ACARP Presentation Cutting A Smarter Metre Process optimisation techniques currently being utilised.
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Transcript of ACARP Presentation Cutting A Smarter Metre Process optimisation techniques currently being utilised.
ACARP PresentationCutting A Smarter Metre
Process optimisation techniques currently being utilised
Sandvik Mining and Construction
Process Improvement – Measure
In order to improve processes you need a yardstick or a constant. With the MB it is reasonably obvious that you should use “Mesh Overlap Roof Bolt” to “Mesh Overlap Roof Bolt” as it is almost always one metre. What you do in that metre will affect greatly your panel advance rates.
Some of the easily recognisable areas for inefficiencies are listed below Cutting Techniques Loading and Haulage Techniques Bolting Techniques and Bolt Patterns (Roof and Rib) Mine Design and Coal Clearance Design People and Consistancy Machine and Road Maintenance
Sandvik Mining and Construction
Process Improvement – Measure
MINING SYSTEM PERFORMANCE
0.00
2.00
4.00
6.00
8.00
10.00
12.00
10 30 50 70 90 110 130
DISTANCE FROM SHUNT S1 (m)
ME
TR
ES
pe
r O
PE
RA
TIN
G H
OU
R
ABM-25
AB M- 20
Sh utt le Car
Shunt (S 1)
Boo t-end
Le
ng
th o
f Pilla
r
Dis
tan
ce
Sh
un
t - Fa
ce
D ista nce S hunt to Boot
AB M- 20
Boo t-e nd
O ve rdrive
Sh utt le Car
Sh unt (S 1)
TW O HEAD IN G PANEL LAYOUT
W idth of Pi ller
4 roof bolt, 2 rib bolt, mesh, 2 S/C only, 8t cars, 3m cut-out
Continuous Haulage
Self Drilling Bolt
Sandvik Mining and Construction
Process Improvement – Measure
The Operational Report is used to easily recognise your inefficiencies and should be used in conjunction with The Bolting Report in order to drill down on your process.
Sandvik Mining and Construction
Process Improvement – Measure
Reports from a Continuous Haulage MB
Sandvik Mining and Construction
Process Improvement - Consistancy
With both these reports there is room for improvement, Ideally there is only one right way to cut a metre – The Fastest and Safest. In order to improve there is a need to look outside the square and
break down each step of the coaling process to identify bottle necks and either eliminate or manage them into your process
Traditional constraints on production are still valid ie. bolting , wheeling, and services but with the introduction of a continuous haulage product in conjunction with a MB other process improvements became apparent.
• surging / coal size
• horizon control
• transfer points
Sandvik Mining and Construction
Process Improvement - Consistancy
Sandvik Mining and Construction
Process Improvement - Consistancy
BM With Haulage. Identify Exceptions
Repeat Behaviours
Cycle variance / m
Sandvik Mining and Construction
Process Improvement - Consistancy
Why such a big difference?
What can be done to improve consistancy? With haulage you need to match your simultaneous tasks to the
slowest component in order maximise component life and minimise surging or peak loading
Horizon control can be difficult to maintain when operators are pushed and tired.
Floor conditions and outbye belts can suffer from overloaded belts and poor horizon control
One solution is Automation of the cutting process to control horizon and surging
Sandvik Mining and Construction
Process Improvement - Consistancy
Sandvik Mining and Construction
Process Improvement - Consistancy
Auto Cut Improvements Traditionally aimed at floor to roof
cutting in a predefined set of limits Focus on consistant machine set up
and operator interface at start of cut to enable a more consistant Roof to Floor methodology
• Consistant Horizon control
• Production can be slowed to match bolting to relieve belts and transfers
• Coal can be sized at the face to enhance output
• Free’s up an machine operator to assist with bolting activity
• Consistant cycle cutting time
• Lineal transducers in stab jacks
Sandvik Mining and Construction
Process Improvement - Consistancy
Sandvik Mining and Construction
Process Improvement - Consistancy
Shearing up can be a viable component of cutting cycle in order to control coal sizing, and flow depending upon hardness of material and sump depth, It can also be used as the final part of your cycle to prevent bogging and overloading of cutters
Must be used in conjunction with condition monitoring Increased load on cutter assembly
Sandvik Mining and Construction
Process Improvement - Consistancy
Digital Bolting Initial problems during
startup Feedback from operators
and MDG35.1 requirements led to refinments
Importance of focusing automation projects on flexibility and ease of use
Consistant cycle bolting time
Consistant bolt installation leads to better roof support and possibility for reduced bolt density
Sandvik Mining and Construction
Process Improvement - Consistancy
Bolts installed 3-5 minutes
Consistancy issues are related to consumable handling and tooling
Ability to put up primary roof support consistantly, while still having the flexibility to bolt manually and deal with adverse roof conditions
Maintenance and understanding of system
Sandvik Mining and Construction
Process Improvement - Consistancy
Sandvik Mining and Construction
Process Improvement – Bolt Patterns
It is hard to measure your metre when you are forced to put up a centre bolt, With MB Operators See available coal so continue to cut thus only
use the last 50cm of sump
Ineffective bolting technique because you are lengthening the cycle time by adding this standalone process
Is it possible to maintain the same roof bolt density ie. 4 on the metre and 2 on the half, By just installing 6 in a row?
Consider other forms of bolting, QDS, SDB, Secondary support
overdrive then pre bolt intersections before they become intersections from QDS bolters to enable “tram through”
Sandvik Mining and Construction
Process Improvement - Haulage
When installing haulage consider the following Pillar length Vs expected M/OH and shift duration ie.
• 8MOH over 12 hr shift = 96m production but
• 1 hr travel = 88m production
• 1 hr pull back to resupply and return to face = 80m
• Therefore maximum effective shift mining range is 80m if everything goes right
• Can we match mine design to mining range?
• Can we shorten pillars to allow side loading resupply and add 1hr production back to shift?
• Or double consumable storage to allow 2 shifts out of one supply = 140m range
How do you resupply your miner? pre-bolted intersections 60 degree cut throughs
Sandvik Mining and Construction
Process Improvement – Storage For 90m Development we need to carry
270 + Roof Bolts, and chemicals 180 + Rib Bolts, and Chemicals 90 sheets roof mesh 180m rib mesh
Sandvik Mining and Construction
Process Improvement – What Does 8MOH plus look like?
Sandvik Mining and Construction
Process Improvement – What Does 8MOH plus look like?
Sandvik Mining and Construction
Process Improvement – Where Next?
Cutting faster when your bolting constrained can cause panel downtime
In order to allow machines to cut and bolt big metres simultaneously, more consideration has to be given to operator comfort
Focus on cyclic behaviours, find a place for consumables, the next metres bolts, drills, fit implements to machines for drill tip removal and cleaning etc…
Focus on mining and bolting patterns to optimise process efficiency
Support and maintain Autonomous Operations is dependant on supervisors and managers, It may take some getting used to but it will pay dividends
Focus on maintenance due to high cycle rates