comms international minetec smarts underground above ground planning management simulation

Mining Transformation: MINETEC´s Underpinning Technologies

Minetec provides the underpinning technology and force mul6plier for mining transforma6on

Our Customers said: “I congratulate Minetec on having the best underground communica6ons technology and the only technology that actually works”

-‐ Codelco Head of Underground Technology Sep 2013

“Minetec outstood its compe6tors not just on a single ver6cal but on all ver6cals for the mechanised and opera6onal requirements. Minetec is our partner of choice to make this happen”

-‐ Anglo American New Mining Technology Manager Oct 2013

WASP

“Whether in my office, or in the muster area, at mine control, or my home in Melbourne, I can see at a glance what is going on in the mine. It is a new world”

– Newcrest Toguraci Mine Manager June 2013

Mining Industry Status

§  Demand for increased efficiency and innova7on in mining technology through ‘Smart Mining’ due to:

§  Turbulence in Commodity Prices

§  Cost Reduc7on

§  Skills Shortages

§  Asset U7lisa7on

§  Consumable management

§  Increasing demands, driven by the needs of emerging economies, maturing ore bodies and fewer tier-one surface deposits being discovered are forcing migration from surface to underground operations

§  Australia is considered to be the world’s most innovative mining technology

community

Opera7ons Management

Mining ac7vi7es are projects •  they are ac7vi7es designed to produce a result •  they are temporary in that they have a defined beginning, end, scope and resources

To deliver the on-‐7me, on-‐budget results they must be expertly managed


Inputs

Simula1on

Plan

Con1nuous Improvement

Actual

Reports and Reconcilia1on


Inputs ú  Long term mine design and principal mining methods

−  U7lising specialised design and visualisa7on tools −  Ground support requirements

ú  Constraints such as −  Schedule, including face availability, linked tasks, crew ingress/egress and breaks −  Gear selec7on and availability −  Heading priority −  Grade control −  Environmental −  Manpower and skill level −  Financial, including consumable costs, fuel costs

ú  Short term opera7onal targets updated with most recent actuals results

Inputs

Simula1on

Plan


Actual



Long term Simula7on ú  Sensi7vity analysis ú  Visual analysis ú  Usually only occasionally done formally – perhaps annual business plan and budget cycle ú  Op7misa7on for such things as:

−  Equipment u7lisa7on −  km travelled −  Fuel use reduc7on −  Hours worked −  Tonnes moved (and handled through individual stockpiles) −  Idle 7mes −  Traffic management

Short term Simula7on

ú  OYen informally done weekly and daily by mining management and/or shiY boss ú  OYen also known as “experience” ú  Depending on mechanisms of long term simula7on, can be very adhoc ú  Detailed task crea7on and review ú  Update for actual work done ú  Considera7on for opera7onal constraints ú  Develop a schedule consis7ng of tasks ú  Training and skills requirements

Approve and Communicate the Plan

Inputs

Simula1on

Plan


Actual



Keeping an eye on day-‐to-‐day ac7vi7es such as ú  Tracking changes to the plan ú  Communica7ng changes to all affected staff ú  Tracking equipment and loca7on down7me and availability ú  Tracking and loca7ng staff ú  Tracking and loca7ng equipment ú  Tracking events as they occur ú  Recording PLOD data ú  Ensuring skilled personnel are assigned the right tasks ú  Reducing delays

Inputs

Simula1on

Plan


Actual



Standard Repor7ng ú  EOD, EOS, EOM ú  “Mine Managers” preferred report ú  Desire for high amounts of data ú  Desire for trends and graphs showing good depth to data

Reconcilia7on ú  Rarely mul7 dimensional ú  Usually only grade and produc7on schedule against specific plan ú  Does not regularly include variance analysis or trend analysis

Inputs

Simula1on

Plan


Actual



Con7nuous Improvement •  Usually done as a specific project •  Usually suffers from lack of opera7onal data •  Not just a decision on how to get back to target •  Decisions on how to achieve the same with fewer resources – efficiency and produc7vity improvements

•  Trend analysis on failures to remove root causes •  Tradi7onal systems require too much work to get to this stage and insufficient corporate resource available

Inputs

Simula1on

Plan


Actual


Open Pit Opera7ons Management

§  Mine control and monitoring systems are now common in open pit mining §  Why has it become so pervasive over the past 5-‐10 years? §  Some game changing technology:

ú  WiFi ú  GPS device availability and removal of Selec7ve Availability(SA)

§  Sites that have deployed this technology have realised significant increases in opera7onal performance through visibility on performance leading to beder planning

Financial Opportunity

Variability within a ‘typical’ single heading development model based on development rate:

100 $6,000 $2,400 $3,400 $2,200

$1,400,000

$14,000

2.30

150 $3,960 $1,900 $2,800 $1,500

$1,524,000

$10,160

3.40

200 $3,000 $1,600 $2,500 $1,100

$1,640,000

$8,200

4.50

Development -‐ meters/month -‐ Labour ($/meter/month) -‐ Maintenance ($/meter/month) -‐ Consumables ($/meter/month) -‐ Capital ($/meter/month) Total Cost ($/month) Total Cost per Meter ($/meter) Meters per Man per Month

Benefits 150m/m -> 200m/m: •  For 8% increase in overall costs, 30% increase in development rate •  Economy of scale reduces cost per meter by 20% •  Manpower efficiency rate of 132%

Open Pit to Underground

How do we leverage the open pit model into the underground environment? Do the ‘game changers’ exist?

WiFi for Underground

ELF is the Minetec Ethernet-‐over-‐Leaky Feeder solu6on that delivers high bandwidth voice and data (Ethernet) communica6ons for underground applica6ons where RF-‐based systems are not able to be deployed

• Fully Ruggedized: designed for harsh underground condi7ons • High Speed Data, Voice & Ethernet up to 60Mbs • Deliver high bandwidth from the backbone broadband network to the development and opera7onal areas of the mine

• Centralized Management • Rapid Installa7on and Maintenance • Cost Effec7ve & Scalable

Proximity Awareness

SafeDetect ™ is the Minetec real-‐6me proximity awareness and detec6on system for personnel, equipment and assets in underground and open pit (above-‐ground) mining opera6ons • Simple to use • Sub metre accuracy down to 10cm (proven) • Designed for a wide variety of installa7ons

•  Stand Alone or Integrated •  Two levels of operator console •  Fully integrate-‐able with machine control systems (RS485, RS 422 & I/O) •  Data logging for review and analysis

• Highly Configurable •  Mul7ple zones with unlimited number of contacts per zone •  Configurable alarm sequence and incremental warning •  360 degree contact monitoring •  Configurable contact classifica7on and display •  Dynamic zone adjustment

• Op7ons include: •  Camera interface •  Dynamic zone adjustment on machine status

GPS for Underground

Trax+Tags™ is the Minetec wireless tracking system that enables operators to track the loca6on of personnel, equipment and assets by u6lising WASP technology.

• WASP (Wireless Ad-‐hoc System for Posi7oning) developed in partnership with CSIRO • Centrally managed, low cost, robust technology • Designed for severe mul7path radio environments • High accuracy

•  0.1 m outdoors line of sight (low mul7path) •  0.2 m indoors line of sight (high mul7path, including underground) •  Down to 1 m non line of sight •  1D, 2D and 3D

• Features include: •  Anchor Nodes – at fixed and known loca7ons •  Mobile Nodes – adached to person or object to track •  5.8 GHz (ISM) band, 125 MHz bandwidth, typical 50 mW transmit power •  All nodes can provide up to 8Mbps data network capability •  Supports mesh installa7on with limited infrastructure requirements •  Full historical repor7ng and playback

GPS for Underground

UG Mine Management Solution

•  Planning & development simula7on •  Scenario evalua7on based on knowledge of mine design, asset configura7on and

many other criteria •  Create daily ac7on lists based on real-‐7me and recent history performance •  Monitor assets, people, task status & comple7on to modify the plan in real 7me •  Real 7me repor7ng of performance and progress according to plan •  Team management approach, not individuals working in isola7on •  Configured for centralized control room or mobile management •  Opera7onal data capture of down7me and u7liza7on tracking for maintenance

planning •  Leverages Game Changer Technology

SMARTS is a suite of advanced software applications and leading edge hardware devices for integrated real-time mine operation, simulation, management, tasking and reporting.

NOT a Rear View Mirror Approach

§  Combines long-‐term produc7vity modelling with short term real-‐7me op7misa7on

§  Exis7ng Mine Management & Control (MMC) products cannot do this and typically model produc7vity based on past performance -‐ Rear View Mirror Approach

§  Ongoing simula7on using latest opera7onal data

Industry Standards

• A Windows ‘Smart Client’ database applica7on with web access portal and repor7ng interface

• Users are able to enter data and report informa7on from anywhere on your network or the Internet.

• Wriden in C#.net and ASP.net • SQL Server database that is open and available for external interface • Reports delivered in Excel or Acrobat (.pdf) • Modular • Scalable • Robust •  Integrated

Indica7ve Costs

For the same development model used earlier:

100 $3,000 $12,000

$17 $33

$20,000

$200

150 $3,000 $12,000

$17 $33

$22,500

$150

200 $3,000 $12,000

$17 $33

$25,000

$125

Development -‐ meters/month -‐ ‘Head-‐end’ Voice Only ($/month) -‐ ‘Head-‐end’ SMARTS add-‐on ($/month) -‐ Consumables Voice Only($/meter) -‐ Consumables SMARTS($/meter) Total Cost ($/month) Total Cost per Meter ($/m)

~1.5% increase in costs …

Budget 0+12 5+7 8+4

Rolling 13 Week

Month

Week

Day

Shift

Shiftboss: Input Accountable

Superintendent: Input Accountable

Foreman: Input Accountable

Long Term

Short Term

Daily

SMARTS Control Centre

(SMARTcontrol)

SMARTS Mobile Client

(SMARTmobile)

SMARTS Long Term Planning

(SMARTsim)

SMARTS Short Term Planning

(SMARTsched)

Mul7 Level Planning

Comprehensive Input Capture

• Mine design, including import from exis7ng planning and scheduling tools • Define targets such as financial, schedule, movement, grade control • Apply constraints such as gear type and availability, traffic bodlenecks, face availability

• Update opera7onal targets based on most recent actuals ac7vi7es

Inputs Simula1on Plan Con1nuous Improvement Actual Reports and

Reconcilia1on

Long Term Simula7on

Complete calcula7ons, view simula7ons and adjust variables to achieve required outcome/criteria Configure for varied mining processes and methods Op7mise for individual plant & equipment usage including

ú  U7lisa7ons ú  km travelled ú  Hours worked ú  Tonnes moved (and handled through individual stockpiles) ú  Idle 7mes


Reconcilia1on

Long Term Simula7on


Reconcilia1on

Short Term Planning

Specify shiY constraints Develop day plan. Approve and communicate to opera7ons Iden7fy training and skills requirements Long term plans and short term schedules §  A Schedule consists of Tasks. §  Each Task contains a Duty, Loca1on, Start Time, End Time and Asset. §  Task are assigned to Assets – any vehicle or group capable of doing a task


Reconcilia1on

Short Term Planning


Reconcilia1on

Opera7ons Tracking

Mobile client – Operator View •  Ensure training completed and current for equipment •  Respond to allocated tasks •  Add enter delay and abort tasks •  Turn by turn naviga7on •  See all equipment and personnel in vicinity


Reconcilia1on

Opera7ons Tracking

Mobile client – Supervisor View •  View en7re opera7on •  Respond to alerts on services such as dewatering, power, ven7la7on •  View real 7me loca7on and status of all equipment and personnel

•  Re-‐alloca7on of people and equipment to new tasks and re-‐priori7sa7on


Reconcilia1on

Opera7ons Tracking

Control Room • Monitor and react to events and delays


Reconcilia1on

Real Time Dashboards

• Monitor and report on actual performance • Dashboard performance views • Compare to budgets and plans


Reconcilia1on

Current Status

Event History

Jobs Started

Regular Repor7ng

• Fully customised reports through SQL Repor7ng Services • Produc7on reports • Daily shiY reports


Reconcilia1on


Reconcilia1on

Reconcilia7on

Budget 0+12 5+7 8+4

Rolling 13 Week

Month

Week

Day

Shift

Shiftboss: Input Accountable

Superintendent: Input Accountable

Foreman: Input Accountable


•  Vast amounts of data available to make well reasoned high level decisions through trend analysis, etc

•  Includes decisions on how to get back to target or change target • Decisions on how to achieve the same with fewer resources – efficiency and produc7vity improvements

•  Trend analysis on failures to remove root causes •  Business is freed from transac7onal ac7vi7es to allow greater focus on opera7onal improvements • Maintenance planning is beder focused on targe7ng equipment in need based on run hours, etc, but also iden7fy troublesome equipment, condi7ons and operators

•  Staff skills and training development


Reconcilia1on

The Next Level

ú  A large por7on of a typical underground mine’s energy costs are associated with ven7la7on. ú  By intelligently managing secondary ven7la7on fans, the case study indicated up to 30% energy reduc7on ú  Automa7c vent fan control based upon factors such as:

−  Personnel loca7on using Tagging and Tracking −  Time of Day (Scheduling), −  Air Quality -‐ Temperature, gas levels, or minimum air veloci7es reaching undesirable thresholds.

Advanced Environmental and Condition Management Case Study - Ventilation on Demand

Summary

§  Minetec have the experience and track record in engineering and maintaining miner-‐proof solu7ons

§  Minetec products provide high accuracy, in mo7on posi7oning, tracking and collision avoidance throughout the opera7on

§  SMARTS is a cost effec7ve, scalable and extensible management system

§  SMARTS adds a level of mine management and planning to your opera7on through simula7on, data acquisi7on and transparency that will deliver significant improvement in safety, efficiency and costs

Toguraci Update

§  Elf commissioned .. ~50 wireless nodes, ~15km leaky feeder §  Elf over fibre §  Trax&Tags v1

ú  U7lising mul7 zone electronic tag board

§  SMARTS ú  Tradi7onal voice mode dispatch ú  Working on simulator integra7on, semi-‐automa7c planning ú  Comprehensive repor7ng

−  Delay accoun7ng −  Task compliance −  Material movement −  Run hours/equipment hours −  Environment temperature monitoring and repor7ng

Toguraci Update

�13

TecWise Sistemas de Automaçao / Comms International !Phone: +55 31 3019-0129 [email protected]

Rua Rio Grande do Norte, 1164/501 (Savassi), 30.130-131, Belo Horizonte. Brasil

!Phone: +44 207 193 4247 Fax: +44 207 117 4460

[email protected]

comms international minetec smarts underground above ground planning management simulation

Technology

input accountable

input accountable

fewer resources

comms international

open pit

individual

total cost

remove root