ROADWAY DEVELOPMENT IMPROVEMENT PROJECT
CM2010 Update
Greg Pawley, Xstrata Coal
Bob Gordon, BHP Billiton Illawarra Coal
Guy Mitchell, BMA Coal
August/September 2010
CM2010 Update
 CM2010 R&D Strategic Review
 Current Projects
 New Projects Under Consideration
CM2010 Update August/September 2010
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CM2010 R&D Strategic Review
 Strategic review conducted in July 2010 with objective of
reconfirming and/or amending the CM2010 Vision, Goals,
Measures and Strategies in the context of developments to
date, and potential R&D achievements over the next 3 years
CM2010 Update August/September 2010
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Review Inputs
 Existing CM2010 Vision, Goals, Measures and Strategies
 Review of current research initiatives including both ACARP
funded projects and direct industry funded initiatives
(mines and OEMs)
 Fundamental Analysis of Roadway Development System –
Richard Porteous’ excellent analysis of contributing factors
to roadway development performance
 Roadway Development Technology Audit – report of the
Audit completed earlier this year across mines, OEMs and
suppliers
 CM2010 Technology Gap Analysis – as completed by RDTG
CM2010 Update August/September 2010
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Fundamental Analysis of Roadway Development
 Richard Porteous’ 2008 study across Xstrata’s 11 mines illustrated
that adoption of current and emerging technologies has the
potential to achieve significantly improved development rates
 Study based on standard bolting cycle of 6 roof and 4 rib bolts per
metre, with base case of a miner-bolter and 1 SC (bolting
constrained system)
 Study examines effect of various refinements to the system:
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Adoption of a bolter-miner with concurrent cutting and bolting
Employment of a second shuttle car throughout pillar cycle
Adoption of self drilling bolts
Utilisation of a continuous haulage system
 Projected that a rate of 8.5MPOH could be achieved with these
measures
 Fully details of report available at www.undergroundcoal.com.au
CM2010 Update August/September 2010
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2010 Technology Audit
 Recommended that the RDTG maintains general thrust of
CM2010 and review R&D priorities in regards to:
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The development of remote bolting technologies including:
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Self drilling bolts
Bolt, washer and mesh storage/handling
Remotely controlled/automated bolting rigs and manipulators
Associated sensing and monitoring systems
The development of CM self steering technologies including:
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Remote sensing, seam profiling, and video monitoring
Machine navigation and steering
Communication protocols
Machine supervisory/auto-reporting systems (including
development of “black box” data logging system)
CM2010 Update August/September 2010
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2010 Technology Audit
 Recommendations regarding general thrust of CM2010 (cont):
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Addressing issues associated with on-board ventilation systems
Development of SC guidance (automation) systems
Addressing issues associated with management of face services,
by either continuous haulage or monorail systems, including
development of self advancing system in later instance
Developing strategies to address equipment certification and
regulatory issues, including adoption of EMERST design
philosophies
 Also recommended that mines continue to undertake
operational research to optimise face cycle times and engage
change management expertise when introducing new
development technologies and processes
CM2010 Update August/September 2010
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CM2010 Technology Gaps
 Technology gaps identified in CM2010 R&D strategy include:
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CM roof/floor horizon control
Long tendon installation
Monorail advancement systems (or alternatively, ventilation
installation and extension systems)
Higher capacity ventilation systems
Remotely steered (automated) shuttle cars
Collision avoidance systems – people and machinery
Supply/logistics systems
Conveyor advancement systems
Services advancement systems
Technology/systems integration
Communications – both verbal and data
CM2010 Update August/September 2010
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CM2010 Phase II R&D Strategy
 Vision
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An integrated, remotely supervised high capacity roadway
development mining system that enables 15 Mtpa longwall mines
to be established and sustained with a single gateroad mining unit
The system will also enable mining to be safely undertaken under
adverse or extreme mining conditions, thus opening up access to
reserves previously considered un-mineable
 Measures
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A sustained performance rate of 10 metres per operating hour
(MPOH) for 20 hours per day, based on installing primary support
of 6 roof and 2 rib bolts per metre advance together with roof and
rib confinement measures (mesh)
Improved health and safety through reduced exposure to hazards
in the immediate face area
CM2010 Update August/September 2010
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CM2010 Phase II R&D Strategy
 Goals
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By end 2010, demonstrate key enabling component
technologies that will form the basis of an integrated high
capacity mining system, eg; remote operation of the continuous
miner, automated self drilling bolts and mesh installation,
continuous haulage, integrated panel services
By end 2015, demonstrate all the elements of an integrated,
remotely supervised high capacity roadway development system
Progressively reduce the physical demands on personnel
engaged in the development process and reduce their exposure
to workplace hazards
Encourage and support mines to develop the key organisational
and technical competencies required to support a high capacity
mining system eg; improved engineering availability, people
behaviour and skills, and planning, organisation and process
control
CM2010 Update August/September 2010
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Current Projects
 C16022 – undergroundcoalcom.au
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Recently gone live and can be accessed via web-site
Continuing to develop site with industry support
 C17004 – ToughSkin
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Consolidating polymer chemistry research following departure
of lead researcher March 2010
Recently identified an industry partner to continue
development of polymer and coating formulation, including
registration, certification and licensing of product
Evaluating challenge posed by NSW Chief Inspector’s
notification specifying that application or injection of polymeric
materials for strata support is a licensable activity
Stage III of the project to commence January 2011, subject to
ACARP funding
CM2010 Update August/September 2010
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Current Projects
 C17017 – Automated Bolting and Meshing System
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Successfully demonstrated all components of system except rib
bolt manipulation (now due October 2010)
Stage II of the project has commenced and includes an
underground trial and demonstration of system, and concept
design of an integrated logistics system
Initial focus is to fully animate proposed system and examine
issues associated with full automation of system in
underground environment
RDTG member companies identifying suitable site and
continuous miner to conduct underground trial
 C18023 – Continuous Miner Automation
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Successfully demonstrated components of navigation system
Stage II recently commenced and includes an underground trial
of navigation system on Phoenix
CM2010 Update August/September 2010
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Current Projects
 C17010 - CM2010 Project Support
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Development of Roadway Development Handbook temporarily
suspended to allow focus on providing project management
support toToughSkin
Continuing project support role proposed across all CM2010
related projects, including continuation of Roadway
Development Operators’ Workshops to end 2012
CM2010 Update August/September 2010
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New Projects Under Consideration
 Rapid Advance Conveyor
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Oregate Pty Ltd
 Automated Monorail Extension System
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Macquarie Manufacturing and UOW Automation and Robotics
Group
 Development of FRAS Rated Polymeric conveyor Idler for
Underground Coal Mines
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Ellton Longwall/Dotmar Engineering Plastics/Intelligent
Polymer Research Institute (UOW)
CM2010 Update August/September 2010
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