Yallourn Mining

The Yallourn mine in action

Description of Works

Following the post-tender phase of the Morwell River Diversion in 2000, TRU Energy engaged RTL in an alliance to investigate innovative ways to mine brown coal, to replace the fleet of aging 1950's style bucket wheel dredgers and to prepare a five-year mine plan.

An extensive feasibility study was undertaken, with RTL proposing the introduction of new mining techniques using Caterpillar D11R dozers fitted with state-of-the-art Global Positioning System (GPS) technology, pushing to feeder breakers. RTL found that the feeder/breaker system would meet Yallourn Energy's objectives, ensuring coal mining at a rate and cost that would improve its competitiveness in the National Energy Market.

As part of this process RTL worked closely with Yallourn Energy and suppliers Caterpillar and McLanahan Corporation to design a system that has the capacity to cost effectively and efficiently transfer coal. Trials of the first dozer/feeder breaker system began on site in October 2001.  RTL has refined the technology ensure the production targets outlined in the five-year mine plan prepared for Yallourn Energy are met.

Following the success of the dozer/feeder breaker trials, RTL secured a five-year alliance contract to manage and operate Yallourn Energy's open cut brown coal mine using this leading edge technology.

Under this contract RTL is responsible for implementing innovative dozer/feeder breaker mining technology that will lower Yallourn Energy's ongoing operations and capital costs while maintaining 100 per cent coal supply reliability.

D11R Dozer / Feeder Breaker System

The new flexible mining technology consists of a Caterpillar designed 800 horsepower (634 kW) D11R dozer, weighing 120 tonnes and a feeder breaker.

The all weather D11R dozer has a 94 cubic metre coal blade believed to be the largest brown coal blade in the world. At 3.63m high the specially designed blade is capable of moving 70 tonnes of high moisture coal in a single push.

The feeder breaker has been designed by McLanahan Corporation and consists of a rotating feeder tray and a breaker which breaks up the coal. After sizing, the coal passes to a hopper which drops the coal onto the conveyor, which then transports the coal to the power station coal bunkers, several kilometres away.

Each feeder breaker has the peak capacity to process up to 3,000 tonnes of brown coal per hour, significantly exceeding the power station's requirements of 2,400 tonnes per hour.

RTL will have four D11R dozers and four feeder breakers in the mining fleet, with any two dozer / feeder breaker units operating at any one time, while remaining units are being maintained and repositioned for further work.

Dozer operators utilise a global positioning system (GPS), and on-board computer and telemetry to guide the D11R dozer's every move in the mine. The GPS system enables ease of navigation to the feeder breaker and the construction of smooth benches and ramps to design specifications. These constructions are completed to design with no re-work and surveying staking being necessary. The volume of coal excavated can be precisely calculated by hour, shift and operator.