Highwall Mining Technology

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Highwall Mining Technology

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

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