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Open Cut                                          reports

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research. We have supported work on an automated swing loading system for electric shovels, the science of rehabilitation and minimising mining impacts on neighbouring communities.


Maintenance & Equipment (44 Reports)

AC Motor Duty Meter For Excavating Machines: Feasibility Study

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C2104001/10/2013
Author: Galina Mirzaeva | The University of Newcastle

The Australian mining industry has started to adopt AC-driven electrical excavators, draglines and electric rope shovels. This transition is expected to continue and possibly accelerate, necessitating development of condition monitoring tools for AC machines in digging applications.

 ....  read more

 

AC Motor Duty Meter for excavating machines: Part 2 (prototype)

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C2403506/07/2016
Author: Galina Mirzaeva | The University of Newcastle

Australian mining industry is adopting AC motors with variable speed drives in various applications, including shuttle cars, continuous miners, shearers, as well as excavating machines, such as draglines and electric rope shovels. This transition is expected to continue and possibly accelerate, ....  read more

 

Advanced Signal Processing Tools for ShafTest

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C1202911/02/2005
Author: Adam Van Dyck, Heath Raftery, Guy Cotterill | CCI Pope

The SHAFTEST system utilizes a novel approach for the collection and presentation of ultrasonic shaft defect information, by which the normally complex task of monitoring the condition of large shafts and pins is simplified. The collection and recording of results are more accurate and ....  read more

 

Alternative Rope Materials for Dragline Application

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C2002628/03/2012
Author: Olaf Rutgrink | AMOG

This research study focuses on dragline ropes and the feasibility of substituting steel wire ropes with light weight, high performance synthetic fibre ropes.

 

By conducting this study into alternative rope materials significant areas of benefit have been identified for existing ....  read more

 

An Improved System for Dragline Rope Condition Monitoring

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C1803123/07/2013
Author: Erika Margetson, Adam VanDyck | Bureau Veritas Asset Integrity and Reliability Services

In stage one of this project it was demonstrated that it is feasible to use magnetostrictive transducer technologies to generate ultrasonic energy in wire ropes of up to 77mm in diameter and for this energy to be transmitted through the rope and socketing assembly.  The report on stage one ....  read more

 

Application of Environmentally Friendly Lubricants to Open Cut Mining Machines

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C601301/05/1999
Author: Will Scott, Keith Sherwood | QUT

New lubrication specifications are needed to improve the quality of lubricants used in the mining industry.  The mining industry spends more than $20 million a year on lubricants, however, lubrication specifications for machinery are inadequate. ....  read more

 

Application of StressVision Technology to Dragline Booms

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C1603221/01/2009
Author: Adam Van Dyck | Bureau Veritas Asset Integrity and Reliability Services Pty Ltd

Dragline Booms are commonly cited as one of the highest risk assemblies in open cut mining operations. Most operations incorporate a rigorous NDT regime for dragline booms to ensure that risk of in-service boom failure is properly managed.

This project aims to add value to existing NDT ....  read more

 

Bucket Imaging During Rope Shovel Operations

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C1304705/08/2005
Author: Eleonora Widzyk-Capehart, Graham Brooker, Ross Hennessy, Craig Lobsey, Allison McDonald | CRCMining

Bucket fillability in open cut mining operations has a major influence on the productivity of electric rope shovels. The characteristics of bucket filling can be described in terms of the amount and distribution of material in the bucket and the ease of the digging operation. The enhanced ....  read more

 

Chronic Problem Areas, Repair Quality and Improved Repairs for Dragline Structurals

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C1105201/11/2003
Author: Daya Dayawansa, Brian Kerezsi, Gerard Chitty, John Price, Henry Bartoseiwicz | MTI, Monash University

The chronic failures and repairs of field plant structurals have been investigated with a particular emphasis on BE1370 and Marion dragline structurals. The investigation steps included:

  • Review of history of structural failures, their classification and mapping
 ....  read more

 

Collision Control and Avoidance for Electric Mining Shovels

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C1503801/04/2007
Author: Ross McAree, PM Siegrist | CRCMining

This report details the development and demonstration of a collision control technology for P&H-class mining shovels that minimizes the frequency and severity of dipper collisions between the bucket, crawler tracks and floor. The work was funded by ACARP as project C15038.

 ....  read more

 

Condition Monitoring & Predictive Maintenance Using Artificial Intelligence Technologies

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C2603123/05/2018
Author: Richard Marshall | Endellion Technology

The main objective of this project was to demonstrate how subsets of Artificial Intelligence technologies can play a role in reducing the time and cost of processing mine site condition monitoring data, and increasing the number of corrective actions being deployed to the mining fleet to ....  read more

 

DC Motor Duty Meter

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C1603007/04/2017
Author: Galina Mirzaeva | University of Newcastle

Compared to other machines, DC machines are relatively complex, since they require a commutator to mechanically rectify large armature currents. This mechanical commutation is inherently a source of maintenance and lost time. However, the robustness and simplicity of control of DC machines, ....  read more

 

Demonstration of a Dragline Boom Strengthened With Pre-impregnated Composites

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C1702824/04/2009
Author: Guillaume Bunel | Industrial Catalyst Composites Mining

Fatigue cracking in structural members is one of the primary causes of unscheduled downtime in mining equipment. The boom-mast structural system of draglines is vulnerable to fatigue failures. In order to maintain or improve operational reliability and availability throughout the service life ....  read more

 

Development of a Centre Loading Blade

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C1406021/05/2008
Author: David Hall | Yardhurst

The objective of this project was to evaluate the concept of using a spade nosed dozer blade in dozer push applications. The research was undertaken in trials working alongside Caterpillar D11R Carry Blades.  The research showed that the blade had increased fill capacities, reduced load ....  read more

 

Development of a Smart Condition Monitoring Sensor System for Variable Speed Machinery

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C1600721/09/2017
Author: Mingfei Lou | Vipac Engineers & Scientists

The objective of this project was is to design and develop a wireless 'smart' condition monitoring sensor system for variable speed machinery.   This system includes four parts, A Smart Sensor, A Transceiver, PC and A Communication Module. The smart Sensor automatically ....  read more

 

Development of a Smart, Cheap, Autonomous Condition Monitoring Sensor

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C1003801/05/2002
Author: Mingfei Luo | Vipac

The objective of this project was to design, develop and demonstrate a 'smart' autonomous self-contained sensor, which does not require external cabling.

First stage, this Smart Sensor would be suited to ....  read more

 

Development of a Smart, Cheap, Autonomous Condition Monitoring Sensor System: Stage 2

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C1202830/06/2005
Author: Mingfei Lou | Vipac Engineers & Scientists

The objective of this project is to design and develop a ?smart' autonomous condition monitoring sensor system, which does not require external cabling .

This Smart Sensor system can automatically detect machine conditions using a completely selfcontained wireless machine ....  read more

 

Development Of Heavy Maintenance Manipulator For Dragline Jewellery Repair

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C2102701/02/2014
Author: Peter Milani, John Billingsley | University of Southern Queensland

The project's objective was to develop a tele-operated manipulator prototype, in order to separate workers from the hazards of heavy maintenance, in particular, dragline jewellery maintenance. Dragline jewellery maintenance presents a high level of HSEC risk to maintenance personnel. ....  read more

 

Dragline Dutymeter

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C903401/03/2003
Author: Paul Meehan, Zhuan Guan, Hal Gurgenci | CMTE

The aim of the project was to develop, build and demonstrate an on-line Dragline Duty Monitor (Dragline Dutymeter) prototype to continuously monitor the operation and log the incremental damage on the machine caused by present operating practices and the current operating regime.

The ....  read more

 

Dragline Machine House Cooling and Dust Control

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C1503022/09/2017
Author: Bruce Manser, Nigel Maxwell | BMT WMB

This study has led to the development of a computerised method whereby the efficacy of the ventilation system on draglines can be evaluated by determining whether there is adequate air movement throughout the machine house to remove the heat generated by the drives and MG sets. This approach ....  read more

 

Dragline Machine House Dust Control

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C1703422/09/2017
Author: Bruce Manser, Mike Costello | BMT WBM Pty Ltd

A study has been undertaken into the performance of dust filtration systems on draglines to establish the pros and cons of each system in relation to intake air configurations, fan and motor arrangements, dust filtration elements and scavenge system layouts.

As a result of the study, ....  read more

 

Dragline Rope Life Extension

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C1204601/05/2005
Author: Daya Dayawansa, Fidelis Marshiri, Mahinda Juruppu, Henry Bartosiewicz | MTI, Monash University

A detailed analysis conducted by MTI in 2002 on dragline maintenance costs identified dragline ropes, including suspension, IBS, drag, hoist and dump ropes, to be a major driver of maintenance costs. These account for 10-15% of the total maintenance costs, and amounts to ~$300K per annum ....  read more

 

Dragline/Shovel Bucket Teeth Retainer System

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C601201/02/1998
Author: Rodney Clarke | Keech Castings Australia

Current above ground mining practices in open cut / strip mining requires the topsoil or 'over-burden to be removed so as to provide easy access to the target material ie coal and ore. Over-burden can be removed by numerous methods, but is predominantly performed by the walking draglines ....  read more

 

DynaCut Fundamental Development and Scalability Testing

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C2504101/06/2018
Author: Dihon Tadic, Joji Quidim, Isaac Dzakpata | Mining3

The primary aim of this project was to validate the performance of the DynaCut rock cutting technology in representative overburden materials, to de-risk further work towards an up-scaled high capacity overburden mining system. A secondary component aimed to investigate new mining approaches ....  read more

 

Getting the Most Out of Current Dragline Booms Safely

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C1204701/06/2005
Author: Daya Dayawansa, Brian Kerezwsi, Gerard Chitty | MTI, Monash University

Investigations conducted on dragline boom structures by MTI have shown that there has been a lack of clear understanding of the main parameters affecting the strength and loading of this structural system. The loading and design criteria used for the original design of the structures ....  read more

 

In-situ Inspection of Dragline Boom Suspension Ropes

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C1303929/08/2005
Author: Roger Metcalfe, Stephen Allen, Kelvin Card | CCI Pope

Our objective during this project was to develop a procedure that optimised radiographic image quality for the assessment of internal wire fractures within practical time constraints. It was also hoped that a determination of the likely uncertainty of assessment would be obtained to ....  read more

 

Investigate Swing Shaft and Pinion Failures on Draglines

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C1203520/10/2003
Author: Bruce Manser | WBM

This report presents the findings of a study conducted as ACARP Project Number C12035, which was aimed at investigating swing shaft failures on draglines with a view to developing some specific proposals for ameliorative measures.

A large proportion of the Australian ....  read more

 

Life Extension and Reliability Improvement of Large Electric Mining Shovels

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C1304401/02/2008
Author: Gerard Chitty, Tony Carpinteri, Gary Cassidy, Tom Rucinski, Scott Randall, Osvoldo Cortes | MTI, Monash University

Electric shovels are the primary production machine for many mine sites. They offer mine operators relatively low-cost production and a much higher degree of mobility than draglines.  The industry monitors nominated the P&H XPB shovel at Goonyella Riverside (GYRS) mine for the ....  read more

 

Minimal Perception Requirements to Support Effective Remote Control of Bulldozers

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C2002101/03/2013
Author: John Dudley, Jonathan Aw and Ross McAree | CRCMining

Bulldozers often work in hazardous environments. Teleoperation provides a viable means for enabling operators to perform work without being directly exposed to the hazards of these environments. The benefits of utilising teleoperated bulldozers in coal stockpile management tasks, for example, ....  read more

 

Mining Tyre Integrity Monitoring

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C2503401/02/2018
Author: Garry Einicke, Jim Callow | CSIRO, BMT WBM

Driving mine trucks with underinflated and overloaded tyres subjects the steel cords within the tyre walls to cyclic stress and causes them to fatigue. Reinflating such damaged tyres can lead to what is termed a “zipper” failure. This is a rapid progressive failure of the cords and ....  read more

 

Online Monitoring of Lubrication Oil Contamination and Degradation

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C903701/04/2002
Author: Shengen Hu | CSIRO Energy Technology

Issues
The repairs and downtime caused by oil-related engine or other machine failures represent about 30-50% of the operational cost in the Australian mining industry. The reliable monitoring of the effectiveness of working lubrication oils and the condition of lubricant wetted ....  read more

 

Online Monitoring of Wear and Lubrication Oil Contamination Using a Novel Detector - Field Trials

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C1203705/11/2008
Author: Shenggen Hu, Robert Dixon, Ian Hutchinson, Adrian Burger | CSIRO Energy Technology

Reliable monitoring of the effectiveness of working lubrication oils and the condition of lubricant wetted components is crucial to preventing oil related failures of mining equipment.  However, current diagnostic tests based on Scheduled Oil Sampling and used oil analysis cannot promptly ....  read more

 

Optimisation of Structural Performance of Trucks

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C1304301/03/2006
Author: Gerard Chitty, Priyath Amaratunga, Alan Hon, Brian Kerezsi, Daya Dayawansa, Hui Jiao, Henry Bartosiewicz, Osvaldo Cortes, Tom Rucinski | MTI, Monash University

The majority of truck and shovel operations in the Australian coal industry use Caterpillar 789, 793 or Komatsu 830, 930 trucks. These trucks are at various stages of their service life and many of them have experienced fatigue cracking at several locations after a relatively short ....  read more

 

Performance of Dragline Revolving Frame and Tub Structures at 125% RSL

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C1504301/02/2008
Author: Daya Dayawansa, Tony Carpinteri, Henry Bartosiewicz | MTI, Monash University

With mine operators moving to re-rate their draglines to 125% RSL, any structural problems are likely to be exagerated and need investigation. This project sought to evaluate higher loads on the dragline revolving frame and tub structure and develop responsive structural improvements and ....  read more

 

Quarter Scale Synthetic Rope Testing For Dragline Applications

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C2202221/01/2015
Author: Nick D'Arcy-Evans, Olaf Rutgrink | AMOG

This report presents the findings of an ACARP research study that continues the investigation, from ACARP project C20026, into the potential of synthetic ropes to provide productivity and safety improvements to mining dragline excavators.

 

This study focused on testing a ....  read more

 

Reinforcement and Strengthening of Mining Structures with Pre-Impregnated Composites

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C1602801/06/2008
Author: Daya Dayawansa, Jason LeCoultre | Industrial Catalyst Composites Pty Ltd, Maintenance Technology Institute

This project covered the preliminary investigation into using Sitecured Fibre Reinforced Plastics (FRP's) for strengthening structural members in dragline booms, more particularly tubular members in boom and mast structural system.  Sitecure is a process developed by ICD to cure the ....  read more

 

ShafTest System

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C700501/06/2001
Author: Guy Cotterill, Adam Van Dyke, John Perceval | CW Pope & Associates

This report details the advances made by CW Pope in their determination to develop a system that enabled the monitoring of crack propogation in large shafts.

Shafts and pins are vital components of large items of coal production equipment including:

  • Draglines
 ....  read more

 

Shovel Load Assist Project

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C1603101/07/2016
Author: John Dudley and Ross McAree | CRCMining

This project, also known as SLAP, commenced in 2007 with the vision to develop an autonomous mining shovel that was able to:

· automatically dig material without requiring human involvement;

· load this material into trucks in such a way that the tray capacity is fully ....  read more

 

Stage Two Report: 11 KV Cable Coupler Systems and Stage One Report: 3.3kV 425 Amp Coupler System

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C2003019/03/2018
Author: Stephen Williams | Connec

STAGE 2 REPORT - 11 KV Cable Coupler Systems

There has been insufficient product innovation over the last 25 years to improve mining cable connectors in order to reduce the incidence of cable arcing incidents. These incidents have the capacity to ignite coal dust or flammable ....  read more

 

Stress Relieving and Pre-Fabricated Nodes for BE Dragline Booms

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C1304501/08/2005
Author: Daya Dayawansa, Brian Kerezsi, John Price, Ana Paradowska | MTI, Monash University

A previous ACARP project (C11052) identified weld quality and residual stresses as two major factors contributing to poor fatigue life of BE boom clusters compared to Marion clusters. The traditional fabrication methods that have been used for decades without much improvement are ....  read more

 

Structural Integrity Evaluation and Crack Detection in Booms with Acoustic Emission

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C802901/10/2001
Author: Brian Wood, Robert Harris, Jason Porter | Metacoustics

Metacoustics has been involved in a number of research projects jointly funded by Metacoustics (71.5%) and ACARP (28.5%) over the past 6 years. One project has been the adaptation of acoustic emission techniques for use in monitoring the integrity of dragline booms. Now that the research ....  read more

 

System for Dragline Rope Condition Monitoring

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C1503121/08/2007
Author: Adam Van Dyck, Heath Raftery | CCI Pope

As a successor to the encouraging results of an earlier project (C13039), the purpose of this project was to confirm and formalise the possibility of producing and measuring vibrations in large wire ropes in order to form an assessment of the condition of the wires within that rope, ....  read more

 

Voltage Stabilisation Using Power Electronics.

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C2103030/08/2014
Author: David Gay, Robert Betz and Terrence Summers | University of Newcastle, CRCMining

ACARP project C21030 looked at the applicability of using power electronics for voltage stabilisation in open cut and underground coal mining. The primary outcome has been the analysis of voltage stability issues and the systematic validation of the capability of a Static Compensator (STATCOM) ....  read more

 

Wear Particle Characterisation - Auto Ident. of Wear & Contamination Particles Found in Lubrication Systems

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C305001/10/1997
Author: Elliott Duff | CMTE

Microscopic examination of wear debris for machine condition monitoring was first introduced in the 70's It is reliable but, for the human analyst, can become a tedious and time consuming task. This has limited its widespread usage. In 1994, CMTE ....  read more

 

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C21013Improving Cavity Prediction On Longwall Faces Through A Combination Of Reliable Convergence, Canopy Attitude And Leg Pressure Monitoring

Most Australian coal mines have shield leg pressure monitoring in real t...

C24014Distributed Acoustic Conveyor Monitoring

CRC Mining have investigated the application of fibre optic Distribu...

C25054Distributed Acoustic Conveyor Monitoring - Phase 2

This project is phase 2 of the distributed acoustic sensing project ...

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C23053A Study Of Sustainability And Profitability Of Grazing On Mine Rehabilitated Land In The Upper Hunter NSW

This study was initiated by the Upper Hunter Mining Dialogue (UHMD) ...

C25035Coal Subsurface Mapping For Open Cut Selective Mining

A reliable coal seam sensing system is required to improve the produ...

C23025Coal Pit Lake Closure By River Flow Through: Risks And Opportunities

In 2011, the river diversion channel around Lake Kepwari, a former o...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C26007 Revised Dustiness And DEM Test Method (Update Of AS4156.6) Part 2:Preparation

In 2015 project C23054 investigated and reviewed the Australian Stan...

C22033Advanced Control And Optimisation Of DMC Operation

The objective of this project was to develop, implement and demonstr...

C24045Adaptation Of Coal Grain Analysis To Improve Flotation Yield Estimation

Yield estimation from resource data is notoriously difficult. Facto...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C25045Stage Two - Assessment Of In Situ High-Temperature Strength Of Cokes

Stage I of this project established a reliable and repeatable proces...

C25044Trace Elements In Coal; Status Of Test Methods In Use And Their Applicability

 STAGE 1 REPORT

The key objectives of this stage...

C25042Mechanistic Model Of Coke Development In A Coke Oven Situation

The standard approach to evaluate the potential of coals or blends t...

Technical Market Support

Mine Site Greenhouse Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C24061Proof-Of-Concept Photocatalytic Destruction Of Methane For Coal Mining Fugitive Emissions Abatement

Australia's fugitive emissions in 2015 were 41 Mt CO2-e (representin...

C23052Novel Stone Dust Looping Process For Ventilation Air Methane Abatement - Phase 3

This multi‐phase project is concerned with the mitigation of m...

C19054VAM Enrichment With A Two-Stage Adsorption Process

Treatment of ventilation air methane (VAM) with cost-effective technolog...

Mine Site Greenhouse Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC