A breakthrough underground excavation guard at Aquila Mine has been recognised nationally for setting a new safety and productivity benchmark for the resources sector.
The new system — dubbed “The Armadillo” because of its unique shield design and first-of-its-kind industry adaptability in Bowen Basin coal mines — has been named a finalist in the Innovative Mining Solution category at the 2025 Prospect Awards.
Aquila Mine, based near Middlemount, is one of Anglo American’s five steelmaking coal mines in Central Queensland.
Developed in partnership with the Jet Group in Mackay, The Armadillo evolved when the mine turned a complex engineering challenge into an opportunity to innovate.
The Aquila team needed to retrofit a conveyor dewatering transfer installation underground but had several constraints, including low seam height and the need to keep the conveyor running for production continuity.
Aquila Mine General Manager Braedon Smith said a novel solution to protect the conveyor while allowing shot firing excavation overhead needed to be developed.
He said the resulting mobile conveyor excavation guard had redefined how mining operations could safely excavate above live infrastructure without compromising production or safety.
The Armadillo integrates rolling covers, a pivoting tipping platform, hydraulic controls and a custom rail system – all designed to shield the conveyor while enabling safe excavation and debris removal.
“The Armadillo has delivered significant downtime reductions, zero injuries and a blueprint for safer underground excavation across the industry,” Mr Smith said.
He said the system was trialled and refined through rigorous risk assessments, 3D tunnel scans for precision, and stakeholder workshops.
“The transferability of this first-of-its-kind system make scaling the innovation and adapting to site specific needs a value-add development for the industry,” he said.
“The Armadillo is already being considered for future applications across the mine site and other Anglo American mining operations in the Bowen Basin. Its modular design and transferability make it a standout for sites facing similar excavation challenges.”
Anglo American Australia CEO Dan van der Westhuizen said this project demonstrated the value of collaborative partnerships within the industry to achieve an innovative outcome.
“We are proud to be finalists but, more importantly, we’re proud of the collaboration and out-of-the-box thinking that made this solution possible,” Mr van der Westhuizen said.
“It’s a testament to what is achievable when safety, engineering and production teams come together."
Key Armadillo features include:
• Rolling covers for flexible protection during blasting
• A tipping platform to safely transfer spoil to designated zones
• A bolting deck that doubles as a secondary safety layer
• Hydraulic cylinders for precise, low-risk tipping control
• Survey-guided installation for pinpoint accuracy
Aquila Mine previously won the Outstanding Mine Performance category in 2023 for technology advancements to minimise human presence underground and was finalist in the Excellence in Mine Safety category at the same national awards.
Anglo American was also named a finalist in the 2024 Prospect Awards for the Excellence in Mine Safety and Safety Advocate of the Year categories.
The 2025 awards will be held in Adelaide on September 24.
In Australia, Anglo American has five steelmaking coal mines in Queensland’s Bowen Basin, along with additional joint venture interests in steelmaking coal and manganese, and base metals exploration projects in Queensland.
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