Highwall Mining in India: extending mineable reserves a ... Mining in India: extending mineable...

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


Caterpillar Highwall Mining History

Beckley WV United States

First delivered in 1994

Over 80 machines delivered Caterpillar since July 2011


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


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.


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.


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 !


Seams Outcropping under high Overburden

Contour mining


Contour mining (Typical Appalachian Application)


Sterilized under Surface Obstructions (Spoil heaps, roads, forest, … )

Sterilized Coal


Sterilized Coal (Mining Under Spoil Heaps)


Sterilized under forest and/or and hills

Trench Mining


Trench Mining Reduced Environmental Footprint

Trench Mining


Trench Mining under spoil heaps

Trench Mining


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.


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


The Caterpillar Highwall Miner


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


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


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


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


Anchoring System

Stabilizes the Highwall Miner.

Two Machine mounted drills.

Two high strength 2,5 m pins.


Operator controls

Operated from the cabin

Fully graphical touch screen interface with PLC

Machine diagnostics

Automated mining mode


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


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


Following seam contours

Automatic following seam:

Cutter motor current

Gamma Ray Sensor (Optional)


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.


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


Support during feasibility and planning process

Caterpillar Highwall Mining Quick Scan

Mining Engineering Aspects

Productivity, Efficiency, TCO


Caterpillar Highwall Mining Quick Scan

Caterpillar Highwall Mining Department provides assistance in:

Technical Feasibility Studies

Recoverable Reserve Calculations


Caterpillar Highwall Mining Department provides assistance in:

Highwall Mining related Mine Planning

Integration in existing Mine Planning

Mine Planning


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


Questions provided by CMPDI

What is experience of the HWM, working at SECL?

Specific challenges faced ,related to Indian mining condition.?



The majority of HWM systems have been sold at North America, what is the

reason it has not expanded in other regions?



What is the time required for installation & commissioning of the machine?



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?



How is safety ensured for the drive created by the HWM?



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.



When mining up dip, there is a potential accumulation of Methane Gas.

Will this create a safety issue?



What is the economic viability of highwall mining in India, considering the cost of

coal produced by either UG or OC mining.



Coal is not a scarce commodity in India, why should HWM be considered at all

in India?



Is a highwall miner an UG or an OC machine?

Different safety standard apply.


Any other Questions?


Thank you for your attention.

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