Room & Pillar Project Status Update - OCT 2012
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The document provides a status update for the Room & Pillar Project. It summarizes the mine plan and design, typical mining method, mining equipment, face cutting sequence, roof support plan, ventilation plan, electrical issues, manpower summary, training plans, legislative procedures, safety considerations, productivity assessment, project scheduling, capital and operating costs, economics, and the proposed Joy Smart Services program. The project involves room and pillar mining using a Joy 12CM30 bolter miner and other equipment in seams 30 and 33.
Room & Pillar Project Status Update - OCT 2012
- 1. Room & Pillar Project Status Update Tapas Das, Special Project Manager Wednesday, 03 October 2012 OKD, a.s. | Prokešovo náměstí 6/2020 | 728 30 Ostrava
- 2. Summary Slide No 1. Mining Plan & Design 3–4 2. Typical Mining Method 5 3. Mining Equipment 6–9 4. Face Cutting Sequence 10 5. Roof Support Plan 11 6. Ventilation 12 – 15 7. Electrical Issues 16 – 17 8. Manpower Summary 18 9. Training 19 10. Legislative Procedures 20 11. Safety 21 12. Productivity Assessment 22 13. Project Scheduling 23 14. CAPEX and Contracts 24 15. Economics 25 15. Joy Smart Services 26 2
- 3. VIC VIB M I VIA I N V E P VID II L IIIA IIIB A IV N 3
- 4. Mine Design Mine plan has been layout along the favorable orientation of following variables Horizontal stress (good roof condition) Seam dip (lowest mining angle) Geological Disturbance (fault and over-thrust) Old mine working (longwall Gob) ARMPS (Analysis of Retreat Mining Pillar Stability) software developed by NIOSH, USA has been used to design proper dimension of mine pillars and barrier pillars. AutoCAD and Micro-station has been used to layout mine plan. Mine design has been supported and being accessed by 1) Dr. Syd S. Peng, West Virginia University, USA 2010. 2) Prof.Dr.Hab.Inż. Kot Unrug, University of Kentucky, USA 2012. 3) Dr.-Ing. habil. Anton Sroka, TU Bergakademie Freiberg, Germany 2012. 4) Dr.-Ing. Krzysztof Tajdus, AGH University of Science and Technology, Poland 2012. 5) Prof. Ing. Vlastimil Hudecek et al, VSB-Technical University, Czech Republic 2012. 6) Doc. Ing. Richard Šňupárek et al, Ústav geoniky, Czech Republic 2012. 4
- 5. Typical Mining Method Return Main Belt Section Belt Feeder Breaker Return Stoppings Aux. Fan Shuttle Car 2 Bolter Miner Intake Power Center Shuttle Car 1 Active Face Passive Face Intake Outby Scoop In-by Scoop ALMINCO Bolter 5
- 6. 12CM30 Joy Bolter Miner 6
- 7. 12CM30 Joy Bolter Miner 7
- 8. 12CM30 Joy Bolter Miner 8
- 9. Mining Equipment 10SC32B ALMINCO Scorpion Bolter BF 14Q58 GE Fairchild 35C-WH2-30-AC HILTI THM Handheld Bolter 9
- 10. Face Cutting Sequence 10
- 11. Roof Support Plan Intersection Roof Bolting Plan Gallery Roof Bolting Plan 11
- 12. Exhausting Ventilation Czech Regulation: If concentration of Methane is more than 0.5%, Velocity of air should not be less than 0.5 m/s. If concentration of Methane is less than 0.5%, Velocity of air should not be less than 0.3 m/s. Return Return Aux. Fan Active Face = Q (CH4>0.5) Stoppings = 5.2m X 4 m X 0.5m/s = 10.4m3/s Intake Passive Face = Q (CH4<0.5) = 5.2m X 4 m X 0.3m/s = 6.24m3/s Intake 12
- 13. Miner Inbuilt Face Ventilation Rigid ducting Flexible ducting connecting End of Ducting on miner and rigid ducting Miner Bolter
- 14. Face Ventilation Options CH4 monitor will be hung T T T T T T from the last roofbolt Additional CH4 monitor will be placed on miner near the boom Option 1: Face exhausting ventilation with trombone setup CH4 monitor will be hung T T T T T T from the last roofbolt Additional CH4 monitor will be placed inside the miner inbuilt duct Option 2: Face exhausting ventilation with miner inbuilt vent. setup
- 15. Face Air Movement Simulation Dr. Andrzej Wala, Professor of University of Kentucky is preparing a 1:15 real scale prototype and CFD simulation to show the exact air movement in the face with different ventilation system. 15
- 16. Electrical Issues Voltage Nominal section voltage is 1000 volts supplied by power center. Auxiliary Voltage is 220V. Joy has verified that all motors can operate satisfactorily at this nominal voltage. Feeder Breaker controls Joy will provide toggle switch to turn on feeder conveyor when shuttle car arrives at feeder. Feeder will shut off at a set time. Methane Monitoring CH4 monitor will be installed on miner Voluntary to shut off the cutting at 0,8% Methane that we do not reach 1% CH 4. An additional CH4 monitor as required by law will be hung from the roof above miner duct as approved by the Czech Mining Authority. Battery charging Chargers will have ATEX approval. The charging station will be at the equipment assembly room. CO and Hydrogen will be monitored at the charging station . Proximity Equipment will not be initially equipped with proximity systems . The available systems do not meet our requirements from functionality and approval. European funded R&D program (FEATureFACE) has started and we are participating. Shuttle car cameras Each shuttle cars will be equipped with two cameras and two monitors to provide a view of the opposite side of the shuttle car. 16
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- 18. Manpower Summary Shift Job Responsibility Total I IV V VI Workers (Hourly Paid) Chief Foreman Hlavní předák 1 - - - 1 Miner Operator Operátor BM 1 1 1 1 4 Roof Bolter Svorníkovači 3 3 3 3 12 Shuttle Car Operator Obsluha shuttle car 2 2 2 2 8 Alminco Bolter Operator Obsluha Bolter Alminco 2 2 2 2 8 Face Scoop Operator Obsluha scoop 1 1 1 1 1 4 Supply Scoop Operator Obsluha scoop 2 1 1 1 1 4 Belt Operator Obsluha odtěžení 1 1 1 1 4 Utility Crew Četa 4 - - - 4 Belt Maintenance Crew Údržba odtěžení 2 - - - 2 Mechanic Specialista zámečník 2 1 1 1 5 SSV Control Kontrola SSV 2 1 - 1 4 Electrician Electro 1 1 1 1 4 Total 23 14 13 14 64 Total with Absentees (25%) 28 17 16 17 78 Technical Personnel (Salaried) Area Manager Vedoucí úseku 1 - - - 1 Shift Foreman Revírník 1 1 1 1 4 Foreman (Mechanic) Mechanik úseku 1 - - - 1 Surveyor THZ-OMG 1 - - - 1 Surveyor Helper Dělník – OMG 2 - - - 2 Total 6 1 1 1 9 ALL TOTAL 34 18 17 18 87 18
- 19. Training Safety Training (Mandatory) – Classroom training to familiarize with room and pillar methods and requisite “Do’s & Don'ts” in the section. Operator Training – Surface Training – A surface facility will setup to teach Shuttle car and Scoop operator. Underground Training – One month 1:1 training with a trainer in B shift and then two months in C and D shift under supervision. Mechanic/Electrician Training – Vendor Training – Equipment suppliers will provide training to electricians and mechanics. On-machine Training – Training will be given during disassembly (Surface, Tychy, Poland) and assembly (underground, ČSM, CZ) of equipment. Underground Training – One month 1:1 training with a trainer in B shift and then two months in C and D shift under supervision. Training Providers Proposal received Waiting for proposal Initial Communication has begun 19
- 20. Legislative Procedures 1. Project of “New not approved mining method“ (further only NNMM) In accordance to the Decree 22/1989 Coll. from Czech Mine Authority and Decree 300/2008 from Local Mine Authority in Ostrava. Project should be assessed by independent organization → VŠB – TU, Ostrava. 1. Update of Long-term mining activity In accordance to the Czech Mine Authority Directive No. 659/2004 Coll. Initiation of works: 10/2012; Estimation of processing: 1 month. 1. Permission for mining in the safety pillar of the shafts In accordance to the Czech Mine Authority Directive No.415/1991 Coll. Initiation of works: 10/2012; Estimation of processing: 1 month. 1. POPD - Plan of initial entry, development & mining for permission of mining activity - NNMM 1. In accordance to the Czech Mine Authority Directive No. 104/1988 Coll. 2. Initiation of works : 11/2012; Estimation of processing : 2 months. 3. Documents above the standard parts of POPD will be taken from the project documentation. 20
- 21. Safety OKD will respect Czech mine legislation maximally (The Decree 22/1989 Coll. from Czech Mine Authority). According to necessity special division will be created as a part of the project “New Mining Method”. Project team is focused especially on: CH4 sensor placing and measurement. Coal dust disposal. To have efficient and reliable ventilation system. Utilization of a communication system. To protect people against the moving machines. (RED ZONE = NO ZONE) 21
- 22. Productivity Assessment Cut and Load Bolting Sump 20 Place strap and Mesh 108 Shear down 25 Drill one cycle Shear up 31 Position drill steel 20 Lower head and load 37 Drill hole 48 Raise head 10 Insert resin 24 Sump 20 Spin and torque 48 Shear down 20 Reposition 20 Raise head and Shear down 25 Time for one cycle 160 Lower head and load 30 5 Cycles (3 roof bolts and 2 rib bolts) 908 seconds Cut cusps and position 82 300 seconds In agreement with Joy contract 5 minutes Joy contract bolting time 15 minut Total cycle time for one meter Cut = 5 minutes + Bolt 15.1 minutes = 20.1 minutes Available time in shift 360 ÷ Total cycle time 20.1 Theoretical meters per shift 17.9 x shifts per day 3 Theoretical meters per day 54 Available production time 65% Possible meters per day 35 Target meters per day 24 24 to 35 Meters per day 22
- 23. Project Schedule 23
- 24. CAPEX and Contracts CAPEX Smart Services, Training Spare Parts Equipment USD Contract USD Contract USD Contract JOY 5 717 462 signed Bolter Miner JOY Concept 1 829 478 signed 560 000 Shuttle cars (2) agreed Smart JOY Services 1 019 726 signed 479 670 Feeder breaker Both HANSEN ELECTRIC contracts 606 545 signed being _ _ Electrical equipment negotiated Training ALMINCO 200 000 Concept 1 346 206 agreed 84 000 Scorpion bolters (2) agreed FAIRCHILD Concept 2 161 510 agreed 113 000 Scoops (2) agreed CFT 600 000 to be agreed _ _ _ _ Ventilation and de-dusting FERRAM 1 108 320 to be agreed _ _ _ _ Haulage system RAG 35 000 agreed _ _ _ _ Quality inspection TOTAL 14 424 247 679 670 757 000 24
- 25. ECONOMICS Sensitivity Financial KPI's - Shuttle Car Plan Seams 30 and 33 only Base Breakeven BEST Average ROTP per year 115 79 144 Average meters per day 24 17 30 Met sales price 4 169 4 169 4 169 Thermal sales price 1 717 1 717 1 717 Average sales price 3 908 3 908 3 908 Average cash cost 2 314 2 558 2 206 Average cash flow tis Kč 149 600 87 900 199 386 NPV @ 10,4% tis Kč 233 550 0 421 997 IRR 37,3% 10,4% 56,7% Note: 5 year plan in only seams 30 and 33 25
- 26. Joy Smart Services What it provides Services Equipment Prognosis. 30 Days of training for Joy equipment. Vibration, oil and stress analysis. 1 (One) visit per week from Life Cycle Trending analysis to identify failures. Management coordinator. Remote health monitoring. 24X7 Remote health monitoring and Asset management. technical support from remote Joy site. Training. 1 (One) visit per Week from Process optimization. Performance Analyst to optimize Equipment maintenance on all Joy productivity. provided equipment. 3 on site maintenance engineers. TIPS - Technical Information Portal TIPS for technical service and parts Parts catalogs. catalogs. Service manual. Monthly condition monitoring visit for Training manuals. vibration and oil analysis. Extended Warranty. 26
- 27. Acknowledgement Group A - ČSM-CMRPP Team 1.Tapas Das, OKD, Special Project Manager Tapas 2.Richard Pavlík, OKD, Vice-director (Technical Planning) 3.Jiří Golasowski, OKD, Vice-director (Mine Projects) 4.Bill Schloemer, OKD, Senior Engineer (new mining areas) 5.Jiří Korbel, ČSM, Vedoucí Projektu RP Group B - ČSM-CMRPP Support Team 6.Antonín Klimsa, OKD, CAO Vice-director 7.George Allekotte, OKD, Senior Engineer (Electrical & automation) 8.Ladislav Rožnai, OKD, Poradce vedoucího odboru BOZP 9.Libor Ryška, OKD, Manažer operativního nákupu 10.Petr Antoszyk, ČSM, Technolog pro svorníkování 11.Robert Vochta, ČSM, Vedoucí odboru měřictví a geologie 27
- 28. Discussion 28