ACARP PROJECT C15005 AUSTRALIAN ROADWAY ...ACARP PROJECT C15005 AUSTRALIAN ROADWAY DEVELOPMENT -...

ACARP PROJECT C15005 AUSTRALIAN ROADWAY DEVELOPMENT - CURRENT STATUS

APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name? M0013 Seam Thickness? 7m4 Roadway height as mined - Mains? 3.2m

5 Roadway height as mined - Panels? 3.2m

6 Roadway width as mined - Mains? 4.8m7 Roadway width as mined - Panels? 4.8m8 Pillar dimensions (centres) - Mains? 40m between adjacent headings, cut throughs vary.

9 Pillar dimensions (centres) - Panels? 45m x 100m

10 Number of development units - Mains? 1

11 Number of development units - Panels? 2Dual miner 2 entry gateroad development.

12 Normal crew manning - Mains? 81 deputy (supervisor), 5 operators, 1 mechanical and 1

electrical tradesperson.

13 Normal crew manning - Panels? 131 deputy (supervisor), 10 operators, 1 mechanical and 1


14 CM type - Mains? 12CM30

15 CM type - Panels? 2 X 12CM30Dual miner unit.

16 Roof bolting system - Mains? Hydramatic rigs 4 x roof 2 x rib

17 Roof bolting system - Panels? Hydramatic rigs 2 x roof 2 x rib (CM95) Hydramatic rigs 4 x roof 2 x rib (CM37)

18 Coal clearance system - Mains? 2 Noyes Hydracars

MINE RESPONSES


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name? M001

MINE RESPONSES

19 Coal clearance system - Panels? 2 Waratah "Waracars"

20 Material supply system - Mains? Eimco and trailers transport bolt pods and mesh into panels with roof bolting pods then lifted onto continuous miner with an Eimco with a jib. Roof mesh modules are

manually loaded individually onto racks on the miner. Rib mesh modules are stored outbye face and manually

handled around immediate face area.

21 Material supply system - Panels? Eimco and trailers transport bolt pods and mesh into panels with roof bolting pods then lifted onto continuous miner with an Eimco with a jib. Roof mesh modules are

manually loaded individually onto racks on the miner. Rib mesh modules are hung from monorail and manually

handled around immediate face area. 22 Working arrangements:

Days/week? 7 day development, 5 day longwall.

Shift duration? 8 hours Monday - Friday.12 Hours Friday - Sunday.

Roster system? Fixed roster Weekday roster 5 x 8 hour shifts

Weekend roster 3 x 12 hour shifts

23 Mine challenges:Depth? 380mSeam grade? Slight

In situ and residual gas levels? Neglible in situ gas levels.

Ventilation?

Stress levels and regime? High stress domain associated with close proximity of basal lineaments and strike/slip structures.

Labour availability and turnover, industrial, etc?

Long term, mature workforce.

Limited skills base among miners and trades to replace personnel leaving due to retirement.



MINE RESPONSES

Mine life cycle? 35Mtonnes recoverable remaining in reserves - approximately 10 years life remaining.

24 What other factors may differentiate the mine from other similar mines?

Longwalls orientated at 90 degrees to that typically employed in region.

Adverse ground conditions associated with regional lineaments and strike/slip structures necessitates spiling of

roadway in advance of mining to secure roof - approximately 10% of development drivage considered

adverse.Soft floor associated with adverse ground conditions also necessitated concreting floor of entire maingate roadway.Mine culture exhibits features typical of mines that were

formerly publicly owned.

25 Please specify the typical primary support measures installed in Mains development (ie; number, length, and density of roof bolts, rib bolts, and roof tendons), and the type, sizing and extent of roof and rib meshing and/or straps.

6 X 2100mm roofbolts with roof mesh module /0.9m advance, plus 2 X 1500mm steel rib bolts with rib mesh

module / 0.9m on each rib 4 X 4m JSS tendons/0.9m advance in intersections.

26 Please specify the typical primary support measures installed in Panel development (ie; number, length, and density of roof bolts, rib bolts, and roof tendons), and the type, sizing and extent of roof and rib meshing and/or straps.

6 X 2100mm roofbolts with roof mesh module /0.9m advance, plus 2 X 1500mm steel rib bolts with rib mesh

module / 0.9m on each rib 4 X 4m JSS tendons/0.9m advance in intersections.

27 Please specify any secondary support measures normally installed in Mains development (ie; number, density, type and sizing), and the typical time lag between primary and secondary support installation.

8m twin strand mini-cage cable bolts where required by Strata Action Plan



MINE RESPONSES

28 Please specify any secondary support measures normally installed in Panel development (ie; number, density, type and sizing), and the typical time lag between primary and secondary support installation.

8m twin strand mini-cage cable bolts where required by Strata Action Plan

29 How would you describe the typical roof conditions and support measures installed at the mine?

2 Roof strata to 4m consists of coal interbedded with weak

siltstones and claystones. Above 4m weak sandstone strata

30 How would you describe the typical rib conditions and support measures at the mine?

1 Ribs fully meshed with 2 x 1.5m bolts / metre / rib.

Rectification work frequently required especially on corners. Currently trialling use of 3m rib cables

31 How would you describe the typical floor conditions experienced at the mine?

2 Often experience soft floor in geologically disturbed areas

requiring concreting to continue haulage

32 How many kilometres of roadway development were completed in 1994/95?

6.15km

33 How many tonnes were mined by longwall and/or pillar extraction in 1994/95?

1.34Mt

34 What was the typical development rate in 1995 (m/week/CM) - Mains?

35 What was the typical development rate in 1995 (m/week/CM) - Panels?


8.59km


3.13Mt

38 Current development rate 2005 (m/week/CM) - Mains?

50m/wk/CM



MINE RESPONSES

39 Current development rate 2005 (m/week/CM) - Panels?

70m/wk/CM

40 How many kilometres of roadway development are projected to be mined in 2014/15?

10km

41 How many tonnes are projected to be mined by longwall and/or pillar extraction in 2014/15?

3.25Mt

42 Projected development rate 2015 (m/week/CM) - Mains?

58m/wk/CM

43 Projected development rate 2015 (m/week/CM) - Panels?

80m/wk/CM

44 How would you describe the effectiveness of the coal cutting phase of the roadway development process?

2+ - 3-, low to good.Coal cutting is not the issue, coals falls off face.

45 How would you describe the effectiveness of face roof bolting equipment and systems typically utilised at the mine?

2 - low.In adverse roof conditions need to install 4m and 6m

tendons close to face.

46 How would you describe the effectiveness of the coal clearance system from the face to the conveyor?

3 - good.15SC Warracars a bit big for seam conditions however like

the technology. Looking at 22SC as replacements to enable face to be cut

with two 9 -10 tonne payloads per metre advance.



MINE RESPONSES

47 How would you describe the effectiveness of the materials supply and distribution (logistics) system utilised to service roadway development units?

2+ - 3-, low to good.Switching to rubber tyred system from rail mounted

system.Lot of inefficiency in system currently, labour intensive.

48 How would you describe the effectiveness of panel conveyor and services extensions and practices?

2 - low.Has been area of biggest improvement, now consistently achieving dual miner 2 heading panel moves in 24 hours.

49 How would you describe maintenance effectiveness as it is realised on roadway development equipment?

2 - 3, low to good.Some improvement noted, implementing maintenance

plan.

50 How would you describe the capacity and the effectiveness of the mine's overall coal clearance system?

3 - 4, good to very good.Has been a nightmare, but recently upgraded.

51 What factors contributed to the reported increase in annual development over the past decade (eg; additional units, additional shifts or days worked, increased development productivity)?

Standardisation of equipment.Focus on development process and attention to detail.

Five 8 hour shifts rather than four 9 hour shifts with consistent crews.

Improved panel moves.Improved maintenance management.

52 What factors contributed to the improvement in development productivity (m/week) over the past decade - Mains?



MINE RESPONSES

53 What factors contributed to the improvement in development productivity (m/week) over the past decade - Panels?

54 What factors are likely to contribute to the reported increase in annual development over the next decade (eg; additional units, additional shifts or days worked, increased development productivity)?

Still targeting 9 - 10kms of development per annum, although expect to achieve a 10 - 20% improvement ion

productivity due to incremental technology improvements.

55 What factors are likely to contribute to the projected improvement in development productivity (m/week) over the next decade - Mains?

56 What factors are likely to contribute to the projected improvement in development productivity (m/week) over the next decade - Panels?

57 If you were able to improve the continuous miner cutting rate by a factor of 2 - 3 what other elements of the roadway development process would then limit the overall panel advance rate? - please identify and illustrate.

Bolting and meshing face.Supplies and logistics.

Panel advances in dual panels.

58 Please rank these limiting factors in order of their perceived impact upon panel advance rates (from highest to least adverse impact).

1 - Bolting and meshing face.2 - Supplies and logistics.

3 - Panel advances in dual panels.



MINE RESPONSES

59 If you were able to specify, design, manufacture, commission and successfully operate a new generation roadway development system, what would the system consist of? - please identify and illustrate.

Something like a Joy Sumps Shearer that allows close, intensive face support, cuts and bolts continuously, and

has good ergonomics.Integrated with continuous haulage system that has low

floor bearing pressure.Automated materials handling system.

Improved systems and hardware for installing longer than seam height tendons.

60 If you were able to specify, design and manufacture a new generation roadway development system, what barriers would need to be addressed in order to successfully commission and operate the new system? - please identify and illustrate.

No OEM support.Challenging mining conditions.

Lack of capital.Too early to determine if ABM25 the right technology.



MINE RESPONSES

61 What "new technology" or "new to the mining industry technology" needs to be developed and/or applied in order to allow you to successfully demonstrate the new generation roadway development system? - please identify and illustrate.

Faster systems of bolting.Automation of materials handling.

Roof support technology and systems - using CM as a secondary support platform.

Cutting technology OK.

65 In regards to roadway development, please list and prioritise the 3 most critical issues for research and development over the next 5 -10 years.

New integrated mining system - continuous cutting and bolting machine.

Roof and rib support materials and associated handling systems.

Materials supply (and automation) to reduce labour involved and injuries sustained in manual handling

systems.

66 What involvement have you had with earlier roadway development improvement initiatives and/or research and development?

Introduction of place change mining.Introduction of Joy Sumps Shearer.

Aware of ACBM.1995 ACARP roadway development workshop.



MINE RESPONSES

67 How would you describe those initiatives in respect to their success or otherwise?

Joy Sumps Shearer - as good as 12CM30 when cutting, however suffered from lack of OEM support, lack of parts,

and lack of skilled people.ACBM - exciting, but not sufficiently generic enough for all

mines.Place change mining - highly dependant upon seam

conditions, requires good conditions across major part of mine to justify, lacks roof support flexibility other than

reduced cut outs.ACARP workshop - good initiative, but went no where (here comes ACARP again!!), didn't do the economic

evaluation..

68 What learning was gained from these improvement initiatives in respect to issues or matters that we need to either further address, avoid, or capitalise upon?

Probably better at focussing on process now and involving people to gain ownership - has been refined over past 5

years.

69 What level of interest and support is there at the mine to participate in selected research and development over the next 5 -10 years into roadway development?

3 - very interested in industry based incremental change initiatives.

Particularly in initiatives that are site relevant.Mine is reported to have suffered as a result of earlier trials

of Joy Sumps Shearer and VVVF conveyors.



MINE RESPONSES

70 What specific research and development initiatives into roadway development would the mine be interested in pursuing on an industry basis?

Horizontal drilling technology for installation of Wiborex spiling bolts.

Smaller, lower ground pressure haulage systems.Roof support systems, hardware and consumables.

Monorail systems.Supply systems.

71 Would the mine be interested in collaborating with other mines to jointly develop and trial integrated mining systems, or parts thereof?

Yes

72 What other matters are there that the mine would like to bring to the attention of the ACARP Underground Technical Committee and Roadway Development Task Group?

Company now trying to be more proactive since it has developed critical mass.

Do we need to develop global products or do we need to adapt and customise global products?

Investment in trial of TBM technology would require full commitment from mine and OEM.

A Does mine require a copy of the study report? Yes.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?3 Seam Thickness?4 Roadway height as mined - Mains?

5 Roadway height as mined - Panels?

6 Roadway width as mined - Mains?7 Roadway width as mined - Panels?8 Pillar dimensions (centres) - Mains?

9 Pillar dimensions (centres) - Panels?

10 Number of development units - Mains?

11 Number of development units - Panels?

12 Normal crew manning - Mains?

13 Normal crew manning - Panels?

14 CM type - Mains?

15 CM type - Panels?

16 Roof bolting system - Mains?

17 Roof bolting system - Panels?

18 Coal clearance system - Mains?

M0022.8 - 3.2m2.8 - 3.2m

2.8 - 3.2m

5.2m5.2m

45m between adjacent headings, cut throughs vary.

45m X 150m.Intended to reduce to 45m X 125m in new panels.

1Currently completing Mains before relocation to panel

development.

Second development unit scheduled for panel development late 2005 following delivery of a refurbished

and overhauled continuous miner.

81 deputy (supervisor), 5 operators, 1 mechanical and 1


ABM20

Joy12CM12 due for delivery late 2005.

4 Joy HFX roof bolters and 2 Joy HFX rib bolters.

12CM12 to be fitted with 4 Joy HFX roof bolters and 2 Joy HFX rib bolters.

2 Joy 15SC delivering to breaker feeder.Temporary haulage system currently in place during

installation of Mains conveyor - shuttle cars discharge coal into storage and an FBL loader recovers coal and transports it up to 2km to trunk conveyor system.

MINE RESPONSES


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?19 Coal clearance system - Panels?

20 Material supply system - Mains?

21 Material supply system - Panels?

22 Working arrangements:Days/week?

Shift duration?

Roster system?

23 Mine challenges:Depth?Seam grade?

In situ and residual gas levels?

Ventilation?

Stress levels and regime?


M002MINE RESPONSES

Eimco and trailers transport bolt and mesh pods into panels with roof bolting pods then racked onto continuous

miner with racking jib. Rib bolts and rib mesh are transported in a separate pod, with materials manually

handled around immediate face area.

7 days per week.

9 hours for weekday roster employees.12 hour shifts for weekend roster employees.

Fixed roster.Weekday roster 4 shifts plus RDO per week, and two 12 hour weekend shifts. Overtime rostered to man units on

RDO (Fridays), with D/S Fridays utilised for panel maintenance.

500mSlight

In situ gas levels 12 - 18m3/tonne. Residual gas levels after drainage <2 - 8m3/tonne.

Predominantly methane.

No ventilation issues experienced in development due to provision of high capacity mine ventilation system.

High horizontal stress levels, typically 2 - 2.5 times vertical stress. Principal stress direction varies.

Long term, mature workforce.Labour turnover increasing.Labour availability limited.

Limited remaining mine life detracts recruitment.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?

Mine life cycle?





M002MINE RESPONSES

2 years at current planned production levels.

In situ gas levels, with zones of boggy, low permeability coal. Outburst risk, with remote mining capability being

developed for low permeability zones.

6 X 2400mm roof bolts/metre with full mesh.2 X 1200mm steel rib bolts/metre/rib installed through 1.2m

long 2m high rib mesh. Noted problems experienced with full rib mesh sheets

when retracting CM from roadways.

6 X 2400mm roof bolts/metre with full mesh.2 X 1200mm steel or plastic rib bolts/metre/rib installed

through 1.2m long 2m high rib mesh.

6m or 8m mega bolts installed where required by TARP. Noted that rarely required, and generally only on longwall

installation faces.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?28 Please specify any secondary support

measures normally installed in Panel development (ie; number, density, type and sizing), and the typical time lag between primary and secondary support installation.











M002MINE RESPONSES

3 - good.

2 - poor.Ribs generally good however rib mesh installed to minimise requirements for secondary rib repair.

3 - good

11.55kms

2.18M tonne

9.61kms

2.96M tonne

127.5m/week/CM (1/7/05 - 27/8/05)


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?39 Current development rate 2005 (m/week/CM) -

Panels?








M002MINE RESPONSES

3 - good.Target 2.3MPOH, achieved 1.8MPOH August 2005m

Considered that not cutting constrained.Noted that monorail used for face services including;

cables, water, air, pump out and communications. Also noted that panel sequencing had to include provision for

overdriving roadways for monorails as part of development sequence, otherwise difficulty experienced when flitting

between places.

3+ - good.Joy HFX rigs reported as good.

Noted that at another mine within group that where the development crews had achieved 35 - 40m/12 hour shift

on a consistent basis over 4 days that operators complained of being exhausted due to demands of manual

handling roof and rib support materials.

3 - good.Temporary system being utilised while new mains

conveyor being installed.Mining process haulage constrained beyond 120m from

boot end, even with 2 SC in operation.Shuttle cars considered to be very inflexible.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?47 How would you describe the effectiveness of the

materials supply and distribution (logistics) system utilised to service roadway development units?






M002MINE RESPONSES

2 - low.Roof bolting materials considered to be reasonable

however supply of rib bolt materials and ventilation ducting considered to be a problem.

1 - very low.Typically 5 shifts complete 150m panel advance.

Scheduling, sequencing and coordination of the panel advance and ancillary activities (eg; equipment

maintenance) considered to be the issue rather than labour availability.

3 - good.Typically one of two operating CM units scheduled for

maintenance on day shift on alternate days, Monday to Friday.

2 - low.Ageing infrastructure.

Annual development metreage reduced from 11.5km(1994/95) to 9.6km (2004/05).

Reduced number of development units offset by adoption of 7 day development operations.

Development requirements have reduced as mine has matured.

No statistics available from 1994/05 to compare development performance however considered that

development rates had improved as a result of improved maintenance practices with has resulted in higher levels of

equipment availability.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?53 What factors contributed to the improvement in

development productivity (m/week) over the past decade - Panels?






M002MINE RESPONSES

Redesign of mine to address surface constraints has increased development requirements by 10km for first

longwall block in new area.Deployment of additional development units coupled with

higher utilisation of development units (eg; increased working days).

Considered that difficult mining conditions would constrain development performance and that new technology and

equipment would be required to address future development challenges.

Face support activities.Coal clearance.

Ventilation - dust and gas emissions, extending ducting system.

Supplies - getting them to the face and onboard the continuous miner.

1 - Coal clearance.2 - Face support activities.

3 - Ventilation tubes and face ventilation quantities.4 - Supplies.

5 - Panel advance.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?59 If you were able to specify, design, manufacture,

commission and successfully operate a new generation roadway development system, what would the system consist of? - please identify and illustrate.


M002MINE RESPONSES

Medium diameter borehole drilled from mains to sub-mains (at other end of proposed gateroad) in the centre of each

gateroad and utilised as a return airway to eliminate use of ventilation ducting within development panel (ie; high pressure fan installed in sub-mains). Such medium

diameter drill holes would also provide gas drainage capability and obviate need for much of the small diameter

drilling done currently.Application of tunnelling technolgy and equipment

including continuous haulage systems, ventialtion and supply systems, and design of roadways for purpose

(rather than adopting roadways that suit the seam cross section).

Considered that highwall mining technology may also be successfully applied to roadway development.

Noted that place change mining could be successfully applied providing conditions suitable.

Also noted that in place, place changing with narrow continuous miner and bolter solves the roadway support constraint however does not address the coal clearance

issue.Also noted that any number of continuous miners could cut at rates of 6 - 8m/operating hour, however the problem is

roadway support and coal clearance. Availability of capital.

Commitment from industry to develop and trial equipment - noted that coal mine operators are not in the business of technology development, but rather prefer to apply new

technology developed elsewhere. Considered that operators failed to make strategic

investments in technology and as a consequence did not have the technology available to take advantage of

improved market conditions - spending too much time on recovery plans, labour shedding, and running down plant

and equipment.Further, operators considerd to be too risk adverse and too conservative in their approach to the development ime on

recovery and application of new technology and equipment.

Commitment of OEM sector to build and support new technology and equipment, potentially without fixed sales

contracts in place. Legislative requirements and the existing approvals

system were seen as major barriers to the timely development of new technology and equipment.

Existing roadway design and roadway profile paradigms limit our ability to contemplate new designs and profiles.

Poor record of successfully introducing and managing change.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?61 What "new technology" or "new to the mining

industry technology" needs to be developed and/or applied in order to allow you to successfully demonstrate the new generation roadway development system? - please identify and illustrate.



M002MINE RESPONSES

Not sure whether we know what technology exists in other industry sectors that might be applied within underground

coal sector.In regards to long hole medium diameter drilling the

technology exists in the sewage and water supply sector and potentially be may readily applied (eg; Wollongong -

Port Kembla sewage pipeline). Further, existing technologies are available for drill guidance in coal mines,

together with dewatering coal slurries that would be generated from the drilling process.

Considered that the application of TBM technology may also be appropriate.

Kemcoal Beaver.Introduction of place change mining.

Introduction of dual miner/single crew super units.Development and introduction of monorail services

handling system.Klockner Becorit continuous haulage system.

Paurat miner trials.Cyclic mining systems.

Marietta and Goodman Borer continuous miners.Introduction of ABM20 and 12CM30.In place, place change mining trial.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?67 How would you describe those initiatives in

respect to their success or otherwise?



M002MINE RESPONSES

Kemcoal Beaver - god concept, ventilation a problem in immediate face area, insufficient clearance above

machine.Place change mining - very successful with purpose

designed panel geometry, although condition dependant.Dual miner/single crew super units - parallel tasking of cutting and bolt processes, lot of walking, lot of capital.Monorail services handling system - very successful, practical, and huge advantage with mature workforce.

KB continuous haulage - good principle however system to complex (particularly hosing and cabling), excessive coal

spillage and poor steerage around cut throughs.Cyclic mining system - very successful, consistent

performance with minimal variation.Paurat miner - another complex machine, roadways too

high and narrow, not successfully applied.Marieta and Goodman borers - good roadway profile with

minimal support required, roadways still intact.12CM30 - single pass machine with onboard rigs got

people out of hazardous area, light years from hand held bolting, controlled roadway width.

ABM20 - closest thing to an integrated cuting and bolting machine.

In place, place changing - not given a reasonable chance.

Refer above.

2 - pursue mine related initiatives.Limited opportunities due to stage of development of mine

and existing development priorities, however will readily transfer proven technologies and systems from other

mines.


APPENDIX III - MINE SITE RESPONSES NO FACTOR1 Mine Name?70 What specific research and development

initiatives into roadway development would the mine be interested in pursuing on an industry basis?



A Does mine require a copy of the study report?

M002MINE RESPONSES

Materials handling system for Joy 12CM12.Major focus is on applying and standardising existing

technologies and systems.

Not at this stage.

Would appreciate feedback from study.

Yes










14 CM type - Mains?





M0033 - 6.5m

3.2m

3.2m

5.0m5.0m

45m X 100m

45m X 100m and 30m X 100m.

0

2

7.51 deputy, 5 miners, 1 mechanical and 0.5 electrical trades.

ABM20

Hydramatic Series 2000 and Series 4000 bolting rigs, 4 roof bolting and 2 rib bolting rigs per CM.

Shuttle car and 1500mm conveyor

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M003MINE RESPONSES

1200mm conveyor.

Eimco and QDS Material pods (manual handling) and Capricorn Mining Supply Pod system.

Eimco and QDS Material pods (manual handling) and Capricorn Mining Supply Pod system.

7

8.5 hours N/S Mon - Thurs, 10 hours D/S and A/S Mon - Thurs.

12.5 hours Fri - SunMon - Thurs 3 shift rotating.

Fri - Sun 2 shift rotating.

450 - 650m in working areas.1:15 to 1:5.

3 - 6.5m3/tonne, predominantly CO2.

High horizontal stress regime.

140 employees currently, project 250 employees when longwall and 3 development units fully operational.



Mine life cycle?





M003MINE RESPONSES

20 years.

High horizontal stress regime.High sulphur content in top portion of coal seam.High in-seam water make from adjacent, up dip

abandoned mine workings.Propensity for spontaneous combustion.

Minimum 6 X 2100mm roof bolts/m advance plus 2 X 4m JSS tendons each 3m advance.

Roof meshed with 4.8 X 1.2m mesh.3 X 1200mm mechanically anchored rib bolts/rib/m

advance. Ribs meshed with 1.7 X 2.4m galvanised rib mesh.

Minimum 6 X 2100mm roof bolts/m advance plus 2 X 4m JSS tendons each 3m advance.

Roof meshed with 4.8 X 1.2m mesh.3 X 1200mm mechanically anchored rib bolts/rib/m

advance. Ribs meshed with 1.7 X 2.4m galvanised rib mesh.

2 X 4m point anchored super strands installed at 3m spacing at TARP level 1.

An additional 1 X 8m super strand installed at 3m spacing at TARP Level 2 (post grouted).

If poor ground is expected roadways are developed under TARP Level 1 roof supports.














M003MINE RESPONSES

2 X 4m point anchored super strands installed at 3m spacing at TARP level 1.

An additional 1 X 8m super strand installed at 3m spacing at TARP Level 2 (post grouted).

If poor ground is expected roadways are developed under TARP Level 1 roof supports.

Secondary support regime for longwall gateroads to be finalised prior to longwall commencement.

2 - poor.

1 - difficult.Rapid deterioration of rib bolt holes results in loss of encapsulation therefore mechanical anchors utilised.

1 - difficult.

Mine not operational throughout period.



Panels?








M003MINE RESPONSES

Average 105m/week/CM

Have only scheduled to 2011 although 57kms per annum projected at this time.

Have only scheduled to 2011 although 8.5Mt per annum projected at this time.

Currently scheduled at 320m/Cm/month. Minimum ground support is 12 bolts and one flexi bolt per metre advance.

The roadway is fully meshed on roof and ribs.Currently scheduled at 400m/Cm/month. Minimum ground support is 12 bolts and one flexi bolt per metre advance.

The roadway is fully meshed on roof and ribs.

3 - good.Machines are more than capable - not an issue.

Problem is tramming machines around, training issues, high floor bearing pressure, and lack of self levelling.

Target rate is 2.0MPOH.ABM20 not designed to move in 0.5m increments and

balance bolting/coal haulage cycle.

1 - very low.12 bolts/metre plus 1 X 4m tendon/m, fully meshed roof

and ribs.Poor ergonomic due to multiple bolting rigs.

Rigs are high maintenance.Complicated machines, flat out putting bolts where they

are required.Hole closure of rib bolt holes.

3 - good.Roof and rib bolting operations putting water onto floor

exacerbates soft floor conditions.Considered that industry should look at tyre profiles utilised

in other mining sectors to improve traction and minimise damage to floor.

While considered that continuous haulage may offer some benefits in conditions experienced it was noted that shuttle car based systems capable of 500m/week at other mines.









M003MINE RESPONSES

3 - 4, good to very good.3 hour maintenance window each day, face supplied in this

time.Considered that industry hasn't got on top of this issue yet as system is down while supplies are being replenished.

2 - low.Development only commenced recently, targeting 10 hour

panel moves.Noted that commencing panel moves at same point in

process was ineffective as it was likely that different crews would initiate move and therefore each crew would be doing different part of panel advance process. Intend to

commence move with same crew to ensure repeatability.Ventilation ducting considered a major problem and

development of a duct handling device was recommended.

3 - good.3 hour maintenance window each day.

Duplication of equipment and improved engineering design should allow "very good" levels of maintenance

effectiveness to be achieved.Currently 23% planned maintenance with 12 - 13%

breakdown delays.

3 - good.Delays of 11% experienced on Mains conveyor system

during August 2005 - major refurbishment planned.

Mine has had a checkered history with a number of owner operators, and has trialed a variety of strata support systems and mining methods to cope with the high

horizontal stress regime experienced.









M003MINE RESPONSES

Projected that 3 CM units will not be able to maintain longwall continuity at a level of 2.5 - 3.0Mtpa due to

development conditions and extent of Mains development required to access new working areas.

Seriously considering potential application of single entry development systems (Principal has extensive experience

in single entry drivage overseas).

Increased available cut time.Decrease in time to advance panel services.Reduction in rib support requirements due to

improvements in rib support technology.Improved efficiency in materials handling.

Increased available cut time.Decrease in time to advance panel services.Reduction in rib support requirements due to

improvements in rib support technology.Improved efficiency in materials handling.

Roof and rib bolting constraints.Coal haulage.

Ventilation.Supplies and materials.

1 - Roof and rib bolting.2 - Coal clearance.

3 - Materials handling.4 - Ventilation (of diesel equipment servicing unit).





M003MINE RESPONSES

Single entry system that will utilise the same services system for both development and longwall operations - eg;

monorail services management system and monorail materials handling system.

Roadway to be profiled to mitigate stress effects.Extensible conveyor system.

On-board grouting system for grouting of tendons.Machine guidance systems - coal mines require greater

articulation than that normally incorporated in TBM systems.

Fully automated bolting system.Other tunnelling sector strata support systems.

Legislation eg; restrictions on use of aluminium (eg; monorails), single entry development systems, and the use

of booster fans underground.Hazardous zone limitations on gas levels and the ability to have a transformer and HT power supply in a single entry

return roadway.






M003MINE RESPONSES

R&D to look at the effects of roadway profiling and support requirements.

Self drilling roof bolts.Full automation of face bolting systems (including

cassettes).Application of TBMs.

Capture of face water make and returning outbye, or alternatively, application of dry drilling at the face.

Use of data logging and communications capabilities already existing on equipment.

Non blocking drill bits and steels (eg; on board "shearer" high pressure water pumps).

Simplification of machine electronics and hydraulics.

Development of profiled roadways.Self drilling bolts, particularly rib bolts, with full automation

of drilling/bolting.Continuous haulage

Surge car with mobile boot end.Sumps Shearer.

Surge car with Joy Sumps Shearer.Sumps Shearer and FCT.

Process control.






M003MINE RESPONSES

Surge cars - problems experienced with desorption of coal from standing coal in surge car behind continuous miner,

together with restriction on face ventilation due to additional equipment in roadway.

Sumps Shearer - good concept, high potential, good roadway profile, suitable platform for automated bolting system. Unfortunately, was imposed on mine without a dedicated project team and without suitable support.

Mobile boot ends - problems experienced getting around machine.

Necessity for involvement of people who are to utilise equipment in the development of the equipment and the

associated systems.Not possible to develop fit for purpose equipment suitable for all conditions and purposes - need to develop classes of equipment suitable for specified range of conditions.

Should develop one type of technology at a time, and not try to develop multiple technologies concurrently in one

system or demonstration.

3 - 4 , very interested in industry based incremental and step change initiatives.

Can't wait for industry to develop roadway development system/s.







M003MINE RESPONSES

Purpose built TBM.

Possibly, subject to corporate views on ownership of intellectual property.

Reluctant to pour money in for large scale step change - ACARP needs to successfully demonstrate capability to develop incremental technology improvements and earn

the right to grow.Establish a single entry task group to develop that concept -

potential to utilise the technology in the short to medium term to develop long term access for new mine area.

Involve mine site personnel and keep head office involvement to a practical minimum.

Lock in a long term development site eg; highwall.

Yes










14 CM type - Mains?





M0042.6 - 4.0m

2.8m

5.4m

30m X 100m

1

142 deputies, 10 operators, 1 mechanical and 1 electrical

tradesmen - operate as super unit.

2 X 12CM3012CM12D machine on order, pending delivery.

1 X 12CM30 fitted with 4 Joy HFX roof bolters and 2 rib bolters.

1 X 12CM30 fitted with 2 Joy HFX roof bolters and 2 rib bolters.

New 12CM12D to be fitted with 4 Joy HFX roof bolters and 2 rib bolters.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M004MINE RESPONSES

2 X Joy 15SC shuttle cars discharging through Stamler feeder onto 1500mm wide gateroad conveyor.

Pods, with jib and carriers.Approximately 100m advance p set of pods.

7 days

8.75 hours Monday - Friday.12 hour shifts weekends.

8 week roster cycle with four crews rotating through roster on 2 week increments - A/S, N/S, D/S, 1 X Weekend plus 1

X week off.Monday - Friday N/S, D/S and A/S production.

Saturday - Sunday D/S production, with 5 man N/S maintenance crew on (fixed roster).

40 - 220m1:20 - 1:13

Very low

2 X 18m3/s auxiliary fans

Minor stress issues noted in association with geological structures and seam rolls.

Labour availability low -usually limited to employees being promoted or making career steps.

Low labour availability, but no issues experienced replacing limited numbers of personnel.



Mine life cycle?





M004MINE RESPONSES

Development complete end 2009, mine development life cycle approximately 7 years.

Process based organisation structure with strong accountability for each of 3 processes (eg; development, longwall and surface). Mining and engineering personnel

jointly responsible with process teams.New mine, new workforce, positive culture.

4 X 1800mm rib bolts per 1.5m advance, installed through full roof mesh modules (1700mm).

1 X 1200mm rib bolt/rib/1.5m advance, increasing to 2 X 1200mm rib bolts/rib/1.5 metre advance at depths greater

than 175m. All rib bolts spot bolted.














M004MINE RESPONSES

2 X 4m tendons installed per 2.0m in geologically disturbed areas and longwall installation faces. Contractors utilised unless tendons installed as part of development cycle in

difficult conditions.

4 - very good.

3 - good.Although reducing to "poor" (2) at depths greater than

175m when 2 rib bolts installed/rib/1.5m advance.

4 - very good.Although reducing to "good" (3) at depth.

17kms (2004).1 X CM for 7 months, 2 X CM for 5 months.



Panels?








M004MINE RESPONSES

3.5MPOH (1,200m/month) single unit.5.0MPOH, or 316m/week (1,400 - 1,600m/month) super

unit.4.6 days to complete a pillar cycle - super unit at 100m cut

throughs.

3 - good.Existing machines does not cut and load very well (E/W

conveyors)

3 - good.

1 - very low.22 year old shuttle cars, poor suspension and ergonomics.









M004MINE RESPONSES

3 - good.Handling of 1.7m wide mesh modules and vent tubes

considered problematic.

3 - good.Average 20 hours per move, range 13 - 24 hours.

Monorail handling system for services and vent tubes under consideration to expedite panel moves.

3 - good.Sequence driven maintenance process with A Heading

machine being serviced at 130m chainage (completion of cycle) during extension of services, with B Heading

machine being serviced on weekend maintenance shift.Continually challenging cost benefit of marginal

improvement in equipment availability versus maintenance downtime - typically operating at 89% availability.

3 - good.Good underground system (99.5% availability) impacted by

limited surface stockpiling (100,000 tonnes) and overland coal clearance system to CHPP.









M004MINE RESPONSES

Process driven.Good maintenance system.

Involvement of personnel in all facets of operation including process definition, new equipment specifications,

etc.Monitoring and measuring performance.

Adoption of 3 heading gateroads to support 400m wide longwall faces and longer longwall blocks.

Requirement to develop Mains due to delay in establishing highwall access with open cut mining.

Improved coal clearance system.Application of new technology including automation and

integrated cutting and bolting.Making things easier and lighter for men to use ie;

minimising fatigue (eg; lighter conveyor structure, pipes, bolts, mesh, hoses, cables).

Roof and rib bolting.Coal clearance.

Parallel tasks eg; extension of services.Belt extensions.

1 - Coal clearance.2 - Roof and rib bolting.

3 - Belt extensions.4 - Parallel tasks.





M004MINE RESPONSES

Integrated cutting and bolting with automated roof and rib bolting (and self drilling bolts).Continuous haulage system.

Extensible panel conveyor system with light weight structure.

Something other than steel mesh eg; plastic mesh on rolls.

Funding new development.Finding key people to develop system (product champions) and keeping those champions through entire development

process.Suitable site access and real estate to do so not on critical

path. People considered more receptive to change providing involved in improvement process, however may have

some difficulty sustaining high development rates unless processes are automated and/or made lighter and easier

to use.Availability of experienced and skilled personnel.

Legislation written to control worst case scenarios (eg; deep and gassy), not typical mines.

Globalisation of OEMs and the development of global products, with consequent unwillingness to develop and

support non standard equipment.Lack of flexibility and poor product support by OEMs.






M004MINE RESPONSES

Considered that many of the elements of an integrated, continuous cutting, bolting and coal clearance system

already exists, just need refinement and simplification (eg; ABM20).

Automation of bolting systems.Lightweight materials and structure.

Monitoring of both production and maintenance functions.Ergonomics - to improve operating environment for

personnel working in system.

1 - Ergonomics.2 - Coal clearance.

3 - Light weight and easy to use materials, structure, bolts, pipes, cables, etc.

Self drilling bolt (in association with CSIRO).Improved ergonomics on shuttle cars.

Introduction of 100m pillars in lieu of 30m and 70m pillars as previously utilised for wheeling around the pillar.






M004MINE RESPONSES

Self drilling bolt - limited success at this stage but shows a lot of potential.

Improved ergonomics - huge gains be made.Introduction of 100m pillars in lieu of 30m and 70m pillars - reduction in 100m panel advance by 0.8 shifts (15%) per

cycle.

OEMs have lack of knowledge of own products built overseas.

The identification of additional problems and issues when re-engineering equipment - need to persevere and follow

through to address all identified issues.Hard to do R&D at coal face in production critical

environment - need to have equipment developed to a higher standard before introducing into mine for trials.Need to simplify ABM20 and make it suitable for 2.8m

mining height.

4 - very interested in industry based step change initiatives.

Passionate about improving development, and has a workforce with a high degree of maturity and willingness to

trial new things.







M004MINE RESPONSES

Continuous haulage systems.

Yes, subject to corporate approval.

Would like to be involved in roadway development R&D process.

Should get workforce involved to ensure equipment and systems under development are kept simple, practical, and workable, and to ensure maximum buy in and ownership of

equipment under trial and development.Develop and maintain product champions.

Give feedback and keep us up to date with developments.Need to somehow improve the uptake of technology and equipment developed elsewhere - noted that automated

bolting rigs are utilised in salt mining operations overseas, while satellite bolters are used successfully in the US

underground coal sector.Should foster development of improved monitoring and

measuring systems with surface read out capability.

Yes










14 CM type - Mains?





MOO57m

3.6m

5.2m

2 heading gateroads, typically 120 X 40m.Initially developed at 60 - 80m centres but pillars

lengthened to minimise intersections that may be affected during longwall extraction.

2

8ERZ controller, 5 miners, I mechanical and 1 electrical

tradesperson.Two trades often responsible for two separate gateroads

due to labour shortages.

12CM12

One 12CM12 fitted with 4 Hydramatic Series 4000 rib rigs and 2 Hydramatic rib bolting rigs, with second CM fitted

with 2 Hydramatic Series 4000 roof rigs on slides, 2 Hydramatic rib bolting rigs.Single pass roof bolting.

Rib rigs being modified to allow single pass drilling.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



MOO5MINE RESPONSES

1 Joy 15SC shuttle car.Stamler breaker feeder.

MBE to be trialed late 2005.

Materials delivered by Eimco and hand loaded onto continuous miner.

7

12 hours

4 on:5 off:5 on:4 off:5 on:5 off - rotating

90 - 200m1:10

CH4, Up to 5m3/t

No problems noted

Low horizontal stress regime.

Difficulty recruiting and maintaining labour Limited skills base among miners and trades.

No industrial issues.



Mine life cycle?





MOO5MINE RESPONSES

New mine development.

Highwall punch mine.Contractor responsible for all development.

1.8m long resin encapsulated bolts, 4 bolts/1.5m installed in a 2/2 pattern. W straps.

1.5m fully encapsulated rib bolts, 2 bolts/1.5m/rib. Spot bolted.














MOO5MINE RESPONSES

2 X 8m tendons at 2m spacing in areas affected by geological structures.

3 - good.Support requirements for development considered "very

good" however primary support being installed during development has been designed to facilitate longwall

extraction. 3 - good.

Approximately 30% of roadways mined to date have required rib support levels typical of "difficult" to "poor" rib conditions, with balance comprising "good". Rib support

measures have been typically designed to facilitate longwall extraction.

3 - good.90% described as "good"

Floor affected by water if not properly managed.1.0m coal bottoms left on floor to minimise risk of exposing

soft floor strata.

10 -12kms



Panels?








MOO5MINE RESPONSES

200m/week/CM

#NAME?

3 - good.12CM12 good cutting platform, consistently achieving

target development rate of 2m/hour.One 12CM12 will shortly require major overhaul.

2 - low.Not fit for purpose, with number of refinements necessary

to both roof and rib bolters.

3 - good.Haulage constraints evident when haulage distance

exceeds 120m and roadway floor conditions deteriorate.









MOO5MINE RESPONSES

2 - low.High manual handling required for Eimco supplied bundles.

Materials supply system does not cater satisfactorily to changes in roof support regime and requirements for

changed hardware and/or support consumables.

1 - very low.Typically 30 hours plus per panel advance although two

recent moves have been completed in 22 - 24 hours.MBE to be trialed to facilitate faster panel moves.

2 - low.Frequent breakdowns due to overhaul deficiencies, exacerbated by lack of experienced tradespersons.

1 CM and 1 SC require further major overhaulContractors don't own equipment and are not prepared to

invest to improve maintenance due to limited contract term.

2 - low.In-pit conveyors (mains) not fully commissioned to date, whilst provision of panel conveyor systems (by Principal)

was also delayed and necessitated long haulage distances.









MOO5MINE RESPONSES

Increased productivity.Improved up-time.

Increased equit availability.

Support phase and requirements (longwall specified).Services and panel extensions.

Coal clearance.

1 - Roof and rib support.2 - Services and panel extensions.

3 - Coal clearance.





MOO5MINE RESPONSES

Continuous haulage.Integrated cutting and bolting.

Automated bolting.

TBM not considered relevant by one participant on basis that 12CM12 provides good cutting platform and good

roadway profile.

The level of caution evident throughout the industry to the commitment of expenditure and resources to the

development of new equipment and systems. The level of expenditure required to develop and trial new

equipment.Risks associated with development of new equipment -

what equipment and systems development sponsored by the Advanced Mining Program has been successfully

demonstrated and incorporated into the industry?Development priorities at mines and the risks associated

with trialing new equipment and systems when development constrained.

Inability to build effective relationships with non-performing OEMs.






MOO5MINE RESPONSES

Self drilling roof and rib bolts.Ergonomics associated with installation of roof and rib

bolts - automation?Improving the working environment - dust control, noise

and lighting (noisy dust scrubbers).Effective utilisation of the data generated by existing and

future machine monitoring systems.Machine guidance - to reduce the level of skills required to productively operate a continuous miner (continuing skills

shortages experienced with operators and trades).Metalliferous strata support systems, hardware and

equipment.

One step bolting.

Development and deployment of effective "systems approach" management models necessary to underpin any

developments in technology and equipment.

Introduction of place change mining into an Australian mine.

Introduction of VA continuous haulage system (bridge conveyor) in South Africa.

Introduction of 7 day operations (South Africa).






MOO5MINE RESPONSES

Introduction of place change mining was frustrated by existing workplace culture which was embedded in its pre-

existing in-place mining system.Introduction of VA continuous haulage system was

successful however was not conducive to changes in mine design (eg; changed cut through and roadway spacings).

Managing the cultural change process.Introduce new equipment and systems into mines before

the organisational culture solidifies.

3 - very interested in industry based incremental change initiatives, particularly in relation to self drilling roof and rib

bolts.







MOO5MINE RESPONSES

One step bolting.

Yes

Still room for technology development.Need to understand why the Sumps Shearer and FCT projects failed as the were considered to be worthwhile

developments.Still room for development and deployment of the "systems approach" and improved management of mining systems.

Higher capacity mines will be constrained by the mines ability to manage rib emissions - should therefore continue

to develop gas drainage equipment and systems.Development of systems to extract energy from

underground reserves without mining.

Yes










14 CM type - Mains?





M005B7m

3.6m

5.2m

2 heading gateroads, typically 120 X 40m

2


tradesperson.Two trades often responsible for two separate gateroads

due to labour shortages.

12CM12

2 Hydramatic Series 4000 roof rigs on slides, 2 Hydramatic rib rigs.

Single pass roof bolting.Rib rigs being modified to allow single pass drilling.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M005BMINE RESPONSES

1 Joy 15SC shuttle car.

Materials delivered by Eimco.

7

12 hours


90 - 200m1:10

CH4, Up to 5m3/t

No problems noted

Low horizontal stress regime.

Difficulty recruiting and maintaining labour particularly during early phase of development where 5 and 6 day

rosters trialed.Accommodation constraints reported to limit establishment

of full manning complement while accommodation standards have affected labour retention.

Limited skills base among miners and trades. No industrial issues.



Mine life cycle?





M005BMINE RESPONSES

New mine development.

Highwall punch mine.Contractor responsible for all development.

1.8m long resin encapsulated bolts, 4 bolts/1.5m installed in a 2/2 pattern. W straps.

1.5m fully encapsulated rib bolts , 2 bolts/1.5m/rib.Spot bolted.














M005BMINE RESPONSES

2 X 8m tendons at 2m spacing in areas affected by geological structures.

4 - very good.

4 - very good.More intense rib bolting required at depths greater than

150m, then "3" typical.

4 - very good.1.0m coal bottoms left on floor.

10 -12kms



Panels?








M005BMINE RESPONSES

200m/week/CM

3 - goodReliability and availability of 12CM12 low due to overhaul

deficiencies and continuing maintenance issues.

2 - low.Rib bolting the issue due to need to dual pass bolting. Rear

retract single pass modification to rib bolters underway.

2 - low.Low bolting intensity results in frequent delays waiting on shuttle car, particularly once haulage distance is in excess

of 80m.









M005BMINE RESPONSES

1 - very low.High manual handling of Eimco supplied bundles.

2 - low.Typically 22 - 24 hours to complete.

MBE being overhauled to facilitate faster panel moves.

2 - low.4 hour maintenance window each day.

Frequent breakdowns due to overhaul deficiencies, exacerbated by lack of experienced tradespersons.

2+ - low.In-pit conveyors (mains) not fully commissioned to date.

Not relevant.However noted that were achieving approximately 80% of budgeted performance levels, with performance affected by machine breakdowns, site access delays, manning

availability and low skills levels.









M005BMINE RESPONSES

Coal clearance.Materials supply.

Roof and rib support.

1 - Coal clearance.2 - Materials supply.

3 - Roof and rib support.





M005BMINE RESPONSES

Integrated cutting and bolting.Automated bolting.

Continuous haulage.Continuous panel conveyor extensions.

Arch profile - reduced support requirements.

Enclosed operator's cabin.Coal clearance along one side rather than centrally.

Roof bolting cassette and carousel as per metalliferous equipment.

Concertina panel belt.

Vacuum cleaner in lieu of coal haulage?Coal slurry system?

FCT or bridge conveyors.

Industrial issues associated with requirement for fewer people.

Technology gaps.Extending conveyor.

Skill levels and training requirements.Gas drainage technology (MRD).

Need to have better resolution of mining environment prior to mining.

Need flexibility in system to adjust to changes in geology.






M005BMINE RESPONSES

Automation.Mine/machine monitoring and tracking.

Training simulator for "play station" generation of miners and technicians.

Automation.Continuous haulage.

People/skills training (training simulators).

Updating hydraulics technology or finding alternate energy source (eliminating hoses full of high pressure fluid).Better application of current technologies - get rid of

pulleys and wires.

Application of systems approach.






M005BMINE RESPONSES

Good concept, should be part of way of doing things, however new technology, hardware and systems required

for step change.

Understand and monitor the process.Should be incorporated in development of new technology,

hardware and systems.







M005BMINE RESPONSES

Need to have higher proportion of practical, operations personnel on Underground Technical Committee and

RDTG.Improve profile of ACARP - little known on site.

Should be going overseas and into other industrial sectors to understand technological developments and how they

can be applied, particularly the metalliferous sector.

Yes










14 CM type - Mains?





M0061.8m

0 - Mains development completed

0 - Panel development completed

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M006MINE RESPONSES

7 day

8 hours D/S, 10 hours A/S and N/S

7 day rotating roster.

440mBoth dip and cross grades in development.

18m3/tonne.Drained to less than 6m3/tonne for development



Mine life cycle?





M006MINE RESPONSES

Longwall extraction due to complete end 2005.

High temperatures being experienced underground at depth.














M006MINE RESPONSES



Panels?








M006MINE RESPONSES









M006MINE RESPONSES





M006MINE RESPONSES

Unmanned development panels.






M006MINE RESPONSES

Transfer of appropriate technologies form high wall mining including machine guidance, machine monitoring and

equipment reliability.Automated bolting.

An alternate to automated bolting - 2 pass development and bolting (eg: wider roadways with in-place place

changing).Unmanned development panels.

Machine design to facilitate maintenance and breakdown repairs.

Larger ventilation ducting to reduce pressure losses and extend ventilation distances, enabling longer cut through

spacing (with larger ducting mounted on monorail system)

Continuous haulage system.Improved cut and bolt system.

Automation to remove men from immediate face area.

Continuous improvement and process improvement programs - getting people involved.

Utilisation of 14BU pick up loader behind CM.Place change mining.






M006MINE RESPONSES

Continuous improvement and process improvement - very successful due to involving people.

Utilisation of 14BU pick up loader behind CM - very successful, consider should be more broadly adopted if

continuous haulage systems not utilised.Place change mining - pillar sizes not suitable, depth of cut limited, insufficient headings to properly implement system,

auxiliary ventilation not conducive to adoption of system, corporate thrust with limited involvement of personnel.

Involvement of personnel who are intended to be utilised in system in the development and implementation of the

system.Need to consider the social implications associated with

the introduction of new technologies and mining systems, particularly in limited manning environments/systems.







M006MINE RESPONSES

Don't forget the people involved in the process.Don't be limited by peoples imagination.

Need to incorporate flexibility in working arrangements.

Yes










14 CM type - Mains?





M0072.9 - 4.2m3.3 - 3.6m

3.3 - 3.6m

4.8m4.8m

Vary, typically 85m X 35M

130m X 35m

Nil - Mains development completed end 2004.Previously 1 Mains development unit.

1 typically.1 contract unit to commence shortly to assist complete

gateroad development mid 2006 prior to transfer to new mine.

81 ERZ controller, 7 operators (operator manning levels

includes for all absenteeism).No tradesmen allocated to panels - on call basis plus

planned maintenance shift/day.

91 ERZ controller, 8 operators (operator manning levels

includes for all absenteeism).No tradesmen allocated to panels - on call basis plus

planned maintenance shift/day.Previously 12CM323 (originally 12CM30 but retrofitted with

shovel in lieu East/West conveyor).

12CM32 (originally 12CM30 but retrofitted with shovel in lieu East/West conveyor).

4 Aro Series 4000 hydraulic bolters on each CM, 2 Aro Series 5000 hydraulic rib borers.

2.1m roof bolts, 1.2m rib bolts - single pass drilling.

4 Aro Series 2000 hydraulic bolters on each CM, 2 Aro Series 5000 hydraulic rib borers.

2.1m roof bolts, 1.2m rib bolts - single pass drilling.4 roof bolting rigs and 2 rib bolting rigs can be operated

simultaneously with 4 operators due to significant improvements to on-board ergonomics and machine

hydraulics.Mesh modules racked against rib in bundles of 20

immediately behind miner and walked forward.1 Joy 15SC32 delivering to MBE or Stamler feeder

breaker.MBE fitted with panel DCB and conveyor stand inserting

mechanism.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M007MINE RESPONSES

1 Joy 15SC32 delivering to MBE.MBE fitted with panel DCB and conveyor stand inserting

mechanism.

2 cassettes per CM - colour coded for steel and or plastic rib bolts/dowels.

42m advance per two cassettes

2 cassettes per CM - colour coded for steel and or plastic rib bolts/dowels.

42m advance per two cassettes

1 CM unit 7 days per week, 1 CM 5 days per week

12 hour shift 7 day roster, 9 hour shift Mon-Fri roster

85 -210m30

Very low, no outburst risk.Some limited experience with H2S

No issues reported

No issues reported

No issues reported, although noted that part of mines success was recruitment of clean skins



Mine life cycle?





M007MINE RESPONSES

Development complete mid 2006 and transferred to new mine.

Good people, good attitudes, no problem accepting and implementing change, continuous improvement,

involvement of and ownership by personnel, greenskins.High underground standards from Day 1, particularly

roadworks.

2.1m long resin encapsulated bolts, 6 - 8 bolts/m depending upon strata conditions (either 6 bolt or 6/2 bolt

pattern).4.5m X 1.2m welded mesh roof modules.

1.2m long resin encapsulated rib bolts, 2 bolts/m/rib.1.8m X 1.5m mesh sheets installed on ribs.

2.1m long resin encapsulated bolts, 6 - 8 bolts/m depending upon strata conditions (either 6 bolt or 6/2 bolt

pattern). In some instances 10 bolts/m (6/4 pattern) required.

4.5m X 1.2m welded mesh roof modules. 1.2m long resin encapsulated rib bolts , 2 bolts/m/rib and

1.8m X 1.5m mesh sheets on chain pillar side of roadways. 3 cuttable 1.2m dowels/m/rib spot bolted on block side.

2 X 8m Mega bolts or JSS super strands installed per 2m in Zone B conditions (8 roofbolts/metre) - approximately

10% of Mains development.














M007MINE RESPONSES

2 X 8m Mega bolts or JSS super strands installed per 2m in Zone B conditions (8 roofbolts/metre).

3 - good.

1 - difficult.

3 - good.300mm of coal left on floor to minimise risk of cutting into

2Mpa floor.

11.2 kms (1995/96) W straps.

3 CM units, 5 day operationLongwall commenced during 1996

11.1 kms.1 CM 7 day operation, 1 CM 50% utilised on 5 day week

4.1Mt



Panels?








M007MINE RESPONSES

218m/week (7 days)

Not relevant - mine expected to complete development mid 2006 prior to transfer to new mine.

4 - very good.12CM32 good cutting platform.

Consider that 12CM32 as modified is process constrained, not cutting constrained.

4 - very good.Mine has made number of major improvements to roof and

rib bolting systems employed on 12CM32 under continuous improvement philosophy.

3+ - good.MBE used although stationary between panel moves.

No problems for first 100 - 110m from boot (130m pillars).300mm coal bottoms left to protect soft floor.









M007MINE RESPONSES

4 - very ggod.Supply cassettes can be changed between cars.

Use a mine designed QDS jib for installing and changing out cassettes.

3 - good.12 -20 hours to complete 130m panel move.

MBE fitted with conveyor stand insert mechanism. DCB on MBE.

Travelling roadway driven first and services installed during drivage of conveyor roadway.

3 - good.Recently went to a single CM 7 day operation as opposed

to previous two CMs on 5 day basis - push for development metres.

Now utilises one 12 hour maintenance shift (minimum) per week on mine wide basis, with maintenance issues now

being addressed more effectively.

3 - good.Over 1,000 hours lost in 2004 due to conveyor delays.

Major campaign implemented to address conveyor delays. Adoption of one 12 hour maintenance shift (minimum) per

week on mine wide basis now allows conveyor maintenance issues to be addressed more effectively.

No significant change in annual development between 1995/96 and 2004/05 although number of operating units

has reduced from 3 to 1.5, while roof and rib support intensity has increased markedly.

Wide spread adoption of continuous improvement techniques to address machine design deficiencies,

particularly in respect to operator ergonomics associated with support and ventilation elements. Has markedly

reduced workplace injuries and improved labour availability.









M007MINE RESPONSES

Same as Mains development.

Currently 22 - 25m/shift, envisage 30 -40m/shift available with enhanced CMs (ABM25S).Self drilling roof and rib bolts.

Full automation of bolting processes.Man less shuttle cars.

Integrated cut and bolt with ABM25S.

Coal haulage.Consumables supply.

Roof bolting (unless self drilling bolts successful).Noted that increased cutting rates are likely to significantly increase noise levels in the immediate face area to levels

which cannot be reasonably tolerated by humans. Therefore need to work towards full remote operation with

man less faces.Envisage total change to work processes with 2 man crews primarily engaged in consumables supply and extension of

services.

1 - Roof bolting.2 - Coal haulage.

3 - Consumables supply.





M007MINE RESPONSES

Fully automated cutting and bolting machine with continuous haulage system, 2 men/panel for supply and

services.Longer pillars.

Upgraded Sump Shearer (although Joy not committed to such).

TBM - but what about cut throughs?Self drilling bolts.

Bolter automation including carousel.Noted that envisage that current cutter head design will

underpin equipment over next 5 - 7 years.

Don't have OEMs available who will readily commit to making necessary machine modifications, adaptations, new designs associated with continuous improvement

process.Getting industry champions to manage the technology

development process. Availability of people and access to mines to develop, trial

and modify equipment.Need to look outside the square because the integrated cutting and bolting machine needs to be designed from

ground up and won't look like a conventional CM.






M007MINE RESPONSES

1 - self drilling bolts.2 - automated bolting and carousels.

3 - further development of FCT, including incorporation of services.

4 - supplying CM.5 - flexible ducting for exhausting ventilation applications

and/or development of forcing ventilation system including enhanced dust and gas capture/control.

6 - development of improved tendon installation rigs to facilitate wider adoption of long tendons.

Mine has successfully utilised continuous improvement techniques to make significant improvement to CMs and

associated systems, including; 12CM32 shovel adaptation, on-board ergonomics, rib protection system, semi-

automation of bolters, mapping of roof strata during roof drilling process, on-board hydraulics (6 bolters can operate simultaneously), on-board electricals (one FLP enclosure

in lieu of 7 as supplied), removal of ATRS, on -board monitoring data transmission to surface, on-board 2 way radio and telephone, improved maintenance access, on-board ventilation ducting, materials handling and supply

systems.All enhancements now being incorporated in redesigned

ABM25S.






M007MINE RESPONSES

Highly successful.

Getting ergonomics right.Involvement of workforce in continuous improvement process, with high corporate support for implementing

agreed improvements (estimate being prepared of expenditure committed to CM improvements).

Use of "counters" rather than machine pressure sensing to improve automation of bolting processes.

2 - 3, interested in pursuing mine related development issues and industry based inremental change initiatives.

Demonstrated track record.







M007MINE RESPONSES

New ABM25S will probably see current and new mine site out (ie; anticipated life of new mine 8 years).

Industry communications need to be significantly upgraded to facilitate transfer of technology and systems across

mine leases - few opportunities to get together with industry peers to workshop problems and develop new

ideas and technology.Need to develop collaborative working arrangements with

selected OEMs.R&D should be focussed on developing technology and

systems that can be applied and of benefit to all segments of industry (eg; fast CM, self drilling bolts, bolter

automation) rather than to that technology that has limited application (eg; ACBM) - direct money to the right areas.

When selecting trial sites and projects need to ensure that target organisations have high levels of corporate commitment and support for project together with

organisational values and culture that will foster continuous improvement.

Need to develop and agree an industry wide R&D strategic plan.

Yes










14 CM type - Mains?





M008Average 4.0m

3.4m

3.4m

5.4m5.4m

Varying 35m X 45m - 100m

Varying 26m - 43m X 150mNote that chain pillar width increases with depth.

1

1

8 1 deputy, 5 operators, 1 mechanical and 1 electrical trades.

8 1 deputy, 5 operators, 1 mechanical and 1 electrical trades.

ABM20Mark3 Height modified to suit mining height.

ABM20Mark3 Height modified to suit mining height.

4 X Hydramatic Series 4200 Prismatic roof bolters.2 X Hydramatic rib bolters bolter - LHS rib bolter rotary

actuated for ergonomics.Gripper jaws to be fitted for installation of tendons.4 X Hydramatic Series 4200 Prismatic roof bolters.

2 X Hydramatic rib bolters bolter - LHS rib bolter rotary actuated for ergonomics.

Gripper jaws to be fitted for installation of tendons.

1 X Joy 15SC discharging onto 1050mm Mains conveyor.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M008MINE RESPONSES

1 X Joy 15SC discharging onto 1200mm panel conveyor.

Cassettes - roof and rib bolts, and plates.Mesh and chemicals in separate cassettes.

Cassettes - roof and rib bolts, and plates.Mesh and chemicals in separate cassettes.

7 days per week.

8.5 hour, 10 hour and 12 hour shifts.

Dayshift 5 X 8.5 hour shifts fixed roster.A/S and N/S 4 X 10 hour rotating roster Monday -

Thursday.Weekend 12 hour rotating Friday - Monday.

Excellent roster reported.

75m in Mains increasing to 270m inbye end of gateroads.1:20 - 1:15

Limited gas reported in development, although longwall experiences gas migration from other seams during

longwall extraction.

21.5m3/s auxiliary fans - no problems reported.

Guttering experienced in area affected by coalescing seams.

Principal stress parallel to gateroads.

Increasing turnover reported due to new opportunities arising closer to coast.



Mine life cycle?





M008MINE RESPONSES

10 -20 years.

No significantly differentiating factors reported.

4 X 2100mm roof bolts/metre with mesh modules, increasing to 6 X 2100mm roof bolts/metre at intersections.

1 X 1200mm steel rib bolts/metre/rib spot bolted.

4 X 2100mm roof bolts/metre with mesh modules, increasing to 6 X 2100mm roof bolts/metre at intersections.

1 X 1200mm steel rib bolts/metre/rib spot bolted.














M008MINE RESPONSES

2 X 6m tendons/2 metres being installed in face areas as part of development process in area affected by coalescing

seams, and other areas as determined by TARPs - QDS bolting rig being sourced to enable tendons to be installed

as secondary supports.

3 - good.Generally good excepting in areas affected by coalescing

seams and increased horizontal stress levels.

3 - good.

3 - good.Seam rolls and clay band experienced in floor and unless CM operator attentive can quickly cut into and bog in soft

underlying floor.

Only started mine operations late 2004.

80m/week.Mains generally wet, with number of mine construction

activities completed during development (eg; overcasts, driveheads).120m/week.

Primary unit, 5 days per week.14.9kms (2004).

7.39kms YTD (2005) - affected by 8 week suspension of one CM for longwall changeout.

Anticipate 12 - 13kms for calendar 2005.

3.38M tonne (2004).1.35M tonne YTD (2005).

120m/week.



Panels?








M008MINE RESPONSES

160m/week.Will increase as gain experience dealing with coalescing

zone.

13.5kms/annum.

4.5M tonnes.Wider longwall face, maintain same development rate.

Maintain same development rate.

Maintain same development rate.

3 - good.Achieving target of 3.0MPOH in gateroads and 2.4MPOH

in Mains development.First 60m of development in cycle bolting constrained then

SC constrained.

3 - good.Mesh carrier could be improved.

3 - good.Road conditions could be a constraint at times.

Noted that 2 shuttle cars utilised behind each continuous miner, and 150m pillars.









M008MINE RESPONSES

4 - very good.Machines aren't designed for modular loading of materials.

3 - good.No breaker feeder and two auxiliary fans and boot ends allows "ghost" belt move to be part completed prior to

completion of pillar cycle. Have also introduced contract labour to complement own

labour during panel moves.

3 - good.Availability reported as quite good, 2 X 12 hour

maintenance shifts per panel, Tuesday and Thursday D/S.

3 - good.Availability >90%.

Additional days worked per week, and changed shift duration.

New mine established with new mine practices including; employee selection, hot seat change, management

systems, data recording and performance monitoring.

Fit for purpose equipment.Panel design and layout.

Installation of ancillary services (eg: overcast, stoppings) in parallel with mining operations.









M008MINE RESPONSES

Fit for purpose equipment.Panel design and layout.

Installation of ancillary services (eg: overcast, stoppings) in parallel with mining operations.

Use monorail services handling system including ventilation ducting.

Increased longwall output, greater longwall float required.Inability to complete exploration by surface based

methods, therefore increasing reliance on exploration by continuous miner, therefore greater development float

required as a contingency.New seam, dif ferent equipment, higher roadway section

allowing reintroduction of monorail services handling system.

Reintroduction of monorail services handling system.Establishment of spare panel to allow full "ghost" panel

moves to be completed in parallel with continuous production.

Coal clearance (breaker feeder would make a difference).Supplies.

Secondary support.Panel preparation.

Drivehead installations.Travel times.

Geological conditions and interpretation of exploration data.

5 - 6MPOH considered possible with existing continuous miner, 1 shuttle car, and monorail services handling

equipment.

1 - Geological conditions.2 - Secondary support.3 - Panel preparation.

Noted that there was enough technology available to take coal clearance out of the equation.





M008MINE RESPONSES

Advancing longwall with pump packed gateroads, possibly 2 pump packed roadways in maingate.

Monorail mounted services handling and/or CM mounted scrubber to eliminate requirement for handling ventilation

tubes.Modular system for supplies.

Automated bolting.Separate development functions to allow each to be

separately accountable.TBM with flexible roadway profile.

Hoseless continuous miner (to remove major downtime).Automate manual handling, or improve fitness of

employees to enable manual handling to be fully adopted (ie; don't compromise, all of one).

Hard rock mining technologies such as long hole jumbos and shotfiring.

Different roof and rib support systems such as shotcreteing or temporary passive support systems (eg; modular

concrete rings as used in tunnelling).Box cutting and/or drift access to gateroads in shallow

mines in lieu of developing Mains. Elimination of cut throughs with adoption of wide, pump

packed segregated roadways.

Money.Existing paradigms which favour retrofitting space age technology on 50 year old platforms (eg; continuous

miners), and the associated issues of design compromise.Legislation and approvals processes.

Overcoming IS issues with application of robotics and automation.

Developing a higher skilled workforce able to operate and maintain high technology equipment.

Emerging issue in respect to mandatory provision of forward support systems for use of road headers in

roadway development.

Considered that significant gains can be realised from the development and refinement of existing technologies

coupled with the rigorous application of process control and improved management of people.






M008MINE RESPONSES

Machine guidance systems utilising exploration data bases, on-board computers, and seam following

techniques for automatic machine guidance and steering.Hoseless continuous miner.

Automation and/or robotics of manual handling systems.Integration of high wall mining techniques and small

diameter ventilation shafts to allow single entry mining systems to be employed.

Monorail mounted materials supply system.Bridge conveyor or monorail mounted continuous haulage

system.Monorail mounted services system.

Forward injection of strata with strata binder as a roof and rib support mechanism - possibly incorporating roadway

slotting.

Exploration and mapping and the interface of geological data bases with development systems to facilitate machine

guidance systems.Hoseless technology.

Automation and robotics.Modularisation of machine components to allow rapid

replacement and remote repair.Use of aluminium underground.

Introduction of cut and flit mining.Monorail services handling systems.

Introduction of ABM20s.Extension of rib support and ergonomics to ABM20s.

Development tail ends.Tapered pillars.






M008MINE RESPONSES

Cut and flit - in right conditions good, but has its limitations, not sure whether it can be successfully applied to 2 entry

gateroad development, too site specific.Monorail services - extremely successful, however at

engineering limit in respect to managing steeper grades.ABM20 - successful, high productivity integrated mining

system.However too big, difficult to tram, poor breakaways, heavy

on maintenance. Limited to what they can do regarding alignment and spacing of bolts, as are other current

generation continuous miners. Took 3 years to retrofit rib bolting enhancements to operator's standards.

Development tail ends - suited to high seam application and roof mounted gateroad conveyors.

Tapered pillars - can be successfully applied to site specific geotechnical parameters, and reduce development

requirements.

Cut and flit - in right conditions good, but has its limitations, not sure whether it can be successfully applied to 2 entry

gateroad development, too site specific.Monorail services - extremely successful, however at

engineering limit in respect to managing steep gradients. Is limited in its application as requires predrivage some 500m

of roadway before installing system, and also requires angled cut throughs to be effective.

Could be further integrated with longwall to provide for reuse of monorail system during retreat.

Materials handling - handling of mesh sheets still problematic.

Development tail end - initially set up with extensible boot end but found that couldn't service miner beside conveyor.

Big piece of gear however managed transition from roof mounted structure in high roadway to floor mounted tail

end very well. Limit on storage capacity in LTU.Process driven approach to installing longwall, roof

mounted conveyor in high roadway - 10 hours for 100m belt extension.

Tapered pillars - linear relationship in roadway spacing as depth increases, however extent of horizontal stress may not be linear. Longwall requirements to store equipment in

cut throughs may limit minimum pillar dimensions at shallower depths.


New seam to be accessed by 2009, require proven concepts to be available within 2 years so that they can be

incorporated in planning.History of pushing boundaries at mine, however now a

margin sensitive operation and would only be prepared to pursue developments if they would make a positive

contribution and could be done without threatening mine's critical path.







M008MINE RESPONSES

Monorail services system.Geological exploration and machine guidance systems.

Automated bolting.Single entry development systems.

Advancing longwalls and roadway pump packing systems.

Yes.

Considers that whole of body vibration is an emerging OH&S issue of significance, and that ACARP should

facilitate research into machine ergonomics particularly in relation to operation of RTVs.

Also considers that ACARP should research use of alternate lightweight materials, and address legislative issues with respect to use of aluminium underground.

Yes










14 CM type - Mains?





M0099.0m3.3m

3.3m

4.9m4.9m

39.8m X 130m

39.8m X 120m

2 Dual unit, 3 heading configuration.

2Independent units, 2 entry gateroads.

8Deputy plus 7 (or 8) operator technicians, with up to 2

mechanical and 2 electrical qualified operator technicians within each crew.

2 X ABM20 Mark III

4 Hydramatic Series 4000 roof bolting rigs and 2 Hydramatic Series 4000 rib bolting rigs per machine.

1 X 15SC shuttle car per continuous miner discharging onto a Stamler feeder breaker.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M009MINE RESPONSES

Cassette system for roof and rib bolts and plates, mesh in separate cassettes with chemical anchors palletised.

40m advance per set of bolt cassettes.

7

12

4 on:5 off:5 on:4 off:5 on:5 off - rotating.

250m - 300mFlat - 1:30.

In situ gas levels in current area 2 - 4.8m3/tonne, 50:50 CH4:CO2.

Future areas contain 16 - 18m3/tonne, predominantly CO2.

1 X 18.3m3/s and 1 X 22m3/s auxiliary fans.

TBA

High labour turnover reported, particularly among staff. No experienced labour available.



Mine life cycle?





M009MINE RESPONSES

20+ years.

Surface constraints and adjacent mine workings limit extent of longwall mining areas and length of longwall

blocks. 3 separate longwall domains.Part of workings overlain by water bearing old mine

workings.Lack of surface exploration due to surface constraints.Thick seam, only partially extracted due to coal quality.

Employees paid an annual salary which incudes productivity component.

6 x 2.4m roofbolts/metre and 2 X 1.8m rib bolts/metre/rib in best strata conditions.

Roof and ribs fully meshed with mesh modules (roof) and 1.8m high rib mesh sheets.

As strata conditions deteriorate 4m JSS tendons are introduced in addition to standard roof support, and may be

replaced with 8m tendons if face conditions further deteriorate.

8m Mega bolts as required.














M009MINE RESPONSES

8m Mega bolts installed 1/1.0m on block side of maingate roadway prior to panel advance, together with mega

bolting of maingate and tailgate intersections at 2/1.0m spacing.

1 - 3, diificult to good. Highly variable roof conditions experienced.

1 - difficult.

1 - difficult.Soft, volcanic tuff floor strata underlying coal seam, readily

affected by face and seam water.

Typically 80 - 90m/week/CM.



Panels?








M009MINE RESPONSES

3 - good.3.0 - 3.5MPOH targeted in best strata conditions.

2 - 3, low to good.6 roof bolts and 4 rib bolts installed after each metre of

advance.Bolting rigs described as fit for purpose, however support

measures are intensive.

3 - good.2 shuttle cars mined per metre advance.

System becomes haulage constrained 70m from boot end.









M009MINE RESPONSES

4- - very good.40 metres/set of cassettes.

15 - 20 minutes to change cassette depending upon location in pillar cycle.

1 - very low.48 - 72 hours typical duration, best 24 hours.

1800mm roof mounted, bolted Mains conveyor structure, 130m extensions.

Sequencing issue with 3 heading 2 CM unit configuration, one CM may be stood down for up to 5 days awaiting completion of development sequence by second CM.

3 - good.2 hour maintenance window each day (Mon - Fri) used for routine inspection, testing and servicing. One CM stood

down each day on alternate basis (Mon - Fri) for further 5 hour maintenance window.

26 - 28% utilisation reported, with reliability factor of 48 - 52% also reported.

Contractors reported to achieve 45% utilisation.

4 - very good.

Upgrade of continuous miners to ABM20 Mark III series.Refurbishment of shuttle cars.Bigger capacity transformers.

Improved supply and logistics system.7 day operations (as opposed to 5 day operations

previously).









M009MINE RESPONSES

Separation of dual mining unit to two discrete units.Projected that 4 CM units will be required on continuing

basis.Improved roadway maintenance and reduced operational

delays.Rectification of inherent design issues associated with new

mine establishment.


Roadway conditions, and a lack of resources to apply to roadway repair and maintenance.

Panel advances.Logistics and supplies

1 - Bolting.2 - Coal clearance/roadway conditions.

3 - Panel advances.4 - Logistics and supplies.





M009MINE RESPONSES

Self drilling bolts and/or roof nails.TBM.

Continuous haulage system.Automated bolting systems.

Money, and budget timing issues.Ability to justify project to corporate, and the ability to prove

availability and reliability of equipment.Everyone already too busy - getting peoples' time and commitment - inability to find a dedicated champion.

Projected longwall discontinuities and inability to take equipment and resources from critical development.

Availability of spare equipment.Variable and difficult ground conditions impacting

demonstration and trials.Legislation constraints and the approvals process.






M009MINE RESPONSES

Automation and robotics.

Roof and rib bolting - self drilling bolts - automation - elimination of hydraulic hoses.

Improved maintenance design incorporated into equipment.

Roadway maintenance - dealing with coal and clay slurries and pastes.

Operating Excellence projects - process improvement and control.

Use of auger holes for roadway dewatering.Use of different additives to assist in roadway stabilisation

and treatment.






M009MINE RESPONSES

Operating Excellence initiatives - some success, particularly the electro-hydraulic cable bolting machine for

installation of secondary supports.Roadway maintenance improvement initiatives - limited

success.

A stitch in time saves nine! - if something indicates an emerging problem, fix it immediately before it gets out of

control.Need for commonly accepted and agreed standards and

trigger points that are observed by all.

2 - 3, interested in pursuing mine related and industry based incremental change initiatives







M009MINE RESPONSES

Roadway maintenance initiatives.Horizon control for continuous miners.

Yes, but unsure about management.

On the money with regards to current project - all mines are development constrained.

Need to establish communication and networking processes to enable transfer of experiences, learnings and

ideas.Conduct of regular roadway development conferences.Fostering corporate support for the involvement of site

based personnel in such conferences.

Yes










14 CM type - Mains?





M009B9.0m3.3m

3.3m

4.9m4.9m

39.8m X 130m

39.8m X 120m

2Independent units, 2 entry gateroads.

8Deputy plus 5 operators, 1 mechanical and 1 electrical

trades.

2 X 12CM30

4 Joy HFX roof bolting rigs and 2 Joy HFX rib bolting rigs per machine.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M009BMINE RESPONSES

1 X 10SC32 shuttle car per continuous miner discharging onto a Stamler feeder breaker.

Cassette system for roof and rib bolts and plates, mesh in separate cassettes with chemical anchors palletised.

40m advance per set of bolt cassettes.

5 (Monday to Friday crew)3 (weekend crew)

8.5 - 9.5 Monday to Friday.12 hour weekend D/S Friday to Sunday.

9 day fortnight.

250m - 300mFlat - 1:30.

In situ gas levels in current area 2 - 4.8m3/tonne, 50:50 CH4:CO2.

Future areas contain 16 - 18m3/tonne, predominantly CO2.

Some labour turnover reported, as typical of mine contractors, although have developed a core of long term

employees.No experienced labour available.



Mine life cycle?





M009BMINE RESPONSES

2 years remaining on existing contract.

Contractor utilised to complete initial mine development and to commence gateroad development.

8 x 2.4m roofbolts/metre and 2 X 1.8m rib bolts/metre/rib in typical strata conditions.

Roof and ribs fully meshed with mesh modules (roof) and 1.8m high rib mesh sheets.

Noted that client currently providing roof and rib mesh that only provided an effective 900mm length in lieu of 1200mm

effective length previously adopted. Consequently bolt spacings were at 900mm spacing rather than 1000mm as

nominated.














M009BMINE RESPONSES

8m Mega bolts installed 1/1.0m on block side of maingate roadway prior to panel advance, together with mega

bolting of maingate and tailgate intersections at 2/1.0m spacing.

1 -3, difficult to good.Highly variable roof conditions experienced.

1 - difficult.

1 - difficult.Soft, volcanic tuff floor strata underlying coal seam, readily

affected by face and seam water.



Panels?








M009BMINE RESPONSES

Target 110m/week/CM, equivalent to 450m/month/CM including 2 panel advances/month.

Achieved 130m/week/CM last week.

3 - good.Average 1.5 - 1.6MPOH, with range of 0.84 - 1.99MPOH

on monthly basis since commencement (3 years).

3 - good.

3 - good.2 shuttle cars mined per metre advance.

The 10SC32 was reported to have a higher ground clearance than other shuttle cars used at the mine which reduced the risk of bogging in the soft floor conditions.









M009BMINE RESPONSES

3 - good.20 - 30 metres/set of pods

10 - 15 minutes to change pods.10 sheets of mesh installed on CM at a time from mesh

carrier.

1 - very low.40 - 48 hours typical duration.

1500mm longwall conveyor installed in 120m extensions.Duration of panel advance impacted by requirement to install 120 X 8m mega bolts as secondary support in

conveyor roadway prior to advance. Development sequence modified to allow this work to proceed in parallel

with development in adjacent heading.

3 - good.1 shift per week (Thursday D/S) scheduled maintenance plus during panel advances and weekends if required.Average utilisation 48 - 50%, range 33.4 - 59.3% on

monthly basis project to date (3 years).Roof and rib bolting rigs changed out on a preventative

maintenance cycle.

4 - very good.

Integration issues with client continue to impact performance. Target 3.5 - 4.0MPOH however typically

achieve 2.0 - 2.5MPOH.Improved familiarity with machines.

Operators becoming more experienced and capable of dealing with the conditions as experienced.









M009BMINE RESPONSES

Introduction of 7 day operations with second weekend crew.

Unknown geology may prove to be problematic.

Roof and rib bolting.Coal clearance.Supplies to face.

Other process work including secondary support, services and roadway maintenance.

1 - Roof and rib bolting.2 - Other process work including secondary support,

services and roadway maintenance.3 - Coal clearance.





M009BMINE RESPONSES

Self drilling bolts - automated bolting systems - minimisation of associated manual handling.

TBM.Continuous haulage system.

Monorail mounted services - pantech going the other way.Continuous parallel processes.

Legislation constraints and the approvals process.Authority to mine - gas drainage - making it safe to mine.

Ventilation.Real time monitoring.

Having personnel available to support the high productivity, automated mining system.

Ensuring equipment supplied "fit for pit".






M009BMINE RESPONSES

Metalliferous mining technology eg; bolting and drilling.Metalliferous mining OEMs.

Robotics.Get out and look at other industry sectors to identify

potential technologies.Roadway maintenance.

Supporting roadways - roof and rib bolting - self drilling bolts - automation.

Elimination of manual handling.Roadway maintenance - minimising impact on equipment and personnel eg; transmission, steering, cable damage,

personnel injuries.

Operating Excellence projects - optimisation of primary and secondary support installation.






M009BMINE RESPONSES

Some success spending money on electro-hydraulic secondary support rigs to get away from hand held

secondary support installation, together with optimisation of the primary and secondary bolting phases..







M009BMINE RESPONSES

Picked the right issue with the current project.Communicating outcomes of research and improvement

initiatives to industry to prevent the reinvention of the wheel.

Developing a body of knowledge of best practice.

Yes










14 CM type - Mains?





M0102.8 - 3.2m2.8 - 3.2m

2.8 - 3.2m

5.2m5.2m

45m between adjacent headings, cut throughs vary.

2

Panel development yet to commence.

71 deputy (supervisor), 6 operator maintainers.

7 - when panel development commences.1 deputy (supervisor), 6 operator maintainers.

1 X 12CM30, 1 X ABM20

ABM20s when panel development commences.

4 Joy HFX roof bolters and 2 Joy HFX rib bolters.

As above when panel development commences.

Shuttle cars delivering to breaker feeder.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M010MINE RESPONSES

As above when panel development commences.

Eimco and trailers.

Eimco and trailers when panel development commences.

5 days per week currently, intend to move to 7 day roster.

9 hours

Fixed roster.4 shifts/week plus overtime on RDO.

Intend to move to 7 day roster.

500mSlight

In situ gas levels 12 - 18m3/tonne. Residual gas levels after drainage <2 - 8m3/tonne.

Predominantly methane.

No ventilation issues experienced in development due to provision of high capacity mine ventilation system.

High horizontal stress levels, typically 2 - 2.5 times vertical stress. Principal stress direction varies.

Labour turnover increasing.Labour availability limited.

No industrial lost time to date.



Mine life cycle?





M010MINE RESPONSES

20 years at current planned production levels.

In situ gas levels, with zones of boggy, low permeability coal. Outburst risk, with remote mining capability being

developed for low permeability zones.

6 X 2400mm roof bolts/metre with full mesh.2 X 1800mm steel rib bolts/metre/rib installed through 1.2m

long 2m high rib mesh.

6m or 8m mega bolts installed where required by TARP. Major mega bolting project underway in roadways adjacent

to longwall in adjoining mine.














M010MINE RESPONSES

Extensive mega boltng typically installed in gate roads prior to longwall retreat in adjoining mine, with 1 - 6 months

lag between installation and subsequent extraction.

3 - good.

1 - difficult.Note 1800mm rib bolts, 2/metre/rib.

2 - poor.

0.36kms

50m/week/CM (1/7/05 - 27/8/05).Operators currently under training.



Panels?








M010MINE RESPONSES

11.27kms

3.42M tonne

136m/week/CM

136m/week/CM









M010MINE RESPONSES







M010MINE RESPONSES

Yes










14 CM type - Mains?





M0112.7m2.7m

2.7m

5.2m5.2m

30 X 100m, with variations for gateroad alignment.

2 heading tailgate, 30 X 100m.3 heading maingate, 35 X 100m and 25 X100m for primary and secondary pillars (secondary pillar increases to 100 X

32m as depth increases)1

2


tradesperson.


tradesperson.

12CM32

12CM32

2 Aro Series 4000 roof bolting rigs, 2 Aro rib bolting rigs.

2 Aro Series 4000 roof bolting rigs, 2 Aro rib bolting rigs.

DBT FRR15 diesel hauler - typically 2 but can be increased to 3 in extended wheeling situations.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M011MINE RESPONSES

1 X DBT FRR15 diesel hauler per panel.

2 X modular pods - 100m advance/2 pods.

2 X modular pods - 100m advance/2 pods.

Nominal 7 day, 2 X 12 hour production shifts.

Varies 8 - 12 hours depending upon roster cycle.

Production crews 7 on:7 offMon - Fri maintenance and services crew 5 X 8 hour shifts

250 - 375mRelatively flat.

CH4, 7 - 15m3/t.Reduced to maximum 5.75m3/t by gas drainage in

accordance with frictional ignition management plan.TRD, MRD (1,200m) and in seam drilling/drainage.

No problems noted.

No problems noted.

Tight labour market.



Mine life cycle?





M011MINE RESPONSES

New mine development, completing initial maingate and tailgate roadways.

Shaft mine with shaft access for M&M.3 heading gateroads.

1.8m long resin encapsulated bolts, 6 bolts/1.4m installed in a 4/2 pattern.

4.5m mesh modules with additional spot bolt on overlap1.2m fully encapsulated steel rib bolts , 1 bolt/1.4m/rib,

spot bolted.

1.8m long resin encapsulated bolts, 6 bolts/1.4m installed in a 4/2 pattern.

4.5m mesh modules with additional spot bolt on overlap.1.2m fully encapsulated rib bolts , 1 bolt/1.4m/rib. Spot

bolted with plastic dowels on longwall block side.

2 X 4.1m JSS tendons on 2m centres when geological structures intersected, in accordance with mine TARPs,

and installed during development.














M011MINE RESPONSES

2 X 4.1m JSS tendons on 2m centres when geological structures intersected, in accordance with mine TARPs,

and installed during development.

4 - very ggod.Immediate roof strata 45 - 50 MPa with overlying 100Mpa.

4 - very good.

4 - very good.Immediate floor strata 45Mpa with +50Mpa below.

Diesel haulers can break floor up when extended haulage distances adopted.

2004 (6 months) 6.5kms.2005 (7 months) 11.5kms.

150m/week



Panels?








M011MINE RESPONSES

180m/week (2 entry tailgate)200m/week (3 entry maingate)

25kms - 3 units - 3 heading gateroads.

5Mtpa (including development)

3 - good.

3 - good.Need a system to replace or reduce numbers of roof bolts

installed - yielding pillars?

3 - good.Development sequence designed to eliminate wheeling

under ventilation duct, allowing haulers to be fully loaded.16 tonne hauler payload allows cut out for 4 bolt pass with second hauler then allowing 2 bolt pass to be completed.









M011MINE RESPONSES

3 - good.Shaft winding system introduces constraints on access and

delivery of supplies.

2 - low.Typically 30 hours in 2 entry tailgate (services and

conveyor in one roadway).Typically 25 hours in 3 entry maingate where services and

conveyor in separate roadways.

3 - good.Still commissioning and debugging OEM equipment.4 hour maintenance window M,T, T , F, with 12 hour

window on Wednesdays primarily used for shaft maintenance

3 - good.Constrained due to limited shaft winding capacity during

initial development phase.(noted that shaft winder only operating at 75% of designed

420tph capacity).









M011MINE RESPONSES

Full implementation of mine's existing development capacity and systems.

Roof support.Coal haulage.

Services - ventilation, power, water, compressed air

1 - Ventilation2 - Roof support.

3 - Coal clearance.





M011MINE RESPONSES

Advancing longwall.

Self powered CM (cableless).Roadways and pillars designed to eliminate/minimise

support requirements (very wide roadways/narrow pillars).Automated bolting, self drilling bolts, automated carousels.

Need to address integrity of ribs.Ventilation??






M011MINE RESPONSES

Advancing longwalls.

Battery/power technologies.Site specific geomechanics (managing risks of

pillar/roadway failure).Self drilling bolts.

Flexible exhausting ventilation fabrics, or forcing ventilation and dust control.

People - individual personalities and group dynamics, how to systemise work processes, boring repetitive processes,

developing and maintaining enthusiasm, lack of experience from coal face to mine management.

Roof support.Coal haulage.

Pillar and roadway design.

Trial of Kemcoal Beaver, and introduction of ABM20s, battery haulers, diesel haulers, MBE, place changing.






M011MINE RESPONSES

Kemcoal Beaver Mk I - hybrid prototype, not robust enough, good idea at time, however lacked the cutting

capacity of the then existing mining systems.ABM20 - suited mine at time and went well.

MBE - cumbersome, poor design, not as flexible as current system.

Battery haulers - good carrying capacity, hard on floor conditions, difficult to make change from SCs.

Diesel haulers - flexible, good carrying capacity, may introduce heat effects during summer periods once mine

deepens.Place changing - didn't suit mine design, pillar dimensions

not suited, some people didn't want to make it work, difficult to make change from in place mining, directive

change not involvement.Didn't like FCT and KB conveyor, too big and cumbersome.

Need to introduce new technologies early in mine life cycle before attitudes and culture hardens.

Pick right people to manage and be part of change process.

Costs and risks associated with introduction of new technology.







M011MINE RESPONSES

Be aware of RSI conditions and effects related to operation of equipment with high advance rates.

Good initiative to have mine workshops and interviews. Industry workshop/s may provide opportunity for

brainstorming of ideas and improving collective wisdom.

Yes.










14 CM type - Mains?





M0122.4m to 3.6m

3m

>2.7m

5m5m

Nominal 100m X 35m - varies due to gateroad arrangements.

2 heading99m X 40m

1 - not continuously operated, currently 2 year contract to complete mains development in current area.

21 normal CM unit

1 modified twin unit (two CMs with only 1 manned at a time).

81 ERZ controller, 1 supervising operator technician, 6 operator technicians including one mechanical and 1

electrical trades specialist.

91 ERZ controller, 1 supervising operator technician, 7 operator technicians including one mechanical and 1

electrical trades specialist.

VA Eimco ABM20 Series 1 and Series 2

VA Eimco ABM20 Series 1 and Series 2

4 hydraulic bolters on each CM, 2 hydraulic rib borers.2.1m roof bolts, 1.2m rib bolts - single pass drilling.


Single SC each unit, feed onto 1800mm 5000 tph Mains conveyor.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M012MINE RESPONSES

Single SC each unit, feed onto 1500mm 3500 tph gateroad conveyor.

CM mounted supply pods, loaded on surface, handled with QDS attachments.

30m development per pod.Roof mesh handled manually.





Mine life cycle?





M012MINE RESPONSES

2.1m long resin encapsulated bolts, 8 bolts/m (4/4 pattern), support density 1.6 bolts/m2.

4.8m X 1.2m welded mesh roof modules. 1.2m long resin encapsulated rib bolts, 3 bolts/m/rib, cuttable dowels used where extra roadways may be

developed off Mains roadways.

2.1m long resin encapsulated bolts, 8 bolts/m (4/4 pattern) in first 8 pillars of panel, all weak areas, and ALL cut

throughs.6 bolts/metre (4/2 pattern) in rest of gateroads

4.8m X 1.2m welded mesh roof modules. 1.2m long resin encapsulated steel rib bolts installed on

chain pillar side, 4 bolts/m.1.2m long cuttable dowels installed on block side, 5

dowels/m.Installation of rib mesh during development to be trialed.

6.1m long fully encapsulated HiTENS tendons typically installed 2.5m linear spacing all roadways, reduced to

2.0m spacing in poor conditions and intersections.8.1m long fully encapsulated HiTENS tendons installed in

wide intersections.Pre-tensioned post-groutable Bowen cables (patent

pending) installed in broken roof conditions (eg; faulted areas).

Secondary supports in parallel with mining cycle post relocation to next pillar.














M012MINE RESPONSES

6.1m long fully encapsulated HiTENS tendons typically installed 2.5m linear spacing all roadways, reduced to 2.0m spacing in poor conditions and intersections, with

additional 4 HiTENS across mouth of cut through.Additional row of HiTENS installed on block side of

conveyor roadway.Pre-tensioned post-groutable Bowen cables (patent

pending) installed in broken roof conditions (eg; faulted areas) and on block side of conveyor roadway.

In conveyor roadway secondary supports installed in parallel with mining cycle while travelling road being mined

(9 - 14 days after mining).In travel road secondary supports typically installed no

closer than section transformer position.Plastic tensar mesh installed with split sets on ALL walk side of conveyor roadways and sections of of block side

where rib spall extensive.(Trial to install rib mesh during primary support cycle in

progress).3 - good.

1+ - difficult.

3 - - good.Providing good face management practices maintained.

Floor conditions tend to adversely impact tailgate conditions and maingate roadway inbye face during

longwall extraction.

17.7 km (1996) - 5 development units

4.2Mt ROM (1996) - 2 longwalls

73m/week (1996)

185m/week (1996)

14.7km (2004)

4.1Mt ROM (2004)

Not consistently worked.In 2003 Mains was 48m/week including lot of stonework

(driveheads, overcasts).



Panels?








M012MINE RESPONSES

193m/week modified twin unit.124m/week single CM unit.

2+ > 3-, low to good.One CM modified to high load out capacity, others yet to

be modified.ABM20 capable of 6 - 8m/hour, target 4 - 5m/hour due to

support density, achieve 3 - 4m/hour.

2 - low.Roof and rib bolting in series, lot of areas for improvement

to parallel bolting task and remove roof/rib support from critical path.

3 - good.Only time constrained by coal haulage is in cut throughs, at

times. However if roof/rib bolting removed from critical path one

SC would be insufficient to cope with coal clearance.









M012MINE RESPONSES

4 - verty good.Manual handling of mesh modules a problem.

1 - very low.Typically 48 hours to complete 99m panel extension (from

stop cutting to start cutting). Lot of opportunity for improvement.

2+ - low.Appeared to be a number of unresolved repetitive delays.

4 - very good.

Insufficient data available from previous owners to verify whether real improvements have been made. Conditions in early panels very favourable although conditions in current

mining area deteriorated significantly.Have developed internal capability for panel extensions and improved panel standards and face management to

maintain earlier productivity levels.Achieving consistency of performance and standards.

Getting the most out of personnel.High labour turnover reported as an issue, only manning 7

of 8 development crews.









M012MINE RESPONSES

Better understanding of process and better utilisation of data.

New technology such as drillable bolts.Improved roof and rib bolting equipment and systems

(although other bottlenecks will then need to be addressed eg; coal haulage).

Reducing duration of panel extensions.

Roof and rib bolting.Panel extensions.

Installation of secondary supports in parallel with mining operations.

(Noted that height restrictions and requirement to install block side tendons in conveyor roadway prior to panel

extension was major constraint in development process, with drivage of cut through from travelling road to conveyor

roadway sub-optimal).

1 - Panel extensions.2 - Secondary support.

3 - Face bolting.





M012MINE RESPONSES

TBM (Mojura) system incorporating temporary positive roof and rib support restraint and automated roof and rib bolting

together with integrated FCT and services extensions (fewer people working at face and working within a steel

envelope).Extendable services (reported developments at Newstan).

Continuously extending panel conveyor.ACBM good concept - no champion.

Tube conveyor?

Improved management and utilisation of data to complete business evaluations.

Longwalls are development constrained, therefore no capacity to trial new hardware and systems in non-critical

panel.Only underground mine within a larger corporate entity,

difficult to build critical mass.






M012MINE RESPONSES

Systems incorporating better use of data. Noted that open cuts successfully utilise data loggers to improve

performance.Machine guidance (with aim of removing personnel from

immediate face area).Use of plastic "husker" mesh for roof and rib support to enhance automation of roof and rib bolting and remove requirement for close alignment of drill steels and bolts

with mesh.Better control of dust produced from cutting and drilling to

enable activities to be carried out outbye in return.Potential application of shotcreteing as roof and rib support

measure as per metalliferous mines (noted that requirement to have personnel bolting at face introduced number of hazards and constraints on mining process).

Multi-phase bolting (noted that installed support was designed for longwall requirements, not to meet actual

development support requirements). Removing stop/start from development process, ie;

improve bolting equipment and systems to drive other improvements (ie; currently roof/rib bolting constrained).

1 - Automation - getting people away from the face area - a vision of 1 person operating CM (eg; metalliferous jumbo

operators).2 - Eliminate SC and associated roadway clean up and

maintenance - reliable FCT.3 - making system continuous, ie; extendable conveyors,

support installation in parallel with cutting, ventilation extensions - need to understand the process better.

Improving uptime and cutting.Setting and maintaining standards.






M012MINE RESPONSES

Maintained development rates in deteriorating conditions and with increased secondary support requirements.

Need to understand the development process and the business better in order identify and make improvements.

3 - - very interested in industry based incremental change initiatives.

Particularly in relation to improved bolting and coal clearance systems.

Encourage major mining companies to develop new generation mining systems, and then take up proven

systems if justified.







M012MINE RESPONSES

Self drilling bolts.Services extensions.Roof and rib bolting.

Yes

Need to ensure focus maintained on improving safety (noted that automation of bolting and elimination of manual

intervention will significantly improve safety). Development of an industry based roadway development

expert system that would enable mines to monitor and fine tune development process.

Yes










14 CM type - Mains?





M0133.2 - 7.5m

3.3m

3.4m

5.2m5.2m

33m roadway centres, cut throughs at various centres to suit longwall, minimum 33m centres.

46m X 105m

1

2Operates as a dual miner unit.

9Deputy plus 8 mineworkers including trades.

16 dual unit - 10 single unit.Dual unit - 2 deputies plus 14 mineworkers (including

trades).Single unit - 1 deputy plus 9 mineworkers (including

trades).ABM25

2 X ABM25


Rigs feature auto feed plus single pass capability.


Rigs feature auto feed plus single pass capability.

1 shuttle car discharging into a feeder breaker.1600mm trunk conveyor, with some temporary 1200mm

trunk conveyors.1,500 tonne underground bin feeds coal into two separate

customer streams.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M013MINE RESPONSES

1shuttle car per continuous miner discharging into a common feeder breaker.

1400mm panel conveyors, with some temporary 1200mm panel conveyors.

Trailer mounted pod system.300 bolts or 50m advance per set of pods.

Duckbills used for mesh and other materials.

Trailer mounted pod system.300 bolts or 50m advance per set of pods.

Duckbills used for mesh and other materials.

7

8 hours D/S Mon - Fri.9.5 hours N/A and A/S Mon - Thurs.

12 hour shifts Fri - Sun.Fixed roster, D/S 5 days/week, N/S and D/S 4 days/week

Weekends three 12 hour shifts..

160 - 350mSeam grade variable 1:30 - 1:8.

800m wide steeply dipping section crosses mining area at 30 degrees.

Up to 700mm cross grade experienced in roadways in gateroads.

Up to 6m3/tonne with extremely variable permeability (2 - 2,000 millidarcies)

1 X 22m3/s auxiliary fan in Mains development and 2 X 22m3/s auxiliary fans in dual miner gateroad development.

Major and minor horizontal stress measured at 10MPa and 4MPa respectively.

Labour relatively stable with 50:50 combination of permanent employees and employees of contractors.

Age of permanent workforce averages 50 years.



Mine life cycle?





M013MINE RESPONSES

15 years with potential for further 15 years in adjacent exploration licence area.

Mine designed to minimise surface subsidence by utilising a massive overlying conglomerate beam to span between

gateroad, resulting in narrow 115 - 150m wide longwall blocks. Development:longwall ratio of 3:1 metres.

Mine culture exhibits features typical of mines that were formerly publicly owned.

4 or 6 X 2100mm AX roof bolts per metre, depending upon depth of workings. Mesh used in all roadways.

1 X1200mm steel or fibreglass dowels per metre/rib, with rib mesh used if conditions warrant.

2 X 4m tendons per 2 metres installed as additional primary support in poor or broken roof conditions (typically

30% of Mains roadways).

4 or 6 X 2100mm AX roof bolts per metre, depending upon depth of workings. Mesh used in all roadways.

1 X1200mm steel or fibreglass dowels per metre/rib, with rib mesh used if conditions warrant.


5% of gateroads).


30% of roadways).














M013MINE RESPONSES

2 X 6m tendons per 2 metres installed in maingate and tailgate roadways in deeper area of workings (approx

50%), 2 - 6 months after development.

3 - good.

2 - poor to good.Poor rib conditions occur in conjunction with variable joint set and are more frequent from midway along gateroads and further inbye as the seam rolls and depth of cover

increases.

3 - good.Some areas extremely good, some areas extremely soft.

10km3 CM units available however averaged 2.5 CMs in

operation throughout the year

1.1Mt

80m/week/CM



Panels?








M013MINE RESPONSES

110m/week/CM

15km

3.4Mt

100m/week/CM

150m/week/CM

2 - low.OEM rates equipment at 6 - 7MPOH, typically achieve

1.5MPOH.Flitting continuous miners is an issue due to poor

tramability, while they also have problems loading coal out.

3 - good.Not roof bolt constrained when installing 4 bolts/metre, rib

bolting is more of a constraint however, particularly in areas affected by variable joint set.

2 - low.Old shuttle cars, putting a specification together for new

SCs.









M013MINE RESPONSES

3 - good.Vary rare that production stopped due to lack of supplies,

however have had trouble sourcing expansion shell anchored rib bolts at times (delivery ex USA).

2 - low.Average 27 hours to complete panel advance.

Panel advance initiated by metreage milestone, however length of shuttle car cables and requirement to form 50m

overdrive for monorail mounted services (eg; power, water, return water, compressed air and 25m flexible ducting) are

operational issues.

3 - good.One shift maintenance/CM/week on a routine cycle, plus 0.5 shifts per week during outbye conveyor maintenance

windows. Roof and rib bolters reported as high maintenance items,

although Kevlar wrapped rib bolt hoses have proved beneficial.

Reported that CMs are a high maintenance machine and require high labour levels to effect.

Issue raised in respect to supply of continuous miner with non integrated bolting equipment.

3 - good.Planned maintenance windows on outbye conveyors 4 - 8

hours per week.Longwall can currently produce at higher levels than

outbye capacity, although this will be addressed when second customer feed system completed.

Longwall mining commenced early 2005.Narrow longwalls, hence high development:extraction

ratios.Additional units and shifts worked, new mining equipment.

Introduction of ABM25 continuous miner.









M013MINE RESPONSES

Introduction of ABM25 continuous miner.

Focus on process mapping.Noted that projected 20kms of development required in

2005/06.

Focus on process mapping.Increased utilisation of equipment with adoption of cycle

based maintenance system.Utilisation of data logging on CMs to monitor and manage

performance.

Changed sequence to minimise exclusion zones in gateroad development.

Bigger shuttle cars, allowing 2 SC per metre advance.Introduction of a 150mm pipe installation trailer to reduce

panel advance duration.Possibly relocate breaker feeder to panel/mains transfer

point to take out of panel advance process.Adoption of steel rib mesh to control rib break and

minimise damage to rib bolter hoses.Still a lot of potential to go from 1.5 to 4 - 6MPOH.Installing/extending ventilation ducting in 3.4m high

roadway - need Eimco to put ducting up.Supplies and logistics.

Panel advances.Rib bolt constrained - should design machine around rib

bolters, not retro-fit.Supply of longwall conveyor belting and structure.

1 - Rib bolting.2 - Installation of ventilation ducting.

3 - Panel advance.





M013MINE RESPONSES

TBM with integrated continuous haulage and monorail mounted services and supply system, with all supplies incorporated into 3m modules (eg; support materials,

conveyor materials, etc).Newstan style monorail services management system.

Extensible panel conveyor, with mobile boot end.Eliminating time losses in the development process (eg; cutting out niches for DCBs, feeders, fans, breakaways).

Getting a champion to drive improvement projects to fruition - won't be a site a site based person, too busy.

Funding.Ventilation of single entry TBM roadways.

Connecting TBM roadways.






M013MINE RESPONSES

Self drilling bolts, and automated bolting.Extensible conveyor system and mobile boot end designed

to allow access beside conveyor.3.3Kv continuous miners.

Bigger capacity transformers to minimise transformer moves.

Bolting systems.Continuous haulage systems.

Integration of services (fan, power, ventilation, water) and supply systems.

Monorail services management systems including crawler mounted auxiliary fans.Development tail end.14BU pick up loader.

Process improvement.






M013MINE RESPONSES

All were successful developments.

Need for site and corporate support of project champions, particularly in relation to the provision of appropriate

resources.Potential ventilation issues associated with use of pick up

loaders, particularly in gassy seams.Benefit of including tool storage facilities on monorail

systems.

4 - very interested in industry based step change initiatives.







M013MINE RESPONSES

Continuous haulage or anything that facilitates a continuous process.

Rib bolters and rib bolting.Self drilling bolts.

Yes.

Need to have committed developers prepared to fit into site and make things work.

Need to have concepts more fully developed prior to trials at mine sites.

Persistence and perseverance for 3 - 5 year projects?How to build critical mass behind successful projects and

transfer it to other sites?

Yes.










14 CM type - Mains?





M0143.2 - 3.6m

3.6m

3.2 - 3.6m

5.0m5.0m

40m X 60m, and 40m X 40m

40m X 90m

1

1

71 deputy, 6 operators.

91 deputy, 7 operators, 1 mechanical trades.

Eimco (DBT) Dash 3Cut and Flit

Eimco (DBT) Dash 3Cut and Flit

Fletcher Mobile Bolter

Fletcher Mobile Bolter

Joy 15SC, Stamler breaker feeder, 1200mm conveyor.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M014MINE RESPONSES

Joy 15SC, Klockner Becorit breaker feeder, 1050mm conveyor.

Eimco EJC 130 and bulk materials pods.Roof bolts, rib bolts, roof and rib mesh in individual pods,

manually loaded onto mobile bolter in panel.

Eimco EJC 130 and bulk materials pods.Roof bolts, rib bolts, roof and rib mesh in individual pods,

manually loaded onto mobile bolter in panel.

7 days per week

9 hour weekday shifts.12 hour weekend shifts

Weekday roster 5 days per week (9 day fortnight).Weekend roster 3 X12 hour shifts and 2 X12 hour plus 1

X9.5 hour shifts on alternate weekends.

420 - 500m1:40

In situ gas levels 12- 16m3/tonne. Residual gas levels after drainage <6m3/tonne.

Varies widely from predominantly CH4 to predominantly CO2

Mine ventilation capacity 230m3/sec.Ventilation of extensive old workings utilises significant

portion of mine capacity.High horizontal stress levels, typically 15Mpa.

No problems noted, and currently in process of recruiting 11 additional employees.



Mine life cycle?





M014MINE RESPONSES

20+ years.

Utilisation of place change (cut and flit) for all roadway development, including 2 entry gateroads.

In situ gas levels and gas composition.Extent of mine ventilation system and outbye roadways

requiring maintenance (+100 year old mine).Distance travelled to working districts.

Shaft access for manriding, 10 men/wind.Combined drift, rail and RTV material supply system.

Size limitations on equipment being transported underground.

Extensive, tortuous trunk conveyor system.

6 X 2100mm roof bolts/1.1 metre with mesh modules.2 X 1500mm steel rib bolts/1.1 metre/rib installed through

narrow rib mesh straps.

6 X 2100mm roof bolts/1.1 metre with mesh modules.2 X 150mm steel rib bolts/1.1 metre/rib installed through

narrow rib mesh straps. Noted that trials of plastic rib dowels underway.

Fully grouted 6m and 8m mega bolts installed as required, based upon monitoring. Noted that limited secondary

support in Mains other than double breakaway intersections and longwall takeoff access roadways.

Tin Cans installed in some areas.














M014MINE RESPONSES

Fully grouted 6m and 8m mega bolts installed as required, based upon hazard mapping. Typically 2 X 6m tendons/2

metres throughout tailgate roadways with to 2 X 6m tendons/1.5 metres in maingate intersections and identified

hazard areas.Mega bolts typically installed minimum 2 pillars in advance

of retreating longwall in both gateroads.Tin Cans installed in some areas.

4 - - very good.Noted that roof allows adoption of place change mining in

both Mains and Panel development.

2 - poor.One side of roadway typically good, other side typically poor - factor of angle of intersection of high angle cleat.

Propensity to slough off rib in high angle wedges on affected side.

2 - poor.Floor conditions rapidly deteriorate at intersections -

considered be a factor of repeated flitting of CM through intersections with place change mining.

Longwall mining commenced in 1995.

8.87kms

1.50M tonne



Panels?








M014MINE RESPONSES

Anticipate approximately 10kms/annum.Mine plan based on continued adoption of 158m wide

(centre to centre) longwall blocks. Considered that narrow longwalls minimise subsidence issues in environmentally sensitive areas, whilst narrow blocks also minimise risk of floor breaks during longwall extraction and the need for cross measures drainage of

floor strata.

3 - good.Continuous miner not considered to be a development

constraint.

2 - low.Bolting is considered to be the development constraint and

the mobile bolters require a high level of maintenance activity in terms of time and cost.

3 - good.Only operate with 1 shuttle car behind place changing CM due to congestion in panel, and the fact that mining is bolt

constrained even with one shuttle car in operation.









M014MINE RESPONSES

2 - low.Manual handling of support materials from bulk pods to

mobile bolters is extremely labour intensive. Retrofitting of supply pods onto mobile bolters would deliver considerable

benefits.

2 - low.Typically 20 -30 hours, with duration of panel advance

greatly affected by extent of preparatory work completed. Noted that a major disadvantage of the 2 entry place change mining system is that there are no standing

roadways where preparatory works can be completed prior to panel advance.

Noted that installation of "bat bags" in current panel advance process extends overall duration by half a shift.

4 - very good.Maintenance has improved dramatically with adoption of

routine 1 shift per week maintenance.

3 - good.Suggested that few mines can consistently operate 22 - 23

hours per day, as is routinely achieved at the mine.Provision of surge capacity mid way through the coal

clearance system improves overall availability and utilisation, with development given priority in event of high

surge bin levels.Additional unit shifts and additional days worked.

Change of mining system to place change mining.Development given priority to longwall operations.









M014MINE RESPONSES

Potential introduction of an additional development unit to facilitate development of new mining area.

Continuing improvements to development process - anticipate that current performance level of 16m/shift could

be increased to 24m/shift.

Roadway support.Gas drainage.Panel services.

Coal clearance capacity (1500tph in Mains to surge bin, 650tph outbye).

1 - Roadway support.2 - Panel services including gas drainage.

3 - Coal clearance capacity.





M014MINE RESPONSES

Continuously extensible panel conveyor and panel services.

Automation of CM and bolter operation with machine guidance/seam following capabilities.

All services monorail mounted. An effective means of mining cut throughs.

Development costs.Lack of operator and OEM commitment to pursue

developments to successful conclusion.History of past failures, lack of commitment, failure to

follow through, and a lack of perseverance in respect to development of new roadway development technology.

Availability of mine real estate for the trial and development of equipment and systems away

from critical path operations, and the business risks associated with such trials and development if no suitable

real estate is available.Time required to prove up reliability of equipment, and

develop a comprehensive integrated system - noted that the introduction of ABM20 was affected by the failure to

provide a complete, proven development system.Time required to develop new technologies.






M014MINE RESPONSES

Self drilling bolting systems.Automated bolting systems.

Better transfer of hard rock mining technology to underground coal sector generally.

Bolting technology, or some other means of supporting roof and ribs.

Panel advance technology.Continuously extensible panel conveyor system.

Horizon control/terrain following and machine guidance systems.

Better exploration technology to enable production affecting structures to be detected prior to mining (and mitigation strategies to be implemented in a timely and

effective manner).Self drilling bolt (P Gray).

Paurat and KB Continuous haulage.12CM20.ABM20.

Place change mining.Vent tube monorail handling system.






M014MINE RESPONSES

Self drilling bolt - great potential.Paurat miner - dog, broke through floor, too heavy, couldn't

clean up.KB Continuous haulage - poor reliability, excessive fines

and spillage, problem steering through cut throughs.12CM20 - machine nose heavy, hydraulic rigs

troublesome, unreliable, E/W conveyor system problematic and inefficient.

Place change mining - successful, safer, removed people from immediate face area, allowed elements of process to

be completed simultaneously, requires good roof conditions, system still being used successfully.

ABM20 - cutting capacity reduced to capacity of bolting system, limited on board storage capacity required

frequent replenishment, complicated machine requiring more regular maintenance and higher skill levels, lack of

OEM support coupled with OEM skill shortageVent tube monorail - lot of potential, lack of commitment to

follow through.

Progress of self drilling bolt impacted by politics and issues between various parties involved in project.

1 - remain aggressive followers.Limited manning and technical support on site to make a

major commitment to operational R&D.







M014MINE RESPONSES

Self drilling bolts and bolting automation.

Put a package together of existing best practice technology and trial.

Yes










14 CM type - Mains?





M0155.46m3.2m

3.2m

5.5m5.2m

40m X 50m (original Mains)

90m cut through centres.

1 Contract bord and pillar - to commence Mains

development October 2005.

2.


tradesperson.

6 - 7 per panel.

Jeffery 1036

ABM25

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M015MINE RESPONSES

Transportable pod system.

Transportable pod system.

7 days per week

12 hours.

4 on:5 off:5 on:4 off:5 on:5 off - rotating.

280mRelatively flat.

In situ gas levels 7m3/tonne. Residual gas levels after drainage <4m3/tonne.

Mine ventilation capacity at limits.High humidity levels experienced during summer months,

and refrigeration utilised to cool intake air.No problems experienced to date.

High turnover of labour.Struggling to recruit experienced deputies, trades, and

miner drivers.



Mine life cycle?





M015MINE RESPONSES

Mine currently in first half of life cycle.

Annualised salary with no overtime or incentive bonus scheme.

6 x 1.8m X grade roof bolt per metre with mesh in travel and belt roads, butterfly plates only in other roads. Ribs

consists of 2 x 1.2m S grade bolts per metre with mesh in belt and travel roads and butterfly plates only in other

roads.

4 x 1.8m X grade roof bolt per metre increasing to 6 per metre in intersections. Future tailgate roadways are fully

roof meshed with the belt roads using only butterfly plates. Typically 2 x S grade (pillar side) and 2 x cuttable

(blockside) 1.2m rib bolts are used per metre. Often rib conditions dictate that 3 bolts per metre are used or

occasionally full rib meshing.

Only in response to TARP triggers ie faults movement but not normally conducted.














M015MINE RESPONSES

Typically 2 x 8m post grouted tendons are installed every 2m in future TG roadways. This is place prior to longwall

side abutment loading. Additional link n lock standing support will be installed prior to tailgate retreat at approx 1 per 3m. Rib will be fully meshed and supported with 1.8 to

2.1m bolts.

Belt roads are additionally supported with 6m point anchored tendons 2 per 2.5m prior to retreat.

2 - 3, poor to good.

1 - 2, difficult to poor.

Nil

Nil

Nil

Nil

10.62kms plus 14.18kms of bord and pillar development.

4.95Mt.



Panels?








M015MINE RESPONSES

Budget 200m/week/CM.Actual 93m/week/CM.

Previous gateroads 140m/week/CM.

20.6kms plus 21.8kms from bord and pillar development.

6.22Mt.

150m/week.

145m/week.Noted that mine will be in a entirely different domain in

2014/15 at significantly greater depth and higher in situ gas levels.

3 - good.Principle of continuous miner is good, however suffers from a crowded operational area and poor ergonomics.

Target rate is 3MPOH.

3 - good.Hydramatic drill rigs experiences lubrication problems and

a lot of downtime with blown hoses.

3 - good.Recent conversion to Joy 16SC with capacity of 20 tonnes,

allows 2 SC loads per metre advance.Big improvement in floor conditions noted with shuttle cars

(in lieu of diesel haulers).









M015MINE RESPONSES

2- - low.Pod capacity reduced from 100m to 50m with introduction

of new CMs.Lot of work to be done to improve supply system and use

of trailers.Nee to have underground storage area for heavy lift, high

capacity trailers.1 - very low.

Target 24 hours, generally in excess of 30 hours.1800mm roof mounted longwall structure installed with development crew (previously utilised contractors to

complete panel advances of a weekend).

2 - low.Scheduled for 1 maintenance shift/week during a mine

wide 12 hour maintenance window.Problems experienced with CM and SC maintenance if

panel advice done in conjunction with mine wide maintenance window.

2 hour window available each day for maintenance and servicing, however no maintenance labour available at that

time.

2 - low.Capacity good however reliability reported to be terrible

with 30 hours lost per week due to conveyor delays.

Development rates decreased due to higher gas levels and ventilation constraints being experienced, together with more intensive support requirements. Also noted that

problems being experienced installing bottom rib bolts due to friable nature of ribs.









M015MINE RESPONSES

Will need to completely mesh ribs on development which will further impact development rates.

Also expected that in situ gas levels will increase as mine gets deeper, requiring more intensive gas drainage.

Additional units likely to be required to maintain develop-ment and develop access to new mine area.

Services.Supplies.

Coal clearance to boot end.Roof and rib bolting.

1 - Roof and rib bolting (particularly longwall preparation).2 - Services.3 - Supplies.

4 - Gas drainage.5 - Coal clearance





M015MINE RESPONSES

Go back and simplify existing hardware - too many delays with high technology, technicians cannot keep up with

technology - move back to manual control.Attached coal clearance system.

Monorail services management system.Mobile boot end.

Ventilation fan mounted on feeder, with hydraulic cable reeling.

Extensible coal clearance system with mobile boot end.Self drilling bolt with carousel bolter.

Machine guidance systems.Don't think there is too much wrong with existing

continuous miner platform.Better geological detection and exploration at face.

High tendency to overcomplicate things.Too many inherent safety systems.

Skill shortages among all levels of organisation.Failure to address major delay cause.

Lack , and A lack of OEM expertise to maintain and troubleshoot their

own equipment, and a lack of OEM support generally.






M015MINE RESPONSES

Metalliferous and open cut technology generally - seen to be more advanced and reliable.

Utilisation of marine diesels in coal mines - temperature controlled, water cooled.

Machine and personnel tracking systems together with an integrated control system.

Alternatively powered equipment to obviate the need for trailing and reticulation cables.Light weight pipe and fittings.

Conveyor extensions - making belt moves more friendly.Downsizing cables and flameproof components.

Self drilling bolts.Dust capture.

Skill development.

Joy Sumps Shearer.Monorail and mobile boot ends.






M015MINE RESPONSES

Joy Sumps Shearer - good concept, too many electric motors.

Monorail - failure, due to level of manning required to support high rate of development.Mobile boot ends - still in infancy.

Need to involve people in the development and introduction of new technology and equipment.

Need to better manage the change process and overcome the NIH (not invented here) syndrome and pig peoples

headedness.Understanding site characteristics and conditions, and

what will work in those conditions.Legislative requirements impacting the ability to efficiently and quickly modify and adapt equipment and technology.








M015MINE RESPONSES

Training.The utilisation and management of labour.Hanging systems for ventilation ducting.

Quietening of on-board dust scrubbers to allow forcing ventilation systems to be employed

Capture the learnings of the grey heads (who are leaving the industry) to enable the new generation of miners to be more effectively trained (and minimise reinvention of the

wheel).The industry is not putting enough consolidated effort into addressing the industry skills shortage and rebuilding the

industry skills base.Need to address the workforce's typical lack of ownership

and pride in their work, a lack of incentive to do better (noted that the mine is one of a few to not to utilise an

incentive scheme).Need to pay tradesmen in accordance with their skills -

inadequate margin above operators.Ned top improve the transfer of ideas and technology

within companies as well as across the industry.

Yes.










14 CM type - Mains?





M015B5.5m3.4m

3.2m

5.5m6.5m

40m X 40m (varies)

23m x 21m

1

1


tradesperson.


tradesperson.

ABM20.

Noted that ABM20 is to be replaced with ABM25.Jeffery 1036.

Noted that 1036 CM is to be replaced with ABM25.

On board rigs ABM20

Joy (Cram) Multibolter

Jeffery Ramcars1050mm Conveyor.

Noted that diesel haulers are being replaced with 21 - 22m3 capacity shuttle cars.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M015BMINE RESPONSES

3 Jeffery Ramcars.1050mm Conveyor.

Noted that diesel haulers are being replaced with 21 - 22m3 capacity shuttle cars.

1 X ED7 Cassette on ABM20.

1 X ESC130 Cassette on Joy Multibolter.

7 day

12 hour, 1 hour overlap day/night shifts


280mRelatively flat.

In situ gas levels 7m3/tonne. Residual gas levels after drainage <4m3/tonne.

Mine ventilation capacity at limits.High humidity levels experienced during summer months,

and refrigeration utilised to cool intake air.No problems experienced to date.



Mine life cycle?





M015BMINE RESPONSES

Medium term contract for bord and pillar and Mains development.

Contract bord and pillar (place changing) development.Major mining equipment supplied by Principal.

Contractor's focus is on systems, development sequence, standards, people and supervision.

1.8m high tensile roof bolt, 6 bolt per metre. Mesh modules in conveyor and travel roadways, butterfly plates all other

roadways.1.2m rib bolt.

4m or 6m super strands in high/wide/faulted/TARP specified areas.

1.8m high tensile roof bolt, 4 bolt per metre headings and cut throughs, 6 bolts per metre intersections. Butterfly

plates and 100mm washers all roadways.1.2m rib bolt.














M015BMINE RESPONSES

4 - very good.

4 - very good.

3 - good.

Mains development to commence September 2005.



Panels?








M015BMINE RESPONSES

Budget 420m/week.Typically achieving 400m/week, although development

affected by poor roof conditions over past 2 months and limited development to 250 - 300m/week.

4 - very good.Utilisation of 3 diesel haulers with multiple haulage routes

around small pillars.









M015BMINE RESPONSES

4 - very good.46m (2 pillar) panel extension typically completed in 7 - 8

hours.









M015BMINE RESPONSES

Contractor's focus on people, systems, equipment, and associated standards.

Replacement of aged mining equipment.





M015BMINE RESPONSES






M015BMINE RESPONSES

Implementation of place change mining.Establishment of three new mines.






M015BMINE RESPONSES

Implementation of place change mining and development of 2 new mines reported as successful.

Involvement of personnel in improving equipment suitability and availability fundamental.

Structured maintenance programs.Commitment and priority given to safety.

Establishing and maintaining work standards.

Unsuccessful mine establishment marked by lack of structured maintenance and failure to rectify equipment

suitability and availability issues. Difficult mining conditions further compounded problems created by poor equipment

standards.







M015BMINE RESPONSES

Industry has a propensity to overcomplicate equipment and systems - need to simplify.

Yes.










14 CM type - Mains?





M016Up to 7.0m

4m

5.8m

36m X 100m

1

9Deputy, 6 miners, I mechanical and 1 electrical

tradesperson.

Joy 12CM12

4 Hydramatic Series 4000 roof bolting rigs and 2 rib bolting rigs

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M016MINE RESPONSES

1 X 15SC32 Shuttle Car.Stamler breaker feeder.

1050mm "temporary" panel conveyor.

Manual load on-board pods with 160 X 5.6m straps and 800 roof and rib bolts.

7 day production, 5 day maintenance.

10 and 12 hour production shifts, 7 day basis.7 hour maintenance shifts 5 day basis.

7 on:7 off production.5 day Monday to Friday maintenance.

Up to 280mUp to 1:10

In situ gas levels 6m3/tonne.Residual gas levels of 1 - 2m3/tonne after drainage to

highwall.

24m3/s auxiliary fan at face, 300m3/s main mine fan.

No problems experienced to date.

Labour sourced from adjacent mine during staged transition of operations.



Mine life cycle?





M016MINE RESPONSES

5 years development of mine and 6 years longwall extraction to recover 34Mt

Highwall punch mine with one development unit maintaining longwall float, approximately 16kms of

development per annum.Management style and attitude.

Extent of application of short interval process control.Good machine ergonomics.

4 or 6 X 2100 X 24mm roof bolts every 1.5m, installed through 5.6m long roof straps.

2 X1200mm X 24mm rib dowels every 1.5m/rib.

13 different strata control zones identified with 13 different support systems.

4m couple bolts installed in 10% of roadways driven.6m tendons installed in 15% of roadways driven.

4 bolt pattern installed in 50% of roadways driven.6 bolt pattern installed in 25% of roadways driven














M016MINE RESPONSES

4m couple bolts or 6m super strands in poor ground, depending upon conditions experienced.

Combination of 4m couple bolts and 6m super strands used for longwall installation face roadway drivage.

4 - very good.

4 - very good.

4 - very good.

N/A

N/A

N/A

N/A

13.6kms

Nil - no longwall at present.



Panels?








M016MINE RESPONSES

312m/week.16.288kms for 12 months.

Not projected at present.




4 - very good.Target 4MPOH, average 5MPOH across pillar cycle.

12CM12 considered to be best cutting platform available.

3 - good.Cannot bolt close to face or bolt in centre of roadway in

poor conditions.

3 - good.34t/metre advance, 3 X SC loads per 1.5m cycle.

Wheeling time considered one of the bigger constraints on performance.









M016MINE RESPONSES

4 - very good.Effective system with current roof support regime.

3 -good.Complete on average 1.5 panel advances per week, with

each move completed in one and a bit shifts.Process currently limited by installation of conveyor and pipe services in one roadway. Design to be amended for

future gate roads.

4 - very good.Maintenance scheduled on a daily basis Monday to Friday.Hydramatic Series 4000 rigs were considered to be a high maintenance component particularly in respect to slides,

packers, and hoses.

3 - good.Coal clearance one of the mine's larger delays at this stage

due to communications issues on control system - currently being addressed.

Application of short interval process control with attention to detail.

Improved performance measurement techniques promote accountability.

Utilising pareto analysis to identify key factors for improvement.

Deputy in control of face operations.Rigorous selection procedures.

Motivated crews make it happen.









M016MINE RESPONSES

Application of widehead continuous miner (5.7m wide) eliminates need for cutting out DCB, fan, and feeder niches

thereby minimising associated rework.Attention to CM ergonomics and providing fit for purpose

equipment that allows high development rates to be achieved.

Continued refinement of short interval process control and continuous improvement process.

Coal haulage.Roof and rib bolting.

Panel services and panel advances.

1 - Coal haulage.2 - Roof and rib bolting.

Panel services and panel advances.





M016MINE RESPONSES

Integrated cutting and bolting system.Self drilling bolts, including cuttable rib bolting equivalent.

Better haulage system.Reliable man transporters.

Maintenance friendly machines.

The concept of a single wide face roadway drivage with a pump pack system for installing a dividing septum was also

considered a viable alternative, as was the application of TBM technology, providing it was recognised that the

primary objective was gate road drivage, not technology development..

Noted that one of the respondents had visited a mine in China where a DBT continuous miner and bridge conveyor system was utilised to drive gateroads with reported rates

of 3,600m/month.

Availability of funding to pursue initiatives.Economics of self drilling bolts and availability of cuttable

rib bolting equivalent.

Ability of people to take responsibility and accountability for project execution.

Noted that the full cost of a lack of development performance was difficult to identify due to the propensity of mines to deploy additional resources to ensure longwall

continuity.






M016MINE RESPONSES

Integrated cutting and bolting system.Self drilling bolts, including cuttable rib bolting equivalent.

Better coal haulage systems.Reliable man transporters.

Maintenance friendly machines.Metalliferous sector technology including semi automated

cable bolting.Effective desilting systems for face pumps.






M016MINE RESPONSES

3 - very interested in industry based, incremental change.







M016MINE RESPONSES

Self drilling bolts and cuttable rib bolting equivalents in particular, others depending upon site specific relevance.

Yes, depending upon the initiative and its relevance to the mine, and providing it didn't require major funding.

ACARP was challenged to make funded R&D more effective.

Yes.










14 CM type - Mains?





M0174.0 - 4.2m3.2 - 3.4m

3.2 - 3.4m

5.2m5.2m

30m X 100m

30m X 30 - 100m

2

1

8Deputy, 5 operators, 1 mechanical and 1 electrical trades.


1 X ABM20 and 1 x ABM25

ABM25



1 X 15SC shuttle car per CM.1600mm Mains conveyor.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M017MINE RESPONSES

1 X 15SC shuttle car per CM.1200mm wide development conveyor.

SMV Brumby prime mover and pods plus MPV and pods.Approximately 20m advance per set of pods.

SMV Brumby prime mover and pods plus MPV and pods.Approximately 20m advance per set of pods.

7 days.

10 hours.

3 shifts per day, Monday to Thursday.3 shifts per day, Friday to Monday (mine employees).

3 shifts per day, Friday to Sunday (contractor's employees).

100 -120m1:30

1 -2 m3/tonne

18m3/s auxiliary fans with 760mm flexible ducting and 600mm rigid ducting.

Horizontal stress 2.3 times vertical, not an issue excepting adjacent to structures.

Stable workforce, contract weekend labour.



Mine life cycle?





M017MINE RESPONSES

20+ years remaining

Aged, mature workforce.Have had major problems with slabbing of floor strata.Conditions vary widely without clear pattern, difficult to

predict limits of good/bad areas.Similarly, structures (mostly faulting) also vary widely

across mine.

6 X 2100mm roof bolts installed in 1.0m mesh modules.Increased to flex bolts where conditions warrant.

2 x 1200mm rib bolts installed per metre/rib through domed plates (no rib mesh).

6 X 2100mm roof bolts installed in 1.0m mesh modules.Increased to flex bolts where conditions warrant.

2 x 1200mm rib bolts installed per metre/rib through domed plates (no rib mesh).

6m and 8m point anchored and/or fully grouted tendons installed on a 2 per 2m spacing where conditions dictate (approximately 15% of roadways developed so treated).














M017MINE RESPONSES

6m and 8m point anchored and/or fully grouted tendons installed on a 2 per 2m spacing where conditions dictate (approximately 15% of roadways developed so treated).

Standing supports installed in tailgate roadway prior to lo0ngwall retreat.

1 - 4 (difficult to very good).15% very difficult, 20% poor, 30% good, 35% very good

2 - 3, poor to good.Rib conditions generally don't vary a lot however adoption

of 600 angle cut throughs to facilitate monorail services management system has improved rib conditions.

2 - poor.Very hard sandstone floor throughout mine however floor slabs off and requires considerable roadworks to maintain

(3 shifts/day, 4 - 5 days per week).

1.76Mt

12.67kms

2.88Mt

7.7m/unit shift.Now utilise time to complete pillar as key indicator.

Abnormal drivage required in Mains for excavation of overcasts and driveheads - long wheeling distances

typical.



Panels?








M017MINE RESPONSES

10m/unit shift.

14.6kms

4.0Mt

9.4m/unit shift.

8.0m/unit shift.

3 - good.Achieving 4MPOH against possible 6MPOH

Good coal cutting machines but not good stone cutters.ABM25 considered to be too complex - an electronics

madness with maintenance issues.

3 - - good.Bolting rigs fit for purpose however Hydramatic rigs

reported to be not as good as Joy HFX rigs.

2 - low.Capacity and age of shuttle cars.Slabby and wet floor conditions.









M017MINE RESPONSES

2.5 - low to good.Experience some delays.

Mesh carrier reported to work well however pod loading jib reported to not suit ABM25.

Reported to take some 45 minutes to change out pods.

3 - good - Mains.4 - very good - Panels.

Utilisation of monorail services management system has allowed ghost belt moves to be suspended and enables panel belt moves to be completed in less than a shift (10

hours).

3.5 - good to very good.Allow 2 shifts/week/CM for maintenance however can be

relented if circumstances dictate otherwise.With DCB mounted on monorail services management system maintenance can be completed during panel

moves a power can remain available throughout process.

4 - very good.Large lumps of longwall coal can cause problems at

transfers and at crusher.

Statistics not readily available however don't consider that there has been any significant change in annual

development levels.Used to be only some bad areas, now there are a lot of

them.Simultaneous cutting and bolting considered the norm.









M017MINE RESPONSES

Full utilisation of monorail services management system throughout the mine.

New shuttle cars>Improved face pumping strategies.

New conveyor structure.New bolting rigs

Incidence of fewer geological structures.Better road management equipment and systems.

Roof and rib bolting.Coal haulage.

Materials supply.Extension of steel services (eg; pipework).

Additional maintenance on bolting rigs.

1 - Roof and rib bolting.2 _ Materials supply system.

3 - Extension of services.3 - Coal haulage.3 - Maintenance.





M017MINE RESPONSES

Continuous haulage system and/or surge car.Self drilling bolts with automated bolting carousels.

Joy Sumps Shearer front end.Spray on rib reinforcement eg: Techflex.

Funding.Personal motivation to do it, or lack thereof.

Company vision to do it, or lack thereof.Workforce acceptance.Right bonus scheme.






M017MINE RESPONSES

Machine guidance systems.Seam following techniques.

Tunnelling sector - visit to see what is being done and can be transferred.

Freezing of underground water to in certain areas to control water make into roadways.

Noted that incremental improvements were there to be got now that the monorail services management system had

been successfully developed

Self drilling bolt, bolter automation and improved bolters.Laser guided machines.

Flexible drill rods to facilitate longer than seam height drilling.

Simplifying, minimising, or eliminating electrical bells and whistles (breakdown sources)

Trials of "flexidrill" drilling equipment.Introduction of ABM25.

Demonstration of Joy Sumps Shearer.Development of monorail services management system.

Different forms of rib support (eg; hydrafoam).Different forms of fall recovery (eg: cavity filling).

Introduction of advancing/retreating longwall mining.






M017MINE RESPONSES

Flexidrill - a good overseas system improperly applied to Australian technology - "half arsed".

ABM25 - definitely not finished with refinements and improvements.

Joy Sumps Shearer - theoretically still the best platform out there.

Monorail services - big improvement, not finished with refinements.

Alternate rib support - future concept.Advance/retreat longwall mining - an engineering feat.

Absolute necessity for a passionate champion.Necessity for strong support from corporate sector and

from OEMs.Need for perseverance and persistence.

Lack of technical expertise and support from OEMs.

3 - very interested in industry based, incremental change, subject to the relevance of any specific initiative.

Also noted that have been previously bitten by lack of OEM support and would require appropriate safeguards to

be in place before proceeding.







M017MINE RESPONSES

Different roadway support systems, equipment, hardware and consumables.

Coal clearance systems.

Yes, no dramas in this regard.

ACARP should initiate and maintain an annual roadway development conference/workshop to facilitate networking

and the transfer of ideas and technology across the industry.

ACARP should coordinate a workshop with suppliers and OEMs to express the industry's concern with their lack of

interest and support.

Yes










14 CM type - Mains?





M0185.5 - 6.5m

3.4m

3.4m

5.2m5.2m

40m roadway centres, cut through centres vary.

2 heading gateroads, typically 100m X 48m centres but increasing to 100m X 60m with depth.

1

2Mine previously deployed two CM to a single unit and

alternated crew between CMs however is now operating the 2 CMs as a super unit. Face operations currently

impacted by ventilation, gas and geological conditions (and manning shortages) which is consistently limiting operation

of both CMs.

ABM20 Mk III

ABM25

4 Cram roof bolting rigs and 2 Cram rib bolting rigs.

4 Cram roof bolting rigs and 2 Cram rib bolting rigs.

2 Joy 15SC shuttle cars

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M018MINE RESPONSES

2 Joy 15SC shuttle cars with one SC servicing each of the two CMs that comprise the super unit.

2 on board cassettes - 20m advance per pair.

2 on board cassettes - 20m advance per pair.

7

12 hours

4 on:4 off - rotating.2 hour overlap between day and night shifts, with a

maintenance shift rostered to cover gap between night and day shifts.

280 - 450m1:12

CH4, 8 - 12m3/t.Typically drained to 3.5 - 6m3/t, with 7m3/t outburst

threshold.

2 main mine fans and booster fan with 350m3/s circulating. Currently sinking an additional ventilation shaft.

Low horizontal stress regime - principal horizontal stress 7Mpa.

No major problems experienced with labour availability of miners however some shortages experienced with ERZ

controllers and trades.



Mine life cycle?





M018MINE RESPONSES

15 - 20 years remaining.

Difficult geological conditions with extensive small displacement faulting.

2.1m roof bolts, 6 bolts/metre installed in single row with full meshing of roof.

1.2m rib bolts, 3 bolts/metre/rib with full meshing of ribs.

2.1m roof bolts, 6 bolts/metre installed in single row with full meshing of roof.

1.2m rib bolts, 3 bolts/metre/rib with full meshing of ribs.

4m mega bolts installed on 2 X 2m centres in all intersections.














M018MINE RESPONSES

4m mega bolts installed on 2 X 2m centres in all intersections.

2+ - poor.

1+ - difficult.High density rib support installed to facilitate longwall

extraction.

3 - good.1.0m of bottom coal left to protect soft underlying strata. Where floor coal inadvertently mined underlying strata is

extremely difficult.Gas drainage has reduced earlier problems associated

with high in-situ water levels however floor coal now soft, friable and dry.



Panels?








M018MINE RESPONSES

3 - good.1.5m/hour typically achieved.

ABM25 (and ABM Mk III) have better loading characteristics than earlier machines.

3 - good.6 bolts/metre normally installed however TARPs require

installation of 4m tendons if any geological structures encountered, then "low" effectiveness experienced.

2 - low.Considered a major constraint due to the soft, friable and dry floor coal parting left to protect soft underlying strata.

Haulage chews floor coal, particularly when wheeling around corners.

Fall of in cutting rate noted as haulage distance increases.









M018MINE RESPONSES

3+ - good.Maintenance and supply window prior to start of day shift

allows for resupply of CMs.

1 - very low.Budget 4 (12 hour) shifts, typically 5 shifts taken.

Installation of longwall conveyor structure impacts duration of panel advance.

2+ - low.New ABM25s.

Due to operational constraints typically only operating one of the super units two CMs, therefore have spare capacity.

Anticipate some problems when super unit fully operational.

3 - good.Conveyor system reported to have 97% availability.

No noticeable increase in development rates noted, although now fully meshing roadways (previously W

straps), with higher in situ gas levels as depth increases.









M018MINE RESPONSES

No noticeable increase in development rates noted, although now fully meshing roadways (previously W

straps), with higher in situ gas levels as depth increases.

More timely gas drainage and improved ventilation resulting in higher availability of units.

More timely gas drainage and improved ventilation resulting in higher availability of units.

Coal clearance.Roof and rib support.

Panel advances.Supplies and materials.

1 - Coal clearance.2 - Roof and rib support.

3 - Panel advances.4 - Supplies and materials.





M018MINE RESPONSES

Systems to facilitate utilisation of tensar mesh for roof and rib support from continuous rolls installed on CM.

Automated bolting with sufficient capacity to install all (roof and rib) bolts simultaneously.

Horizontal vacuum cleaner with CM mounted crusher to size coal to -50mm and transport coal to boot end (which

may also be the auxiliary ventilation system?).Monorail mounted services and coal haulage (keep

equipment of soft floor).Roadway design to facilitate roof support, not larger

longwall equipment.Profiling of roadways eg; TBMs.

Time and resources required to develop, trial and implement new equipment and systems - everyone

currently focussed on existing challenges, with no surplus time or resources available.

No one wants to be a guinea pig, prefer to be aggressive followers - other current and real challenges.

Potential conflict between new roadway profile and the profile of existing equipment utilised in second phase of

operation (ie; longwall equipment).






M018MINE RESPONSES

Automation and use of robotics for bolting.

Noted that current IS standards are likely to limit the successful application of automation and robotics.

Coal clearance.Automation of bolting.

Services extensions, and maintaining standards in a high development rate environment.

KB continuous haulage.MBE.






M018MINE RESPONSES

KB continuous haulage good concept although impacted by floor conditions (eg; too hard and the system slides

across floor into ribs as it traverses corners, too soft and the hydraulic lifters sink into the floor).

MBE good for single roadway development however needs to parked up for drivage of adjacent roadways and cut

throughs.

1 (aggressive followers) or a 4 (industry step change), depending upon the specific initiative, its risk profile, and

development priorities.







M018MINE RESPONSES

Coal clearance.Developing systems to guarantee bolt encapsulation.

Dissemination of results - everyone is too busy to read and go to conferences.

Details of ACARP website provided so that participants can directly access reports - need to determine whether current

system has a facility for subject/item/word searches, and whether sites can then access reports directly,

electronically.

Yes.










14 CM type - Mains?





M0191.8m

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M019MINE RESPONSES

12 hours

4 panel 7 day with 1 hour overlap of shifts to create a 2 hour maintenance window each day.5 day X 12 hour maintenance crew.

200m1:30

In situ 2.3 - 10m3/tonneTry to drain to 2m3/tonne for longwall extraction.Outburst threshold in development 6.5m3/tonne.

Recently upgraded, no issues reported.

Stress levels not considered a major issue.

High turnover typical of Bowen Basin



Mine life cycle?





M019MINE RESPONSES

Approximately 8 years life remaining

1.8m seam thickness and thinning in future.Hard roof and floor material poses a frictional ignition risk

and is abrasive on equipment.














M019MINE RESPONSES

3 - good.

3 - good.

3 - good.

13 kms



Panels?








M019MINE RESPONSES

225m/week

23 kms (2006)

3 - good.

2 - low.Use of 12CM12s with roof bolting rigs are not considered

fit for purpose.

3 - good.Haulage constraints evident once haulage distance

exceeds 70m









M019MINE RESPONSES

3 - good.No materials pods or cassettes utilised.

3 - good.Typically 12 hours (86 manhours)

2 - low.1 maintenance shift per panel per week

2 - low.

Overall development rate reported to have declined due to adoption of 12 hour shifts and associated roster system,

and installation of a more intensive support regime.









M019MINE RESPONSES

Additional mining unit.

Roof bolting.Panel advances.Materials supply.

Maintaining panel standards and services such as pipework.

Mining system can only be intermittent at best, without face storage/bunkering.





M019MINE RESPONSES

Integrated cutting and bolting (must be condition specific).Flanking conveyor in CM rather than centre conveyor - to allow installation of centre bolts to optimise roof support.

Wide roadway (shortwall) with installation of artificial partition to create segregated ventilation and services

roadways.Adoption of automated and semi-automated processes

from metalliferous sector.Need a step change in process to go forward.

Capital intensive.Development priorities at existing mines.

High risk (wide roadway/partitioning)






M019MINE RESPONSES

Adoption of automated and semi-automated processes from metalliferous sector.

TBM with augering of interconnecting ventilation roadways.

Roof bolting - speeding up process.Panel advances.

Continuous haulage.Integrated system incorporating all of the above.

Improved development rates achieved through working with people and getting the detail right.






M019MINE RESPONSES

Difficulty of and time taken to obtain various approvals.Difficulty to maintain champions due to new appointments

and turnover.








M019MINE RESPONSES

Drillable bolts.Equipment reliability.

Why has it taken so long to undertake such an initiative?Need to remove the human element from the development

process.Considered that the industry may be too hard on itself as it has at least maintained development rates while utilising and installing more intensive strata support measures.

Yes










14 CM type - Mains?





M020MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M020MINE RESPONSES

12 hours

4 panel 7 day with 1 hour overlap of shifts to create a 2 hour maintenance window each day.5 day X 12 hour maintenance crew.

120 - 220m1:30



Mine life cycle?





M020MINE RESPONSES

Approximately 25 years life remaining

Hard roof and floor material poses a frictional ignition risk and is abrasive on equipment.














M020MINE RESPONSES

3 - good.

3 - good.

3 - good.

18 kms



Panels?








M020MINE RESPONSES

230m/week

18 kms (2006)

3 - good.

3 - good.In average going not bad, however in difficult conditions

considered to be a bit of a struggle.

3 - good.Haulage constraints evident once haulage distance

exceeds 70m









M020MINE RESPONSES

3 - good.

3 - good.Typically 12 hours

2 - low.1 maintenance shift per panel per week

3 - good.

Overall development rate reported to have declined due to installation of more intensive support regime, including use

of mesh modules, although development rates are now recovering.









M020MINE RESPONSES

Targeting 20km/annum, subject to equipment availability.

Roof bolting.Panel advances.Materials supply.

Maintaining panel standards and services such as pipework.

Mining system can only be intermittent at best, without face storage/bunkering.





M020MINE RESPONSES

Integrated cutting and bolting (must be condition specific).Flanking conveyor in CM rather than centre conveyor - to allow installation of centre bolts to optimise roof support.

Wide roadway (shortwall) with installation of artificial partition to create segregated ventilation and services

roadways.Adoption of automated and semi-automated processes

from metalliferous sector.Need a step change in process to go forward.

Capital intensive.Development priorities at existing mines.

High risk (wide roadway/partitioning)






M020MINE RESPONSES

Adoption of automated and semi-automated processes from metalliferous sector.

TBM with augering of interconnecting ventilation roadways.

Roof bolting - speeding up process.Panel advances.

Continuous haulage.Integrated system incorporating all of the above.

Improved development rates achieved through working with people and getting the detail right.






M020MINE RESPONSES

Difficulty of and time taken to obtain various approvals.Difficulty to maintain champions due to new appointments

and turnover.

2 - will pursue mine site initiatives.







M020MINE RESPONSES

Drillable bolts.Equipment reliability.

Why has it taken so long to undertake such an initiative?Need to remove the human element from the development

process.Considered that the industry may be too hard on itself as it has at least maintained development rates while utilising and installing more intensive strata support measures.

Yes.










14 CM type - Mains?





M0212.8m to 3.0m2.8m to 3.0m

Full seam height (2.8m to 3.0m)In soft floor conditions 300mm coal left on floor

5.2m5.2m

Nominal 100m X 35m - varies due to gateroad arrangements.

2 heading100m X35m

0 - Mains development completed

2

81 ERZ controller, 5 operators, 1mechanical and 1 electrical

tradesperson

81 ERZ controller, 5 operators, 1mechanical and 1 electrical

tradesperson

Joy 12CM32

Joy 12CM32



Single SC each unit feeding directly onto conveyor boot end

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M021MINE RESPONSES

Single SC each unit feeding directly onto conveyor boot end







Mine life cycle?





M021MINE RESPONSES

1.8m long resin encapsulated bolts, 4 bolts/m (2/2 pattern).4.8m X 1.2m welded mesh roof modules.

1.2m long resin encapsulated rib bolts spot bolted as required.

1.8m long resin encapsulated bolts, 4 bolts/m (2/2 pattern).4.8m X 1.2m welded mesh roof modules.

1.2m long resin encapsulated rib bolts spot bolted as required.

Typically no rib bolts when mining perpendicular to cleat with one rib bolt installed per 1.5m (staggered) when

mining parallel to cleat.

4.1m long JSS Super Strands installed around geological features and where roadways widened in excess of 6.2m














M021MINE RESPONSES

4.1m long JSS Super Strands installed around geological features and where roadways widened in excess of 6.2m

4 - very good.Full meshing of roof described as greatest advance in

mining technology for 20 years.

4 - very good.

3 - good - typically.1 - difficult - currently.

Soft floor conditions being experienced in current working area are not typical of remainder of mine.

Gas drainage also dries out coal with floor coal becoming more brittle and soft.

10.4 km (1994/95) - 3 development panels

2.1Mt ROM in 1994.1.87Mt in 1995.

Nil Mains development in 1995

95.8m/week/CM (1995)

10.2Km (2004/05)No 1priority CM 7.5Km.No 2 priority CM 3.2Km.

Development intensity reduced due to pending closure of mine

2.39Mt (2004/05)

No Mains development completed in period



Panels?








M021MINE RESPONSES

No 1priority CM 150m/weekNo 2 priority CM 70m/week

N/A

N/A

N/A

N/A

3 - good.Good cutting machine however design of machine is not

maintenance or breakdown friendly, eg: too high tech with control components stuffed into small places.

Machines need to be designed to allow ease of access for maintenance and breakdown.

Cutting performance limited at times by gas emission levels and ventilation limitations.

Shovel design impacts clean up performance.

3 - good.Reliability of Aro Series 4000 rigs not good - hoses.

Roof bolting rigs not capable of installing best geotechnical design which results in sub-optimum design to fit in with

machine capabilities, particularly centre bolts.

3 - good.CM often waiting on SC when wheeling distance 100m or

more.









M021MINE RESPONSES

3 - good.Pods changed when empty - 40 to 60 minutes delay to

change out.

2 - low.Typically 24 hours to complete 100m panel extension.Previous system with use of specialist belt crew and

suitable roadway development sequencing allowed panel extensions to be completed in 6 - 8 hours (duplicate boot

end, fan and cabling, with conveyor extension partially completed in first driven conveyor roadway).

2 - low.Development constrained, chasing development,

preventative maintenance restricted resulting in numerous breakdowns.

3 - goodEstimated at 90% availability.

Changed development sequence and use of specialist belt crew (contractors) enabled panel moves to be completed

in 6 - 8 hours, which provided an additional 2 shifts development per week per CM, or 3 additional shifts if

extension completed over weekend (5 day development only).

Cut and flit development system trialed however gas emission levels, short plunges and 2 heading gateroads

impacted performance of system.









M021MINE RESPONSES

7 day development operations with additional units.Integrated cutting and bolting CM (eg; ABM20) with FCT coal clearance incorporating ventilation and services on

monorail.Need to have ABM head rated for cutting high MPa strata.

Reintroduction of specialist belt crews and modified development sequence.

Include development teams into planning and scheduling processes to improve ownership.

Automated drill rigs, however need to be able to manually install bolts in event of breakdowns.

14BU surge loaders or bunkering systems

Extension of face services (ventilation, power, water).Residual gas emission in high permeability strata and

ventilation limitations.Supply system limitations.

1 - Face ventilation.2 - Roof support.

3 - Haulage system.





M021MINE RESPONSES

Continuous, integrated cutting and bolting with continuous coal haulage and/or temporary coal bunkering, FCT

mounted face services (eg; ventilation, power and water), fan mounted on monorail.

Sequencing of panel development to allow conveyor extensions in parallel with development.

Hot seat change.Specialists (or contractors) doing services extensions.Automated bolting (with provision for manual bolting).Utilisation of appropriate high wall mining technologies

including horizon control and machine guidance systems.Improved support systems ...Automated meshing systems.

Fully automated CM - Mojura TBM?






M021MINE RESPONSES







M021MINE RESPONSES

Yes










14 CM type - Mains?





M0227.0m

3.0 - 3.2m

3.0 - 3.2m

4.8m4.8m

40m X 50 - 160m

47m X 110m

1Single unit.

1Tandem or dual unit.

91 deputy, 6 miners, 1 mechanical and 1 electrical trades.

Responsible for all internal absenteeism in crew.

151 deputy, 12 miners, 1 mechanical and 1 electrical trades

in tandem unit.Responsible for all internal absenteeism in crew.

12CM30

2 X 12CM30

4 Hydramatic Series 4000 semi automated roof bolting rigs, and 2 Hydramatic rib bolting rigs.

Temporary rib support shields fitted

4 Hydramatic Series 4000 semi automated roof bolting rigs, and 2 Hydramatic rib bolting rigs.

Temporary rib support shields fitted

1 x Joy 15SC.1400mm Mains conveyor.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M022MINE RESPONSES

1 x Joy 15SC/CM.1200mm Panel conveyor.

CM mounted supply pods, loaded off site, transported with PETs and handled with QDS attachments.

Pods changed out almost every shift.Dayshift responsible for ordering supplies on a 24 hour

basis.

CM mounted supply pods, loaded off site, transported with PETs with monorails used in face area.Pods changed out almost every shift.

Dayshift responsible for ordering supplies on a 24 hour basis.

5 days per week.

8 hours Monday to Friday.12 hour weekend shifts.

Permanent roster.Two 12 hour shifts available of a weekend for pro=duction

if required.

390m - 420mFlat, 1% dip.

No in situ gas.

18m3/s fan in tandem unit, 12m3/s fan in single unit, 120m3/s main mine fan.

No heat or dust issues experienced.5 7 MPa horizontal stress.

High stress zones around geological structures.Stress notching evident.

Coal strength 8MPa.Low labour turnover although some staff turnover reported.



Mine life cycle?





M022MINE RESPONSES

30 years life of mine remaining.

No gas, no spontaneous combustion risk.Water management (15Ml/day) major issue, particularly in Mains and from longwall goaves - can double flow rates at

times.Strata control also major issue.

Employees incentive scheme based on development metres mined, safety and quality - no longwall component.

Minimum standard 6 X 2100mm roof bolts/metre and 3 X 1200mm rib bolts/metre/rib, with full roof and rib meshing.

13 different support regimes under SMP, with up to 4 X 8m JSS tendons/metre in worst conditions.

4 X 8m JSS tendons/metre in intersections, commencing 6m either side of centreline.

Surface topography is major issue with mine area crossed by series of valleys and high escarpments.

Stress channelling evident beneath valleys, and 2 X 8m JSS tendons/metre installed under valleys.

Basalt plate lies some 860m below seam and major structures reflected in coal seams as lineaments. 4 X 8m JSS tendons/metre installed through lineament zones.

Minimum standard 6 X 2100mm roof bolts/metre and 3 X 1200mm rib bolts/metre/rib, with full roof and rib meshing.

13 different support regimes under SMP, with up to 4 X 8m JSS tendons/metre in worst conditions.

4 X 8m JSS tendons/metre in intersections, commencing 6m either side of centreline.

Surface topography is major issue with mine area crossed by series of valleys and high escarpments.

Stress channelling evident beneath valleys, and 2 X 8m JSS tendons/metre installed under valleys.

Basalt plate lies some 860m below seam and major structures reflected in coal seams as lineaments. 4 X 8m JSS tendons/metre installed through lineament zones.

Passive supports, cables and tendons installed as required.














M022MINE RESPONSES

Fit as mush secondary support as can be done prior to longwall extraction.

1 additional 8m cable/metre installed where roadway previously supported with tenons, 2 X 8m cables/metre

installed in areas not previously tendoned.Lag of up to 2 years between development and secondary

support installation.

Longwall installs cans in next tailgate roadway prior to extraction

2 - poor on average.CMs and roof bolters set up for conditions.

1 - difficult.Full meshing of ribs with 3 rib bolts/metre/rib.

3 - good.Hard sandstone capping 150 -300mm thick. Conditions

good unless capping cut and soft underlying strata exposed.

Floor and roof swilleys also occur throughout mine.

6kms (1997).

2.2MT (1997).1997 first year of longwall operations

12 - 13kms (2003 and 2004).

2.4Mt (2004).

225 - 275m/week overall for 3 CMs with 39 X 8 hour and 2 X 12 hour cutting shifts.

Time to complete pillar cycle is KPI, not metres/week or metres/shift.



Panels?








M022MINE RESPONSES

23 - 24 shifts to complete a pillar, including 2.5 shifts for panel advance - best 15 shifts with 1.5 shifts for panel

advance.Due to difference in drivage requirements between two

CMs in 2 entry gateroads, 1 X CM not manned on D/S with labour allocated to preparatory works.

Annual development requirement will reduce to approximately 6kms.

3.0 - 3.2Mt.

No change in development rates projected, budget based on actual achieved.

No change in development rates projected, budget based on actual achieved.

3 - good.Only cutting 15 - 20% of time, CM is predominantly a

bolting platform.

2 - low.Bolters fit for purpose although high downtime experienced

with hoses and slides.

Major work undertaken to enable 8m tendons to be installed at face in 8 minutes or less.

3 - good.









M022MINE RESPONSES

3 - good.Don't lose to much time however do preparatory works

between all shifts - change pods, etc.PETs used to transport materials, with monorail used in gateroad to handle oils, cables, hoses, bolts - reduces

manhandling.

3 - good - gateroads (pinned ACE structure).1 - very low - mains (bolted structure, no process plan,

more services, more clean up).

3 - good.Planned maintenance 2 shifts/week with 1 shift on rigs and

1 shift on rest of machine.Allocate a lot of people as rigs take a lot of time.

Problem with machines not working properly after being overhauled.

3 - good, but improving.Currently upgrading system to remove capacity

constraints.

Better planning and process control.Better strata control.

CM upgrades.Materials handling improvements.Improved machine ergonomics.Improved logistics and supply.

Ensuring development focus is maintained.

Still looking for improvements in drill steels, drill bits, bolts and plates.

Not scared to try new products.









M022MINE RESPONSES

Will need to drop development unit off as will be to far in front of longwall.

Opportunity to address interaction issues in dual or tandem mining units.

Bolting constraints.

1 - Bolting constraints.





M022MINE RESPONSES

Self drilling bolts.Automated bolting systems to get personnel out of

immediate face area.Fancy materials handling system.

Incorporation of all services on monorail system.Alternative loading system (to E/W conveyors) that clean

up better and still enable supports to be installed at immediate face.

Automation of cutting process.Automation of long tendon installation process.

automation of installation of roof monitoring systems.

Ensuring the specifications of self drilling bolts meets likely requirements across a broad spectrum of mine conditions.

Cost of hardware.Ribs a bigger problem than roof at the mine.






M022MINE RESPONSES

Road building technology to facilitate rapid transport of men and materials.

Lighter, more effective face pumps.Automated bolting machines for installation of secondary

supports.

Fit for purpose automated bolting systems that get personnel out of the immediate face area.

Materials handling systems, including monorail mounted systems.

Cleaning up of the 12CM30 (ie; E/W conveyor).

Systems approach.Joy Sumps Shearer.

Mobile boot end behind advancing CM.Klockner Becorit continuous haulage system






M022MINE RESPONSES

Systems approach - reasonable standards prior to commencement, looked at people issues and got people

involved and buying in. good improvements on cutting time and downtime.

Joy Sumps Shearer - good work platform, electrical problems not sorted out.

Mobile boot end - went OK but not a good trial, not long enough.

KB continuous haulage - breakaways an issue, ventilation also an issue as haulage is attached to CM.

Systems approach - unit of measure must be relevant to what you are doing - understanding the process and

measuring performance according to the process. Need someone to drive it all the time, to monitor activities, and

do things with it.Auditing of standards to make sure work is being done,

and to follow up on things to be done.

3 - 4, very interested in industry based incremental and step change initiatives.

Mine has a good record of involvement in R&D and continuous improvement.







M022MINE RESPONSES

The whole mix - bolts, strata, water.

Yes.

ACARP needs to adopt proactive approach to research and development - mine has been unsuccessful in gaining

ACARP support on a number of projects aimed at improving the level of understanding of ground water, and

subsidence. Should focus R&D on safety issues associated with

bolting to remove people from the immediate face area.Should also focus R&D on machine guidance and forward

seeking seam detection.

Yes.










14 CM type - Mains?





M0231.6 - 2.2m

2.6 generally, with some roadways driven at 3.3m for long term trunk returns

2.6m

5.0m5.0m

100m X 25m typically

Typically 75m X 39.5m in gateroads.

3Two units operating in tandem in 4 heading Mains

development of new mine area, plus one single unit in other Mains development.

2 continuous miners in a 2 entry super unit configuration.

142 deputies, 10 miners, 1 mechanical and 1 electrical trades

in tandem unit.8

1 deputy, 5 miners, 1 mechanical and 1 electrical trades in single unit

131deputy, 10 miners, 1 mechanical and 1 electrical trades in

super unit.

2 Joy 12CM30 plus 1 Joy 12CM30(Waratah)

1 Joy 12CM30 plus 1 Joy 12CM30(Waratah)

The two Joy 12CM30s have Joy HFX rigs, total 2 rigs per machine (including roof and rib).

The Joy 12CM30(Waratah) has 2 machine mounted Hydramatic Series 4000 rigs (including roof and rib).

Both the Joy 12CM30 and the Joy 12CM30(Waratah) have Joy HFX rigs, total 2 rigs per machine (including roof

and rib).

The tandem unit utilises 3 DBT battery haulers to haul coal back from the two continuous miners to a side loading

Stamler feeder breaker.The single CM unit utilises 2 Waracar 15SC shuttle cars

directly loading onto a Stamler feeder breaker.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M023MINE RESPONSES

The two CM super unit utilises 2 Waracar 15SC shuttle cars directly loading onto the 1200mm wide panel

conveyor.

Both mains and gate roads utilise a materials pod system. These universal pods sit on the top decks of the A series

CMs and are loaded onto the CMs with a Roberts Engineering QDS loading jib. The pods are brought

underground on dedicated materials pod trailers with the use of Eimco 913 LHDs. Typically advance 30m/set of

pods.

Development 5 day 24 hour basis, with longwall mining on a 7 day 24 hour basis

8 hour shifts plus voluntary 1 hours overtime for the ninth hour Monday to Friday.

12 hour shifts Saturday - Sunday.Fixed roster system with three nominal 8 hour shifts

Monday to Friday and two 12 hour shifts of weekend (for longwall and mine services).

420 - 460mTypically 1:20 to 1:33.

Insitu gas levels are approx 13m3/tonne with gas composition typically 75% CO2 and 25% CH4 in current

area. Residual levels vary depending on a number factors but with approximately 90 days of drainage are generally

around 4 – 5 m3/tonne and are below threshold levels, excepting in areas that experience tight, extremely low

permeability coal..

Studies underway to determine options to improve and upgrade overall mine ventilation system.

High horizontal stress regime with the orientation of the principal stress direction being modified around geological

structures.

Difficult to obtain experienced personnel. Turnover typically low however now being affected by labour poaching.



Mine life cycle?





M023MINE RESPONSES

15 years plus remaining in leases area.

High insitu gas levels with high CO2 levels necessitates intense gas drainage measures prior to mining. Grunching

employed to negotiate tight, poorly drained areas.High horizontal stress regime in certain areas of mine

which requires extensive primary and secondary support. Yield pillars adopted in Mains development.

8 x 2.1m AX fully encapsulated high tensile steel roof bolts installed per metre advance in a 4/4 pattern, and are pre-

tensioned 10 tonnes.Four roof bolts are installed on the overlap section of a

1.2m x 4.8m mesh module approx 900mm to the right and left of centre and then 200mm from the rib line. The next set of 4 bolts are installed forward of the overlap and are set to the roof approx 600 mm right and left of centre and

approx 800mm in from each rib.Rib support is by use of steel rib mesh (100mm x 100m

1.4m long x 600 wide). Two 4m JSS tendons are installed every 2 metres and no more than 2 sets of these tendons are left untensioned

before mining forward. Tension on these bolts is set to 20 tonne. These supports are standard in the tandem panel and on an "as needs" basis in panels as determined by

TARPS.

Roof support in panel development is as per the Mains development.

On the block side rib 1.2m fibreglass rib dowels are installed at 1m intervals in a staggered W pattern. Dowels are fully encapsulated with a 230mm plastic bearing plate.

The chain pillar rib uses the same thrust dowel support except that 1.4m long, 0.6m high rib mesh sheets are

installed behind the plastic bearer plate.

Typically one 8m long mega bolt is installed per metre, with two 8m mega bolts per metre installed in extreme

conditions. Mega bolts are tensioned (20 - 24 tonne) at installation and post-grouted.

Lag between mining and installation depends upon mine priorities and roadway monitoring by geotechnical

engineer.














M023MINE RESPONSES

As for Mains development.

2 - poor.

3 - good.Ribs generally not a problem during development.

2 - poor.Up to 0.5m of floor heave experienced shortly after mining and roadways are routinely brushed to maintain roadway

height specifications.

9.08kms - 1995 calendar year.

1.234M tonne - 1995 calendar year.

48.2m/week - 1995 calendar year.

63.5m/week - 1995 calendar year.

15.47kms

1.937M tonne.

33.1m/week.



Panels?








M023MINE RESPONSES

59.9m/week.

13.4kms.

2.6M tonne.

64m/week/CM.

64m/week/CM.

2+ - low.Typically cut 0.4m to 1.0m of floor stone and 0.2m roof

stone to achieve required height specification. E/W conveyors on CM experience considerable difficulties

dealing with floor stone, whilst the CM has major problems breaking away cut throughs due to canch of floor stone

and shovel limitations (noted that these CMs are designed to cut coal, not stone).

Typically achieving 13m/shift in straight development, reducing to 4m/shift during breakaways.

2 - low.Low height A series machines limit ability to install bolting

platforms.When bolters are working they do a great job however they

are considered to be very unreliable and have low availability.

Noted that CM was specified for 2 roof/rib bolting rigs at purchase due to perceived unreliability of rigs.

Also noted that unreliability and low availability of machine mounted rigs will limit performance of a new generation

integrated cutting and bolting mining system.Concerns expressed due to the over-engineering of bolting rigs as a result of the application of risk management and its basic assumption that miners are idiots and that soft

barriers are insufficient and/or ineffective.

3 - good.Development sequence designed to integrate and optimise

support installation and shuttle car wait time.Noted that the Warracar 15SCs were fitted with larger

cable drums that allowed 270m of cable storage on drum, which had benefits in certain parts of development

process.









M023MINE RESPONSES

3 - good.Mine utilises a "pull system" with standardised pods to manage logistics system. Improved management of oil

supply and logistics required.

2 - low.Typically completing 75m move in 24 - 27 hours, which is a significant improvement on performance achieved prior to

introduction of process approach for panel moves.

2+ - low.Each machine scheduled for 1 maintenance shift per week

on a routine basis, although overall maintenance scheduled managed flexibly to incorporate panel

development cycle.Configuring of hydraulic hoses on CMs considered a major

problem due to non standard installation by OEM, and routing of hoses under supply pods.

Bolting rigs extremely costly in respect to maintenance resources and operating delays.

Major concerns expressed regarding lack of OEM support, failure of OEM to warrant equipment, and failure of OEM to incorporate current generation hydraulic components and

systems on equipment.3+ - good.

Typically 98 - 99% availability with high capacity, state of the art system.

An additional mining unit.Higher utilisation of mining units due to fewer panel

relocations.

Upgraded and improved coal clearance system, with improved conveyor monitoring facilities allowing rapid

deployment of personnel in event of outages.Use of on board bolting rigs in lieu of hand held bolters, and pre-tensioning of roof bolts which has allowed bolt density to be decreased (ie; 8bolts/0.9m increased to 8

bolts/1m).Outburst management gas thresholds reduced while

operation of CMs is now by remote in lieu of enclosed on-board operators compartments.

Adoption of process control approach to manage development process.









M023MINE RESPONSES

As per Mains above.

Projecting development to increase from 15.5kms in 2004/05 to 22kms in 2005/06.

Expect that improved development rates will be achieved through improved reliability of face equipment, avoidance of major floor brushing during development by deployment of a fit for purpose brushing CM, improved process control

and process support, better maintenance practices and systems.

Capacity and availability constraints and limitations of support installation (bolting) system.

Duration of panel advances.Materials supply system, particularly in and around face

area.

1 - Bolting.2 - Panel advances.3 - Materials supply





M023MINE RESPONSES

Minimum capacity 30m/8 hour shift, full automation and integration of cutting and bolting processes, with alignment

control of support installation, integrated coal clearance system with services incorporated on a monorail type system, integrated supply and logistics, detachable cut through driving element, roadway profile designed to

optimise roof support process.Different machines and systems for gateroad and cut

through drivages.Cut through spacing extended to 300m or thereasbouts,

depending upon requirements of longwall, with interconnecting auger driven roadways mined as required

for ventilation.Supply of continuous length tendons with on board cutting

devices.Extendable panel conveyor and services (during normal

mining operations).Single entry roadway system, potentially incorporating

larger arched section roadways to optimise roof support and ventilation.

Integration of coal haulage and ventialtion systyems ie; pneaumatic coal transport.

Safety considerations regarding single entry drivages and the needs for secondary escape and NSW CMRA

limitations.Logistics of labour and materials supply in a single entry

roadway. Commitment and support of OEM.

Corporate support.Managing business risk during trials and development.Inflexibility of equipment design for cut through drivage.Poor track record of managing the change process in

mines generally, and a failure to build employee support, commitment and buy in to the improvement initiatives and

processesInability or unwillingness to share information across

industry.






M023MINE RESPONSES

Considered that component parts and technology is currently available although needs to be integrated into a

complete system.One pass, self drilling bolts.

Improving component and equipment reliability.Integrated supply systems for high development rates.

In-seam exploration and seam following/machine guidance technologies.

Automated bolting process including self drilling bolt.Improved gas drainage effectiveness and drilling

techniques, particularly in regards to extending the range of compliance drilling technology .

Development of continuous haulage system.

Dosco In-Seam Miner.Kemcoal Beaver II.

Satellite Bolters.ABM20.

Road headers.Mobile bolter and two phase bolting.Farthing West process management.






M023MINE RESPONSES

Dosco In-Seam Miner - good roadway profile.Mobile bolter - not utilised for two phase bolting (due to

lack of commitment and follow up).Farthing West process management - very successful.

Dosco In-Seam Miner - lack of OEM support, project not part of overseas based OEM's core business.

Kemcoal Beaver II - Couldn't turn corners, although could cut and bolt simultaneously. Face ventilation issues.

Satellite bolters - not compatible with variable seam profile and seam thickness.

ABM20 - prototype, lack of OEM support. Need to ensure commitment from OEMs and mine

operators.

1- aggressive followers.Can't afford another prototype.

Doesn't have the longwall float necessary to trial and develop new technology - cannot afford the business risk

associated with introduction of new technology, even though the mine needs to reduce the number of operating

development units.







M023MINE RESPONSES

Ventilation and gas drainage.

From a corporate perspective would be interested in supporting industry research and development although mine not in a position to be directly involved for some 2

years.Review is long overdue, however need to get the next

steps right and avoid any further failures.Research use of aluminium underground.

Establish common regulations and standards across NSW and Queensland.

Pursue in-seam exploration and seam following/machine guidance technologies.

Yes










14 CM type - Mains?





M024MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M024MINE RESPONSES



Mine life cycle?





M024MINE RESPONSES

40 hour per week limitation on employees in accordance with Certified Agreement.














M024MINE RESPONSES

14.5kms



Panels?








M024MINE RESPONSES

2 - low.1 X Joy HM9, 2 X Joy 12CM12, 1 X DBT 30MBT

Currently achieving 1.8 - 2.0MPOH

2 - low.2 rigs on either side of Joy HM9 considered not fit for

purpose.Hydramatic Series 4000 rigs on Joy 12CM12 and DBT 30 MBT to be changed out for Joy HFX rigs with a number of

ergonomic issues on current configurations to be addressed during the changeout .

3 - good.Despite a combination of 1978 version Noyes shuttle cars,

Warracars, and Joy 15SCs.









M024MINE RESPONSES

2 - low.

2 - - low.Breaker feeder with roof mounted structure, typically 30 - 36 hours to complete panel advance in dual miner panel.Mine currently has a number of improvement initiatives

currently underway, with panel advances being one of the four key projects.

2 - low.Mine currently has a number of improvement initiatives

currently underway, with maintenance improvement being one of the four key projects.

3 - good.

An additional mining unit coupled with increasing the days worked from 5 to 7.

Mining conditions have deteriorated and require increased levels of roadway support, including installation of mesh

modules.Increased water make being experienced with resulting

deterioration in floor conditions (12Ml/day pumped from the mine).

Currently in the process of rationalising the amount of development required to support ongoing operations.









M024MINE RESPONSES

An additional development unit will be required for a period of 18 - 24 months to develop roadways to access a new

mining area.Moving to introduce a better roster arrangement to improve

mine utilisation (eg; 10 hour shifts Mon - Thurs A/S and N/S, 8.5 hour shift Mon - Fri D/S (9 day fortnight), with two

12 hour weekend shifts Fri - Sun).

Improved roster arrangements.Improved level of process control and accountability.

Improved management skills.

Improved roster arrangements.Improved level of process control and accountability.

Improved management skills.

Coal clearance.Bolting and roadway support.

Supplies and logistics, services and panel moves.

1 - Logistics (due to distance travelled).2 - coal clearance.

3 - Support installation.





M024MINE RESPONSES

Integrated, continuous coal mining system capable of continuously supporting roof.

TBM has been actively considered for an adjacent, new mine development however were unable to get support to

develop and demonstrate the system.

Ability to sponsor and support high capital cost of developing and demonstrating TBM system.

Variability of coal seams across industry which necessitates a variety of mining configurations for differing

seam conditions.Industrial constraints limiting the realisation of automated

bolting systems (with subsequent labour reductions).






M024MINE RESPONSES

Automation of total mining system.Improved communications and control systems.

Equipment - integrated, automated mining system.Exploration - ability to confidently plan mining operations.

Information and management support systems.

ACARP industry workshops (1995).Continuous improvement process.In-mine improvement initiatives.






M024MINE RESPONSES

ACARP workshops - a lot of people but little outcome.Continuous improvement - mostly process oriented, quite

successful.In-mine improvements - variable, consistency of

application difficult to maintain.

Can get improved results through application of continuous improvement process.

However, in current environment at mine will require step change in mining process to establish more appropriate

systems and workforce behaviours (technological determinism).

2 - 4 , incremental mine site initiatives to industry based step change, depending upon technology being pursued.







M024MINE RESPONSES

Development and demonstration of TBM technology at new mine site.

Mobile boot ends and/or extensible panel conveyors.

Yes, depending upon corporate approval.

Yes.










14 CM type - Mains?





M0253.2 - 3.5m2.8 - 2.9m

2.8 - 2.9m

5.4m5.4m

30m X 60m (varies)

45m X 102m (angled cut throughs).

1 dual (two CM) miner unit.1 mine crew plus 1 contract crew.

1 dual (two CM) miner unit.

111 deputy, 8 operators, 1 mechanical and 1 electrical trades

per dual miner unit.

111 deputy, 8 operators, 1 mechanical and 1 electrical trades

per dual miner unit.

1 X 12CM12 and 1 X 12CM29.

2 X 12CM12.

2 Joy HFX roof bolting rigs per machine, no rib bolting rigs.Rib bolts installed with hand held bolters or Fletcher mobile

bolter if required.

2 Joy HFX roof bolting rigs per machine, no rib bolting rigs.Rib bolts installed with hand held bolters or Fletcher mobile

bolter if required.

1 X SC per CM (2 per unit).Breaker feeder discharges onto 1400mm Mains conveyor.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M025MINE RESPONSES

1 X SC per CM (2 per unit).No breaker feeder, 1200mm panel conveyor.

Pod base system, 66m advance per set of pods.

Pod base system, 66m advance per set of pods.

5 day production.Weekend maintenance.

8.5 hour shifts

Monday to Friday 5 day roster.

Up to 265 - 280m in panels, and 140m in Mains.Localised seam grades up to 1:15.

High CH4 content, >10m3/tonne at depth.Post drainage of longwall goaf only.

Mining induced stress evident at 140m depth with horizontal stress also becoming an issue at depths >300m.

No labour issues and no labour turnover.Establish of new mine in vicinity may result in some

turnover due to limited projected mine life.



Mine life cycle?





M025MINE RESPONSES

Project mine closure in 2010 unless access gained to further, limited reserves in close proximity.

Operate as a small business and considered to be very outcome focussed.

Dynamic ownership situation evolved over first 10 years of mine, consequently mine has point to prove.

Mine culture considered to be better than most.

6 X 2100mm roof bolts/metre, spot bolted, and installed on a 4/2 pattern.

Mesh modules used in areas where conditions warrant - approximately 50% of roadways meshed.

Rib support (1200mm bolts and tensar mesh) used in some areas where conditions warrant - approximately 50%

of roadways so supported.

6 X 2100mm roof bolts/metre, spot bolted, and installed on a 4/2 pattern.

Probably could utilise 4 bolts/metre for development, however additional bolts required for longwall retreat

Mesh modules used in areas where conditions warrant - approximately 50% of roadways meshed.

Rib support (1200mm bolts and tensar mesh) used in some areas where conditions warrant - approximately 50%

of roadways so supported.

6m Hi-ten bolts and/or Mega bolts as required from monitoring in accordance with SMP. Typically installed at

3m spacing on roadway centre line.Ribs of conveyor and transport roadways are meshed with

steel mesh as secondary support function.














M025MINE RESPONSES

6m 65 tonne capacity Hi-tens installed in intersections and in accordance with hazard mapping, typically one per 2

metre spacing.Ribs of chain pillar meshed with steel mesh and 1200mm

mechanically anchored rib bolts as secondary support function.

3 - good.

3 - good.Installation of rib supports with hand held bolters has major impact on productivity (approximately 20% of time). CMs to

be retrofitted with machine mounted rib bolters.

3 - good.

14kms.1 continuos miner, 3 shuttle cars in place changing

configuration.0.46Mt

260m/week or 1,200m/month.

260m/week or 1,200m/month.

14kms.

3.13Mt

160m/week (contract crew with 12CM29) or for 1 CM unit in Mains.



Panels?








M025MINE RESPONSES

280m/week for dual unit in panel development

Nil

Nil

Nil

Nil

3 - good.4.8MPOH for 2CM dual unit in gateroad development.

3 - good.Approximately 1.0 hour per pillar lost for roof bolting, although hand bolting of ribs impacts development

performance.

3+ - good.









M025MINE RESPONSES

2+ - 3- - low to good

3+ - good1200mm roof mounted longwall structure, typically 11 -

12.5 hours to complete panel advance in dual miner panel.A Hdg miner stops and installs pipework when at distance, and panel move commenced when B Hdg and cut through

completed. Reported time does not include idle time associated with

installation of pipework in A Hdg.

4 - very good.5 day operation with weekend maintenance plus one shift maintenance per week during scheduled trunk conveyor

maintenance. 96 - 97% availability of face equipment reported.

3+ - good

Annual development performance static over period however have gone from single unit place change

operation to multiple unit in-place roadway development system, with increased support requirements as mine has

deepened.

Increased roadway support measures have impacted development productivity.









M025MINE RESPONSES

6m cut outs initially utilised in a 2 CM super unit however increased delamination and loss of bolt encapsulation led to subsequent issues in gateroad support during longwall mining. Dual mining units then adopted with bolts installed

in a 4/2 sequence and 6 bolt/m pattern

Looking at a life of mine extension (beyond 2010) in area previously excised by faulting.

Increased development productivity and increased number of development units (on part time basis).

Working on systems to improve target setting, communications, short interval process control, reporting

and recording of delays, and shift debriefing.

Working on systems to improve target setting, communications, short interval process control, reporting

and recording of delays, and shift debriefing.

Roof and rib support (system now in balance).Coal clearance.

Advancement of services.Panel advances.

1 - Roof and rib support.2 - Coal clearance.3 - Panel advance.4 - Panel services.





M025MINE RESPONSES

Alternate method for driving of cut throughs to reduce time to break away, time to drive, and reduce issues associated

with holing through and exclusion zones.Self drilling roof bolts and automated bolting system

incorporating utilising cassetted materials supply systems. Dosco In-Seam Miner or Joy Sumps Shearer styled

roadway development machine, with alternate cut through driivage system.

Use of temporary roof support system (TRS) in immediate face area to allow roof and rib bolting to be done away

from immediate face area.

Competition for resources and $ - do we refine current technology or invest in new technology?

Boom and bust, a failure to implement and maintain strategic research initiatives through business cycles.

Longwall focus, coupled with an instant reward culture eg; fill the boat that's coming in, regardless).

Unwillingness to invest same amount of $ in roadway development improvement initiatives as has been invested

in longwall improvement initiatives.






M025MINE RESPONSES

Self drilling bolts.Automated bolting.

Bolt cassettes.Articulated continuous miners to maintain high development rates whilst mining cut throughs.

Articulated shuttle cars to increase payload capacity and improve turning capabilities.

Roof and rib support technology (to enable 30 - 60m/hour advance rates to be achieved, based upon the cutting

capacity of current generation 12CM12 continuous miners).

Coal clearance (if it wasn't for going around corners, the FCT).

Continuous, extensible conveyor systems.

Single entry drivages.FCT.

Bridge conveyors.






M025MINE RESPONSES

Single entry drivages - utilised as a spontaneous combustion control, not a as productivity initiative. 3.6km

long panels developed after holing across planned longwall block at 1.6km chainage with 3.4m wide ventilation

roadway. Utilised 900mm diameter ducting and 24m3/s auxiliary fan. All necessary controls developed and implemented to manage associated risks, however

improvements would be necessary in regards to logistics and supplies (belt move every day!).

FCT - successful, 170m range, 1 man control.Bridge conveyor - labour intensive, over engineered

generally although traction system under engineered.

Single entry development - need for process control to manage process, difficulty supply face with rail mounted

supply system beside conveyor due to poor track maintenance standards (monorail would be more

effective), system limited to 1.6km due to the technology then available (eg; transformers and ventilation).

FCT - high standard of installation of roof mounted monorail required, difficulties transitioning coal from roof

mounted FCT onto floor mounted panel conveyor, traction mules had limited ability to drive conveyor if any of the

drive rollers were worn.Bridge conveyors - require hard floor conditions particularly around boot end where there is a lot of tramming as unit is moved from place to place, limited range (128m), labour

intensive.

3 - 4, very interested in industry based incremental and step change initiatives, depending upon other issues at mine at the time, and providing we can get some short

term benefit, or life of mine extension.Recognise that may have limited benefit at the mine due to limited mine life however would expect to spin off benefits

to other mines in company.







M025MINE RESPONSES

Self drilling bolt, particularly the rib bolt equivalent.

Yes, depending upon corporate approval.

Need to develop a really good continuous miner monitoring system, similar to that utilised on longwalls - can help drive

step change in development performance with improved monitoring.

Big gains to be made from focussing on strata support and continuous haulage systems.

Keep it simple.Onerous approval process in Australian mines, very

conservative departments.Pursue use of aluminium underground.

Utilisation of civil engineering and tunnelling technology to drive wider roadways.

How many "development journals" are published?Lack of recognition for development - if we do better all we

get is another belt move!

Need to encourage Sandvik to develop an integrated bolting system rather than rely on outsourcing this key process (and to take responsibility for its performance).

Yes










14 CM type - Mains?





M0262.4 - 2.7m

3.2m

3.2m

4.8m4.8m

35m X 125m

47.8m X 125m

2

2

1 X 12CM20, 1 X 12CM30

1 X 12CM30, 1 X 12CM32

4 roof bolt rigs and 2 rib bolt rigs per machine, with both Joy and Hydramatic rigs used.

4 roof bolt rigs and 2 rib bolt rigs per machine, with both Joy and Hydramatic rigs used.

1 shuttle car per continuous miner.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M026MINE RESPONSES

1 shuttle car per continuous miner.

Eimco, trailers and supply pods.

Eimco, trailers and supply pods.

7 days per week

N/S and D/S 10 hours, A/S 8 hours.Weekends 12 hours.

4 development units operate N/S and D/S Monday, Wednesday and Thursday.

2 development units operate A/S Monday - Thursday.Maintenance on D/S Tuesday and Friday.

2 development units operate D/S Saturday and Sunday.

420 - 500m1:20

In situ gas levels 14m3/tonne. Residual gas levels after drainage 5 - 6m3/tonne.

Varies from predominantly methane to 50:50 CO2:CH4.

No ventilation issues typically experienced in development excepting when completing long drivages.

Mine has installed booster fan underground.High horizontal stress levels, typically 2 - 2.5 times vertical

stress. Principal stress direction varies.

Labour availability limited.Operating unit short-manned and with sub-contract labour.



Mine life cycle?





M026MINE RESPONSES

10 - 12 years at current planned production levels.

In situ gas levels and gas composition.Mine ventilation system.

Distance travelled to working districts.

6 X 2100mm roof bolts/metre with full mesh.2 X 1800mm steel rib bolts/metre/rib installed through half

roadway height rib mesh.

6 X 2100mm roof bolts/metre with full mesh.2 X 1800mm steel or plastic rib bolts/metre/rib installed

through half roadway height rib mesh.

Fully grouted mega bolts installed as required, based upon geological mapping.

PUR applied and Tin Cans installed in some areas.














M026MINE RESPONSES

Fully grouted mega bolts installed as required, based upon geological mapping - mega bolt intensity varies from 1

bolt/2 metres to 3 bolts per metre. PUR applied and Tin Cans installed in some areas.

Tin Cans installed in tailgate roadways.Typically 6 - 12 month lage between mining and installation

of secondary support.

2 - poor.

2 - poor.

3 - good.

11.8kms

2.21M tonne

100m/week/CM



Panels?








M026MINE RESPONSES

100m/week/CM

Approximately 15kms per annum

Noted that gas content and ventilation infrastructure will limit overall capacity of mine.

2 - low.Achieving 1.6 - 1.7MPOH against target 3.0MPOH

although noted that actual cutting is not the constraint.

2 - low.Rib bolting is the major constraint on development rates.Roof and rib bolting is considered to be the "critical path"

and it was noted that the development process did not become haulage constrained until the face was 180 - 200m

from boot end.

2 - low.Aged and haggard shuttle cars combined with poor

roadway conditions result in less than satisfactory coal clearance system, although it was noted that the

development process did not become haulage constrained until the face was 180 - 200m from boot end.









M026MINE RESPONSES

2 - low.System is labour intensive due to extent of mine workings.

1 - very low.Typically 40 - 50 hours for a 125m extension.

2 - low.Maintenance scheduled D/S Tuesdays and Fridays.

2 - low.Aged infrastructure, 15kms of conveyor in system.

Longwall production rate derated from 1600tph to 700 tph due to conveyor capacity and reliability issues.

Additional units, adoption of 7 day operations.









M026MINE RESPONSES

Better understanding of delays and improved measuring of KPIs and process management.

Intend to get back to the basics, map processes, resource units then make capital commitment depending upon

proper system analysis.Noted that should be getting 6,000 - 8,000m/CM/annum

and currently getting 3,500m/CM/annum.Aim to get down to an average 2.5 operating units in lieu of

current 4 units.

Roof/rib bolter automation.Self drilling bolts with single pass operation.

Equipment to get panel moves down to a maximum duration of say 12 hours eg; extensible conveyors.

Monorail mounted services.

As above. Intend to trial and compare dual CM operation with single crew (super unit) with current dual CM operation and dual crews in 2 entry gateroad development, and with properly

configured integrated cutting and bolting ABM20.


Panel moves and services extensions.Cable handling systems

1- Roof and rib bolting.2 - Coal clearance.3 - Panel advances.





M026MINE RESPONSES

Modularised continuous mining system ie; TBM, driving a single wide roadway which is partitioned (for ventilation) as

mined.Integrated, continuous cutting, bolting and coal haulage,

incorporating automated bolting system.Potential application of tunnelling and highwall mining

technologies.

Lack of OEM support of step change initiatives, ie; OEMs only want to pursue slow, incremental change.

Financial commitment required to pursue step change initiatives.

Previous history of failed improvement initiatives will deter investment and commitment.

Business risk, ie; pit room constraints and longwall continuity.

Technical design barriers.Legislative barriers.






M026MINE RESPONSES

Automation and robotics.Light weight materials eg; aluminium.

Maintenance systems, eg; aircraft technology and systems.

Modularisation and standardisation of components, motors, pumps, etc.

Integrated, continuous cutting, supporting and coal clearance system.

Gas drainage and ventilation - managing increased gas emissions.

Joy Sumps Shearer.FCT.






M026MINE RESPONSES

Joy Sumps Shearer - disaster, lack of OEM support.FCT - unsuccessful.

Joy Sumps Shearer - good concept however needs to be fully trialed and commissioned before incorporating in a

panel development system. Don't introduce new technology into critical path

development panels.FCT - better suspension system and conveyor belt

required (fell down, broke conveyor belt).


Very interested however struggling to get the basics right. In short term (0 - 2 years) more likely to only pursue

roadway development initiatives relevant to the mine (2).







M026MINE RESPONSES

TBM - 2 years time.

Yes, until asked to contribute $.

Need to establish a roadway development "body of knowledge" and forums for interchange of ideas.

Yes.










14 CM type - Mains?





M0275.0m

3.4m, with 3.6m return roadways.

3.4m, with 3.6m return roadways.

5.2m 4.9m transport, 5.2m conveyor roadways

35m X 100m

40m X 115m

1

12CM super unit in 2 entry gateroad.


Contract mining unit, 6 day roster.


Joy 12CM15 (5.2m widehead, 3.8m high cutting range)

2 X ABM20.1 X 4.9m widehead with 3m high cutting range (note: second pass required to mine 3.4m high gateroad).

1 X 5.2m widehead with 3.6m high cutting range2 Hydramatic Series 4000 roof bolting rigs and 2 rib bolting

rigs.

4 Hydramatic Series 4000 roof bolting rigs and 2 rib bolting rigs.

2 X Joy 15SC and breaker feeder.1600mm Mains conveyor.

MINE RESPONSES






Shift duration?

Roster system?



Ventilation?



M027MINE RESPONSES

1 X Joy 15SC per continuous miner discharging onto breaker feeder and 1400mm panel conveyor.

Cassette pods, changed out daily on evening shift maintenance window.

Mesh supplied separately to face.

Cassette pods, changed out daily on evening shift maintenance window.

Mesh supplied separately to face.

7 days per week

8 hours 40 minutes

4 shifts per day Monday to Friday with 3.5 hour maintenance window on E/S.

3 shifts per day Friday to Sunday, with maintenance on Fridays.

Contract development 3 X 9.5 hour shifts Monday to Thursday and 2 X 12 hour shifts Friday to Sunday.

180m to 230mGenerally 1:30

3m3/tonne in situ

16m3/s auxiliary fans, 185m3/s main mine fan

No problems experienced due to stress levels.

5% labour turnover.Average age 48 years.



Mine life cycle?





M027MINE RESPONSES

34 year old, 15 years remaining.

Sandstone channels over current longwall blocks combined with thick seam to create a windblast potential.

Width of longwall blocks limited to control risk.In current mining area mine design requires all gateroads

to be driven through 15m fault system immediately adjacent to Mains - creates significant issue for gateroad

development.

6 X 2100mm roof bolts/metre with full mesh (1.1m X 4.8m mesh modules).

2 X 6m X 21mm super strands per 2m.2 X 1200mm plastic rib bolts/metre/rib spot bolted with a

plate.

6 X 2100mm roof bolts/metre with 4.6m W straps (faulted area meshed with 1.1m X 4.8m mesh modules).

2 X 6m X 21mm super strands per 2m where required.2 X 1200mm plastic rib bolts/metre/rib spot bolted with a

plate.

2 X 6m X 21mm super strands per 2m.8m extos and clockets in selected intersections.














M027MINE RESPONSES

2 X 6m X 21mm super strands per 2m - approximately 50% of roadways require tendon support.

1 - 3, difficult to good.Mostly difficult to poor.

2 - 3, poor to good.

3 - good.

17.5kms.

1.71Mt

100m/week with 1 CM.

300m/week for 3 CMs (100m/week/CM).

10.14kms (plus stonework through 15m fault).

3.1Mt.

125m/week.



Panels?








M027MINE RESPONSES

185m/week - 2CM super unit.Target 3.1MPOH, achieve 2.7MPOH at best.

(Note: A/S required to complete second pass floor brushing in one roadway where CM has insufficient cutting height for

3.4m roadway).

11kms

3.5Mt

120m/week.

300m/week - 2CM super unit

2 - low.Age of equipment results in low engineering availability.

Limited height range.People issues.

2 - 3, poor to good.Better designed equipment available, poor ergonomically,

bolting rigs unreliable, high downtime.

3 - good.KB breaker feeder has limited capacity and is of poor

design.









M027MINE RESPONSES

2 - low.Drift access limited to 1 load per trip, 11kms from drift

bottom to panels - major issue.

2 - low.1600mm floor mounted structure.

Target 3 shifts to complete 2 heading super unit advance however typically 5 shifts

3 - good.27 cutting shifts plus 3 maintenance shifts per week for

super unit, plus weekend maintenance if required.

3 - good.11kms of underground trunk conveyors feeding into 2,000

tonne capacity surface bin, with 4km overland haul to CPP.

Cutting out roof to 3.4m height to remove clay band which would otherwise effect gateroad roof control during longwall extraction - what's best for the longwall.

Cutting higher roof section (3.4m) allowed better bolting rigs to be utilised.









M027MINE RESPONSES

Cutting higher roof section (3.4m) allowed better bolting rigs to be utilised.

Introduction of short interval process control.

Delivery of new ABM25 scheduled for early 2006, with improved bolting set up and improved ergonomics.

Introduction of new roster system.Focus on manual handling.

Continuance of contract Mains development on 6 day roster.

Better mining conditions.Process control.

Sequence move improvements.Improvement to front line supervision and people.

Better mining conditions.Process control.

Sequence move improvements.Integrated cut and bolt with ABM25.

Improvement to front line supervision and people.

Materials supply and logistics.Panel advances.

Support constraints.SC capacity (coal clearance).

Engineering availability of equipment.People.

1 - People.2 - Support installation.

3 - Materials supply.4 - Engineering availability.

Lot more flexibility with 12CM design as compared to ABM20 design which can only cut out in 1.1m or 0.8m

increments, depending upon machine.





M027MINE RESPONSES

Super unit set up, as per Beltana, with scrubber miners able to cut out 6 - 10m in good conditions, with 2 SC

servicing the miner while cutting, with bolting of second roadway being done in parallel.

Support conditions limiting application of ideal system.Budgets and machine design and configuration.

People motivation.Departmental approval processes.

Role, authority and power of inspectorate.Age of workforce.






M027MINE RESPONSES

What happened to the Joy Sumps Shearer? - greatest concept yet developed.

TBMs that can turn around corners.Or alternatively, augering systems for completing

interconnecting roadways.

Improved bolting rigs.Improving machine availability.

Improving machine ergonomics to address issues associated with ageing workforce.

Self drilling roof bolt.

Introduction of development team review of three shift representatives.

Design of new bolting arrangements on ABM25.Introduction of process control.

Bridge conveyors.Introduction of place change mining.

Una haulers.Surge cars and 14BU loaders






M027MINE RESPONSES

First stages of development team review, process control, and new bolting arrangements showing improvements.

Bridge conveyors - in right conditions have huge potential, but need hard floor.

Una haulers - similarly need hard floor.Place change mining - mocked up on surface to assess

how system works and make refinements.14BU loaders - good, clean floor achieved.

People key to success.Supervisor ability and willingness is crucial.

Must reduce manual handling with ageing workforce.








M027MINE RESPONSES

Machine ergonomics.Bolting rig improvements.

Alternative secondary support systems and equipment.

Would consider if advantageous.

Facilitate industry approach to NSW DPINR to address deficiencies in approval process and to limit the role,

authority, and power of the Inspectorate.

Yes

ACARP PROJECT C15005 AUSTRALIAN ROADWAY ...ACARP PROJECT C15005 AUSTRALIAN ROADWAY DEVELOPMENT -...

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