Wirtgen Surface Miner 4200SM
NEW TECHNOLOGY APPLIED TO DELIVER REAL
BENEFITS AT NEW ACLAND MINE
DISCLAIMER
2
IMPORTANT: The information in this document has been provided to you for information only by New Hope Corporation Limited (“NHC”) and is subject to change without notice. Nothing contained in this document constitutes investment, legal, tax or other advice. The information in this document does not take into account your investment objectives, financial situation or particular needs. Before making an investment decision, you should consider, with or without the assistance of professional securities adviser, whether an investment in NHC is appropriate in the light of your particular investment needs, objectives and financial circumstances. Nothing in this document should be considered a solicitation, offer or invitation to buy, subscribe for or sell any security in the United Sates of America (“US”) or in any place in which, or to any person to whom, it would be unlawful to make such an offer or invitation. The distribution of this document outside Australia may be restricted by law. Persons who come into possession of this document who are not in Australia should seek advice on and observe any such restrictions. Any failure to comply with such restrictions may constitute a violation of applicable securities laws. Neither this document nor any copy hereof may be transmitted in the US or distributed, directly or indirectly, in the US or to any US person including (1) any US resident, (2) any partnership or corporation or other entity organised or incorporated under the laws of the US or any state thereof, (3) any trust of which any trustee is a US person, or (4) and agency or branch of a foreign entity located in the US. By accepting this document you agree to be bound by these limitations. NHC has prepared this document based on information available to it. Although reasonable care has been taken to ensure that the facts stated and opinions given in this document are fair and accurate, the information provided in this document has not been independently verified. Accordingly, no representation or warranty, express or implied is made as to the fairness, accuracy, completeness or correctness of the information and opinions contained in this document. To the fullest extent permitted by law, none of NHC, its directors, employees or agents or any other persons accepts any liability for any loss whatsoever arising from any
use of this document or its contents, or otherwise arising in connection therewith.
OVERVIEW
3
New Acland Mine – Seeking step change improvements
Structured Trial - Apply Technology to Local Conditions
Recommendations & Next steps
Outcomes
Background Wirtgen Surface Miner – Basic Principals and Technology
Worldwide market leader in mobile
machines for road construction and road
rehabilitation
WIRTGEN GROUP:
TWO LINES OF BUSINESS
ROAD TECHNOLOGIES MINERAL TECHNOLOGIES
Growth potential in terms of mining and
processing of mineral raw materials with
Surface Miners and Crushers
4
WIRTGEN GROUP HEADQUARTERS:
FOUR NEW FACTORIES
WIRTGEN GROUP HEADQUARTERS:
FOUR NEW FACTORIES
5
WIRTGEN SURFACE MINER
6
Cutting, crushing and loading in one step;
replace multiple processes
Rotating drum with cutting tools to leave a
clean floor
Steerable and height-adjustable crawler
tracks
4200SM:
Adjustable cutting depth:
200 mm – 830 mm
Drum width 4200 mm
Wirtgen GmbH
Wirtgen GmbH
APPLICATIONS BY ROCK TYPE
7
454 units sold as per May 31, 2014
Background Objectives Results Conclusions Recommendations
Cutting Technology – Drum Design
PRINCIPLES OF SURFACE MINING –
CUTTING TECHNOLOGY
OVERVIEW
9
Structured Trial - Apply Technology to Local Conditions
Recommendations & Next steps
Outcomes
Wirtgen Surface Miner – Basic Principals and Technology
New Acland Mine – Seeking step change improvements
CHALLENGES IN COAL MINING
10
Weakening coal pricing trend
Increasingly difficult deposits
Intensified environmental restrictions
Increased international competition
Seeking alternative mining technologies
Highly selective mining
Low unit costs
Low impact on the environment
New challenges
NEW ACLAND DEPOSIT
11
Multiple thin seam mining
Banded coal plies with thinly bedded
sandstone, mudstone and siltstone
layers
47 plies in total
0.23 m average coal seam thickness
Highly selective mining required
WIRTGEN SURFACE MINER
PERFORMANCE PARAMETERS
12
Surface Miner
Performance
Rock properties
• UCS
• Tensile strength
• Abrasivity
• Density
• Rock mass structure
Machine operating settings
• Cutting depth
• Advance speed
Pit design and
scheduling
• Working width
• Working length
• Dimension of turning area
• Allocation of trucks
OVERVIEW
13
New Acland Mine – Seeking step change improvements
Recommendations & Next steps
Outcomes
Wirtgen Surface Miner – Basic Principals and Technology
Structured Trial - Apply Technology to Local Conditions
14
Discontinuous: Multi-handling
Multiple machinery for rock breakage & stacking
and loading
Well-known practice
MODE OF COMPARISON
Loading
Stacking
Ripping 1.
2.
3.
Conventional mining (CM) system Surface Miner (SM) mining system
Continuous system
One single machine for rock breakage and
loading
New technology
KEY OBJECTIVES OF COMPARISON
15
Productivity Quality
Health, Safety and
Environment (HSE) Unit costs
Conventional mining
vs.
4200SM
Particle
Sizing
Coal Loss
and dilution
ROM* coal
Dust
Noise
Safety Ergo-
nomics
Carbon
emission IB:
AUD/bcm
Production
Variability
Number of
machines
required
Coal:
AUD/bcm
ROM= Run-of-mine
Machine
Efficiency
Productivity
BCM/Hr
4200SM
Availability
KEY PERFORMANCE INDICATORS (KPIs)
16
KPIs refer to conventional system
Productivity
HSE aspects
ROM coal Quality
Commercial aspects
Evaluation KPIs Units Comments
Ramp up Percent % Account for training.
Coal - Avg Productivity t/op hour Monthly production x ramp up schedule.
- Max Productivity t/op hour Based on estimates in max thickness.
- Min Productivity t/op hour Based on estimates in min thickness.
Parting - Avg Productivity bcm/hour Monthly production x ramp up schedule.
- Max Productivity bcm/hour Based on estimates in max thickness.
- Min Productivity bcm/hour Based on estimates in min thickness.
Shifts Operating shifts/day Based on NPV Study
Days Operating days/week Based on NPV Study
Noise Limitations dB Average, 1 metre from machine on 4 corners.
Non noise attenuated maachine
Mechanical Availability % Note: (scheduled - downtime) / scheduled
Other KPIs assessed but no numerical limitation set.
1. Whole body vibration in operator cab
2. Top size of coal produced to maximise wash plant efficiency
3. Fine coal generation less than 2mm not to exceed limitation of dozer/loader system
4. Loss and dilution assessments compared to dozer/loader system
5. Fuel usage per operating and meter hour
6. Cutting bit replacement life in coal and parting conditions
7. Consumable costs other than cutting bits
OVERVIEW
17
New Acland Mine – Seeking step change improvements
Structured Trial - Apply Technology to Local Conditions
Recommendations & Next steps
Outcomes
Wirtgen Surface Miner – Basic Principals and Technology
Outcomes
WIRTGEN 4 MONTH STUDY
18
Collecting data
Analysing data
Calculations
Compare different
results to develop
reasonable production
rate range for each
machine
Site-specific
assumptions
Production Rate
Range
Theoretical estimation
Historical data
Reporting system
Time studies
In-field trials
CONCLUSIONS CM - SM
19
Performance
Area
Parameter Surface Miner
Productivity # Machines Replace 3 Machines with Single Surface Miner
BCM/Shift Exceed Conventional Mining Rate
HSE Environmental Lower noise, diesel consumption and dust
Ergonomics Excellent visibility and low WBV
ROM Coal Quality ROM Sizing Reduced top size and less fines
Siderite intrusions Removed potential for blocking
Unit costs Cost inputs Less machine and labour
Unit Mining costs Significant reduction
HEALTH, SAFETY AND ENVIRONMENT
20
Conv. Mining Surface Miner
Noise Higher noise emission level per
bcm Lower noise emission level
Dust More dust emissions per bcm
No installed suppression system
Less dust emissions
Installed suppression system
Carbon emissions More fuel usage per bcm Less fuel usage per bcm
Risk Management
No vertical edges
Well-known practice
Vertical edges
New mining system
More interaction machinery and
personnel Less interaction on work area
Ergonomics High WBV exposure
Twisting to overview work area
Low whole body vibration(WBV)
Rotating cab and seat
HEALTH, SAFETY AND ENVIRONMENT
21
Machinery interaction on mining area, CM Machinery interaction on mining area, SM
Dust emission, CM Dust emission, SM Operator survey
HSE: FUEL USAGE
22
Surface Miner System delivers less fuel usage , so less carbon emission
44% reduction in liters per hour
77 % less fuel usage liters per BCM
QUALITY: IMPACTS ON CHPP
23
No problems observed in handling
of 4200SM ROM coal
First observations: less energy
consumption
PSD trial results indicate
improvements in coal handling
Better handling of siderite coal
seams
ROM COAL QUALITY
24
Conventional Mining Surface Miner
Particle Size Distribution
Wider PSD range
More fines
More oversize material
More consistent material
Less fines
More target size product (2-40mm)
Impact on CHPP More energy consumption Less energy consumption
Handling of siderite Oversize siderite rocks cause
bogging and crusher wear
Siderite milled in pit
Passes through CHPP
QUALITY: PARTICLE SIZE DISTRIBUTION
25
Range of CM PSDs wider, SM
produces more consistent material
SM produces less fines and more
target size product (2 – 40 mm)
Surface Miner produces 12.5 % of
fines <2 mm, CM produces 14.8 % of
fines <2 mm
[mm]
[mm]
OVERVIEW
26
New Acland Mine – Seeking step change improvements
Structured Trial - Apply Technology to Local Conditions
Outcomes
Wirtgen Surface Miner – Basic Principals and Technology
Recommendations & Next steps
QUALITY: LOSS AND DILUTION
27
Fluctuation around the interface can be described as sine-curve with amplitude of 25 mm with period: 6 m
(operator adjusts depth after 3 m)
Assumptions based on assessment of NAC personnel, survey, own observations and Wirtgen experience
Theoretical 10% improvement in coal recovery
Input parameter
Amplitude [m] 0.025
Period Characteristic curve 1
Integral boundary 0 - π
Half-period length [m] 3
Cutting lane length [m] 500
Cutting width [m] 4
Square length [m] 6
sine-equation y=A*sin(bx+t)
A Amplitude
b Period
t Phase
Sine-Area Equation Area=Cutting lane length/Period length*(∫sin(x)dx/π)*A*half-period length
Dilution Eqaution Dilution/(Dilution+Seam volume)
Recovery Equation (Seam volume-Loss)/Seam volume
Loss Equation 1-(Seam volume-Loss)/Seam volume
Thin partings layer
Desired partings layer
RECOMMENDATIONS
28
Establish a site based Continuous Improvement Team (Maintenance, Production and Technical Services) to optimise performance
Continued data collection and analysis across all seams and conditions
Increased detailed information on rock mass properties highlighted as advantageous
Re-assess of Surface Miner performance to identify improvements due to advanced operator skills and experience (including machine configuration)
Further Study to integrate Surface Miner performance with CHPP recoveries
Potential benefits to be gained form central scheduling of Coal and Parting mining
29
Thank you.
Questions?