Professional Documents
Culture Documents
Mining Machinery II
• Coal cutting machines, shearers, coal ploughs, lump breakers, road
headers, TBMs, raise and shaft borers, continuous miners, stage
loaders; their main features and applicability
• Loading machines - rocker shovel, SDL, LHD, gathering arm loader,
shuttle car, LPDTs, scraper ; their main features, applicability, selection
and production capacities
• Opencast Machinery - Shovels, draglines, dumpers, wheel loaders;
their main features, applicability, selection and production capacities;
• Underground coal and rock drills, jumbo drills, rock bolting machines.
Small and large diameter surface blasthole drills, rippers and scrapers,
road graders, dozers; their construction, application, selection, and
operation
• Continuous surface mining equipment- bucket wheel excavators,
surface miners, spreaders, dredging equipment; their main features,
applicability, selection and production capacities
• Pumps : Types of mine pumps, application and related computations.
Miscellaneous Mining Equipment: Power pack and Hydraulic System,
Truck Despatch System, Stacker Reclaimer, Rock Breakers, Impact
Hammers, Slurry Pumps, Equipment used in Shaft Sinking, In-pit
Crushers
Books
1. SME Underground Mining Methods Handbook
Ed. Hustrulid, E. Lopez Jimeno, C. Lopez Jimeno,
Ayala Carcedo
2. Drilling and Blasting of Rocks, 1995, CRC Press
Ratan Raj Tatiya
3. Surface and Underground Excavations –
Methods, Techniques and Equipment, Taylor &
Francis (2005)
4. Surface Mining Equipment by JW Martin, TJ
Martin, TP Bennett, KM Martin; Publ – Martin
Consultants, Inc, Golden Colorado 80402
5. Longwall Mining, Peng and Chiang
Shearer
Shearer 1
Shearer 2
Shearer
• The coal is cut from the Long wall face of a mine by a machine
called the shearer . It cuts the coal from one end of the face to
another and the coal gets loaded into the AFC through a
curved guide plate known as cowl plat.
• This machine comprises a main body, housing the electrical
functions, the tractive motive units and pumping units.
• The either end of the main body are fitted the ranging arms
which can be ranged vertically up down by means of hydraulic
rams, and onto which are mounted the shearer cutting drums
which are fitted with 40–60 cutting picks.
• The cutting drums are rotated to cut the coal from the coal
seam. The shearer body is mounted on the AFC.
Types of Shearer
• Fixed Drum Shearer
1 Unidirectional
2. Bidirectional
Cutting Drum
Gear Electric Power Gear
Box Motor Pack Box
Ranging Arm
Ranging Arm
Powered Cowl
• Advantage:
1. High production
2. Uniform size of coal is produced
3. No use of explosive
4. More safety
5. Smooth floor is maintained
6. Seam of greater thickness can be extracted
7. Straight line of face is maintained
8. It does not need any assistance of roof pressure.
9. Supports are less frequently moved.
• Disadvantage:
1. High Capital Investment
2. Size of coal produced is less
3. High amount of air borne dust
When a double ended ranging drum shearer
cuts coal in a longwall face: GATE 2012
Q = 60HSVH Tones/Hr
Power Consumption
increases with increase in rotational
speed as shown in fig.
• With increased rotational speed , the
specific energy requirement is more. Drum RPM
• With increased rotational speed , the
cutting efficiency is less.
• With increased rotational speed , the
moment acting on the drum is less.
Factors affecting Shearer Performance
2. Haulage speed
• Under constant rotational speed, the
power consumption of a shearer increases
Power Consumption
with increase in haulage speed however
this rate is very high, as shown in fig.
• With increased haulage speed , the specific
energy requirement is less.
Haulage speed
• With increased haulage speed , the cutting
efficiency is more.
• With increased haulage speed , the
moment acting on the drum is more.
Factors affecting Shearer Performance
3. Cutting Depth
70 RPM
• AS shown in fig, that under constant
Power Consumption
drum speed, the power consumption 50 RPM
Power Consumption
Soft coal
• AS shown in fig, that power
consumption increases linealy with
increase in hardness of coal.
5. Bit condition
• The cutting efficiency of a new bit or sharp bit is higher
than the worn bit.
Motor Power =
129.6
0.65
KW 199.4KW
Mechanics of coal cutting by Shearer
VH1 VH
VH
α1 α2
α3
VR VR
VR 1
Mechanics of coal cutting by Shearer
• As illustrated in the fig. that as the haulage speed of
the shearer increases, the cutting depth of the drum
also increases which in turn increases the size of
coal produced.
• However, if the rotational speed of the drum is
more, it will result in production of more fine coal as
well as more dust.
• Therefore a proper ratio between haulage speed and
rotational speed must be maintained for desired size
and production of coal.
• For cutting hard coal rotational speed should be
more while for cutting in the soft coal the haulage
speed should be more.
Sumping of a Shearer
• Each time shearer completes a cut
along the whole face before starting
the next cut, the drum must first cut
into the coal face. The process of
making the drum cut into the coal
face is called sumping.
Methods of Sumping
• Push Sumping (Pre niching)
• Drill Sumping (Self niching)
• Inclined Sumping (No niching)
a. Full face triangular inclined sumping
b. Full face inclined sumping
c. Half face inclined sumping
Push Sumping or Pre niching
In this method a pre cut
called nich is prepared
at the face end. The
shearer is pushed into
the nich by the advance
of either tail or the
head drive.
This method of
sumping is rarely used.
Inclined Sumping a. Full face Triangular Inclined sumping
In this method when one cut is
completed, the shearer is at
one end, AFC is snaked, and the
Shearer moves over it towards
the face, making a nich in the
face. Then shearer moves in
backward direction to remove
the triangular part as shown in
fig.
After that it moves in the
forward direction and cut the
remaining coal on the face.
Inclined Sumping b. Full face Inclined sumping
In this method when one cut is
completed, the shearer is at
one end, AFC is snaked, and the
Shearer moves over it towards
the face, making a nich in the
face and continues to mve in
forward direction to cut the
coal as shown in fig.
Rack a track
Total weight 24 T
8. Investment
Continuous miner
Continuous miner
Continuous miner
• Continuous miners are used in board and Pillar
Mining Methods as a production machines.
• It consist of a large rotating drum comprising of
cutting picks mounted over it to scrape coal from the
face of the mine.
• The continuous miner rotates the cutting drum to cut
the coal from the face, and the coal extracted is
collected by the gathering arms to convey it to the
rear end by a chain conveyor.
• These machines are able to cut the full face in one
pass .
Specifications of a Continuous Miner
Eickhoff GERMANY , Model CM2H-45
Total Installed Power 620 KW
Machine Weight 78 T
Lump
Breaker
Lump Breaker
• The Lump Breaker is used in the line of Chain
Conveyor used in mining to crush / reduce the large
lumps of R O M Coal.
• It is able to reduce lumps created in the production
without generating excessive dust and fines.
• When the material is conveyed through the Chain
Conveyor, the large lumps entered between deck
plate of line pan and crusher rolls get crushed by the
breaker wheel to required size by impact of picks
mounted to the wheel.
• A typical crusher has a housing with a
crushing chamber and one or two rotating
shafts (rotors) with teeth or blades that are
mounted to them.
• There is usually a sizing screen of perforated
metal in crushers to hold back larger pieces
for further crushing after the material passes
the rotors.
• By reducing the size of lumps, it becomes
easier to handle and transport the material
by belt conveyor.
Raise Borer
Reamer head
raise borer
Raise Borer
Raise Borer
• The raise borer is set up on the upper level of the
two levels to be connected, on an evenly laid
platform (typically a concrete pad). A small-
diameter hole (pilot hole) is drilled to the level
required; the diameter of this hole is typically
230mm - 445mm (9" - 17.5"), large enough to
accommodate the drill string.
• Once the drill has broken into the opening on the
target level, the bit is removed and a reamer head,
of the required diameter of the excavation, is
attached to the drill string and raised back towards
the machine.
• The drill cuttings from the reamer head fall to
the floor of the lower level. The finished raise
has smooth walls and may not require rock
bolting or other forms of ground support.
• The one of impressive use of raise boring is a
7.1 m diameter shafts in South Africa. Master
drilling is currently the world's biggest raise
boring firm with operations throughout all 7
continents.
Tunnel Boring Machine
Full Face Tunnel Boring Machine
• Open-type TBMs