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Highwall Mining in India: extending mineable reserves
a presentation for CMPDI.
August 22nd , 2013
2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Introduction Caterpillar Highwall Mining History The Method The Highwall Miner Questions
3 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Caterpillar Highwall Mining History
Beckley WV United States
First delivered in 1994
Over 80 machines delivered Caterpillar since July 2011
4 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Source: HWM Status List, Beckley, WV
Cat 72
Cat 1
Australia
China US
Cat 4
Russia
India
Cat 2
Installed base and potential
Indonesia
South Africa
Colombia
Canada
Cat 1
5 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
What is Highwall Mining
Mining coal from a visible, horizontal coal seam, by making rectangular, parallel, unsupported drives, with an unmanned cutter head and coal transport system, controlled from a mining unit positioned outside the drive, in front of the highwall.
Additional method to underground mining and open cast/pit mining
increase the extractable reserves
extend the mine life.
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What it does
Typical coal reserve recovery of 50 to 70% depending on geological conditions.
Mines coal from exposed coal seams when economical surface mining limits are reached.
Mines parallel entries to a depth of 300 m without personnel working underground.
Flexible System – can mine multiple seam heights.
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Typical applications
• When economic strip limit is reached
Soft Strip Limit:
Wait until coal price rises? But:
Highwall mine before backfill!
Hard Strip Limit:
Under mountain, and/or
Steep dipping seams
Highwall Mine now !
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Seams Outcropping under high Overburden
Contour mining
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Contour mining (Typical Appalachian Application)
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Sterilized under Surface Obstructions (Spoil heaps, roads, forest, … )
Sterilized Coal
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Sterilized Coal (Mining Under Spoil Heaps)
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Sterilized under forest and/or and hills
Trench Mining
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Trench Mining Reduced Environmental Footprint
Trench Mining
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Trench Mining under spoil heaps
Trench Mining
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Requirements for Highwall Mining
Competent coal.
Competent immediate overburden.
If overburden is not competent, coal may be left as roof.
Coal seams dipping from +5 to -15 degrees.
Relative flat seams, no faults
Coal seams thicker than 80cm.
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Web- and Barrier Pillars
Web pillars ensure support of OB
Barrier pillars prevent cascading collapse
Calculation method to be approved by the local Mine Safety Authorities
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The Caterpillar Highwall Miner
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The Caterpillar Highwall Miner
Length base 16.6 m Width base 8.3 m Length pushbeam 6 m 49 pushbeams per miner Max. force:
Push in: 136 t Pull out: 276 t
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Cutter Module
Low seam cutter module
Capable of cutting coal from 80cm to 150cm and 295cm wide
Mid seam cutter module based on CM235
Capable of cutting coal from 110cm to 305cm and 350cm wide
The cutter modules are quickly interchangeable
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Pushbeams
Pushing / pulling cutter module Conveying Coal Sturdy, simple, 2 moving parts only Enclosed, no External Ash Low Ground Pressure Protect cables/hoses Coupled to a String: Hor. rigid: Straight Drives Ver. hinged: Follow seam undulations
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Power chain for cutter module
Electrical cables
Hydraulic lines
Cooling water lines
Methane sensor cable
Control cables
Hoses / cabling protected by steel plating
Auto unwinds/winds in trough on pushbeams
300 meter
Hose Reel
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Anchoring System
Stabilizes the Highwall Miner.
Two Machine mounted drills.
Two high strength 2,5 m pins.
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Operator controls
Operated from the cabin
Fully graphical touch screen interface with PLC
Machine diagnostics
Automated mining mode
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Power
From the grid
60Hz at 4.2kV or 50Hz at 6.6kV both 2000kVA
Or from generator set
1500 kW Caterpillar Generator Set
50 kW Caterpillar auxiliary set
Build in a sound attenuated container
Mounted on tracks (optional)
Tropical / Arctic version
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Navigation & Horizontal Steering
Navigation by state of the art Fiber Optic Gyro (FOG) on cutter module
Accurate heading
Accurate determining of position
Steering by hydraulic powered steering arms on cutter module
Active pillar width control
Prevents cutting into previous mined drives
Optimizes and Minimizes Pillar Widths
Optimizes coal recovery
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Following seam contours
Automatic following seam:
Cutter motor current
Gamma Ray Sensor (Optional)
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Mobility
Tracks for positioning in the mine, relative short distances.
Longer distances on heavy weight special transport low loader.
Long distances; disassembled, operational 3 – 4 days.
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Key Characteristics
Penetration up to 300 meters
Dip of up to -12 degrees
Maximum monthly production typically between 40,000 and
100,000 tonnes depending on site characteristics
Operates with a 3 / 4 man crew
No external ash dilution.
Typically 50%-70% recovery
Personnel safety
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Support during feasibility and planning process
Caterpillar Highwall Mining Quick Scan
Mining Engineering Aspects
Productivity, Efficiency, TCO
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Caterpillar Highwall Mining Quick Scan
Caterpillar Highwall Mining Department provides assistance in:
Technical Feasibility Studies
Recoverable Reserve Calculations
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Caterpillar Highwall Mining Department provides assistance in:
Highwall Mining related Mine Planning
Integration in existing Mine Planning
Mine Planning
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Productivity, Efficiency, TCO
Caterpillar Highwall Mining Department can assist you in Total Cost of Ownership calculations: • Production that can be achieved considering site and operational
aspects.
• Finance costs
• Operational and Maintenance costs
• Personnel costs
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Questions provided by CMPDI
What is experience of the HWM, working at SECL?
Specific challenges faced ,related to Indian mining condition.?
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Questions provided by CMPDI
The majority of HWM systems have been sold at North America, what is the
reason it has not expanded in other regions?
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Questions provided by CMPDI
What is the time required for installation & commissioning of the machine?
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Questions provided by CMPDI
What is the time & resource required for moving the miner from one bench to
another? What is the maximum gradient and speed, machine can travel?
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Questions provided by CMPDI
How is safety ensured for the drive created by the HWM?
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Questions provided by CMPDI
When mining down dip, there is possibility of water accumulating in the open
drive.
In case there is a coal seam below that seam, with potential future UG mining ,
there will be a safety issue.
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Questions provided by CMPDI
When mining up dip, there is a potential accumulation of Methane Gas.
Will this create a safety issue?
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Questions provided by CMPDI
What is the economic viability of highwall mining in India, considering the cost of
coal produced by either UG or OC mining.
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Questions provided by CMPDI
Coal is not a scarce commodity in India, why should HWM be considered at all
in India?
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Questions provided by CMPDI
Is a highwall miner an UG or an OC machine?
Different safety standard apply.
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Any other Questions?
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Thank you for your attention.