MECHANISED COAL workshop, and others to the surface. MineDash was used in the control room to monitor real-time progress.
MST and the mine worked together to build business rules for the process. Any exceptions to PRS paths and travel times were quickly identified and signalled by MineDash as non-compliances using visible and audible alerts
on the MineDash screen. It Each PRS was fitted with an MST RFID tag also communicated with
personnel via rule-based emails and MinePhones. Divergence from the plan
For instance, checking and reporting the could be quickly and proactively corrected. location of Powered Roof Supports( PRS) was a During the first use of the solution, the mine manual process performed by a person successfully completed the longwall move two exclusively assigned to this task. The control days ahead of schedule. According to the mine, it room operator managing the longwall move produces 24,000 t / d and assuming a value of recorded PRS movements on paper after the $ 114 / t, the new solution saved A $ 2.7 million of information reached the surface. This meant that production and two days of labour costs, MST non-conformances were only identified after the reports.“ Identifying and remedying issues quickly fact, resulting in poor utilisation of personnel and ensured high levels of productivity. It provided assets. Even implementing a dedicated Longwall information, which they used to plan more Move Control Room did not improve matters as it effectively in subsequent longwall relocations, still relied on a manual process. which resulted in further time efficiencies.
In reviewing these inefficiencies, the mine
“ The investments in tracking and identified two critical aspects that could improve communications technologies provided the process. To make proactive decisions they successful monitoring, reporting and proactive needed to know the real-time location of management tools which functioned as core personnel, PRS, PRS transporters, loaders, tool support systems for the longwall move. This carriers, forks, baskets and other critical assets. project delivered a performance baseline for In addition, they needed improved voice and data planning future longwall moves. The mine now communications to manage deviations from plan has a documented benchmark for measuring to minimise delays and downtime. efficiency and maintaining a cycle of continuous The mine deployed MST’ s MinePhone and operational improvement.”
Personnel & Asset Tracking system. MST Denis Kent, MST’ s Business Manager – transformed location data into meaningful International, explains that the mine“ continues information for faster and more effective to use the tracking information and communication decision-making; directly contributing to capability to really improve and manage the improving achieving specific business objectives various tasks and processes each shift. for the longwall move.
“ The success at Moranbah North has seen
MST’ s MineDash control room software, Anglo Coal looking to roll out similar solutions at provided real-time visualisation, reporting and its other coal mine operations in Australia and management tools to drive proactive decision South Africa.” He also said“ it was the people making and adherence to plan. Together with the that drove the turnaround at Moranbah.” deployment of the MinePhones, communication Other beneficial initiatives at Moranbah have was transformed, both between personnel included a Tailgate Support Optimisation underground and between personnel
Strategy that increased safety significantly, underground and surface personnel. Mobile increased uptime while saving operating communications and immediate access to manhours, assisted stone dust compliance and information meant that decisions could be made reduced costs. quickly to reduce delays and maintain productivity. Improved lightweight structure of conveyors
MST assisted the mine in fitting tracking tags reduced the weight from 415 to 185 kg per 3 m to all PRS and other key assets. Each of the PRS bay. This has reduced manual handling injuries had a specific route and destination; some going and increased longwall run time due to ease of to the new face, others to an underground removal during removal of the structure.
Mechanical and electrical belt upgrades have reduced downtime, increased capacity and provided additional redundancy.
Ventilation, gas, heat and spontaneous combustion( sponcom) management has been important in panels of more than 6 km in length. A mid panel shaft manages and improves rib emission, heat, sponcom and ventilation. The MG 110 mid-panel shaft with surface cooler, achieved 2 ° C reduction in WBT( wet bulb temperature) at face area or 6.8 times less air power required.
The mine has also developed an innovative goaf gas management system with monitoring trailer.
Britton presented a paper on much of this, Moranbah North mine – the journey to improved performance, at the 2014 Annual Longwall Conference in the Hunter Valley.
Last year, Moranbah North became the first mine in Australia to be named Coal Mine of the Year for a third time after taking the award at the prestigious 12th annual Australian Mining Prospect Awards in October.
Anglo American Coal Chief Executive Officer Seamus French said the win was an outstanding achievement for the mine and testament to the hard work, dedication and commitment to best practice by all across the mine.
“ Moranbah North has been on a journey of continuous improvement in safety and production for a number of years, which has seen the mine achieve industry-leading safety performance and consistently high production of 6.8 to 6.9 Mt annually.”
“ Moranbah North has continued to lead the way in innovation and technology and achieve world-leading best practice longwall performance,” Moranbah North General Manager Craig Manz said.
“ A significant operational restructure in 2012 helped take the mine’ s production output to the highest in its history, with the best safety results ever seen,” Britton said.“ What has been truly remarkable is how the mine has continued to improve on this safety performance and underground and surface standards to achieve excellence in production output and industry leading innovation.”
Britton explained that the mine’ s Total Recordable Injury Frequency Rate at the time was significantly below industry average, while eight years Lost Time Injury Free( LTI) at the mine’ s Coal Handling Plant and five years LTI free at the Warehouse had been achieved through initiatives that have built resilience in safety.
The award recognised the mine’ s implementation of key safety and productivity innovations including specifically designed shotcrete for strata support and reduced gas rib emissions, and the introduction of an Underground Intrinsically Safe Tablet allowing
136 International Mining | SEPTEMBER 2016