ACARP Australian Coal Association Research Program Australian Roadway

ACARP Australian Coal Association Research Program Australian Roadway Development Improvement Project OPERATORS’ WORKSHOPS March 2008 ACARP Project C 15005

SAFETY ASPECTS OF VENUE As advised by venue ACARP Project C 15005 2

OBJECTIVE AND FORMAT Provide a forum for roadway development operators to: Learn of emerging best practice and roadway development initiatives Learn of developments in equipment and technology Network with peers, and share their experience and learnings (and not just their successes) Identify areas for targeted research ACARP Project C 15005 3

FORMAT 5 presentations by operators detailing current operational practices together with one presentation giving an international perspective on roadway development A number of research and technology updates by researchers The presentations each comprise a 20 -25 minute presentation with a 15 -20 minute open forum for discussion and sharing of experiences and learnings The research and technology updates each comprise a 20 minute presentation and a 10 minute open forum for discussion Conclude with a review to capture key findings, identify opportunities to improve the workshop process, and to identify presentations for future workshops Workshop report with copies of presentations to be provided to all participants ACARP Project C 15005 4

INTRODUCTION Prerequisites for attendance: A passion for roadway development, and A willingness to participate in discussions and share experiences ACARP Project C 15005 5

ACARP Australian Coal Association Research Program Australian Roadway Development Improvement Project RESEARCH AND DEVELOPMENT STRATEGY March 2008 Glen Lewis, Xstrata Coal Bob Gordon, BHP Billiton Guy Mitchell, BMA Coal ACARP Project C 15005

ROADWAY DEVELOPMENT R&D STRATEGY - 04/07 Following the March 2007 Roadway Development Workshops the RDTG developed a Roadway Development R&D strategy based upon input given by participants at those Workshops ACARP Project C 15005 7

ROADWAY DEVELOPMENT R&D STRATEGY - 04/07 Immediate (1 year project) Ø “project management” systems for roadway development (including maintenance) Ø “fundamentals of roadway development” handbook Ø process model for development Ø management structure, style and skills; Ø functional specification for “CM 2010” Medium term (2 -4 years) - “CM 2010 project” (similar to LW project) Ø Ø components that can be retrofitted to current generation machines automated bolting system alternate skin reinforcement and rib confinement services Longer term (+5 years) - “continuous mining system” Ø integrated system incorporating cutting, loading, conveying, support, and logistics flowing on from CM 2010 project ACARP Project C 15005 8

KEY ELEMENTS - CM 2010 R&D STRATEGY Later in 2007 we attempted to develop a model which demonstrated the relationship between key elements of the CM 2010 R&D strategy as it became known as ACARP Project C 15005 9

ACARP FUNDING 2008 Pleasing to advise that a number of roadway development related R&D projects have been funded by ACARP commencing 2008 following recommendations made by the RDTG, including development of: Ø A polymer based alternative skin reinforcement and confinement system - to eliminate the installation of steel mesh and, in conjunction with SDB, allow operators to be removed from the immediate face area while improving roadway development performance Ø An automated system for installing SDB and mesh, including an integrated logistics and materials handling system from the supplier to the face - to similarly remove operators from the immediate face and improve roadway development performance Ø A simulation model to enable the limitations of current development processes to be understood, and to evaluate potential roadway development technologies and practices before committing scarce resources to pursue development and/or conduct field trials Ø A handbook to capture the industry’s current “body of knowledge” of roadway development practice for future generations ACARP Project C 15005 10

CM 2010 R&D STRATEGY - MARCH 2008 The RDTG has continued to develop the CM 2010 R&D strategy to provide the framework for an integrated approach to developing a new generation high capacity roadway development system Now like to share the strategy with you and invite your review and critique ACARP Project C 15005 11

KEY STRATEGIES – CM 2010 Develop “self-steering” technologies and systems that enables mining equipment to mine roadways in accordance with predetermined survey controls and to maintain both azimuth, horizon and grade control within a variable seam horizon, and to totally automate the cutting and loading cycle (including mining breakaways) thus enabling equipment to be remotely supervised Ø Will require a combination of fundamental and applied research building upon Highwall Mining and Longwall Automation technologies Ø CSIRO Queensland Centre for Advanced Technologies has demonstrated capabilities Ø Key R&D element over next 2 -3 years ACARP Project C 15005 12

KEY STRATEGIES – CM 2010 Develop technologies and systems that enables face services to be extended within the 3 minute cut, load support cycle and without direct operator involvement Ø One monorail system currently being reinstalled at Mandalong with recent orders placed for 2 new monorail systems Ø Expected to be largely driven by mine sites, with support from and feedback to RDTG Ø Will predominantly require operational improvement to apply existing technologies with some applied research required to automate installation of monorails and integrate into a remotely supervised, high capacity mining system ACARP Project C 15005 13

KEY STRATEGIES – CM 2010 Develop systems that enables the automated installation of conventional resin anchored bolts and self drilling bolts, and to feed bolts and mesh to the installation hardware without direct operator involvement Ø Will require a combination of fundamental and applied research Ø UOW recently awarded ACARP funding to pursue this initiative Ø Joy have prototype carousel bolter and Sandvik have operational carousel bolters (metaliferous sector) that could provide basic equipment platform, whilst CSIRO has developed a range of technologies for the ACBM that could potentially be applied Ø Key R&D element over next 2 -3 years ACARP Project C 15005 14

KEY STRATEGIES – CM 2010 Develop alternative skin reinforcement and confinement technologies and systems that eliminates the installation of roof and rib mesh and provides an enhanced roof and skin reinforcement medium Ø Will require a combination of fundamental and applied research Ø UOW recently awarded ACARP funding to pursue this initiative Ø Initial research shows considerable promise (refer Chris Lukey’s presentation) Ø Key R&D element over next 1 -2 years ACARP Project C 15005 15

KEY STRATEGIES – CM 2010 Demonstrate, adapt and refine continuous haulage technologies and systems currently being used overseas for use in Australian longwall mines, and subsequently combine suitable coal clearance technologies into an integrated, remotely supervised high capacity mining system Ø Two continuous haulage systems currently being installed or commissioned in Australian mines, with a third system expected to be ordered mid 2008 Ø Expected to be largely driven by mine sites, with support from and feedback to RDTG Ø Will predominantly require operational improvement to apply existing technologies with some applied research required to integrate into a remotely supervised, high capacity mining system ACARP Project C 15005 16

KEY STRATEGIES – CM 2010 Develop technologies and systems that enables panel services to be advanced on a continuous basis in parallel with mining operations or alternatively, within scheduled maintenance windows Ø Expected to be largely driven by mine sites, with support from and feedback to RDTG Ø May require some applied research to develop extensible conveyors and integrate major services (H/T power reticulation, transformers, etc) into a services management system Ø May also require some applied research to develop more efficient mine compliant services (eg; pipework) ACARP Project C 15005 17

KEY STRATEGIES – CM 2010 Develop mine logistics systems that enables mining and maintenance supplies and consumables to be delivered to the immediate mining area at a rate consistent with a 3 minute cut, load support cycle. Logistics systems should similarly enable materials and equipment required for panel infrastructure and services to be delivered to the mining area at a rate consistent with a 200 m per day advance rate Ø Expected to be largely driven by the yet to be determined design of the primary mining equipment, and mine specific parameters Ø Therefore expected to be driven by mine sites, with support from and feedback to RDTG Ø May require some applied research to develop a mechanised, extensible supply system, and for overall system integration Ø Expected to draw upon logistics systems expertise from other industries ACARP Project C 15005 18

KEY STRATEGIES – CM 2010 Develop technologies and systems that enables high speed haulage roadways to be constructed and maintained without impacting the continuity of face operations Ø Expected to draw upon roadway and pavement construction and maintenance expertise from other industries Ø Expected to be largely driven by mine sites, with support from and feedback to RDTG ACARP Project C 15005 19

KEY STRATEGIES – CM 2010 Develop strategies to improve engineering availability of equipment and enable equipment to operate at design rates (10 MPOH) for 20 or more hours per day Ø Expected to be largely driven by mine sites with strong support from OEM sector Ø Industry wide coordination will be necessary to improve overall engineering competency standards across the industry and to ensure industry wide standards are developed and adopted. Hence anticipate continuing support from and feedback to RDTG ACARP Project C 15005 20

KEY STRATEGIES – CM 2010 Develop pre-mining systems, including gas drainage, seam dewatering, and the detection and pre-treatment of faults and other geological anomalies, to enable a safe, compliant and productive mining environment to be maintained Ø Expected to include a combination of fundamental and applied research, together with a major operational improvement component at a mine site level Ø CSIRO Queensland Centre for Advanced Technologies and CRC Mining have demonstrated research capabilities in this field Ø Anticipate that specialist service providers (eg; drilling contractors) will also have significant input into developing industry wide capabilities ACARP Project C 15005 21

KEY STRATEGIES – CM 2010 Develop hazard management and safety compliance systems to enable sustained high performance levels to be achieved, including gas content testing, the detection and location of geological structures, and the management of variable strata conditions Ø Expected to include a combination of fundamental and applied research, together with a major operational improvement component at a mine site level Ø CSIRO Queensland Centre for Advanced Technologies and CRC Mining have demonstrated research capabilities Ø Anticipate that specialist service providers (eg; geotechnical consultants) will also have significant input into developing industry wide capabilities ACARP Project C 15005 22

CM 2010 CRITIQUE Later today we will invite your feedback and critique on the CM 2010 project including Ø What improvements could we make to the CM 2010 Research and Development strategy? Ø Any champions interested in being involved at a R&D, OEM or mine site level? We would also ask that you take the CM 2010 Research and Development strategy document back to site, whether it be a mine, workshop or laboratory, and to share it with your colleagues and give feedback directly to the RDTG via Gary Gibson (gary@yarrowlumla. com. au) ACARP Project C 15005 23

ACARP Australian Coal Association Research Program FUNDAMENTAL ANALYSIS OF DEVELOPMENT CYCLES AT XSTRATA NSW MINES Richard Porteous, Xstrata NSW ACARP Project C 15005

ACARP Australian Coal Association Research Program IMPROVING ROADWAY DEVELOPMENT PERFORMANCE AT ULAN Ben Smith, Ulan ACARP Project C 15005

ACARP Australian Coal Association Research Program MORNING TEA ACARP Project C 15005

ACARP Australian Coal Association Research Program ROADWAY DEVELOPMENT AND THE INTRODUCTION OF HILTI SELF DRILLING BOLTS AT BROADMEADOW Matthew Jones, Broadmeadow ACARP Project C 15005

ACARP Australian Coal Association Research Program SELF DRILLING BOLT UPDATE Peter Gray, Ground Support Services ACARP Project C 15005

ACARP Australian Coal Association Research Program THE NEWSTAN/MANDALONG MONORAIL SERVICES MANAGEMENT SYSTEM Ray Coppins, Newstan/Mandalong Scott Jensen, Macquarie Manufacturing ACARP Project C 15005

ACARP Australian Coal Association Research Program LUNCH ACARP Project C 15005

ACARP Australian Coal Association Research Program EVOLUTION OF GATEROAD DEVELOPMENT IN THE PITTSBURGH NO 8 SEAM (USA) Brian Thompson, Joy Mining Machinery ACARP Project C 15005

ACARP Australian Coal Association Research Program RESEARCH UPDATE - ALTERNATIVE SKIN REINFORCEMENT PROJECT Chris Lukey and Jan Nemcik, UOW ACARP Project C 15005

ACARP Australian Coal Association Research Program RESEARCH UPDATE – AUTOMATED BOLTING AND MESHING PROJECT Stephen Van Duin, UOW ACARP Project C 15005

ACARP Australian Coal Association Research Program AFTERNOON TEA ACARP Project C 15005

ACARP Australian Coal Association Research Program ROADWAY DEVELOPMENT AT CRINUM Martin Zgrajewski, Crinum ACARP Project C 15005

ACARP Australian Coal Association Research Program FUTURE DIRECTIONS – CM 2010 PROJECT Glen Lewis, Xstrata Coal Bob Gordon, Centennial Coal Guy Mitchell, BMA Coal ACARP Project C 15005

CM 2010 CRITIQUE What improvements could we make to the CM 2010 Research and Development strategy? Any champions interested in being involved at a R&D, OEM or mine site level? ACARP Project C 15005 37

VISION - CM 2010 An integrated, remotely supervised high capacity roadway development mining system that enables 15 Mtpa longwall mines to be established and sustained with a single 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 unminable ACARP Project C 15005 38

MEASURES - CM 2010 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 ACARP Project C 15005 39

GOALS - CM 2010 • 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 2010, establish programs that enable the key organisational and technical competencies required to support a high capacity mining system to be developed throughout the industry, eg; improved engineering availability, people behaviour and skills, and planning, organisation and process control • By end 2011, improve industry roadway development performance to current industry best practice levels of 5 MPOH for 12 or more hours per day • By end 2012, demonstrate 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 ACARP Project C 15005 40

KEY OBJECTIVES - CM 2010 A high capacity roadway mining and support system capable of 1 metre roadway advance cycles in 3 minutes, with all functions of the system remotely supervised without personnel in the immediate face area A coal clearance system that enables the mining and support system to achieve the target cycle times, without impacting the ability to service and support that (mining and support) system A panel advance system that enables services to be advanced without impacting operation of the mining, support and coal clearance systems A mine logistics system that ensures on-time delivery of mining and maintenance supplies and consumables, and panel infrastructure and services. The system also includes the construction and maintenance of roadways to facilitate the rapid distribution of personnel, materials, and equipment Pre-mining systems that remove potential impediments to high performance levels, including gas drainage, seam dewatering, and the location and pretreatment of faults and other geological anomalies ACARP Project C 15005 41

KEY OBJECTIVES - CM 2010 Mine design systems that optimise the high capacity roadway development system, Significant improvements in engineering availability and reliability levels through improved equipment specification, design, pre-manufacture simulation and equipment manufacture, and improved operating and maintenance standards Development of people’s behaviour and skills to better lead, communicate, plan, supervise, operate and maintain technologically complex systems and equipment Hazard management and safety compliance systems that enable sustained high performance levels to be achieved Process management tools that enable sustained performance levels of 200 m per day of roadway development to be achieved • Development of mining and ancillary equipment that reduces the exposure of personnel to work place hazards, eliminates manual handling, and improves ergonomics ACARP Project C 15005 42

CM 2010 CRITIQUE What improvements could we make to the CM 2010 Research and Development strategy? ACARP Project C 15005 43

WORKSHOP CRITIQUE What improvements could we make to the structure and format of the Workshop: Suitability of location, venue and facilities? Timing (eg; day of week, and actual times) What issues should be the subject of future workshops? Any volunteer presenters? Anything else? ACARP Project C 15005 44

END OF WORKSHOP Thank you! Please join us for some for refreshments and further networking! ACARP Project C 15005 45