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Highwall Mining Technology

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  • 1. HIGH WALL MINING TECHNOLOGY Venkat
  • 2. History
    • Based on 1980 USA/Netherlands design for low seam contour mining.
    • Superior Highwall Miners commenced production of current models in 1994.
    • 15 Acre production facility in Beckley – West Virginia USA
    • 34 Miners operating in the USA, 4 in Siberia early 2005
    • Committed to entering Indian market.
  • 3. Dimensions
    • Length base approx. 22 meters
    • Width base approx. 8.3 meters
    • Weight base approx. 160 tonnes
    • Length of push beams – 6 meters – 6 tonnes each
    • 50 push beams per miner
    • Max. force in: approx. 170 tonnes, out: approx. 350 tonnes.
  • 4. Cutterhead
    • Interchangeable, for seams 0.8 to 5.0 meters
    • Width 2.9 to 3.5 metres
    • Automatically following seam contour
  • 5. Push beams
    • Front loader loads into magazine
    • Every 6 meter new push beam is inserted by PTM
    • Operator checks latching and inserts lock pins
    • Augers connect by striker plates
  • 6. Reel and Chain
    • Power chain for
          • Electrical cables for cutter
          • Hydraulic lines for shear
          • Cooling water lines for cutter motors
          • Methane sensor cable
          • Control cable
    • Hoses protected by steel plates and links
    • Hose chain approximately 330 meters
    • Automatically unwinds/winds into/from channel on push beam
  • 7. Tracks
    • 4 Hydraulically powered tracks articulate 90 degrees for straight and cross travel
    • Circle mode for accurate heading
    • Each track 1 meter vertical movement for adjusting seam dip and floor contour
    • Turning of each track is achieved automatically
  • 8. Anchoring
  • 9. Controls
    • Operated from the cabin by touch screen technology
    • Automatic shearing, various options
    • Automatic sumping, various options
    • Straight holes due to rigid string in horizontal direction
    • Follows layers due to flexibility in vertical direction
    • Accurate heading is important to ensure parallel cuts
  • 10. Controls
  • 11. Mobility
    • Public road transport: Operational within three days excluding travelling time.
    • Optional: Machine movers for longer hauls, fully assembled
    • Example: During 9 months SHM-20 was moved to 7 different mining pits - some moves over 6 kilometers in distance
  • 12. WHERE THE TECHNOLOGY CAN BE APPLIED
    • Thin Seams
    • Beyond Strip Limit
    • Coal Blocked in Boundaries
      • Previously Augered Area’s
      • Spoils, Roads, Power Lines
      • Villages
  • 13. Methods of Mining
    • Contour Mining
    • Finished Open Cut Mining
    • Trench Mining
  • 14. Trench Mining
    • Trench mining application at Arch Coal’s Samples Mine
    • Underneath sandstone channel and spoils
    • Trench measures 700 meters in length and averages 45 meters in width
    • Multiple seam operation
  • 15. Production
    • Penetration 300 meters
    • Dip of up to 15 degrees
    • Monthly production typically around 100,000 tonnes
    • Operates with a 3 / 4 man crew
    • Up to 70% recovery, subject to
      • - Coal compression resistance
      • - Overburden load
      • - Seam height / Pillar stability
  • 16. Recovery Rate SHM vs Auger 300 m = 100% 150 m= 50% 60% 30% SHM 60% Auger 15% 4x SHM Auger
  • 17. THE STRENGTH OF TECHNOLOGY
    • No ash dilution
    • Wet coal
    • Very high up-time
    • Only crew of four
    • Stacking Pushbeams saves space
    • Narrow bench or trench
    • Free travelling
    • Quickly to relocate mine to mine
    • Less capital than underground
    • All spares on stock
    • Internationally Trained Operator & service crew
    • Short delivery times
  • 18.
    • APPROVAL OF TECHNOLOGY AND MINING METHODS FROM DGMS
    • SUPPLY OF EQUIPMENT
    • APPROVAL OF EQUIPMENT FROM DGMS
    • OPERATIONS
    • MAINTENANCE OF EQUIPMENTS
    • ENSURE PRODUCTION GUARANTEE
    • UNDERTAKE SCIENTIFIC STUDY TO ENHANCE % OF RECOVERY
    SCOPE OF WORK OF SHM
  • 19.
    • TO PROVIDE GEO-TECHNICAL & GEO-MECHANICAL DATA OF THE MINE
    • TO PROVIDE POWER SOURCE
    • TO PROVIDE THE BENCHES REQUIRED FOR HIGHWALL MINING
    • TO TRANSPORT COAL FROM COAL-FACE TO SIDING
    • TO ARRANGE FILLING MATERIALS
    • TO PROVIDE LAND AND SITE ACCESSABILITY
    SCOPE OF WORK OF OWNER
  • 20.
    • TO OBTAIN PERMISSION FROM DGMS
    • TO MAXIMISE % OF RECOVERY
    • TO DEVELOP ALTERNATIVE COST EFFECTIVE TECHNOLOGY FOR LONG TERM STABILITY SO FAR SUBSIDANCE IS CONCERNED
    • TO FORMULATE A MATHEMETICAL MODEL TAKING INTO CONSIDERATION OF PANEL WIDTH, PANEL BARRIER , SEAM THICKNESS, OB HEIGHT, & COAL STRENGTH.
    SCIENTIFIC STUDIES
  • 21.
    • COAL WHICH IS BLOCKED / LOST EITHER IN HIGHWALL OR BARRIERS CAN BE RECOVERED AT REASONABLE COST
    • MAXIMUM CONSERVATION OF COAL
    • EXTRACTION OF COAL @ 0.7 TO 0.8 MILLION TON PER YEAR CAN BE ACHIEVED IN ADDITION TO EXISTING PRODUCTION FOR ANOTHER 8 TO 10 YEARS
    • OPERATION OF MACHINE CAN BE PHASED WITHOUT OVERLAPPING EXISTING OPEN CUT OPERATION
    • EXTRA PROFIT PER YEAR WITHOUT ANY ADDITIONAL FINANCIAL INVESTMENT .
    WHAT BENEFIT THE TECHNOLOGY CAN BRING
  • 22.  
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  • 24.