www.csiro.au back to components high capacity underground coal mining (l15) a joint project (scoping...
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www.csiro.au
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High Capacity Underground Coal Mining (L15)
A joint project (Scoping Study) between CSIRO Exploration & Mining and University of Queensland’s
Sustainable Minerals Institute (SMI)
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Scoping Study Objectives
Benchmark current practices and determine what is needed to achieve a high capacity underground coal mine (15Mtpa) and optimisation of existing operations
Report on strategic research directions needed to support future high capacity mining.
Identify specific, high impact research and development projects to facilitate high capacity mining.
Identify opportunities for operational, technical and postgraduate training in areas relevant to high capacity coal mining
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Process
Develop a predictive model (15Mtpa coal mine) on which comprehensive research proposals would be dependent. Incorporates LW productivity, utilisation, seam characteristics, development requirements, sensitivities and cost model.
Considerations included: 1.8 – 4.5m seam thickness; LTCC and multi-seam operation
Segregate the overall strategy into 7 sub-categories for further study, under the respective objectives
Provide separate reports addressing the requirements of the scoping study
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15Mtpa model identified key issues
Criticality of system uptime
High shearer speed/power to deliver tonnages
Support hydraulics for rapid support cycle times
Optimise cutting cycle – uni-di; bi-di; half web
Development rate increase
Improved coal clearance for minimal bottlenecks
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Coal Resources and Deposit Delineation
Update of UNSW thick seam database from public
sources (113 mines-330 point source data)
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To create confidence that a deposit will be able to host a 15Mtpa operation requires integrated analysis of geologic data across company boundaries at the district scale, similar to that in the ACARP Supermodel 2000 project
High tonnage longwall operation will require enhanced interpretation of structure and interburden characteristics
Multi-scale modeling of fault geometries and simulation of behaviour under variable rock mass, stress and mining methods
Research Direction
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Current Status
Greater propensity for stability problems in thick seams operations
Geotechnical downtime generally occurs comparatively more frequently on the face (a shift from gateroads)
Geophysical methods of rock mass characterisation are preferred but there is a lack of experienced people to interpret the information
Typically 1-2 normal faults per panel
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Research Direction
Implementation of real-time face and gate road “Smart” monitoring which includes interpretation and control measures
Determination of interaction between cutting height and operational characteristics
Interaction of seams in multi-seam operations
Enhanced fault detection and definition for mining through in-panel faults – possibly utilising microseismic technology
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Current Status
Later generation, best practice mines with good conditions could attain 15Mtpa mines without major developments in mining equipment and systems
Infrastructure limitations will constrain older mines from making major improvements in mine capacity, while adverse conditions generally associated with depth pose additional productivity challenges to these mines (and to later generation mines as they mature)
Technology developments are currently underway that are likely to address a number of key process constraints in the short to medium term, thus providing the potential to improve system capability across all mines
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Specific Research Projects
Extensible (monorail mounted) face services (e.g. ventilation, power, water, compressed air, pump out)
Integrated development mining system
Extensible, self advancing coal clearance system
Alternative skin reinforcement and confinement measures
Complementary technology developments including automation and robotics, machine guidance systems, light weight materials, face pumping systems, roadway construction and consolidation
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Longwall Gas Emissions Related to FaceProduction
0
3,000
6,000
9,000
12,000
15,000
18,000
21,000
0 3 6 9 12 15 18
LW Production (MTpa)
LW
Go
af g
as e
mis
sio
ns
(l/s
)
Vent gas capacityBest practice with goaf drainage
SGE 5 m3/tSGE 10 m3/t
SGE 20 m3/tSGE 35 m3/t
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Research Direction
Gas Drainage
Extensive pre-drainage of gas including optimisation of MRD gas holes for pre-drainage/deep gas drainage technology and stimulation
Coordination and cooperation with petroleum and gas developers to utilise/reduce gas reservoir
Optimise goaf inertisation strategies for operational use – including exclusion foams
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Research Direction
Spontaneous Combustion
Development of low impact inertisation systems
Heat
Development of heat extraction techniques for fixed and possibly mobile plant
Dust
Optimise coal seam water injection techniques prior to mining
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Current Status
Water Consumption
Highest users have the highest losses; lowest users have the lowest losses
Water Inflow
Typical inflows range from 3-5 Ml/day; some up to 15Ml/day
Water use ML/Mtpa
Water loss ML/Mtpa
Range 55 – 192 29 – 180
Average 130 90
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Strategic Research Directions
Reduction in water consumption and variability through integration of research into water usage, management and technology
Integrated approach to hydro-geology and geotechnical aspects
Underground water recycling and reuse technology
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Current Status
Current equipment is capable of delivering at or about the 15Mt target
Average production from the top 5 mines based on the last 3 years was 4,647,660 tonne
The average cutting hours per year calculated from the 8 mines studied over the last 3 years was 2745 hours
The average output per hour from the longwall faces was 1693 tonne
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Current Status
Longwall faces cut for only 31% of the total time in a year
Breakdown maintenance outweighs planned maintenance by 4 to 1
The shearer, panel belt and AFC, respectively, are the largest contributors to down time totalling over 50%
Planned maintenance effort does not reflect the downtime statistics and is ad-hoc
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Downtime Breakdown
Longwall Downtime Allocations
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Equipment
Perc
en
tag
e
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Research Directions
Further development and implementation of face automation
Effective analysis of monitoring data on a real time basis for maintenance purposes
Real-time maintenance prioritisation system
New sensors and systems for condition monitoring
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Specific Research Projects
Assessment, prediction and validation of the impact of increased mining height and width on local and regional water resources and catchments
Development of realistic and achievable engineering controls for dust, noise and heat management
Assess and validate current subsidence prediction methodologies for high capacity contexts