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WORKING OF ICC-BWE-ROCK BREAKER

          I. Satyanarayana,
                           M.Tech,MBA,MCA



 Dy. Manager, Project Planning, SCCL,

        isnindian@gmail.com,

               visit at

    www.slideshare.net/isnindian
2
3. In pit crusher conveyor technology




•The drilled & blasted OB is loaded by shovels and transported by dumpers
to Crushers. The crushed OB is then transported by a series of conveyors
into a spreader for dumping.

•Can be used in steep seams where laying of transport roads for the trucks
is difficult.

•While S.R indicates volumes, cut off ratio indicates depth and reflects in
dumper haulage cost, which increase with depth and may become
prohibitive where in alternative haulage system may have to thought off.

•Ideally suited where material has to be transported over a longer distance
& high lift.
3.IN-PIT CRUSHER CONVEYOR TECHNOLOGY

•    Haulage costs have been an area that have risen significantly with the
     increase of diesel prices.
•    One alternative to reduce haulage costs is to shorten the truck haul
     distance by bringing the dump point into the pit using an in pit movable
     crusher/ crushers and conveying the Over burden out of the pit can
     reduce the haul cost.
•    When the gradient is too steep, dumping the material within the mine is
     not practicable as the dumped OB slides on to the coal face. In such
     cases in pit crushing is preferred.
•    The flow of material utilising an inpit movable crusher and conveyor
     system starts with OB material being dumped into crushers by
     dumpers. The material is crushed and fed on to horizontal transfer
     belts within the pit or directly on to a major up slope belts taking the
     material out of the pit. There may be one or more belts depending on
     the pit Geometry and depth. The conveyed material is dumped as per
                                                          Video
     the requirement and the dump design by using spreaders.
In pit crusher conveyor technology:

 •   Can be used in steep seams where laying of transport
     roads for the trucks is difficult.
 •   Ideally suited for large capacity projects.
 •   Ideally suited where material has to be transported
     over a large distance with huge lift.
 •   Requires huge capital.
 •   The transport cost will be much less than compared
     to shovel dumper combination.
 •   Requires heavy equipment like crushers, conveyor
     distribution point and spreaders.
Ramagundam OC-II with Inpit Crushing & Conveying Technology
Depth and gradients makes dumper haulage prohibitive due to high operating
cost. The alternate choice is ICC where material has to be transported over a
large distance & lift.

The drilled & blasted OB is loaded by shovels and transported by dumpers to
Crushers. The crushed OB is then transported by a series of conveyors into a
spreader for dumping.
Salient features of RG OC-II Project
No.of seams- 10
Gradient- 1 in 3.6 to 1 in 4
Depth planned- 400m
Capacity of the project- 4 MTPA
Technology- Shovel dumper combination with ICC technology
Life of the project- 27 years
Stripping Ratio- 7.73 Cum/T (107.46 Mt of coal and 808.46 M.Cum of OB)
Grade of the coal- ‘D’
OMS- 6.88 planned
Cost of production in Rs/T - 1606.94
Total Capital outlay of the project is estimated at Rs 896.32
Slope stability is a vital aspect in this project, as final highwalls will have a height
of up to 400 m which need to be planned as steep for better economics.
The 120m high dumps with crushed OB(low cohesion) will pose different
problems in dump stability which needs a comprehensive study on design,
maintenance, monitoring and stabilisation altogether.
IN-PIT CRUSHER CONVEYOR TECHNOLOGY
ICC at RG OC-II
Ramagundam OC-II Mine with Inpit Crushing & Conveying Technology




Compacted floor sloped 2-3°towards toe of the upper deck to direct the water to the
drain to avoid seepage into the dump. Better we provide lined drains/channels.
Working of icc bwe-rock breaker
Working of icc bwe-rock breaker
The spreader can rotate with an angle of 120 degrees.




  In SCCLtd, the inpit crushing and conveying system introduced in RG OC II,
  Ramagundam. The capacity of each crusher-conveyor system is 1200
  cum/hour. There are 3 such systems in addition to coal conveying system in
  RG OC II mine.
4) Continuous Miner Technology:- Bucket Wheel Excavators



•Presently being used in Naveyali, Lignite Opencast mines,
having soft strata.


•The bucket wheel excavates the material without blasting
which is transported by a series of belt conveyors to
spreader.
4. BUCKET WHEEL EXCAVATOR(BWE)
BUCKET WHEEL EXCAVATOR(BWE)
This machine is suitable for excavating soft and non sticky material in
large quantities.
Lignite deposits usually associated with soft over burden. Most lignite
mines in world use these BWEs for both OB and Lignite, as is the case
of “Nyveli Lignite Corporation” of India.
Semi hard material also be made suitable for BWEs by small blastings.
The BWE is a continuous excavating machine and capable of removing
of OB up to 1200 cum / per hour.
The excavation component of BWE is a large rotating wheel mounted on
an arm/boom.
On the outer edge of wheel is a series of scoops/ buckets as the wheel
turns, the Bucket removes soil
As the wheel turns, the bucket removes OB/Coal from the target areas
and carries it around to the back side of the wheel, where it falls on to a
conveyor which carries the material to the identified destination.
BWE are generally worked in combination with crusher & conveying
system.
Working of icc bwe-rock breaker
Working of icc bwe-rock breaker
Overview – 3D view
Structural Components of the
               BWE – Side View
Hoist Unit for Bucket         Maintenance Crane                    Counterweight Boom                    Maintenance Crane
   Wheel Boom

                                                                                  Pylon                                 Operator’s Cabin


                                                                                                                       Bucket Wheel Boom

      E-House
                                                                                                                             Bucket Wheel




                                                                                                                 Slewing Platform
Discharge Boom          Discharge Boom Slew
 with Conveyor              Arrangement
    System                                                                                                             Rotary Plate and Drive




                                                  Crawler Travel                 Crawler Undercarriage                  Main Ball Race
Equipments Installed on
               BWE
Crawler Drive

Bucket wheel

Rotary Plate

Boom Conv. Systems

Slew Systems

Boom Hoist System
LIGNITE FIELDS OF INDIA

                           NLC is also the Nodal agency
    4                    for  Exploration   of   Lignite
                         Deposits in India.
                           The Lignite Reserves in
                         various states of India was
    2                    proved and estimated by NLC.
3
                               Lignite Reserves (as of April 2009)
                         Sl.            State            In MT       %
                         No.

                         1     Tamilnadu &
                                                        31818.42     81.7
                               Pondicherry
                         2     Rajasthan                 4443.65     11.4
                         3     Gujarat                   2662.25      6.8
        1
                         4     Jammu & Kashmir             27.55     0.07
    5
                         5     Kerala                       9.65     0.02
                         6     West Bengal                  1.15   0.003

                                                Total   38963.17   100.0
LOCATION OF NEYVELI LIGNITE MINES (SATELLITE IMAGE)


                             Neyveli
                            Township




               TPS-I & IE



      TPS-II
Safety Department – Mine-II & Expn.
     SALIENT FEATURES OF MINE – 2
                           Mines-2        Expansion   Mine-2
        Description        ( 10.5 MTPA)   (4.5MTPA)   (15.00MTPA)

Overburden thickness         50-100 M      57-112 M    50-112 M

Lignite Thickness             4-24 M        6-22 M       4-24M

Stripping Ratio in m3 :t      1:5.2          1:5.88      1:5.5

Minerable Reserve in M.T      380.81        214.88      595.69

Land requirement in Ha.      5321.99        2031.63     7353.62
Over burden removal in
MCM /A                          51            27          78

Lignite in MT /A               10.5           4.5         15
0.0     Alluvial Clay
 3.0

         Sandstone, Clayey Sandstone ,
         Sandy clay.


 105.5
         Semi – Confined Aquifer Sand
 112.0
 113.5    Carbonaceous Clay

         Lignite – I Seam
133.8 – 137.0    Carbonaceous Clay
137.0 – 138.30  Lignite – II Seam
         Confined Aquifer Sand
154.8
156.8    Clay
190.0    Confined Aquifer Sand
Safety Department – Mine-II & Expn.
        MAJOR MINING EQUIPMENTS FOR MINE-II .
                                             Mines-2        Mines-2
Description                                  (10.5 MTPA )   (15.00MTPA)

1400 Lit. STANDARD BWEs                             2              5

1400 Lit. STANDARD BWEs- BRIDGE TYPE                3              3

700 Lit. STANDARD BWEs                              3              4

700 Lit. STANDARD BWEs- Bucket rever. Type          2              3

11000 TPH MTC                                       3              6

4700 TPH MTC/4420Cu.mPH                             2              3

20000 TPH SPREADER                                  2              3

20000 TPH CRAWLER MOUNTED TRIPPER                   2              3

11000 TPH SPREADER                                  2              2

11000 TPH CRAWLER MOUNTED TRIPPER                   2              2

6000TPH STACKER                                     1              1

2800 TPH RECLAIMER                                  2              2

TRANSPORT CRAWLER                                   2              4
METHOD OF MINING

                                   Opencast continuous mining system using
                                          • Bucket Wheel Excavators
                                          • Spreaders
                                          • Conveyor Systems
                    Refilling                      Mine Advancing Side
      NSBS
                                                                            NSBS



                                                                                           SBS
SBS
                                                                                     TBS
 TBS
Spoil Bank
                                                                      MBS

        MBS                                                      OB bench Avg. Height – 25 m
       Spoil Bank                                          BBS
                                                                 Av. Height – 15 m
 Spoil Bank         BBS                         Lignite Bench
                                                                 Maximum Height = 22 m
1400 LITRE BRIDGE TYPE BWE




Rated Production                          :   2250 m3/hr
Outreach from BW boom to Discharge boom   :   130 ± 12 metres
Maximum High Cut height                   :   30 metres
Service Weight                            :   3193 Tonnes
1400 LITRE BWE




Rated Production                          :   2250 m3/hr
Outreach from BW boom to Discharge boom   :   61.3 metres
Maximum High Cut height                   :   26 metres
Service Weight                            :   2170 Tonnes
700 LITRE BWE WITH DEEP CUT FACILITY

 Rated Production                          :   1100 m3/hr
 Outreach from BW boom to Discharge boom   :   63.8 metres
 Maximum High Cut height                   :   18 metres
 Service Weight                            :   1450 Tonnes
11,000 TPH SPREADER




Theoretical design capacity                      :   11,000 Tonnes/hr
Outreach from Receiving boom to Discharge boom   :   135 metres
Working Gradient                                 :   1 : 20
Service Weight                                   :   1450 Tonnes
BRIDGE TYPE 1400 LITRE BWE IN OPERATION
DUMPING OPERATION OF 20,000 TPH SPREADER
700 LITRE BWE OPERATION IN LIGNITE BENCH
EXCAVATION WITH LOCAL DEPRESSURISATION




  GROUND WATER PUMPING FROM MINES - 110 Mm3 / ANNUM
 45 NUMBERS OF 1000 GPM PUMPS (20” DIA) ARE IN OPERATION
Rock breaker




Rock breaker technology can be applied for breaking of rock/coal/ore
even about 500 kg/sq.cm.
It can be used wherever it is not possible to go for blasting – near
vicinity of structures and habitations.
Technical Parameters of Mega –
               Breaker

Make               :   INDECO
Model              :   8500 UP
Weight             :   4500 Kg
Dia of tool        :   195 mm
HP                 :   120 HP
Striking rate      :   350-450 Blows / Min
Pressure to
     Breaker       :   150-160 bar
Energy Class /
            Blow   :   10,000 joules
Working Parameters of Mega Breaker


Production / Hour    :   190 – 200 tons

Production / Month :     55,000 tons

Diesel Consumption :     30 Lit./ Hr

Life of Moil point   :   275-300 hours

Optimal Bench Ht.    :   3 to 4 M
Advantages
Locked-up reserves can be mined easily
Reduction in Man power
Sump-deepening an easy affair
Digging of foundation pits adjoining the kiln /
valuable structures
More environmental friendly working &
maintaining better social relationship with
villagers
Effective working hours compared to
conventional working methods
Limitations
Floor-level will not be uniform as
compared to Surface Miner
Not suitable for mining huge reserves
Have to be dependent on a single
machine
Cost Particulars
Total Capital Investment   = 330 Lakhs
Cost of consumables        = 1.2 Lakhs

Cost / ton of Limestone (Rs./MT) :
   Owning Cost             = 17.77
   Operating Cost          = 12.25
   Total Cost              = 30.02

Cost of Conventional Mining (Rs./MT) :
   Total Cost             = 24.80
Working of icc bwe-rock breaker

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Working of icc bwe-rock breaker

  • 1. WORKING OF ICC-BWE-ROCK BREAKER I. Satyanarayana, M.Tech,MBA,MCA Dy. Manager, Project Planning, SCCL, isnindian@gmail.com, visit at www.slideshare.net/isnindian
  • 2. 2
  • 3. 3. In pit crusher conveyor technology •The drilled & blasted OB is loaded by shovels and transported by dumpers to Crushers. The crushed OB is then transported by a series of conveyors into a spreader for dumping. •Can be used in steep seams where laying of transport roads for the trucks is difficult. •While S.R indicates volumes, cut off ratio indicates depth and reflects in dumper haulage cost, which increase with depth and may become prohibitive where in alternative haulage system may have to thought off. •Ideally suited where material has to be transported over a longer distance & high lift.
  • 4. 3.IN-PIT CRUSHER CONVEYOR TECHNOLOGY • Haulage costs have been an area that have risen significantly with the increase of diesel prices. • One alternative to reduce haulage costs is to shorten the truck haul distance by bringing the dump point into the pit using an in pit movable crusher/ crushers and conveying the Over burden out of the pit can reduce the haul cost. • When the gradient is too steep, dumping the material within the mine is not practicable as the dumped OB slides on to the coal face. In such cases in pit crushing is preferred. • The flow of material utilising an inpit movable crusher and conveyor system starts with OB material being dumped into crushers by dumpers. The material is crushed and fed on to horizontal transfer belts within the pit or directly on to a major up slope belts taking the material out of the pit. There may be one or more belts depending on the pit Geometry and depth. The conveyed material is dumped as per Video the requirement and the dump design by using spreaders.
  • 5. In pit crusher conveyor technology: • Can be used in steep seams where laying of transport roads for the trucks is difficult. • Ideally suited for large capacity projects. • Ideally suited where material has to be transported over a large distance with huge lift. • Requires huge capital. • The transport cost will be much less than compared to shovel dumper combination. • Requires heavy equipment like crushers, conveyor distribution point and spreaders.
  • 6. Ramagundam OC-II with Inpit Crushing & Conveying Technology Depth and gradients makes dumper haulage prohibitive due to high operating cost. The alternate choice is ICC where material has to be transported over a large distance & lift. The drilled & blasted OB is loaded by shovels and transported by dumpers to Crushers. The crushed OB is then transported by a series of conveyors into a spreader for dumping.
  • 7. Salient features of RG OC-II Project No.of seams- 10 Gradient- 1 in 3.6 to 1 in 4 Depth planned- 400m Capacity of the project- 4 MTPA Technology- Shovel dumper combination with ICC technology Life of the project- 27 years Stripping Ratio- 7.73 Cum/T (107.46 Mt of coal and 808.46 M.Cum of OB) Grade of the coal- ‘D’ OMS- 6.88 planned Cost of production in Rs/T - 1606.94 Total Capital outlay of the project is estimated at Rs 896.32 Slope stability is a vital aspect in this project, as final highwalls will have a height of up to 400 m which need to be planned as steep for better economics. The 120m high dumps with crushed OB(low cohesion) will pose different problems in dump stability which needs a comprehensive study on design, maintenance, monitoring and stabilisation altogether.
  • 9. ICC at RG OC-II
  • 10. Ramagundam OC-II Mine with Inpit Crushing & Conveying Technology Compacted floor sloped 2-3°towards toe of the upper deck to direct the water to the drain to avoid seepage into the dump. Better we provide lined drains/channels.
  • 13. The spreader can rotate with an angle of 120 degrees. In SCCLtd, the inpit crushing and conveying system introduced in RG OC II, Ramagundam. The capacity of each crusher-conveyor system is 1200 cum/hour. There are 3 such systems in addition to coal conveying system in RG OC II mine.
  • 14. 4) Continuous Miner Technology:- Bucket Wheel Excavators •Presently being used in Naveyali, Lignite Opencast mines, having soft strata. •The bucket wheel excavates the material without blasting which is transported by a series of belt conveyors to spreader.
  • 15. 4. BUCKET WHEEL EXCAVATOR(BWE)
  • 16. BUCKET WHEEL EXCAVATOR(BWE) This machine is suitable for excavating soft and non sticky material in large quantities. Lignite deposits usually associated with soft over burden. Most lignite mines in world use these BWEs for both OB and Lignite, as is the case of “Nyveli Lignite Corporation” of India. Semi hard material also be made suitable for BWEs by small blastings. The BWE is a continuous excavating machine and capable of removing of OB up to 1200 cum / per hour. The excavation component of BWE is a large rotating wheel mounted on an arm/boom. On the outer edge of wheel is a series of scoops/ buckets as the wheel turns, the Bucket removes soil As the wheel turns, the bucket removes OB/Coal from the target areas and carries it around to the back side of the wheel, where it falls on to a conveyor which carries the material to the identified destination. BWE are generally worked in combination with crusher & conveying system.
  • 20. Structural Components of the BWE – Side View Hoist Unit for Bucket Maintenance Crane Counterweight Boom Maintenance Crane Wheel Boom Pylon Operator’s Cabin Bucket Wheel Boom E-House Bucket Wheel Slewing Platform Discharge Boom Discharge Boom Slew with Conveyor Arrangement System Rotary Plate and Drive Crawler Travel Crawler Undercarriage Main Ball Race
  • 21. Equipments Installed on BWE Crawler Drive Bucket wheel Rotary Plate Boom Conv. Systems Slew Systems Boom Hoist System
  • 22. LIGNITE FIELDS OF INDIA NLC is also the Nodal agency 4 for Exploration of Lignite Deposits in India. The Lignite Reserves in various states of India was 2 proved and estimated by NLC. 3 Lignite Reserves (as of April 2009) Sl. State In MT % No. 1 Tamilnadu & 31818.42 81.7 Pondicherry 2 Rajasthan 4443.65 11.4 3 Gujarat 2662.25 6.8 1 4 Jammu & Kashmir 27.55 0.07 5 5 Kerala 9.65 0.02 6 West Bengal 1.15 0.003 Total 38963.17 100.0
  • 23. LOCATION OF NEYVELI LIGNITE MINES (SATELLITE IMAGE) Neyveli Township TPS-I & IE TPS-II
  • 24. Safety Department – Mine-II & Expn. SALIENT FEATURES OF MINE – 2 Mines-2 Expansion Mine-2 Description ( 10.5 MTPA) (4.5MTPA) (15.00MTPA) Overburden thickness 50-100 M 57-112 M 50-112 M Lignite Thickness 4-24 M 6-22 M 4-24M Stripping Ratio in m3 :t 1:5.2 1:5.88 1:5.5 Minerable Reserve in M.T 380.81 214.88 595.69 Land requirement in Ha. 5321.99 2031.63 7353.62 Over burden removal in MCM /A 51 27 78 Lignite in MT /A 10.5 4.5 15
  • 25. 0.0 Alluvial Clay 3.0 Sandstone, Clayey Sandstone , Sandy clay. 105.5 Semi – Confined Aquifer Sand 112.0 113.5 Carbonaceous Clay Lignite – I Seam 133.8 – 137.0 Carbonaceous Clay 137.0 – 138.30 Lignite – II Seam Confined Aquifer Sand 154.8 156.8 Clay 190.0 Confined Aquifer Sand
  • 26. Safety Department – Mine-II & Expn. MAJOR MINING EQUIPMENTS FOR MINE-II . Mines-2 Mines-2 Description (10.5 MTPA ) (15.00MTPA) 1400 Lit. STANDARD BWEs 2 5 1400 Lit. STANDARD BWEs- BRIDGE TYPE 3 3 700 Lit. STANDARD BWEs 3 4 700 Lit. STANDARD BWEs- Bucket rever. Type 2 3 11000 TPH MTC 3 6 4700 TPH MTC/4420Cu.mPH 2 3 20000 TPH SPREADER 2 3 20000 TPH CRAWLER MOUNTED TRIPPER 2 3 11000 TPH SPREADER 2 2 11000 TPH CRAWLER MOUNTED TRIPPER 2 2 6000TPH STACKER 1 1 2800 TPH RECLAIMER 2 2 TRANSPORT CRAWLER 2 4
  • 27. METHOD OF MINING Opencast continuous mining system using • Bucket Wheel Excavators • Spreaders • Conveyor Systems Refilling Mine Advancing Side NSBS NSBS SBS SBS TBS TBS Spoil Bank MBS MBS OB bench Avg. Height – 25 m Spoil Bank BBS Av. Height – 15 m Spoil Bank BBS Lignite Bench Maximum Height = 22 m
  • 28. 1400 LITRE BRIDGE TYPE BWE Rated Production : 2250 m3/hr Outreach from BW boom to Discharge boom : 130 ± 12 metres Maximum High Cut height : 30 metres Service Weight : 3193 Tonnes
  • 29. 1400 LITRE BWE Rated Production : 2250 m3/hr Outreach from BW boom to Discharge boom : 61.3 metres Maximum High Cut height : 26 metres Service Weight : 2170 Tonnes
  • 30. 700 LITRE BWE WITH DEEP CUT FACILITY Rated Production : 1100 m3/hr Outreach from BW boom to Discharge boom : 63.8 metres Maximum High Cut height : 18 metres Service Weight : 1450 Tonnes
  • 31. 11,000 TPH SPREADER Theoretical design capacity : 11,000 Tonnes/hr Outreach from Receiving boom to Discharge boom : 135 metres Working Gradient : 1 : 20 Service Weight : 1450 Tonnes
  • 32. BRIDGE TYPE 1400 LITRE BWE IN OPERATION
  • 33. DUMPING OPERATION OF 20,000 TPH SPREADER
  • 34. 700 LITRE BWE OPERATION IN LIGNITE BENCH
  • 35. EXCAVATION WITH LOCAL DEPRESSURISATION GROUND WATER PUMPING FROM MINES - 110 Mm3 / ANNUM 45 NUMBERS OF 1000 GPM PUMPS (20” DIA) ARE IN OPERATION
  • 36. Rock breaker Rock breaker technology can be applied for breaking of rock/coal/ore even about 500 kg/sq.cm. It can be used wherever it is not possible to go for blasting – near vicinity of structures and habitations.
  • 37. Technical Parameters of Mega – Breaker Make : INDECO Model : 8500 UP Weight : 4500 Kg Dia of tool : 195 mm HP : 120 HP Striking rate : 350-450 Blows / Min Pressure to Breaker : 150-160 bar Energy Class / Blow : 10,000 joules
  • 38. Working Parameters of Mega Breaker Production / Hour : 190 – 200 tons Production / Month : 55,000 tons Diesel Consumption : 30 Lit./ Hr Life of Moil point : 275-300 hours Optimal Bench Ht. : 3 to 4 M
  • 39. Advantages Locked-up reserves can be mined easily Reduction in Man power Sump-deepening an easy affair Digging of foundation pits adjoining the kiln / valuable structures More environmental friendly working & maintaining better social relationship with villagers Effective working hours compared to conventional working methods
  • 40. Limitations Floor-level will not be uniform as compared to Surface Miner Not suitable for mining huge reserves Have to be dependent on a single machine
  • 41. Cost Particulars Total Capital Investment = 330 Lakhs Cost of consumables = 1.2 Lakhs Cost / ton of Limestone (Rs./MT) : Owning Cost = 17.77 Operating Cost = 12.25 Total Cost = 30.02 Cost of Conventional Mining (Rs./MT) : Total Cost = 24.80