The document provides an in-depth overview of shovels used in surface mining, highlighting their historical development, various classifications, and technical components, such as rope and electric shovels. It discusses the advantages of these machines, including high productivity, precision, and lower operational costs, as well as modern advancements like automation and electric power sources. Additionally, case studies illustrate the successful implementation of electric shovels in mining operations, along with challenges related to infrastructure and maintenance.

1. Shovels for Surface
Mining
Shovels are a game-changer in the mining industry, allowing for
efficient and careful excavation of earth. In this presentation, we'll
dive into the advantages and inner workings of these machines.
by Dr. Anupam Kher

2. Shovels for Surface Mining

3. Shovels for Surface Mining
Discontinuous/Cyclic Methods of Excavation, Loading and Transport
• Excavation and loading relates to excavating the bench material and
loading them onto the transporting equipment. However, in some cases
the excavator itself transports and dumps the bucket load (e.g. dragline,
scraper). This operation may be accomplished in cyclic/discontinuous
mode or in continuous mode.
• Like excavation and loading, transportation of the loaded material may also
be accomplished either in discontinuous/cyclic mode or in continuous
mode. In this operation, the transporting equipment transport the loaded
material to the respective destinations – coal/ore to coal depot/ore stock
pile, and overburden/waste to overburden/waste/spoil dumps.

4. Shovels for Surface Mining
Development of Shovels
• The shovel is one of the oldest types of excavating equipment. With time,
the machine grew in capacity, steam power was replaced by diesel fuel and
finally by electricity in the larger units.
• The basic configuration has changed relatively less but the efficiency and
sophistication have increased substantially (Martin et.al., 1982).
• The steam shovel was invented and patented by William Otis in 1839. The
first machines were known as 'partial-swing', since the dipper arm could
not rotate through 360 degrees.
• They were built on a railway chassis, on which the boiler and movement
engines were mounted. The shovel arm and driving engines were mounted
at one end of the chassis, which accounts for the limited swing.

5. Shovels for Surface Mining
Development of
Shovels
• The full-swing,
revolving shovel was
developed in
England in 1884, and
became the
preferred format for
these machines.
• Perhaps the most
famous application
of steam shovels is
the digging of the
Panama Canal

6. Shovels for Surface Mining
Development of
Shovels
• The full-swing,
revolving shovel was
developed in
England in 1884, and
became the
preferred format for
these machines.
• Perhaps the most
famous application
of steam shovels is
the digging of the
Panama Canal

7. Shovels for Surface Mining
Development of Shovels
• Shovels were also used for construction, road and quarry work. Steam shovels
became more and more popular in the 1920s with the publicly funded road
building programs around North America.
• Thousands of miles of State Highways were built in this time period, together
with new factories, docks, ports, buildings, and grain elevators.
• During the 1930s steam shovels lost out to the simpler, cheaper diesel-
powered excavating shovels.
• Open-pit mines were electrified at this time that helped the development of
electric rope shovels.
• Bucyrus constructed one of the most famous monsters - the Big Brutus, the
largest power shovel ever built and the largest still in existence.

8. Shovels for Surface Mining

9. Shovels for Surface Mining

10. Shovels for Surface Mining
Classification of Shovels
Shovels
Stripping
Shovel
Production
Shovel
Mechanical
Rope
Shovel
Electric
Shovel
Diesel
Shovel
Hydraulic
Shovel

11. Shovels for Surface Mining
Classification of Shovels
Based on Movement
- Crawler Mounted
- Wheel Mounted
- Tub Mounted
- Mounted on a barge/ rail

12. Rope Shovels for Surface Mining
Classification of Shovels

13. Rope Shovels for Surface Mining
Classification of Shovels

14. Rope Shovels for Surface Mining
Classification of Shovels
Tub Mounted

15. Rope Shovels for Surface Mining
Classification of Shovels
Rail Barge Mounted

16. Rope Shovels for Surface Mining

17. Power Shovel
• A power shovel is a single bucket equipped machine, electrically or diesel
operated for digging and loading earth, fragmented rock or coal/mineral.
They may be classifies as:
–Rope shovel
–Hydraulic shovel

18. Rope shovel

19. Hydraulic Shovel

20. Working of a Shovel

21. Rope shovel

22. Rope shovel

23. Shovels for Surface Mining
Rope Shovels
• The machine typically consists of a boom, bucket, and counterweight
system mounted on a rotating platform called the revolving frame.
• The revolving frame is supported by crawlers, allowing the rope
shovel to move around the mining site.
• One of the key features of a rope shovel is its massive bucket
capacity. These buckets can range from several cubic meters to over
100 cubic meters, depending on the size and model of the shovel.
This bucket is also known as dipper.
• The bucket, often equipped with teeth or cutting edges, is designed
to penetrate the ground and gather the material for loading and
transportation.

24. Shovels for Surface Mining
Rope Shovels
• The operation of a rope shovel involves several essential components. The
boom is the long, rigid arm that supports the bucket and enables it to reach
and dig into the material.
• It can be raised, lowered, and swung to different positions, allowing the shovel
to excavate at various angles. Generally inclination of the boom is 450 to the
horizontal, but it can be varied if required.
• By manipulating the ropes, the shovel can dig into the ground, fill the bucket,
and lift the material for loading onto haul trucks or other transport vehicles.
• Their flexibility and maneuverability allow them to work in various mining
environments, including open-pit mines and surface coal mines.

25. Main parts of a rope shovel
•Bucket
•Revolving deck
•Counter weight
•A boom
•Hoist cable
• Crowd Cable
•Support cable
•A frame
•Saddle block
•Driving and Control pane
•Crawler
•Operator cabin
Shovels for Surface Mining

26. Shovels for Surface Mining
Rope Shovels

27. Shovels for Surface Mining
Rope Shovels

28. Main motions of a shovel
• Hoist - pulling the bucket up through the bank (i.e. the bank
of material being dug)
• Crowd - moving the dipper handle (arm) out or in to control
the depth of cut and when positioning to dump
• Swing - rotating the shovel between digging and dumping
• Propel - moving the shovel unit to different locations or dig
positions
Shovels for Surface Mining

29. Factors affecting performance of power shovel
• Height of cut
• Angle of swing
• Material preparation
• Capacity of hauling unit
• Efficiency of operator
• Working environment
• Condition of shovel
Shovels for Surface Mining

30. Availability and utilization time
Where,
• Available Hours = Worked Hours + Idle Hours Total
• Scheduled Hours = Worked Hour + Breakdown Hours +
Maintenance Hours + idle Hours
100
*
s
duled hour
Total Sche
ours
Avilable h
=
y
Avilabilit
%
100
*
ours
Avilable h
rs
Worked hou
ion=
% Utilizat

31. Advantages of Rope Shovels in
Surface Mining
1 Productivity 📈
Rope shovels have a high
production capacity, making
them ideal for large-scale mining
operations.
2 Precision 🔬
These shovels are capable of
precise, controlled excavation,
reducing waste and increasing
accuracy.
3 Durability 💪
Designed for heavy-duty use,
rope shovels can withstand tough
mining conditions for extended
periods of time.
4 Lower Costs 💰
Rope shovels are cost-effective
due to their high productivity and
low operating and maintenance
costs.

32. Components of Rope Shovels
Boom
The long arm that
carries the dipper
and provides the
shovel's reach.
Cab
The operator's
station, which
contains the
controls for
operating the
shovel.
Dipper
The large bucket
that scoops up
earth and carries it
away.
Crawler
Treads
The treads on
which the shovel
moves within the
mine.

33. Operating a Rope Shovel
1
Pre-Operation
Inspection
Check the oil,
fuel, and
hydraulic levels
and make sure all
components are
functioning
properly.
2
Starting the
Engine
After inspecting
the machine,
turn on the
engine and wait
for it to warm up.
3
Excavation
Use the controls
in the cab to
maneuver the
shovel and scoop
up earth with the
dipper.
4
Transporting
Material
Swing the shovel
to dump the
material into a
truck or other
transport vehicle.

34. Maintenance of Rope Shovels
Cleaning
Regularly remove debris and
dirt from all machine
components to prevent wear
and tear and minimize
downtime.
Oil Changes
Change oil and other fluids
regularly to ensure optimal
performance and lifespan of
the machine.
Replacing Parts
Replace worn or damaged
parts as soon as possible to
avoid more expensive repairs
and downtime later.

35. Innovations in Rope Shovel Technology
Automation 💻
Advancements in
automation technology
have made it possible to
operate rope shovels
remotely, reducing the
risk of human error and
increasing safety.
Electric-Powered 🌿
Electric-powered rope
shovels use renewable
energy sources and
produce lower emissions,
making them more
environmentally friendly.
Improved Hydraulics
🚛
New hydraulic systems
allow for better control
and faster operation,
increasing productivity
and efficiency.

36. Future of Rope Shovels in Mining
Industry
1 Decreased Human Input
The use of automation technology
will continue to rise, leading to more
remote-operated rope shovels.
2
Increased Sustainability
Environmental concerns will drive
the industry towards more electric-
powered and low-emissions rope
shovels.
3 Improved Efficiency
Advancements in hydraulics and
other technologies will lead to faster,
more efficient rope shovels that can
handle larger quantities of earth.

37. Latest Mining Electric
Shovels
Electric shovels are transforming the mining industry. Discover their
features, benefits, and challenges, and explore the latest
developments in this innovative technology.
by anupam kher

38. Introduction
The Basics
Electric shovels are
used for removing
large amounts of rock
and soil in mines.
They're powered by
massive electric
motors and are
connected to an
external power
source.
The Advantages
Electric shovels offer
better energy
efficiency, lower
maintenance costs,
and greater control
and precision. They
also generate less
noise and air
pollution than diesel
shovels.
The Uses
Electric shovels are
used for a wide range
of mining activities,
from surface mining
to underground
mining. They're ideal
for mining large-scale
deposits in open-pit
mines.

39. Components and Technology
1
Drive System
The drive system consists of electric
motors, a motor controller, and a
transformer. It's responsible for
powering the shovel and controlling
its speed and torque.
2
Bucket and Dipper
The bucket and dipper are the main
working tools of the shovel. They're
made of high-strength steel and are
designed to withstand the stress and
wear of continuous use.
3
Control System
The control system manages the
shovel's various functions, including
hoisting, swinging, and dumping. It's
operated by an operator who sits in a
cab and uses joysticks to control the

40. Performance and Productivity
Higher Efficiency
Electric shovels are faster
and more efficient than
diesel shovels. They're
also more precise, with
greater accuracy and
control over the amount
of material moved.
Improved Safety
The use of electric shovels
reduces the risks
associated with diesel
engines, including fire,
explosion, and air
pollution. It also reduces
the noise levels on-site,
making it easier for
workers to communicate
with each other.
Bigger Capacity
Electric shovels can load
more material at once
than diesel shovels, which
means they require less
time and equipment to
complete a task. This
translates into significant
time and cost savings for
mining companies.

41. Case Studies
1 Primary Gold Mine
A gold mine in Australia
replaced its diesel shovel
fleet with electric shovels,
resulting in a 50% increase
in productivity and a 30%
reduction in fuel
consumption.
2 Bingham Canyon
Copper Mine
The Bingham Canyon
Copper Mine in Utah, USA,
uses one of the largest
electric shovels in the world,
capable of moving 180,000
tons of material a day. It has
helped the mine become
one of the most profitable in
the world.
3 Hibbing Taconite Mine
The Hibbing Taconite Mine in Minnesota, USA, has been using
electric shovels for over 25 years, making it one of the early
adopters of this technology. It has reported significant
improvements in productivity and efficiency.

42. Challenges and Limitations
Power Infrastructure
Electric shovels require a
reliable, high-voltage
power source. This can
be a challenge in remote
or underdeveloped
mining areas.
Costs
Electric shovels are
generally more
expensive than diesel
shovels. However, they
offer significant long-
term cost savings, which
can offset the initial
investment.
Maintenance
Electric shovels require
specialized maintenance
and repair services,
which may not be
readily available in all
regions. Regular
maintenance is essential
for keeping the shovel
running at optimal
performance.

43. Future Trends and Developments
1 Automation
Some mining companies are exploring the use of self-driving electric
shovels, which can operate without human intervention. This could
improve safety and efficiency.
2 Battery-powered Shovels
New developments in battery technology could eventually make it
possible to power electric shovels with batteries, instead of reliance on
external power sources. This could allow for greater flexibility and
mobility.
3 Advanced Analytics
Advanced analytics and machine learning algorithms can help improve
the performance and efficiency of electric shovels by predicting their
maintenance needs and optimizing their operating parameters.