Adam Foulstone - Anglo America - The Grosvenor TBM Mine project
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Transcript of Adam Foulstone - Anglo America - The Grosvenor TBM Mine project
GROSVENOR PROJECTDEVELOPMENT OF COAL MINE DRIFTS UTILISING A TUNNEL BORING MACHINE
OVERVIEW
•Site project description
•TBM Specifications
•Methodology
•Drift construction
•Advantages & achievements
•Conclusions
SITE AND PROJECT DESCRIPTION
•Project overview
•Geology
•QLD Mine Regulations
•Options Considered
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SITE AND PROJECT DESCRIPTIONProject overview
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SITE AND PROJECT DESCRIPTIONProject overview
Longwall Panels- 300m Wide- 6200m Long
Man & Materials Drift- 1:8 Decline- 1,100m Long
Conveyor Drift- 1:6 Decline- 900m Long
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SITE AND PROJECT DESCRIPTIONGeology Overview – Conveyor Drift
Chainage Description Classification
0 – 118 Box Cut -
118 – 220 Cainozoic Sediments Soft Ground
220 – 230 Tertiary - Weathered Basalt Soft Ground
230 – 300 Tertiary Sediments Soft Ground
300 – 880 Permian – Siltstone / Sandstone Hard Ground
880 – 914 GM Seam Coal Soft Ground
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SITE AND PROJECT DESCRIPTIONGeology Overview – Man and Material Drift
Chainage Description Classification
0 – 142 Box Cut -
142 – 180 Cainozoic Sediments Soft Ground
180 – 250 Tertiary - Weathered Basalt Soft Ground
250 – 350 Tertiary Sediments Soft Ground
350 – 580 Permian – Siltstone / Sandstone Hard Ground
580 – 700 Permian – P Seam Coal Soft Ground
700 – 1050 Permian Siltstone / Sandstone Hard Ground
1050 – 1154 GM Seam Coal Soft Ground
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SITE AND PROJECT DESCRIPTION
QLD Mine Regulations
• TBM’s have been sporadically used within Coal Mining:
• TBM proposal new to QLD Coal Mining
• Risk Assessment to determine ERZ1/NERZ
• NERZ = CH4 < 0.5%
• ERZ1 = 0.5% < CH4 < 2.0%
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SITE AND PROJECT DESCRIPTIONOptions Considered
• Summary of project conditions
• Variable/mixed ground conditions
• Project schedule
• Cost implications
• QLD Coal Mining Legislation
• Options Considered
• Drill and Blast techniques
• Conventional road header
• Earth Pressure Balance Machine
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SITE AND PROJECT DESCRIPTIONOptions Considered
Options Considered• Excavation Rate• Cutting Profile / Accuracy• Tunnel design parameters• Ground support• Work Environment• Capital cost• Operating cost
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SITE AND PROJECT DESCRIPTIONOptions Considered
Options Considered• Excavation Rate• Cutting Profile / Accuracy• Tunnel design parameters• Ground support• Work Environment• Capital cost• Operating cost
In comparison to conventional drill and blast operations or roadheader the TBM was more favorable.
TBM SPECIFICATIONS
•EPBM (dual mode)
•Gas Compliance
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TBM SPECIFICATIONSEPBM (dual mode)
TBM Design Criteria:
• Purpose built TBM to cope with Grosvenor specific
conditions
• Compliant with QLD Coal Mining Regulations
• Capability to complete multiple drifts (no exit point)
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TBM SPECIFICATIONSEPBM (dual mode)
Drift Layout:
• Vertical Curve – 400m radius
• Segmental lining ID 7.0m
• Consists of steel-fiber reinforced lining (universal
ring 5 + 1 key segments)
• Additional flat segment placed at invert level to
allow transit along the tunnel
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TBM SPECIFICATIONSEPBM (dual mode)
TBM Specifications – Robbins Hybrid / Dual Mode
Bore Diameter (m) 8 Cutterhead Mixed ground / convertible
Total Length (m) 135 Cutters 17” disc / Knife Edge
TBM Weight (t) 994 Cutterhead Power (kW) 12 x 330 kW (3,960 kW)
UCS (MPa) 100 (Max) Cutterhead Speed (RPM) 0 – 6.4
Hydrostatic Pressure (Bar) 3 Maximum Thrust (kN) 22,619
Screw Conveyor Double, shafted Number of Segments 5 + 1 key + invert
Methane Monitors 6 x locations Segment Width (m) 1.4
Explosion-Proof EPB Sensors 10 x locations Segment Thickness (m) 0.35
Segment Backfill Bi-component grout
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TBM SPECIFICATIONSEPBM (dual mode)
Cutterhead Details:
• EPB:
• Rock mode:
EPB Mode – Bi-directional Rock Mode – Single direction Mixed Ground Mode – Bi-directional
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TBM SPECIFICATIONSEPBM (dual mode)
Double Screw Conveyor:
Forward Shield:
• Inner shield - Removed
• Outer Shield – Remain insitu
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TBM SPECIFICATIONSGas Compliance
Sources of Gas:
• Expected: Methane release from carbonaceous
inclusions
• Unexpected: Hydrocarbons released from greases
and foams
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TBM SPECIFICATIONSGas Compliance
Principal Method of Gas Control:
• Pre-cast concrete linings
• Fully grouted into place as shield advances, sealing
from ingress of water or gas
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TBM SPECIFICATIONSGas Compliance
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TBM SPECIFICATIONSGas Compliance
METHODOLOGY
•Box Cut
•EPBM Assembly OFTA
•Conveyor Drift
•Retrieval / Relocation
•Man & Materials Drift
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METHODOLOGYBox Cut
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METHODOLOGYBox Cut
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METHODOLOGYEPBM Assembly OFTA
Onsite First Time Assembly (OFTA):
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METHODOLOGYConveyor Drift
Conveyor Drift Performance
Total Length (m) 798 Average Rings / Day 3.8
Total Rings (number) 578 Maximum Rings / Day 13
Duration (days) 153Average Production
(m/week)40
TBM Mode (%)100% - Mixed Ground
Configuration
Average TBM Availability
(%)67
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METHODOLOGYRetrieval / Relocation
Retrieval Requirements:
• TBM to be used in multiple drifts
• TBM to disassembled
• TBM to be retracted
Design Features:
• Cutterhead inner and outer
• Forward and rear shields
• Cutterhead core
• Self-propelled walking dolly system
• Back-up gantries fitted with jacks to provide anti-slide
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METHODOLOGYRetrieval / Relocation
Retrieval Requirements:
• TBM to
CH
Segments
CH core
Inner Shield
Outer
Shield
CHS
CHS Dolly
Front Dolly Bridge
Dolly
Sliding
Track
Segment
ErectorBridgeScrew Conveyor
5.8m
Lift Jacks
Inner Shield
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METHODOLOGYRetrieval / Relocation
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METHODOLOGYRetrieval / Relocation
Front Dolly Frame on Surface Launching Slab
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METHODOLOGYCommence inseam coal Mining Operations
Free face available to commence Development Operations
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METHODOLOGYRetrieval / Relocation
SPMT For Transport to the Man and Materials Drift
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METHODOLOGYRetrieval / Relocation
SPMT For Transport to the Man and Materials Drift
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METHODOLOGYMan & Materials Drift
Man & Materials Drift Performance
Total Length (m) 988 Average Rings / Day 7.7
Total Rings (number) 732 Maximum Rings / Day 18
Duration (days) 95Average Production
(m/week)70
TBM Mode (%)63% - Scrapper / Knife bits
37% - Full cutter disc
Average TBM Availability
(%)78
DRIFT CONSTRUCTION
•Modifications through “Lessons Learnt”
Conveyor drift
•Performance Comparison – Conveyor Drift vs..
Man & Materials Drift
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DRIFT CONSTRUCTIONModifications
Modifications:
• Operational
• Mechanical
• Foam System – redesign to increase capacity
• Cutter Head Configuration – modifications to grizzly
bar / mixing paddle
• Grouting – revised design for mixing chambers and
auto flushing
• Conveyor System – revise design to improve
efficiencies
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DRIFT CONSTRUCTIONPerformance Comparison
Conveyor Drift Man & Materials Drift
Total Length (m) 798 988
Total Rings (number) 578 732
Duration (days) 153 95
Rings / Day (Average and Max) 3.8 (13) 7.7 (18)
Average (m/week) 40 70
TBM Availability (%) 67 78
ADVANTAGES & ACHIEVEMENTS
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ADVANTAGES
Advantages:
• Improved working conditions
• Increased penetration rates
• Durable concrete lining constructed during boring
process
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ACHIEVEMENTThe End Product
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TBM Breakthrough – Man & Materials Drift
CONCLUSIONS