''West and East Europe in global High Added Value
manufacturing - facts of today and challenges of tomorrow''
October 24-25th 2011, Wrocław
WS6 - Future Mining Session
Novel underground mining methods with the
use of hydraulic powered roof support and
continuous mining in KGHM copper mines.
Henryk Karaś, Corporate Adviser, KGHM, Chairman of ETP SMR
Herbert Wirth, President, CEO, KGHM Polish Copper
Content of the presentation.
1. Testing the use of hydraulic powered roof support in
underground conditions in KGHM copper mines – the
first experiences dating from 70s-80s in XX century.
2. Development of rock fragmentation and continuous
mining technology in world mining.
3. Current KGHM projects on the use of continuous mining
in underground operations.
4. General idea, advantages of continuous mining,
expected results.
In 1973 the KGHM decided to test the use of hydraulic
powered roof support (HPRS) in its Pilot Plant located
at the Lubin Copper Mine. The main reason was finding
solutions for cleaner extraction and lowering losses of
copper ore during the underground winning operations.
Short history on the use of hydraulic powered roof
support (HPRS) in underground conditions of KGHM.
The first tests with the use of HPRS „Hemscheidt” units in
room&pillar mining method, Lubin copper mine, 1974-1975.
Two phase room&pillar mining method with
the use of four HPRS Hemscheidt units
One phase room&pillar ming method with
the use of four HPRS Hemscheidt units
Typical set of HPRS Hemscheidt consisting
of 2 pairs of linked double units.
Tests in shortwall mining method with the use of HPRS
„Hemscheidt” units, Lubin mine, KGHM, 1976-1979.
Shortwall (20 m wide) mining with the use of HPRS
Hemscheidt units – single units along wall face.
Typical HPRS „Hemscheidt” units.
Shortwall (2 x 20 m wide) mining with the use of
HPRS Hemscheidt single units along wall face.
Basic cycle of exploitation in shortwall mining method
with the use of HPRS units,
Phase 1 – after drilling the face of the wall pillar, before charging the explosives.
Phase 2 – after blasting operation of the wall pillar.
Phase 3 – short wall during mucking operation, before drilling and advancement of roof
support.
Phase 4 – after drilling the face of short wall and the advancement of roof support.
The idea of shortwall mining method with „Fazos-70” HPRS
units tested in low seam deposit in Sieroszowice mine.
Protecting barriers installed before HPRS units Made in Poland „Fazos-70” HPRS units
Industrial Performance Testing carried out in 1981-1987
The tests on use of hydraulic powered roof support (HPRS) carried out
in underground conditions were stopped in 1987.
The main reasons were:
1. Problems with advancing the hydraulic support during mining
operations and effective triggering off the natural roof caving behind
HPRS line.
2. Problems with protecting the hydraulic installations inside HPRS
units caused by blasting operations. Protecting barriers installed before
HPRS units did not always fulfill their role. That mostly lowered the rate of
face advance.
3. High costs of using HPRS units in underground operations when
compared with the traditional room&pillar mining method prevailing at all
KGHM copper mines.
4. Financial crisis approaching Polish economy in the middle of 80s.
Results and conclusions from the first tests.
Reserve area - EXTENSION
GŁOGÓW
KGHM – one of the biggest resources of copper ore in the world.
Current area of mining
activity
10
When going down to onto the level 1500 m in mining
operations new solution in underground operations
became more challenging and acute at KGHM.
• Minimising ore dilution and copper ore losses in low seam copper ore deposits ;
• Eliminate human exposure in deep underground conditions (hot rock temperature, humidity, gas and diesel fuel emissions, dust, noise, rock burst hazards)
• Most of of underground mining operations from remote places.
• Implement automated communication and data transfer systems in mining operations.
Traditional the room&pillar mining method
used at KGHM mines with rock blasting.
1
2 3
4
5
6 7
8
Traditional
Drill/Blast
Process
Cycle
Room&pillar method with roof subsidience
Room&pillar method with hydraulic backfill
New approach in continuous mining in
underground mining operations at KGHM.
1. Drill & Blast – the current method.
• Inherently dangerous;
• Cyclic;
• Slower ?.
2. Rock Cutting – the way of the future.
• Continuous operation (non-cyclic mining);
• Easier to automate;
• Easier to respond to geology;
• Faster ? and safer.
Source : Dr Xing Li , Ian Gipps , CSIRO Exploration & Mining, 2008 Narrow Vein Mining Conference
Development of technologies in hard rock
fragmentation and continuous mining.
The basic principle of rock fragmentation
is to break bindings between the grains
and disintegrate the rock. This can be
done by using:
mechanical tools;
laser to heat and melt the rock or
pulsated laser to resonate and break it into
pieces;
microwave induced heat and thermal
stresses,
shocks such as plasma explosion;
erosion method such as water jet. Basic rock excavation mechanisms (Maurer, 1980).
Source: http://www.nap.edu/openbook.php?record_id=2349&page=63
1.Some of the concepts to develop mechanical excavation systems for hard rock
mines have been progressed since 90. XX c. to prototype machines which generally
were capable of excavating very hard, and often abrasive rocks (picks and discs).
2.The real battle is the abrasion wear of the cutting tools.
3. Thus the focus of the research in this area has been to develop cutting tools
that require low cutting forces when cutting hard rock formations.
Source: “A state-of-the-art review of mechanical rock excavation Technologies”,
by A. Ramezanzadeh, M. Hood. IJMEI, vol1, No 1, 2010
Recent innovations in rock excavation.
Mechanical excavation in
mining machine types. source: Aker Wirth GmbH, (www.wirth–
europe.com).
KGHM
TBM - Tunnel Boring Machine
MTM - Mobile Tunneling Machine
Rock Cutting – Possibilities.
1.Roadheaders & picks
1.1 Tungsten carbide picks
1.2 Diamond composites.
2.Mini cutters
2.1 Problems with handling forces on
bearings.
3.Oscillating Disc Cutters (ODCs)
3.1Several attempts over many years.
The two types of cutter heads (Sandvik MT720).
Source: CRCMining 2004-2005 Annual Report, Oscillating Disc Cutter technology, Oscillating Disc Cutter
Source: “A state-of-the-art review of mechanical rock excavation Technologies”,by A. Ramezanzadeh, M. Hood. IJMEI,
vol1, No 1, 2010
Recent innovations in rock excavation - undercutting discs.
Undercutting discs – making use of
lower tensile strength of rock (b) as
opposed to compressive strength (a).
This idea is getting more and more
approval among mining machine
producers.
Two types of Mobile Tunnelling Machine with undercutting discs.
(a) (b)
Recent innovations in hard rock excavation (picks): TSDC picks vs
Tungsten Carbide (TC) ones in comparison of wear development.
1.Reduced wear rates &
longer life
2.The ability to cut hard rock
(>300 MPa)
3.Faster cutting
Advantages of TSDC.
Thermally stable diamond
composite (TSDC).
Source : CSIRO SMART*CUT Technology, 2008 Narrow Vein Mining Conference
Tungsten Carbide (TC)
new
after
30 cuts 100 cuts
New solution in Mass Mining Technology – KGHM.
Tail entry chain conveyor
Powered sectional support
Long wall shearing machine
Armoured flexible conveyor
Longwall mining allows the most effective underground coal extraction today
for thin hardcoal beds between 1,5 to 2,3 m. Most of copper deposits on the
KGHM licence area are flat, high copper grade and and have similar height.
Coming back to the idea of continuous mining and longwall mining system
owing to development of effective rock fragmentation tools for very hard rock .
Solution in Mass Mining Technology - KGHM
Powered sectional support (HPRS)
Longwall shearing machine
Armoured flexible conveyor
Source: https://mining.cat.com/cda/layout?m=435165, Longwall mining systems
Longwall plowing machine
20
Summary of future solutions to implement the
new Mass Mining Technology at KGHM mines.
• No drilling and charging in Near-Face operations;
• Possibility of adaptation of longwall equipment in hard
rock applications (compressive strength 100-150 MPa),
• Roadheaders and continuous miners for hard rock
applications for underground drifts, longwall and room&
pillar mining methods.
• Opportunity to develop techniques for selective mining
operations underground.
Target : Automated continuous mining – an intelligent
and remote controlled robotic technology.
Lithological profile of
the Lubin-Głogów
copper ore deposit.
sandstone
dolomite
shale (Kupferschiefer),
Safe and effective underground mining operations should make use of the development of IT and ES technologies.
source: prof. Pekka Särkkä, Helsinki Technical University, 2008
Stages of Intelligent MineTM ,
project, Finland (1998-2002)
Level of
development
at KGHM
22
Experience of KGHM company with continuous
mining technologies.
• Salt extraction area
2000 – to date Polkowice/Sieroszowice Mine
• Mine development area
2010- to date
• Copper ore extraction area
first tests 2002-2005
Roadheader MH 620 (SANDVIK) at the Lubin Mine
SANDVIK’s Narrow Reef Miner ARM 1100, tests at the
Polkowice/Sieroszowice Mine
2009, KGHM signed the cooperation agreement with
Bucyrus (now Caterpillar, USA) based on patented
Bucyrus Activated Cutting Technology (ACT).
Continuous miner CAT CM210 for low
seam mining in range 0.71-1.52 m
CAT Gliding plow miner for extremely thin seams in the range 1.0 m – 2.3 m
Target : Designing and construction ACT Mining Complex consisting of an
ACT Mining Machine, AFC conveyor, hydraulic roof support together with
power supply.
KGHM’s expectations to construction of longwall
continuous mining and HPRS performance.
1. Remote operation should allow highest safety and maximum
productivity in extraction of low seam copper deposit.
2. The shear/plow system and shield supports can be positioned
exactly where they are needed (roof condition, faults etc.).
3. System is self-correcting for over- or underpush, thereby
maintaining a straight face regardless of floor or roof conditions.
4. Optimum use of installed power for maximum cutting depth for
every area of the longwall face.
5. Automated systems should allow access to extended reserves in
low copper ore seams to achieve a higher percentage of recovery.
6. ACT units should withstand the danger of seismic events (rock
burst) in the production area of KGHM copper mines.
Performance Trials to be carried out at the KGHM Mine (2012) in order to
prove the suitability of the prototype ACT Complex for use in the production.
KGHM: mechanical excavation method in
roadheading and room&pillar system.
Continuous miner (Joy, 14CM series)
Roadheader MH 620 (SANDVIK)
Conception of room&pillar method with
continuous mining and backfilling.
Two wing
operation
Objectives:
Lowering air cooling
costs
Haulage independence
Backfill improves safety
but rise operating costs
New conveyor is ready before
previous step is worked out
Source: K.Barrek, M. Czechowski, A.Ziąber, KGHM, Work Package 10, SMIFU project.
Mining of deep low seam deposits of copper ore (reserve
resources) in KGHM – picks or undercutting discs ?
Lithology
Reserve copper deposits in KGHM
Bytom
Odrzański Gaworzyce Głogów
Radwanice
Zachód Retków Average
Density
Mg/m3
[%]
Carbonates 52,3 83,95 28,53 87,43 8,67 28,14 2,6
Shale 10,25 14,45 12,41 12,57 13,66 12,75 2,5
Sandstone 37,45 1,61 59,07 0 77,67 59,11 2,3
Source: K.Barrek, M. Czechowski, A.Ziąber, KGHM, Work Package 10, SMIFU project.
KGHM’s contribution to the EU consortium to develop
a common vision for future deep mining in Europe.
The invisible, zero-impact
mine
„Fully automated mining method for deep metal mines in
Europe based on continuous mining with near-to-face
processing and waste backfilling”.
Countries which could support that initiative are: Sweden, Germany, Finland, other ?
Conclusions.
1. There is a need for new and modern vision of future deep
mining in Europe based on novel technical approach and zero
impact on environment.
2. International and interdisciplinary cooperation in EU is
necessary, both in the technical and socio-economical area to
design and implement that idea.
3. Europe 2020 programme should be a chance to increase funds
for RTD in the area of securing access to many deep laying
mineral deposits in Europe.
4. Active role of KGHM as a representative of extractive industry
should be valuable input in implementation of novel mining
solutions.
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