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Beltana Development and Roadway Operators Workshop: Advancements in Longwall Mining

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The 2007 Beltana Development and Roadway Operators Workshop in the Hunter Valley, NSW, showcased significant advancements in high-capacity longwall mining. Key presentations included updates from Beltana and Blakefield, a comprehensive USA systems study, and strategies for production efficiency. Highlights featured extensive roadway driveage, impressive coal tonnage mined, and productivity metrics demonstrating substantial improvements. Insights on enhancing operational efficiency, integrating crews, and sustainable practices were shared, aiming for continuous improvement in mining operations.

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Beltana Development and Roadway Operators Workshop: Advancements in Longwall Mining

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  1. Beltana Development ACARP Roadway Development Operators Workshop Sept. 2007

  2. Beltana Hunter Valley NSW

  3. Beltana

  4. Blakefield South

  5. Blakefield South

  6. Beltana Development • Beltana Update. • Blakefield Update. • USA Systems Study. • Supporting a High Capacity Longwall.

  7. Beltana • Total of 28 Million tonnes mined to date. • Total of 80 km of roadway driveage to date.

  8. Beltana 2007 • Total of 5.5 Million tonnes mined to date. • Total of 16.5 km of roadway driveage to date.

  9. Single or Super • Single Miner MG7 Cut Rate m/hr 4.2 Metres/wk 340 Belt Moves17.8 V’s Super Unit MG8 MG9 4.95.6 389373 17.6 19.9

  10. Single or Super • Single Miner MG7 Eng Avail. 91.8 Op Avail. 77.6 Op Time. 78 V’s Super Unit MG8 MG9 93.8 88 74.975.4 74.8 67

  11. Single or Super • Single Miner MG7 Pillar Cycle 3.6 Total Metres 7,421 Days / Panel159 V’s Super Unit MG8 MG9 3.43.5 6,5557,045 114 132

  12. Single or Super • Single Miner v’s Super Unit • Gains • Cut Rate 112% • Metres / Week 125% • Pillar Cycles 103% • Days / Panel 119%

  13. Single or Super • Single Miner v’s Super Unit • Losses • Maint Quality • Standards • Belt Moves / Parallel Tasks • Production Maintenance. • Sustainability

  14. Changes at Beltana • Back into Mains Driveage • Starting a 2nd Crew • Self Hired • Integration of Crews • Change in Development Structure • Addition to Development Management Team • Each Crew self sufficient • Maintain Single Panel Focus.

  15. Single Miner What will it support at Beltana • Development at340m per week • Equates to 144mLWretreat / wk • Equates to 165,600t/ wk • 6.95 Million Tonnes / yr

  16. Strategies • Key Points to our Strategies • Manning. • Standards. • Measurement. • Continuous Improvement. • Fit for purpose equipment. • Communication.

  17. Blakefield South • 173km of Driveage • 44.6 million ROM tonnes • 400m Longwall Face • 6.7 million Tonnes / Year • 9 year Life

  18. Blakefield South • Up to 10m3/t if insitu CH4 • High volumetric capacity ventilation system maximum 580m3/sec. • Force–exhaust (pressure balanced) ventilation system. • 7 heading mains / 3 heading gate roads.

  19. Blakefield South

  20. Blakefield South

  21. USA System Study • Review Strategies for future Development systems. • Review 3 Hdg Gate Road Development. • Review Continuous Haulage. • New Technology.

  22. Mines Visited • Peabody Highland • FCT in Room and Pillar Operation. (High Voltage Miners.) • Consol Loveridge • 3 Hdg Development and changing from batch Haulage to FCT. (ABM’s.) • Cumberland • 3 Hdg Development. (Miner Bolters and Mobile Bolters.)

  23. Mines Visited • Twenty Mile • 3 Hdg Development (Place Changing.) • High Producing Mine. • San Juan • 3 Hdg Development (place Changing.) • Good Technology. • Joy Franklin • New Technology ED miners, Automatic Drill Rigs and FCT’s.

  24. San Juan Transport

  25. Specialise • The Americans Specialise everything they do. • Whether it be in Motels, Restaurants, Roadwork's and Coal Mining.

  26. Development • Place Changing • Up to 8,200ft / mth = 2,500m / mth • Bolter Miners • Up to 6000ft / mth = 1830m / mth • FCT Operation Room and Pillar • Up to 700ft / shift = 210m / Shift • 21m / hr (Approx 8,500m / mth)

  27. 3 hdg DevelopmentOpportunities • Design FCT Operation(Consol Loveridge) • ABM 14’s • Joy 4 FCT • Auxiliary Ventilation • To give a 50% improvement in Gate Road Development. • Process Cost Saving • Up to 9000ft / Month = 2,750m / Month

  28. Where we are at Now • Beltana Bolter Miner • Joy 12CM12 • 2 Joy 10SC32 Shuttle Cars (16t) • Breaker Feeder (18t bunker capacity at 1700tphr) • Auxiliary Ventilation • 5.5m/hr • Up to 6200ft / mth = 1888m / mth

  29. Development • Where does Development need to be? • What maximum production can we expect from a single Longwall?

  30. Some Facts • 7million tonne Longwall (400m face at 1740 t/m) • 2hdg Development 2.88m/hr • 3hdg Development 4.51m/hr • 10million tonne Longwall • 2hdg Development 4.11m/hr • 3hdg Development 6.44m/hr

  31. Some Facts • 12million tonne Longwall • 2hdg Development 4.93m/hr • 3hdg Development 7.73m/hr • 15million tonne Longwall • 2hdg Development 6.17m/hr • 3hdg Development 9.67m/hr

  32. Low Hanging Fruit Obtained • Process Improvement Old 7.2Day Pillar Cycle New 3.6 Day Pillar Cycle • Total Process Improvement 100 %

  33. FCT Model For Beltana • From Data measured at Beltana a Cut Rate after a belt move of 8.92 m/hr can be achieved. • Joy FCT Modelled a rate8.98m/hr with a Joy 12CM12D. • Therefore we believe an average cut rate with an FCT for a 100m pillar cycle would be in the order of 8 to 9m/hr. • This would be a 70% increase in this part of the Process.

  34. Opportunities • Bolter Miners • 14ED25 being built in USA to go into Consol McElroy which commenced production 1st May 2007. • ABM 25’s Used throughout QLD and NSW • Automated bolting • Self Drilling Bolt

  35. Opportunities • Continuous Haulage Systems • Joy4FCT • Stamler Chain Haulage • Prairie System • Sandvik Continuous Haulage

  36. FCT Stats

  37. Summary • To Advance to the next step in Longwall Production Development has to do something different. • By 3 to 5 years time we need to have developed a new system so Longwall Coal is not restricted.

  38. Development • Can’t keep doing the same and expect something different. • 12 Million Tonne Longwalls being supported by 500 people. • This is not sustainable.

  39. USA is BIG

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