Professional Documents
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GROUND
U.Siva Sankar
Sr. Under Manager
Project Planning
Singareni Collieries Company Ltd
E-Mail :ulimella@gmail.com or
uss_7@yahoo.com
Visit at:
www.slideshare.net/sankarsulimella
Mechanical Rock Excavation
Mechanical
Different mechanical Excavation
excavation systems, Systems
like machines
with;
Teeth (Dozer, Shovel, Scraper, Bucket wheel excavator, Bucket chain excavator)
Ripping tool (Coal Plough, ripper, rock breaker),
Pick mounted rotary cutting head/drum (Roadheader, Shearer, Continuous
miner, Surface miner)
Disc cutters and button bits (rock drill, Mobile tunnel miner, Tunnel boring
machine)
Auger tool (Continuous Auger Miner, Surface Auger Miner)
Advantages Disadvantages
Generally gives more rapid advance than Cannot excavate very hard rock
blasting in soft to medium-hard rock.
High capital cost
Fewer unit operations
Require specialist maintenance
Smoother excavation profiles
Not as flexible
No blasting damage to surrounding rock
Inherently safer
Parameters influencing applicability of mechanical miners
Machine considerations
The general technical requirements of excavation machines, in addition to
safety and economy, are selective mining ability, flexibility, mobility and hard
and abrasive rock-cutting ability.
Selective mining ability is the ability to cut selectively in mixed face
conditions so that the mineral can be excavated separately, reducing dilution.
Mobility means easy relocation of machines from one face to another, when
necessary.
Flexibility means easy adaptability to changing operational conditions,
such as face cross-section shape (horseshoe, rectangular, circular, etc.),
gradient, turning radius and unevenness of the floor.
Machine considerations
Hard and abrasive rock-cutting ability is the most important limiting factor on
the performance of mechanical miners; applications show that strength,
texture, etc., of the geological environment are the basic input parameters for
the selection of mechanical miners and performance prediction. the most
efficient type of tool in hard and abrasive rock.
Rock mass
Joint structure: spacing, roughness,
orientation
Anisotropy: orientation, formation
Primary stress conditions
Weathering: type and degree
Hydrothermal decomposition
Compressive strength
Density
Abrasivity
Discontinuities
Moisture content
Abrasivity is influenced by
N= Excavatability index
Ms= Mass Strength number
RQD= Rock Quality Designation
Jn= Joint set number
Js= relative ground structure number
Jr= Joint roughness number
Ja= joint alteration number
Table: Mass Strength Number (MS) of rocks
Weight:
Class Weight
Tucker (1985) classified roadheaders according to weight as:
0 <20 t
- Light Duty; weight up to 30 t, cutting capabilities up to 70 MPa
- Medium Duty; weight between 34 to 45 t, cutting capabilities I 20-30 t
MPa IV >75 t
Forward attack picks are also termed tangential picks, together with point
attack picks due to the orientation of their tool axis. Such picks can also be
used for cutting soft to medium hard rocks.
Point attack picks, also known as pencil point tools, have been increasingly
employed in medium to hard rock cutting and become an inevitable tool on
medium and heavy duty roadheaders.
Table; Factors influencing Cutting performance
Pick spacings around the cutting head are defined as line spacing (SL) and
circumferential spacing (Cs) as shown in Fig.
Line spacing is the distance between the cutting lines along the length of the
cutting head and depends mainly on the depth of cut and cuttability of material
being cut.
Circumferential pick spacing is the angular distance between the picks
measured perpendicular to the axis of rotation, which is mainly related to the
angle of wrap, head diameter, line spacing, total number of picks, tool-holder
size and additional space required for water sprays.
Fig. Line and circumferential spacings on a cutting head. Fig: RH Cutting Action
Fig. Lacing patterns of the first (unequal) and the second (equal) cutting
heads.
Pick consumption rate (pick/solid bank m3) varies from 0.049 to 0.044. If the
rock is very abrasive or the pick consumption rate is more than 1 pick/m3,
then roadheader excavation usually becomes uneconomical due to frequent
bit changes coupled with increased vibration and maintenance costs.
Continuous miner is a mining machine that produces a constant flow of ore from
the working face of the mine. The machine continuously extracts as it is loading
coal with a cutting steel drum and conveyor system.
The continuous miner has been available in some form since the late 1800s. The
first machine to resemble a continuous miner was known as the English Channel
Machine.
Continuous Miners
Though there are many variations in design, continuous miners mostly consist of
five main elements:
A central body to carry all other components mounted on some type of drive
mechanism to provide mobility (most commonly caterpillar tracks).
A "cutting head" usually rotating drum(s) and/or chains with cutting picks
attached
A loading mechanism to pick up cut coal and deliver it into the central part of
the machine
A conveying system, usually a chain conveyor running in a steel trough from
front to rear of the miner
A rear jib section capable of a degree of vertical and horizontal movement to
enable the coal to be delivered into a transport or loaded at a desired point.
Continuous Miners
Continuous Miners
This often results in a very rough rib line (bad for stability and ventilation
flow) and delays the ability to install support into/under freshly exposed
roof for a period. The advantages of the ability to cut the full profile in one
pass was recognized early, but was not easy to achieve.
Fig: Mining of
Steep seams with
roadheader and
miller head
(drum-type)
miners
Overview of Continuous Miner machine Manufacturers
Overview of Continuous Miner machine types vs. Operation heights
Lacing pattern on CM Drums
25,26- End Rings, 27 Left Web Section, 29 Right web section 28 central web section
Fig: Pick Lacing Pattern on Continuous Miner drum for Stone or Hard
rocks
Fig: Pick Lacing Pattern on Continuous Miner drum
The picks are placed on each vane at an attack angle of between 400 to
500.
The vanes extend angularly about at an angle 100 to 300
The spacing between picks is 50mm to 90mm on drums used for coal
and 40 to 50mm on drums used for hard rock cutting.
CM SUMPING SEQUENCE
1
CM SUMPING SEQUENCE
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CM SUMPING SEQUENCE
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CM SUMPING SEQUENCE
2
CM SUMPING SEQUENCE
3
CM SUMPING SEQUENCE
4
CM SUMPING SEQUENCE
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CM SUMPING SEQUENCE
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CM SUMPING SEQUENCE
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CM SUMPING AND SHEAR SEQUENCE
SD
SH 1
CM SUMPING AND SHEAR
SEQUENCE
SD
SH 1 2
CM SUMPING AND SHEAR SEQUENCE
SD
SH 1 2 3
CM SUMPING AND SHEAR SEQUENCE
SD
SH 1 2 3 4
CM SUMPING AND SHEAR SEQUENCE
SD
SH 1 2 3 4 5
CM SUMPING AND SHEAR SEQUENCE
SD
SH 1 2 3 4 5 6
CM SUMPING AND SHEAR SEQUENCE
SD
SH 1 2 3 4 5 6 7
CM SUMPING AND SHEAR SEQUENCE
8
9
SD
SH 1 2 3 4 5 6 7
Auger Mining:
The potential for underground coal production from drilling or augering
machines has been recognized since at least the 1940s.
These machines could bore into the virgin coal from stabilized entries and
provide access to otherwise sterilized coal reserves.
Auger drills mounted with cutterheads cut and fracture through both
overburden and coal, operating very similar to a drill machine.
The cutting action of an auger differs from other coal cutting machines, such
as continuous miners, in that it exploits the lower tensile strength of coal rather
than overcoming the comparatively high compressive strength of coal.
This makes augers more efficient in terms of the power needed to cut the coal.
There are Thin seam auger miner for extraction in thin UG seams and Surface
auger Miner for extraction of seams from highwall of open pit mines
Fig: Auger Miner for Thin seam
extraction
Auger performance is principally governed by two main factors; machine power
and cutter head diameter.
The greater the power available the deeper the penetration and the higher the
mining rate, for the same machine configuration.
The larger the diameter of the cutter head the greater the rate of production
per metre of hole advance and hence the higher the mining rate.
Thin seam miner (TSM) is actually a type of continuous miner that can cut
seams from 0.6m to1.2m height and up to 1.5 m high into a coal seam
situated under a highwall in surface mines
Augers drills used in surface mining can range from 18 to 61 m in length to two
to seven feet (0.6 to 2.1 m) in diameter. The cutter head on the auger bores a
number of openings into the seam, similar to how a wood drill produces wood
shavings. The coal is then extracted and transported up to the surface via the
spiral action of flights. Additional auger lengths or flights can then be added as
the cutter head penetrates and drives deeper down into the bored hole
Auger mining is a low-cost method of recovering coal from horizontal or
slightly pitched seams exposed through geological erosion. The practice of
auger mining is reserved primarily for extracting coal at depths of up to 1,000
feet (305 m).
One of the drawbacks is that once the cutter head enters the coal seam, the
operator is unable to view the cutting action directly and must rely more on a
sense of feel for the machine to determine potential problems.
Auger Advantages
Cheap
Simple (no moving parts on the cutting machine itself)
Relatively low dust make
Able to keep exposed roof area very small (but a large number of chock
movements would be required to maintain this)
Though only a small web is taken, in the right conditions production rates can be
comparable to a shearer as the plough is operated at a relatively fast speed
along the face.
Advantages Disadvantages
It is very suitable for extremely low seams
from 0.6m. Losses due to friction of the plow body
Easy access to a tow chain of the plow. bottom plate on the floor.
High safety while handling with a tow chain
also in inclinations.
BASE PLATE PLOW
The plow system using atypical pan line with plow guide and plow chain on the goaf side.
Plow Systems
Advantages Disadvantages
It is intended for seams from 0.9m to 1.8m. It is unsuitable for seams less than
Well controllable even when the floor is 0.9m.
rolling. Not easy access to a tow chain of the
Low losses due to friction by a plow body. plow.
Difficult and dangerous while handling
with a tow chain.
SLIDING PLOW
The plow system using atypical pan line with plow guide and plow chain on the face side.
Shearers
Pre_Cutting
Fig: Shearer Drums with Radial and Point attack
picks
Shearer drums consist of several spiral vanes and a backplate welded on a hollow
drum shell.
The spiral vanes serve for cutting and loading, while the backplate is mainly used
for corner cutting at the face side to relieve the cutting action of the vane picks.
The linear advance of a shearer drum per entire revolution is produced by the
combined cutting actions of the vanes.
Spiral vanes and the backplate provide space for the picks to be mounted on
drums.
Spiral vanes or cutting sequences on shearer drums are also known as starts,
and the number of starts equal that of the spiral vanes.
The total number of starts on a shearer drum varies(3,4,6) depending on the
shearer drum design
Picks can be classified according to their tilt angles and positions on the cutting
head.
The tilt angle is the angle between the pick axis and a plane perpendicular to the
axis of cutting head rotation (Figure a).
Picks, with their axes perpendicular to the axis of cutting head rotation, are named
traversing or arcing picks, while those mounted on the region closer to the nose
section of the cutting head, with individual tilt angles, are termed gauge picks.
Sumping picks are placed on the nose section of the cutting head with their axes
parallel to the axis of rotation of the cutting head. The last gauge pick on the face
side of the cutting head is known as the corner cutting pick.
Fig. Pick positioning on a shearer drum: (a) profile view of the
drum (b) lacing of spiral and clearance ring picks
Positioning picks on shearer drums
A modern shearer drum also has three groups of picks cutting the coal
seam while it rotates and transfers coal particles from the face onto the
armoured face conveyor.
The first group of picks that cuts most of the coal-seam, which are
mounted on spiral vanes and correspond to the traversing picks on the
roadheader cutting heads, are named vane picks.
The second group of picks mounted on the backplate section of the
shearer drum, and corresponding to the gauge picks on the roadheader
cutting heads, are termed clearance ring picks.
Todays shearer drums also have some sumping picks mounted on the
outer face of the clearance ring to provide extra protection for the drum
The arrangement of clearance ring picks on the shearer drum was reported
to be more complicated than that of vane picks
The forces required to cut the coal at a certain depth by a clearance ring
pick were reported to be two to ten times higher than the forces needed to
cut the coal at the same depth by a vane pick
More the wear of the clearance ring picks than others
Mobile Tunnel Miner (MTM)
Large mass
Hydraulic stabilising jacks
High cutting force provided by hydraulic thrust rams
Cutting discs for rock breakage by indentation
Because of the size and weight of the typical TBM, they are suitable only for the
excavation of long straight drivages such as civil engineering tunnels.
Tunnel Boring Machine (TBM)
TBM provides a good, circular profile which is good for stability and
ventilation but usually requires a false floor to be laid to create a flat floor
for travel.
Limited by grades involved and grade control can be problematic is some
strata conditions. Not suitable for other than very gradual changes of
direction (typically minimum 500m turning radius although tighter radius
machines can be designed and utilized).
Unlike drill and blast or roadheading methods, tunnel boring machines do
not have the capability to readily vary the dimension of the excavation nor
are they suitable in varying ground conditions.
Disadvantages of TBMs
High capital cost (several million dollars)
Can only cut circular section
Large turning radius (100 m)
Time-consuming to install
Minimum tunnel length of 2 km required to justify installation
Wide choice of TBMs for rock tunneling with diameter > 14m for different ground
conditions
Open or Gripper type for hard ground
Single shield hard ground
Double shield hard ground
EPB (Earth Pressure Balance Machines) Soft ground, pressure< 7 bar
Slurry and mix-shield Soft ground with very high water pressure and large
amounts of ground water
Fig: Gripper
TBM
The largest diameter TBM, at 15.43 m, was built by Herrenknecht AG
for a recent project in Shanghai, China. The machine was built to bore
through soft ground including sand and clay.
5
2
1
4
1. Start
boring
stroke
2. End
Main boring
body stroke
3. Start
reset
stroke
Invert Front Thrust Rear Main
scraper lift leg cylinder lift leg motors
4. End
Fig: Cutting cycle of Atlas Copco TBM reset
stroke
Fig: Hydraulic
jacks holding a
TBM in place.
1. Cutter head
2. Front shield
3. Main beam
4. Gripper trolley
5. thrust cylinders
6. Belt conveyor
7. Ring beam erector structure
8. Shortcret
Fig: Gripper Shield
All types of hard rock TBMs excavate rock using disc cutters mounted in
the cutter head.
The disc cutters create compressive stress fractures in the rock, causing it
to chip away from the rock in front of the machine, called the tunnel face.
The excavated rock, known as muck, is transferred through openings in
the cutter head to a belt conveyor, where it runs through the machine to a
system of conveyors or muck cars for removal from the tunnel.
Cutter head of soft rock TBM does not use disc cutters only, but instead a
combination of tungsten carbide cutting bits, carbide disc cutters, and/or
hard rock disc cutters.
Fig. Disc type cutter. Fig. (a) Kerf cutter (b) Pineapple cutter.
Different Cutter Heads - TBMs
Single Shield TBM
1.Cutter head
2.Shield
3.Belt conveyor
4.Excavated material removal trolley
Double Shield TBM
1. Cutter head
2. Shields
2a - Front shield
2b - Double shield
2c - Rear shield and gripper
Belt conveyor
Excavated material removal trolley
EPBMs
Fig: Schematic
representation of EPBM
Fig: Schematic
representation of EPBM
Fig: Types of
Cutting face
of EPBMs
Schematic
representation of a
slurry type shield
machine