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ACARP Roadway Development Operator Workshops March 2009

Modelling ofGateroad Development

Ernest Baafi – UOWGeoff Gray – SMSIan Porter – UOWOsvaldo Rojas - SMS

University of Wollongong

The Development Challenge

• Longwall mining is a cost effective means of extracting coal

• …..provided roadway development can keep pace…

• ACARP initiated a project to assist improving the roadway development process.

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Modelling The Process

• ACARP recognised the need for modelling tools

• The concept of using dynamic simulation technology was proposed

• UOW and SMS worked with industry experts• Modelling tools and Models developed.

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Simulation Technology

• Methodology has numerous alias’s• Monte Carlo Simulation• Discrete Event Simulation• Computer Simulation• Simulation Modelling• Dynamic Simulation

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Simulation Technology

• But not this…

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British Army WWI Horse Simulator

Simulation Technology

• In our context:• Models operate over time• Dynamic interactions between components• Allow for randomness/variability in operations• Provide animated displays

• ……provide WHAT IF analysis capability.

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Scope Of Modelling

• Focus On Gate Road Development• 2 heading development

• Modelling will cover operations from face to boot

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Modelling System For Roadway Development

• Dynamic modelling system• Allows Roadway Development options to be

explored• Predicts:

• Achievable development rates (days/1000m)• Bottlenecks (including unrecorded delays) eg

• Miner waits on shuttle car• Shuttle car waits on miner• Boot end delays• Traffic delays (car interactions)

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Development Process

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RoadSIM – toolkit + models

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RoadSIM DEVELOPER RoadSIM USERBuilds a Mine Specific Model. Uses a Model for …

Process Improvement Who ? Mine planning/design

UOWMining Engineer Who ?Modelling Consultants Mining Engineer

Process Improvement StaffRequires… Modelling Consultants

Basic Arena SkillsAccess to RoadSim Tool kit Requires…

Basic Excel SkillsAccess to developed RoadSim Model

ARENA SIMULATION

SYSTEM

ARENA RuntimeSYSTEM

Knowledge of Layout/Equipment EXCEL

Issues to Address ???? REPORTS

RoadSIMTool Kit

RoadSIMMODEL

Model – Users

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RoadSIM DEVELOPER

Builds a Mine Specific Model. Uses a Model for …Process Improvement

Who ? Mine planning/designUOW

Who ?Modelling Consultants Mining Engineer

Process Improvement StaffRequires… Modelling Consultants

Basic Arena SkillsRequires…

Basic Excel SkillsAccess to developed RoadSim Model

ARENA SIMULATION

SYSTEM

ARENA RuntimeSYSTEM

Knowledge of Layout/Equipment EXCEL

Issues to Address ???? REPORTS

RoadSIMTool Kit

RoadSIMMODEL

Model Setup

• Data Required To Set Up The Model• Configuration (roadway dimensions)• Miner cycle times• Support times• Shuttle Car Performance• Operational Availability

• Planned• Unplanned (randomly imposed on the model)

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Running The Model

• Each Setup is replicated many times• Each replication of the model has the same setup

– but different possible unplanned events.

• Animation to confirm operations

• Reporting available in Excel for assessment.

Animated Display

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Animated Display

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Model Output

• Estimates of :• Time to complete a Pillar

• Scheduled operating time per 1000m• First coal to first coal time

• Exposure rates• Metres/Running Hour

• Utilisation of time.

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Miner Utilisation Definitions

Output – Utilisation Definitions

Utilisation ….

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Calculated from random interactions in the model

Output – Exposure Rates

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Case Study Mine

• Mine was selected to test models ability to reproduce past performance

• Mine 1:• 2 Heading Operation• 1 Bolter-Miner• 1 Shuttle car

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Case Study Mine – Historical Performance

Mine 1 Stats

Pillar Cycle Time (First coal to first coal) 11 days

Exposure Rate (m/op. hour) 1.8 m/op. hr

Exposure Rate (m/rep. run hour) 4 m/rep. run hr

Delay Categories (% of Simulation Time)

Mine Process Planned 0.3

Mine Process Unplanned 0.1

Outbye Services Unplanned 16.2

Panel Engineering Planned 3.6

Panel Engineering Unplanned 3.9

Panel Process Planned 16.3

Panel Process Unplanned 3.1

Sequence Move Planned 15.5

Unscheduled Planned 14.4

Unrecorded Delay 2.0

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Case Study Mine – Model vs Historical

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Case Study Mine – Model vs Historical

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Case Study Mine – Model vs Historical

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Case Study Mine – Model Exposure Rate

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

5.00

0 20 40 60 80 100 120

Rate

(m/n

et ru

n ho

ur)

Metres Cut

Advance Rate (m/net run hr)

Exploring Options

• Simulation model can be used to explore alternative options

• These can include:• Pillar length• Shuttle car size• Discharge rates• Support times• Others …

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Exploring Options

• Impact of Support time

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Exploring Options

• Impact of Shuttle Car Discharge Times

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3.2

3.4

3.6

3.8

4.0

4.2

4.4

4.6

0 1 2 3 4

m/o

pera

ting

hour

SC Discharge Time (min)

Advance Rate (m/op. hour)

In Summary…

• ACARP project has resulted in a modelling tool for Australian industry

• RoadSIM is aimed at assisting in evaluating roadway development options

• Provides a What If tool to assist with process improvement.

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Thanks for your attention…Questions ??

University of Wollongong