CONTINUOUS SURFACE MIN1NG EQUIPMENT, OPERATION AND DESIGN Taylor & F rancis Taylor & Francis Group http://taylorandfrancis.com PROCEEDINGS OF TilE SECOND INTERNATIONAL SYMPOSIUM ON CONTINUOUS SURFACE MINING I AUSTIN TEXAS /2·5 OCfOBER 1988 Continuous Surface Mining Equipment, operation and design Edited by TIBOR G.ROZGONYI Departmtnl ofCivil Engineering, Texas A&M University TAD S.GOLOSINSKI Deparrmenr ofMining, Metallurgical & Petroleum Engineering, University ofAlberta C CRC Press R C Taylor & Francis Group Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 0 1988 by Taylor & Francis Group, LLC CRC Press is an imprint ofTaylor & Francis Group, an lnforma business No claim to original U.S. Government works This book contains information obtained from authentic and highly regarded sources. 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For permission to photocopy or use material electronically from this work. please access www.copyright.com (http://www.copy right.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration fora variety ofusers. For organizations that have been granted a photocopy license by the CCC, a separate system ofpayment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identifica tion and explanation without intent to infringe. Visit theTaylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com Continuous Sllfat»Mining: Equpnsnt, Operation andDesign, Rozgonyf& Go/osinski(eds) 0 1988Babms. Rot191riam.ISBN9061918588 Preface 'The 1st International Continuous Surface Mining Symposium was held in Edmonton, Alberta, Canada in 1986. It became apparent at that symposium that the surface mining industry is now in a very dynamic phase, as most of the presentations involved work-in-progress in the sense of rapid technological development The Central Texas Sectionofthe Society ofMining Engineers ofAIME and the Center for Energy and Mineral Resources at Texas A&M University have a compelling interest in such development Texas, as the sixth largest coal (lignite) producing state in the United States, recognizes the importance of the mining industry since it rivals agriculture in its economic impact in tenns ofgross product value. The 2nd International Continuous Surface Mining Symposiumis designed to bring together those professionals interested in continuous surface mining and related mining equipment This sympo sium, which is only one in a sequence of international events, is the continuation of the first one held in Alberta. The intent has been to supplement the first symposium and to review the progress that has been made in answering questions in mine design and planning techniques, operation methods and practices, mining systems perfonnance, equipment, design, selection and maintenance as well as potential developments of the technology. A wide scale andvariety oftechnological developments in various engineering disciplines have resulted in a high level of technological development of continuous surface mining methods and equipment The spectacular advances in computers have provided a powerful tool for modelling, and made engineering, operation and maintenance simple and foolproof. These are of particular importance since huge amounts of bulk material ftowing through a continuous surface mining system cannot realistically be directed and controlled safely by manual control. The development of centrifugal discharge bucket wheel excavators and new continuous surface excavators, across-the-pit technology and steep angle conveyors and the reliabil ity of these machines have been partially responsible for the current high productivity. A brief look at the breadth of the tides of the papers reveals that it has proven difficult to structure a balanced review for the different areas and produce single subject sessions. Therefore, the papers are arranged in the order of their presentation at the symposium. The keynote paper analyzes and synthesizes the recent developments and consequently, it has a specific significance. However, each of the papers represents a significant contribution to the subject matter, and the order of its presentation does not imply ratings to other papers. We know that this is not representative of the entire field of continuous surface mining, and the different areas will be revisited by additional papers at the following symposia. 1be presented papers were selected from over 60 abstracts submitted. It was not possible within the time frame of this symposium to make significant editorial changes. But we believe that the symposium procec:ding will help set new research, and practice directions, and will increase the conununication and infonnationexchange that the symposium is designed to promote. We hope that the readers will excuse some flaws and lapses in the papers and presentations, and some reduction in v the number ofpapers which resulted from last minute withdrawals due to different reasons. A publication ofthis nature requires contributions and help from many sources.To list all ofthem would be impossible, but a partial Jist can be misleading. However, the editors wish to acknowledge the authors who have spent time preparing their wodc for presentation and publication. It was a great pleasure for the editors to deal with professionals who so graciously share their experiences and achievements with us. The editors would like to thank those who prepared the camera ready manuscripts following the guidelines and met other restrictions, and made the role of editor less difficult We would like to thank the members ofthe organizing committee, reviewers, session chairs and symposium sponsors for theireffort andsupport Special thanks are due to those companies who financially supported the symposium. Publication ofthis volume would not be possible without the help, cooperation and patience ofthe publisher, A.A.Balkema and their staff, to whom the editors wish to express their sincere thanks. It has been a special privilege to serve as editorofthis proceeding, and again, thank you to all who provided the key ingredients to make the symposiuma success. TiborG.Rozgonyi, College Station, Texas, USA Tad S.Golosinski, Edmonton, Alberta, Canada August 1988 ~~Mhklg:Equj)ment. (;peration andDesign, Rozgonyf& Golosinski(eds) C 1988Babma, Rotf9rdam.ISBN9061918588 Organization of the symposium SYMPOSIUM ORGANIZERS AIME-SME Central Texas Section Donald B.Buddecke, P.E. {Chairman) Texas A&M University DrTibor G.Rozgonyi, P.E.(Program Chairman), DeparUnent ofCivil Engineering Feenan Jennings, Director, Center for Energy and Mineral Resources The University of Texas at Austin DrPriscilla Nelson The University of Alberta, Edmonton DrTad S.Golosinski Texas Mining and Mineral Resources Research Institute DrJonathan G.Price, Director VII INTERNATIONAL SYMPOSIUM ON CONTINUOUSSURFACE~G SYMPOSWM ADVISORY COMMITIEE Australia: Robert Hutchings, Dr, Chief Engineer, Fuel, State Electricity Commission ofVictoria. Box 'l765Y G.P.O., Melbourne 3001 CQII(l(/a: Tad S.Golosinski, Dr, P.Eng., Professor Department of Mining, Metallurgical & Petroleum Engineering, University ofAlberta. Edmonton, Alberta T6G 2G6 China: vacant Democratic Republic ofGer Klaus Strzodka, Prof. Dr. Ing. h.c., Sektion Geotechnik und many: Bergbau. Bergabdemie Freiberg, Freiberg Federal Republic ofGemuury: Rolf Dieter Stoll, Prof. Dr. Ing., Institut filr Bergbaukunde ill, Rwrn Aachen, Lochnersttasse 4-20, Aacllen India: AK.Subramanian, Advisor to CMD, Neyveli Lignite Corpora tion Ltd, 26 J.N. Salai, Neyveli, Tamilnadu ro7 801 Poland: 1bigniew Kozlowski, Prof. dr hab. int., Generalny Projektant Betchat6w, Poltegor, Powsta6c6w ~lfskich95, Wroclaw Union ofSovietSocialist Konstantin Vmitsky, Prof. Ox; Deputy Director, Skochinsky Min Republics: ing Institute, Moscow-Ljubertsy, USSR 1400>4 United States ofAmerica: 'Iibor G.Rozgonyi. Dr, P.E., Director, Coal and Lignite Research Laboralory, Texas A&M University, Department ofCivil Engi neering, College Station, TX 77843-3136 VIII Conti'luousSllftlceMining:Equpmsnt, Op6tation andDe!Jgn, Fbzgonyl & GoloslnsJd(eds) C 1988Babms, Ronetttam.ISBN9061918588 Contents Recent trends and advances in BWE and belt systems (Keynote address) 1 AT.Yu Customization in BWE design 9 Werner Rixen & RainerKahrger A second lignite mine at Neyveli: Salient features and problems 15 M.SMani, P.V.AY,Yasamy & R.Deivam Surface mining of Polish lignite deposits with complex geological structure 29 R.Uberman & W.Koziol Planning and implementing direct sidecasting systems in lignite surface mining ofthe GDR 35 K.-D.Bilkenroth, AMeltzer & E.Seliger Field investigations ofoil sand diggability with a bucketwheel excavator 47 Tad S.Golosinski Mining of hard erratics in overburden of lignite mines 55 K.Strzodka & D.Sch4fler Excavation ofbox cuts and mine opening with across-pit (XPS) systems 61 KStrzodka & U.Scholz Selective conveying and homogenization in the Belchat6w mine 67 Z.Kmlowski Application ofthe first continuous mining system in a Chinese lignite mine 73 Wang Xi & Wu Chao Ying Economic design ofbucketwheel excavators and spreaders for medium throughput rates 79 DJiof/man Continuous surface mining of coal in Czechoslovakia 89 .!.Vavra Bucketwheel excavators developed for the Neyveli opencast mines 97 AK.Subramanian Type and application of overburden spreaders 101 HvanLeyen IX