BHP’s 10 years of ABCs: Autonomous haulage, blasting and Caval Ridge

BHP’s (ASX: BHP) Caval Ridge is one of five metallurgical coal mines in Queensland’s Bowen Basin, about 188km south-west of Mackay, and is a 50:50 joint venture between BHP and Mitsubishi Development (BHP Mitsubishi Alliance, or BMA).

This year celebrates 10 years in operation. The greenfield project, which is the largest greenfield metallurgical coal-mining complex in Australia, covers an area of about 6,800ha and comprises two coal pits – Horse Pit and Heyford Pit.

The former deposit lies north of Peak Downs Highway and the latter north of Harrow Creek.

Caval Ridge is one of five mines operated by BMA in the Bowen Basin, with the other four being Goonyella Riverside, Broadmeadow, Peak Downs and Saraji.

The mine processes coal from the adjacent Peak Downs mine via an overland conveyor completed in 2018 and, in FY23, achieved an annual production of 9.36mt.

From the beginning Caval Ridge general manager Justin Doherty says the first coal produced at Caval Ridge mine was in March 2014, followed by consistent Peak Downs mine shuffle feed from July 2016.

“Coal from the Caval Ridge Southern Circuit commenced in October 2018, and in May 2021 the 1CVC was introduced,” he said.

“Previous to this, the mine was producing CVC and another thermal coal called CVT.

“The 1CVC product provides great flexibility as it can be sold on its own or mixed with other products to supplement and complement other premium hard coking coals produced by BMA.”

Having been designed to produce high-quality metallurgical coal, or coking coal, primarily used in steel making, there were some initial challenges in the beginning stages however the mine has evolved drastically since then.

“The geology of the mine has provided some challenges, including thin seams, which has presented some unique challenges to the Caval Ridge team during mining operations,” Mr Doherty said.

“However, Caval Ridge has evolved to be a critically important mine and production site operated by BMA and, in FY24, achieved an annual production of 6.5mt (on a 100% basis) of metallurgical coal which was exported to India and South East Asia, and other countries.”

Community support

Caval Ridge’s opening in 2014 marked the beginning of the mine’s role as a major player in BMA’s portfolio and was seen as a boost to the local economy in Queensland.

At the time, the mine’s production was expected to contribute significantly to Australia’s coal exports, reinforcing the country’s position as a leading global supplier of metallurgical coal.

“Over the years, BMA has invested in the Moranbah Aquatic Centre, and the Moranbah Regional Youth and Community Services Centre Upgrade,” Mr Doherty said, when asked about supporting the local community.

“An important commitment by BMA of $5m to the Issac Affordable Housing Trust has made a significant difference in the community and a range of green initiatives such as environmental programs with Moranbah schools.

“BMA has also been able to provide financial support to Moranbah District Support Services, C&K Childcare, Simply Sunshine Childcare, Gryphon Psychology and the BMA CQ Rescue Helicopter.”

Technological advancements

First coal production was seen in October 2014 – three months ahead of schedule – and was celebrated as a significant achievement as the mine was one of the largest new coal mining operations in the Bowen Basin at the time.

The quality of the coal produced at Caval Ridge was intended to meet the demands of global steel producers, with the first batches of coal quickly prepared for export to international markets, in particular Asia.

Seen as a major success, Caval Ridge’s first coal was a prominent step in ramping up operations.

Soon after, in 2018, Caval Ridge introduced Autonomous Haulage Systems (AHS) as part of BHP’s broader strategy to increase safety, efficiency and productivity across its operations.

Mr Doherty says that the mine is equipped with state-of-the-art technology that allows employees to work at their very best.

“All of our haul trucks are equipped with fatigue monitoring technology; our draglines, shovel and excavators are equipped with high precision GPS; and drones are utilised daily for aerial imagery and surveying,” he said.

“Recently, we implemented portable remote control (PRC) dozer technology at Caval Ridge.

“Our teams have completed four portable remote control dozer conversions, along with training of operators at the mine site, and the team is now delivering four operator control huts to allow for full implementation to be up and running by the end of the year.

“Our distinctive way of working through the BHP Operating System (BOS) empowers our people to bring the best of themselves to improve their work every day.

“Safety is at the heart of everything we do, and the health and safety of our people will always be our top priority.

“We are currently implementing portable remote control (PRC) dozer technology at Caval Ridge to improve safety and reduce exposure to potential falls, especially when working near an edge.”

A world record

In 2020, Caval Ridge set a significant production record, achieving its highest-ever production levels since the mine began operations.

Reports highlighted that the mine exceeded previous annual production targets, and attributed the success to operational efficiency with the successful integration of AHS and optimised mine planning.

Blast off

The year 2020 was also the year Caval Ridge broke a world record, setting a new benchmark for coal mining operations globally with the largest blast in metallurgical coal mining history that December.

The blast, which was a part of its regular mining operations, involved an incredible amount of explosives and covered an extensive area, making it the largest of its kind ever recorded.

For perspective, 4.7mm3 of overburden shifted in a blast fired with 2,194t of bulk explosives across 3,899 holes.

The blast was loaded over 14 days, involving engineers, schedulers and the E and F Blast crews.

It also involved a combination of four related blast patterns, using 8,144 detonators, a significant number never set before at the one time.

Electronic technology was used in the blast, seeing significant safety, efficiency and cost improvements with detonators fully programmable.

Each blast hole physically connected to the surface by a wire – meaning the system was less complicated and fully digitised – a higher fidelity of tie in to reduce misfire potential.

Living in the now

Today, Caval Ridge aims for the highest environmental standards at the site, with a total of 90ha of rehabilitation completed to-date at the mine.

The future is bright

As Caval Ridge celebrates 10 years of production this year, the mine site has a strong financial future ahead following successful milestones and delivering a high-quality coking coal to international markets.

Mr Doherty says the mine will continue to be a significant employer and an important part of BMA, providing metallurgical coal to be exported to India and Southeast Asia and other countries, delivering major economic benefits to the local region and to Australia.

“The Caval Ridge mine continues to be a member of the local community and will continue to give-back and support community projects,” he said.