the move to thin seam gypsum mining and the …...moving into the thinner seam on the east side 2016...

The Move to Thin Seam Gypsum Mining and the Equipment required to do this

“ A Suppliers View”

David M North16th November 2017

Moving into the Thinner Seam on the East Side 2016

Background

Barrow mine was opened in 1989 with an original reserve life 23.5Mt.

Over the intervening 25 years some 15Mt of gypsum have been mined and converted into plaster product.

The mine has always been worked using cutting machines.

Barrow is able to maintain high levels of customer service through a combination of the quality of the gypsum mined.

The Barrow Plant is reliant on gypsum extracted from Barrow Mine.

Barrow Plant … Largest Plaster Plant in the world; 90% of British Gypsum Capacity; Capability of 32M Bags/Year and strategically important in Saint -Gobain’s portfolio (next slides)

The Saint-Gobain Group

British Gypsum

5 Factory’sBarrowEast LeakeKirkby ThoreRoberts BridgeSherburn

5 Mine’sBarrowMarblaegisBirksheadBrightling

ImportsFauld (No Factory)

Barrow Works

Number of employees: 140Products: Backing Coat and Finish Coat Plasters

And as said previously Barrow is the world’s largest bagged plaster plant – capable of producing greater than 32million bags per year


Present Situation

To date mining at Barrow has been concentrated where the gypsum seam was the thickest and the most cost effective to recover.

Approximately 60% of the Barrow reserve area has now been exploited and the remaining reserves are thinner.

The current mining machines can only operate in thicker seam (> 2.25m); however, 60% of the remaining reserves are less than 2.25m thick.

Lower height mining equipment is needed to exploit these reserves. Seams below 2.0m are currently uneconomic to exploit.


Present Front End Mining Equipment

There are three continuous mining machines operated at Barrow Mine.

Main Production - (Joy 3 & Joy 4)Development - (Joy 2)Hauling - DBT (CAT) Ram Cars Ancillary and Stock Recovery - Atlas Copco (Wagner) Scooptrams

The following pictures show the front line machinery

No.4 Joy 12HM36 DBT (CAT) Ram car


Reserves

The extent of the mine workings, the remaining thick seam (>2.25m high), the thin seam reserves (<2.25m high).

The current mining method can only access 7 years reserve life at forecast rates of extraction.

The bulk of the remaining reserve is thinner seam (2.0m to 2.25m) and cannot be mined using the existing mining methods and machines.

It was proposed to purchase sufficient low height mining equipment to establish a thin seam mining districts.


The Mine Team Planned the reserve … “how we mine it and what equipment will we require to do this”

Moving into the Thinner Seam on the East Side 2016Which suppliers could match some or all of the criteria; to send the above too …

…. Either we know the prices or we ask for Budget Quotes; example shows choices of Scoops

Planning what type of equipment would be required and the top level specification to allow suppliers to quote….. …. Lots of alternatives; Choices/Supplier Specification/Our Requirements e.g. A, B, C and D … which will them feed into the British Gypsum’s Capex Purchasing Process; example for the miner.

Selection of what criteria was critical or nice to have …. Priorities

Manufacturer Machine Capacity Height Width Length Engine Notes Price

Atlas Copco ST7LP 6.8 1.452 2.674 8.467 144Kw Cummins QSB6.7 Tier 3 Poor Visibility (Blind) … got Video's of it being used TBA

ST7 6.8 2.16 2.28 8.72 144Kw Cummins QSB6.7 Tier 3 £354,000

ST1030 10 2.355 2.49 9.695 186Kw Cummins QSL9 C250 Tier 3 £447,000

CAT CL110 10.00 1.65-1.95 2 9.78 CAT C7 … NOT Tier 4 QDS; Same engine as No.6 Ram Car

R1300G 6.8 2.2 2.155 8.943 123Kw CAT 3306B DITA … NOT Tier 4

R1600G 10.2 2.4 2.723 9.955 185Kw CAT 3176C EUI ATAAC Tier 2

GHH SLP6 5.5 1.65-1.85 2.46 7.84 104kw Deutz … NOT Tier 4

SLP8 8 1.55-1.85 3.1 10.055 170-181Kw Deutz … NOT Tier 4

SLP8H 8 1.5 3.14 10.733 140Kw Deutz TCD 6.1 L6 Tier 4 Poor Visibility (Blind); Hydrostatic Transmission; Problems with FRF TBA

Joy LT270 2.7 1.857 1.528 6.316 56Kw Deutz BF4M2012C Tier 2

LT350 3.636 2.068 1.629 7.517 86Kw Deutz BF4M1013C Tier 2/ Cummins QSB4.5T Tier 3

LT650 6.591 2.252 2.121 8.644 141Kw Deutz BF6L914C Tier2/ Cummins QSB6.7 Tier3

LT1050 9.979 2.464 2.692 9.692 205Kw Deutz BF6M1015C / Merc MBE926 Tier3

LT1150 10.9 2.434 2.692 10.279 220Kw Merc OM926 Tier 3

7LT Concept (baby 18HD) 7.01 2.158 2,160 8.941 XXXXXXXXXX Tier 4 (18HD has a Merc OM471LA) Development Machine with SR Motors (Proposal)14 months delivery TBA

Sandvik LH209L 9.6 1.69 3.26 9.24 185 Kw VolvoTAD871VE Tier 4 Poor Visibility; Air Con Cab (7th July 2016)-Viewed Poland £431,526

Updated 12th July 2016

North, David:

Can reduce but

Bonnet is 1.767m

without covers

Design Criteria

for example

Gypsum

Hardness and

Road dimensions

Performance

measures,

equipment

requirements

and

acceptance

testing

Contract


Selection of suppliers to take to our Purchasing department and “Pro Source” … (our company rigorous tendering process) … British Gypsum’s Capex Purchasing Process

The individual elements of the Thin Seam project were tendered via ProSource, the Saint-Gobain on

line portal.

These separate projects were each assigned a unique RFX (RFI ‘Request for Information’ ; RFP …

Request for Proposal; RFQ … Request for Quotation) reference.

Multiple suppliers were invited to offer proposals against an output specification. As seen on the

previous slide.

The specification included rigorous performance measures, equipment requirements and acceptance

testing which was also shown on the previous slide

Supporting information, commercial terms and agreed project timescales were provided.

Due to the specialist nature of the Gypsum reserves, a limited number of suppliers were identified by

the Barrow project team


Each supplier was able to log into the project, using an individual password within clearly defined start

and closure dates, accessing the designated documents, and uploading or editing their proposals

whilst the portal was open.

Throughout this process, all suppliers had access to a single, continually updated, Question & Answer

document, generated by queries received from the suppliers.

At the outset of the project a selection matrix was created by the project team for each piece of

equipment.

Weighted criteria allowed each proposal to be scored and compared.

This was modified as ‘Total Cost of Ownership’ sheets were completed, and commercial and technical

negotiations were concluded.

The final decision was based on cross functional input from legal, purchasing, engineering and finance….. selection was based on the best business case; not necessarily the cheapest


• Final tuning of the specification with the supplier• Extras• Ideas• Changes due to improvements/ideas elsewhere

• Signing of supply contracts … • And this was done with ALL suppliers

• Miner• Rock Haulage• Mobile feeder breaker• Conveyor• Dust Collector• Main Fan• LHD …… we call SCOOP

• Build and supply process ……. The next part of the presentation

• This element of the presentation is normally 60 slides long and over one hour long. As operational results are fed into it to show the benefits and successes of the process it gets longer by the day.

• Clearly there is not enough time to go through it all so here is a ‘snapshot’ of the :-Feeder breaker

Rock Haulage

Miner

Scoop



Belt Pantec being Un Loaded @ Barrow Mine Being Un Loaded @ Barrow Mine

Being Driven Underground

Stamler: UFB-14B-77-172C VFD : FB 14695VFD Conveyor Drive and 2m Longer Bed Length


Joy UFB-14 Feeder Breaker

“Stamler No.3”

2m Longer Bed Length for improved Loading

VFD electrical drive for the Chain to reduce hydraulic oil in circuit use and hence reduce fire risk for

unmanned equipment

Improved energy use with Electrical drive and removal of traction coupling when not in use

Improved design of machine for ergonomics, manual handling and for reduced risk of fire

Machine Reliability …. ? Next Part of the StoryTotal Cost of ownership …. ? Next Part of the Story

• VFD drive for Conveyor Chain. Consequently no oil in circuit

reducing fire risk even though its FRF.

• Disconnect of Hydraulics when not tramming ….i.e. 99% of the

time Consequently no oil in circuit reducing fire risk even though

its FRF.

• Disconnect of Hydraulic Pump when running the Conveyor;

reducing energy use

• Pantec with improved access to change rollers; Improved

Interlock with Stamler; Mounted plates for bolting to floor, Belt

cleaner Magnet; Metal Detector; Traveling Bridge


Shuttle cars: 10SC32-48C: ET18392 & ET183932016 Version and Including Enclosed Cab



Joy 10SC32 Shuttle Cars

Shuttle Car No.1 and No.2Reduced Total Operating Height for Thin Seam WorkingElectrical for future proofing rock haulage fleet

Reduced Diesel Vehicle emissions …. NONE

Larger Capacity … 25%

Improved Productivity

Reduced NOS for the Driver … and reduced NOS around the machine perimeter (see Miner slide)

Reduced TAS for the Driver

Improved design of machine for ergonomics, manual handling and for reduced risk of vehicle fire

Machine Reliability …. ? Next Part of the Story

Cable Handling ….? Cost and DowntimeTotal Cost of ownership …. ? Next Part of the Story

• Electric for Diesel so reduction in diesel fumes and particulates …

and future proofing the machines for expected tightening of

legislation on Particulates and NOx

• First Joy Enclosed cab to reduce NOS and TAS to the driver

• Improved lighting on Shuttle Cars over Ram cars for better

visibility

• Cab lights facing forward and backwards to supplement driving

lights.

• LED lights rather than old tungsten bulbs

• Camera for O/S visibility

• Key Control … first Joy has built with … so only trained and

authorised drivers can use.

• Fool Proof Gauges Throughout fleet aiding operators

• Operator Maintenance all signed up and all from the floor

• Shuttle Car covers made of FR plastic to facilitate easy removal on

maintenance and reduce manual handling weights. Covers shown

are those above the cable realer.

Moving into the Thinner Seam on the East Side 2016Miner : 12HM46 A – JM7156Low Height Version: 155 tonnes and increased HP cutter Motors from 275kw to 330kw. 2016 Traction, Electrics and Incorporating all the improvements made and learnt about throughout the world fleet of the 12HM36’s.


Joy 12HM46

Joy No.5

Reduced Total Operating Height for Thin Seam Working

Improved Traction System

Improved Cutting Capability … 20%

Improved Electrics and simplified

Improved Soft Ware … FACEBOS 2

Improved Hand Sets

Improved Stab Jack area

Modular Construction of all elements for maintenance

Improved Productivity Potential through quicker cutting capability (Hauling is the Bottle Neck)

Reduced NOS for the Driver … with the conveyor chain being 7dba quieter than that on the 12HM36’s …

measured at 79/80dbA … both when cutting and Loading

Improved design of machine for ergonomics and manual handling

Machine Reliability …. ? Next Part of the Story …. No.3 and No.4 is 97% average over life.Total Cost of ownership …. ? Next Part of the StoryPerformance Review before committing to Miner No.6 … constantly improving

• No5 Joy NEW handset (top) vs No1 (bottom) .. To reduce HAV’s and

improve ergonomics with a strap to support … joy sticks instead of

buttons and dead man button to be held in at side.

• Conveyor chain with double drive and plastic coated flight bars

(top) to reduce wear and noise to the Joy Operator and Shuttle Car/

Ram Car Operator .. From 92Dba to 78 Dba vs No4’s (bottom).

• No5 Future Proofed for fitting of People/Man vicinity recognition for

safety of personnel … future Mod. But ready to accept when the

testing of the technology in USA is

• Fool Proof Gauges Throughout fleet aiding operators

• Operator Maintenance all signed up and all from the floor

• Miner thick FR plastic in Orange so no requirement to paint and as

with the Shuttle Cars facilitate easy and lighter removal of covers.• Improved Lighting on No5 Joy over previous models for better

surrounding visibility as well as front and back Approved Flame

Resistant Solid

Products taken

into mines –

Approval number

IC-300/4 and

tested to 30CFR,

part18,Section

18.65 .. June 2015

Moving into the Thinner Seam on the East Side 2016Scooptram : Sandvik “TORO” LH209L (w/AC Cabin Option)



Sandvik LH209L

TORO No.1Reduced Total Operating Height for Thin Seam WorkingImproved Traction and Digging Capability 12.5%

Improved Cycle Time with faster Hydraulics 10%

12.5% Larger Bucket …. Improved Productivity

Reduced Diesel Vehicle Gasses ….. In General Body NEW vs OLD…. NO² - 46.34%; NO – 22.25%; CO – 75%

Reduced Diesel Particulates in both Engine emissions and General Air Body … average of 7.46% in GAB

(Some readings from the Exhaust as part of the Stat 90 day tests are 0%)Reduced NOS for the Driver … in the Cab …. NEW vs OLD …. 84dbA vs 100.3dbA – 3.13%

Reduced TAS for the Driver … in the Cab …. NEW vs OLD …. 0.07mg/m³ vs 2.73mg/m³ - 2.56%

Improved design of machine for ergonomics, manual handling and for reduced risk of vehicle fire

Machine Reliability …. ? Next Part of the StoryTotal Cost of ownership …. ? Next Part of the Story

• Tier4 Volvo TAD871VE 252hp Engine

• Extremely low Particulate, CO and NOx readings

• Extremely Low Noise Levels

• All Servicing done from the ground level

• Diesel; Oils; AdBlu all filled from ground level

• Fully Air-conditioned Cab for driver comfort

• Auto Lube System

• Hose protection

the move to thin seam gypsum mining and the …...moving into the thinner seam on the east side 2016...

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