Highwall Mining System
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The document discusses highwall mining, which involves using an unmanned continuous miner to extract coal seams exposed on the face of a pit or quarry. Key points: - Highwall mining uses a remote-controlled cutter module pushed into the seam by push beams to mine and transport coal without personnel underground. - The Bucyrus Highwall Mining System allows versatile extraction from trench, open cast, and contour mines using a self-contained machine operated by 3-4 crew. - It offers affordable and safe coal mining while producing 40,000-110,000 metric tons per month depending on seam height.
Highwall Mining System
- 1. Reliability at work Versatility Highwall Mining System
- 2. Versatility Linking underground and surface mining operations, the Bucyrus Highwall Mining System is a testament to versatile mining equipment. It offers a safe and innovative method for extracting coal from outcropping seams in a multitude of applications. What is Highwall Mining? n Open cast: Highwall mining is used to mine coal from underneath the final highwall, when the strip limit is reached Highwall mining is a proven primary method for mining coal due to economic reasons or surface conditions. from outcropping horizontal seams, in which an unmanned n Contour mining: In a mountainous area, the Bucyrus continuous miner is driven underground and operated in front Highwall Mining System can follow a coal seam along the of the highwall. The highwall mining machine stands on the pit side of the hill. floor or on a bench, directly in front of the exposed seam and n Trench mining: The unit mines coal from both sides of a makes long parallel rectangular drives into the coal seam. A purpose-prepared trench; this mining method is used when remote-operated cutter module is pushed into the seam by a an open pit is not an option. string of push beams (unmanned coal-conveying elements) that transport the mined coal back to the entry of the drive onto a Our highly skilled team is eager to assist you to determine the stockpile. The whole mining cycle is completed by a three- or feasibility of your highwall mining project. The Bucyrus team four-man crew, with no personnel going underground at any uses tools like Bucyrus Quick Scan and an evaluation of your time. geological data and site plan to determine how best to use a Bucyrus Highwall Mining System. We can even assist you The self-contained Bucyrus Highwall Mining System offers an to develop a mine plan if you don’t already have one! innovative method for extracting coal from outcropping seams in a multitude of applications. Whether you’re operating a trench, For an assessment, call us at +31 184 435445 open cast or contour mine, the Bucyrus Highwall Mining System or +1 (304) 253-0206, or email us at highwallminingsales@ can extract coal affordably and safely. bucyrus.com Contour Mining Trench Mining Open Cast Mining
- 3. Bucyrus Highwall Mining System The industry-leading Bucyrus Highwall Mining System is a new, low-cost addition to traditional mining methods. The system can produce 40,000 to 110,000 mt (44,000 to 121,000 tons) of coal per month depending on seam height. Capable of full operation with a three- to four-man crew, the Bucyrus Highwall Mining System averages 27 to 36 mt (30 to 40 tons) per man- hour. Innovative technologies such as an effective cutter module and powerhead assembly contribute to the system’s outstanding productivity. The Bucyrus Highwall Mining System is designed for easy maintenance with a reliable, straightforward design and a comprehensive diagnostic system with troubleshooting capabilities to enhance uptime. Able to be disassembled in modules, the system can be transported over long distances. Everything about this highly efficient highwall mining system is engineered to provide excellent return on investment. Machine Service & Support Every Bucyrus Highwall Mining System is backed by 24/7 support from our highly skilled and experienced staff. Our large warehouse is fully stocked with spare parts to ensure the highest levels of machine uptime, and service and parts back-up can be tailored to your needs.
- 4. Proven Cutter Module Bucyrus offers two electric cutter modules: a low seam cutter for seams 0.76 m – 1.62 m (2.5 ft – 5.3 ft) in height, and a high seam cutter module to mine 1.30 m – 3.05 m (4.3 ft – 10.0 ft) seams. The cutter modules are interchangeable and quickly attached to the powerhead assembly. The cutting cycle is fully automated, yet allows the operator to manually adjust the machine function using an ampere reading as the coal seam varies. This proven technology allows the cutter module to accurately follow the coal seam and produce a clean product. Heavy-Duty Cutter module Powerhead Assembly The powerhead drives the cutter module and push beam string forward using two hydraulically powered sump cylinders with Research and a 6.85 m (22.47 ft) stroke. At 276 bars of hydraulic pressure, Development a pushing force of 136 mt/150 ton (276 mt/304 ton) pulling force propels the cutter module to depths of more than The Bucyrus Highwall Mining System is developed completely in-house 300 m (1,000 ft). by our own engineering department. New product developments are implemented on a continuous basis after being thoroughly tested in the field. Advanced Technology The customers from our worldwide customer base play an important role An optional Gamma Ray Detection system can be used to guide in the development of new product the cutter module through the coal seam, leaving predetermined enhancements. amounts of coal in the roof and floor, if required. This system also Patents and patents pending: allows the mining of coal in soft roof and/or soft floor situations. PCT/NL2004/000518, 372, 793, 794 PCT/NL2005/000024, 115, 123 For even more accurate directional mining operation, Bucyrus PCT/NL2009/050583 USA 5938289 offers an optional solid-state fiber-optic gyro (FOG) based US 11/572,464 navigation and steering system. This US 11/569,520 provides operators with very precise RU 2006145870 CN/0480043435.9 cutter module location data in real time for enhanced cutter module steering and pillar width control. Heavy-Duty Powerhead Assembly
- 5. Excellent Mobility The Bucyrus Highwall Mining System is an agile, self-propelled machine that operates on contour benches as narrow as 18 m (59 ft). It trams easily from entry to entry and discharges coal in tight spaces. An optional right-angle conveyor system discharges coal on the right or left side on narrow benches. It can also discharge onto a stacking conveyor system, where coal is moved to the center of the bench for stockpiling large volumes. Four heavy-duty, hydraulically powered tracks articulate Tram mode independently in two operating modes — mine mode and tram mode — and can rotate the machine 360°, which improves maneuverability in congested areas. Mine mode is used for moving parallel to the highwall, while tram mode is used when moving from pit to pit. Operator Comfort The Bucyrus Highwall Mining System is equipped with a comfortable air-conditioned cab that offers a full view of the mining operation and the highwall. The full-suspension operator seat and the two user-friendly touch-screens create an ergonomic workplace, placing controls and system information at the operator’s fingertips. Mine mode User-friendly touch-screens
- 6. Dependable Push Beams Bucyrus push beams are 6 m (20 ft) long rectangular reinforced steel box structures joined together to form a string, which connects the highwall mining system to the cutter assembly. The push beam string is the backbone of the machine; pushing and pulling the cutter module in and out of the highwall with retract forces up to 363 mt (400 tons) at 345 bars. The push beams also transport mined coal and support the hose chain that supplies control and power to the cutter. Moving coal inside the push beam (via a pair of screw conveyors) protects the coal from contamination and the moving mechanical parts from rock debris, resulting in higher availability. Other Bucyrus push beam advantages include: Push beams n A strong method of attachment that is secured and disengaged quickly n A horizontal hinge design that allows the string and cutter to navigate through coal seam rolls and undulations n Structural rigidity that ensures mining in parallel drives n A simple design free of electrical and hydraulic connections n Push beams that can be stacked six high for storage in narrow worksites Robust Reel & Chain A steel-armored hose chain stores and protects all electric power cables, hydraulic and water lines, and the control cable to the cutter module. The hose chain is automatically unrolled and retracted on a reel during mining. Control System with Diagnostics The Bucyrus Highwall Mining System’s operation is controlled by a Programmable Logic Controller (PLC) which provides reliable performance for greater uptime. A comprehensive diagnostics system, including troubleshooting assistance, streamlines maintenance procedures. Anchoring System Two drills mounted on the front of the machine are used to drill into the pit floor up to 2.5 m (8.2 ft). High-strength pins are then inserted through the base frame into the pit floor to help stabilize Reel and chain the machine and to maintain its accurate position, even under tough pushing and pulling conditions.
- 7. Easy Equipment Relocation For quick relocation over long distances, the Bucyrus Highwall Mining System can be taken apart in modules. Rapid disassembly and reassembly is facilitated by convenient hydraulic and electrical connectors, and all modules are sized for transport using regular public roads. Depending on local conditions, and without disassembly, the system can also be transported between sites and without disassembly, by heavy haul trucks. Specialized Training Our operational and technical training covers every aspect of the Bucyrus Highwall Mining System. We offer a two-week training program from our Beckley, West Virginia, USA, facility to new customers and to existing customers as a refresher. We can also offer a tailored program at your location. Remote operation
- 8. Bucyrus Highwall Mining System OPTIONS: Push Beam String Holding System: When mining on a dipping seam, this Width: 10.0 m (33.6 ft) option prevents the push beam string and cutter module when disconnected Mine Mode Dimensions Height: 8.4 m (28 ft) from the power head from sliding back down into the mined entry. Length: 16.6 m (55.3 ft) Width: 9 m (30 ft) Gamma Ray Sensors: A direct-ship product is produced with rock and debris Tram Mode Dimensions Height: 8.4 m (28 ft) left underground when gamma sensors are used in either a top and/or floor Length: 16.6 m (55.3 ft) application. Weight: Highwall Tropical Package: For hot climate applications, this package extends the 225,000 kg (496,040 lb) Mining System operating temperature of the equipment up to 55° C (131° F). Weight: Push Beam 5,624 kg (12,400 lb) Arctic Package: For extreme cold climates, this package extends the operating Weight: Low Seam temperature to -40° C (-40° F). Infrared or electrical heaters are equipped for 21,800 kg (48,061 lb) the cab, BPM, generating set and working platforms. Hydraulic oil is circulated, Cutter Module cylinders are insulated and heat tracing cables are added. Weight: High Seam 43,084 kg (93,000 lb) Cutter Module Right-Angle Discharge: This feature discharges coal to the right or left of the machine. 8 degrees nominal in any direction, 10 degrees maximum in any Stacker Belt: This is a heavy-duty conveyor that moves coal from the right angle Pit Floor Gradient direction for traveling. Contact conveyor to produce a surge pile for loading coal into trucks. Bucyrus for steeper applications. 8 degrees down dip relative to Push Beam Grapple: This tool is mounted to the front of a wheel loader to Maximum Seam horizontal (Level side-to-side, pit provide safe and efficient transportation of push beams to and from the Highwall Gradient floor prepared at 3 degrees). Contact Mining System. Bucyrus for steeper applications. Generator Set: A self-contained, trailer-mounted generator system provides Coal Seam Height Range 76 cm (30 in) to 3.05 m (10 ft) electrical power to the Highwall Mining System in remote locations where connection to a utility grid is not practical. It includes a 16-cylinder Cummins Maximum Penetration diesel engine with a 4,160 V, 1,500 kW alternator, a fuel supply tank and all 305 m (1,000 ft) Capability required electrical switch gear, packaged in a silenced container. Bucyrus is committed to improving environmental and safety performance through minimizing air and water emissions and reducing waste. We will control and eliminate, where possible, any source of hazards, hazardous materials and emissions involved in manufacturing and support processes. B_HM_HighwallMining_10_5_E www.bucyrus.com/highwall Reliability at work