimise face cycle times
  and engage change management expertise when
  introducing new development technologies and
  processes

8
CM2010 Technology Gaps

• Technology gaps identified in CM2010 RD strategy
  include
• CM roof/floor horizon control
• Long tendon installation
• Monorail advancement systems (or alternatively,
  ventilation installation and extension systems)
• Higher capacity ventilation systems
• Remotely steered (automated) shuttle cars
• Collision avoidance systems people and
  machinery
• Supply/logistics systems
• Conveyor advancement systems
• Services advancement systems
• Technology/systems integration
• Communications both verbal and data

9
CM2010 Phase II RD Strategy

• Vision
• An integrated, remotely supervised high capacity
  roadway development mining system that enables 15
  Mtpa longwall mines to be established and
  sustained with a single gateroad 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 un-mineable
• Measures
• 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

10
CM2010 Phase II RD Strategy

• Goals
• 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 2015, demonstrate all the elements of 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
• Encourage and support mines to develop the key
  organisational and technical competencies
  required to support a high capacity mining system
  eg improved engineering availability, people
  behaviour and skills, and planning, organisation
  and process control

11
Current Projects

• C16022 undergroundcoalcom.au
• Recently gone live and can be accessed via
  web-site
• Continuing to develop site with industry support
• C17004 ToughSkin
• Consolidating polymer chemistry research
  following departure of lead researcher March 2010
• Recently identified an industry partner to
  continue development of polymer and coating
  formulation, including registration,
  certification and licensing of product
• Evaluating challenge posed by NSW Chief
  Inspectors notification specifying that
  application or injection of polymeric materials
  for strata support is a licensable activity
• Stage III of the project to commence January
  2011, subject to ACARP funding

12
Current Projects

• C17017 Automated Bolting and Meshing System
• Successfully demonstrated all components of
  system except rib bolt manipulation (now due
  October 2010)
• Stage II of the project has commenced and
  includes an underground trial and demonstration
  of system, and concept design of an integrated
  logistics system
• Initial focus is to fully animate proposed system
  and examine issues associated with full
  automation of system in underground environment
• RDTG member companies identifying suitable site
  and continuous miner to conduct underground trial
• C18023 Continuous Miner Automation
• Successfully demonstrated components of
  navigation system
• Stage II recently commenced and includes an
  underground trial of navigation system on Phoenix

13
Current Projects

• C17010 - CM2010 Project Support
• Development of Roadway Development Handbook
  temporarily suspended to allow focus on providing
  project management support toToughSkin
• Continuing project support role proposed across
  all CM2010 related projects, including
  continuation of Roadway Development Operators
  Workshops to end 2012

14
New Projects Under Consideration

• Rapid Advance Conveyor
• Oregate Pty Ltd
• Automated Monorail Extension System
• Macquarie Manufacturing and UOW Automation and
  Robotics Group
• Development of FRAS Rated Polymeric conveyor
  Idler for Underground Coal Mines
• Ellton Longwall/Dotmar Engineering
  Plastics/Intelligent Polymer Research Institute
  (UOW)