Automation @ Northparkes

What we will cover today:

1 2 3 4 5 Vision Context Automation trials building the case for LHD automation Implementation pathways The way forward

Who we are!

Unincorporated JV Rio Tinto (80% & manager) and Sumitomo Group (20%) 230 staff and 500 contractors Copper and gold producer Total production to the end of 2009 715,000 tonnes Cu 985,000 ounces Au

1,630 ha of mine lease within 5,670 ha of agricultural land (+ 2,102 ha nearby) Current Life of Mine is 2024

Site Overview
TSF1

E27 E22
TSF2

E48

E26
2 km

Operations based on block-cave mining

First block cave in Australia: E26 Lift 1 commissioned in 1997 E26 L2 in 2004 and E48 L1 in 2010 5.5 - 6.0Mtpa production rate Industry-leading mine productivity (t/manhour; t/m2 footprint)

S
Hoisting Shaft

N
E48
L1 L1
Access Decline

E26
L1
9800 Level Main Decline

L2
9450 Level

L2N
Conveyor Declines

800m

Vision A fully autonomous mine

Context:
The rock factory: safe and productive A highly productive extraction level layout Automating crushers, conveyors, transfers and hoists is existing technology An autonomous loader fleet is our next goal

An autonomous production fleet:

Operators removed from hazardous environment Equipment able to operate 24/7 (during shift-change and blast clearance times) Equipment operating within specification 100% of time
6

The Northparkes mining concept continuous, automated & minimal intervention

400t primary feed bin

4-Way Tipple

BK Crusher

400t ore bin

Hoist to surface

1050tph conveyor

The Safety Proposition

Removing LHD operators from a hazardous environment: Wall collisions
3-4 LHDs to achieve 18ktpd Each LHD operator will load 300+ buckets in a 12 hour shift 23kph top speed (3.5m wide machine in a 4.5m wide drive)

Multiple equipment interactions Dust Uncontrolled draw point flows Rock falls Whole body vibration

History of LHD automation extension of teleremote loading

NPM joined AMIRA Autonomous Underground Mining Vehicle project First trial in SW quadrant of Lift 1 mine 1 Design of compliant barrier systems

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2 Second production trial at Lift 2 mine E48 Project commences construction E48 Project scope varied to include autonomous LHDs Full implementation of autonomous loaders on E48 Production level

Concept to Production
Concept
Develop Scope: Network Barriers LHD interface

Conduct Risk Assessment (each aspect) Handover to production: Risk register Operating procedures Maintenance procedures Documentation Training systems

Commission and Test: Proof of concept Build business case

Trials based on a mixture of systems

Sandvik 450E electric LHD 3rd party automation system (DAS)

Operator located in surface control room

Scanning ladars allows machine to monitor its location Operator is located remotely in the surface control room Operator loads in tele-remote Tramming and tipping functions automated (learnt) Front and rear cameras provide visual control for operator Audio feedback to allow operator to feel loading process

Man-Machine Interface Tactical Screen

Man-Machine Interface - Strategic

Trial 1: Proof of concept

Aims: Confirm reliability of navigation system Confirm ability to operate in the underground environment

Lessons Learned: Navigation system able to accurately control the location of the LHD Automated haulage and dump cycle successfully tested Operator comfortable with teleremote load function

Issues raised: Reliability (sensitivity) of barrier system Barrier system required to comply with AS61508 On-board processing capacity limits LHD speed to 12-13kph

Barrier system is THE critical interface for autonomous mining equipment

Barrier system must contain the LHD under all circumstances Prevent access of unauthorised personal and trips the LHD in the event the area is accessed Comply with the requirements of AS 61508 to achieve an appropriate level of safety Typical Barrier Setup

Trial 2: Building the business case

Aims: Test the system as a front line production tool against manual loaders Evaluate system availability, productivity factors, maintenance costs

Trial design: Automated loader operating in central two extraction drives on Lift 2 extraction level LHD running in 3rd gear Automated loader responsible for 25% of mine production Barrier system compliant with AS 61508 9450 L Extraction Level

Crusher

ED3 ED4

Trial 2 didnt start well

Problems encountered: Steering bias LHD driving into bull noses (cracking loader boom) Unplanned movements relating to joystick feedback Whipping trailing cables tripping light barriers Loss of Rio Tinto network interface Inadequate operator training Initial assessment: Insufficient spare parts Automation system NOT Lack of OEM automation specialist coverage operationally ready,
LHD2 PRODUCTION TRIAL METRICS
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
W e W ek e 1 W ek e 2 W ek e 3 W ek e 4 W ek e 5 W ek e 6 W ek e 7 W ek W eek 8 e W ek 9 e 1 W ek 0 e 1 W ek 1 ee 12 k 13

BUT, glimmers of hope!

1600 1400 1200 1000 800 600 400 200 0

Production metrics:
mins Availability Utilisation MTBF

Max 24hr production of 414 buckets vs 382 buckets/24 hr period in Week 11 Max 12hr production of 212 buckets vs 207 buckets/12 hr period in Week 13

Trial stopped and issues addressed

Upgraded automation equipment and software Additional offsite OEM technical support 24/7 Upgraded communications between site and OEM offices Additional training for both maintenance and operations personnel

Second stage of trial was successful

Results achieved during 2006:
No additional wall contacts 15% reduction in maintenance costs reduced gearbox, tyre and cable damage Peak demonstrated production rate 4,973 t/24 hrs 78% system availability (8 mths) vs 85.9% (manual) Auto LHD operating up to 22.5hrs/day vs 17hrs/day manual

Required* Production Rate 221tph

Trial Average (2nd Stage)

Availability & Utilisation Analysis

600 500 400 Hours 300 200 100 0
S ep te m be r LH D 2 O ct ob er L M H D an 2 ua A ve lF ra le et ge Y TD Av er ag e LH D 2 LH D 2 A ug us t Ju ne A pr il M ay Ju ly

100.0% 90.0% 80.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% Avail. & Util. 70.0%

206.4tph Manual LHD restricted to 3rd gear 204.5tph

LH D 2

LH D 2

LH D 2

LH D 2

Machine Run Hours

Availability

Utilisation

* Assuming 4 LHDs to achieve 17ktpd

Forks in the road

We have demonstrated operability of the automation system achieving comparable results to manually operated machines!

Do we continue to test and develop the MineGem automation system? Improve reliability of the system 4th gear function (speed) Traffic management (multiple units interacting) How does automation fit with our future plans? At Northparkes (E48 Project)? Within Rio Tinto? What are the alternatives?

Options review undertaken through Rio Tinto Underground OEM Directorate

Northparkes requirements

Available systems
Sandviks AutoMine Caterpillars MineGem (DAS) Atlas Copco

REVIEW

Other company implementations

De Beers (Finsch) Codelco (El Teniente) Freeport (Grasberg)

Rio Tintos requirements

Automated LHDs are key enabler for Rio Tintos UG mining ambitions
Final Pit Grasberg Pit

Grasberg Underground Kucing Liar

Big Gossan

Dom

Ertsberg East Skarn System

ESZ

DOZ MLZ Deep MLZ

re

Two key alternatives at the time

De Beers: AutoMine on Sandvik truck

Fully integrated

OEM LHDautomation system

Codelco: AutoMine on Sandvik LHD

Freeport: Hybrid - LHD + party automation system 3rd MineGem on Caterpillar LHD

Northparkes: MineGem on Sandvik LHD

Northparkes decided to change to Sandviks AutoMine system based on LH514Es

Functional Specification: 1. 2. 3. 4. 5. 6. No speed limitation Full traffic management Barrier systems compliant with AS61508 Tyre Management (TKPH Calcs) Integrated production planning & accounting system Remote support Fully integrated

OEM LHD
automation system

Additional: 7. 8. Support both electric and diesel LHDs Support very large complex mass mining operations

E48 Automation

Complete turn key package with Sandvik 5 x AutoMine-ready LHDs delivered by Q3 2010 Control room upgrade Automation install to commence in Sep 2010 with Zone 1 commissioning in Feb 2011 Completion in Jun 2011

Typical ACS Barrier Arrangement

E48 Automation maximum flexibility

Barrier design ensures maximum flexibility for production teams
E48 AutoMine Hardware Layout

Automation is an integrated production system

Cave Management System

AutoMine
Daily draw order Extraction tunnel priorities Production scheduling input Manual production list modifications

Daily drawpoint tons Progressive drawpoint tons Current drawpoint statuses Cycle time data Drawpoint status history

Updated drawpoint status

Operating Manager

Production schedule Production reports Manual production list Auto mission list Updated drawpoint statuses Fleet status Drawpoint status

Production Control System

Fleet status Production area statuses Production data Cycle time data Mission statuses Production order statuses

Secondary Breaking Crew

Drawpoint status & history reports

Operator Station

Mission Control System

Missions (drive orders) Auto LHD/truck location Measurements & statuses LHD bucket weights

SCADA (Citect)

System Operator

Crusher bin level Crusher operational status Crusher bin withdrawal rate U/Cut pass levels Rockbreaker status

Tele-operation commands

Auto LHD/Truck

E48 + LHD automation not the end of the line

Automation systems a key enabler for Northparkes next stage of mining Future innovation: LHD loading, secondary breaking, hang-up drilling

S
E26 GRP314
Hoisting Shaft
Lift 1 Not mined Lift 1

N
E48
Concentrator

E22

Lift 1

9800L
Lift 2/2N

9450L
Lift 3 Lift 1

n or Decli Convey

es

Monzonite Stock
Lift 2

9100L Step Change Infrastructure 1 kilometre

Cross Section

Automation @ Northparkes
VISION

+
EXPERIMENTATION

+
PERSEVERANCE

INNOVATION