HIGHWALL MINER

Presented By :- Pulkit Paliwal

Introduction to Continuous Miner
 Machine produces constant flow and used in Room
and Pillar method.
 Today driverless and remote controlled are used.
 Consist of large rotating Drum comprising Steel and
Tungsten Carbide Teeth, scraps the coal from
seam/face. (Rooms 6.1 to 9.1 m in Length).
 Extracted Coal is Transported Via Conveyor System.
 Can produces 5 Tons of Coal in minute (Max.).
 Mounted on Rubber Tyres and Crawler Track.
Introduction to Highwall Miner
 Effective and Efficient means of coal recovery.
 New technology, which can extend the life of opencast
mine without disturbing the Surface Dwellings,
maintaining economy and productivity.
 Highwall Face has series of unsupported drives.
 The Pillar Remaining Between Adjacent Drives are
Capable Of Supporting the Overlying Structure.
 In India, 60% Energy requirements are met by Coal itself
and this accounts for 500MT Coal/Year and 80% is met
by opencast mining.
Introduction to Highwall Miner
 Existing pits are reaching beyond which economic
mining is not possible, So there is a great need of
Highwall Miner.
 Method comprises extraction of coal from a series of
parallel entries driven in the coal seam from the
Highwall Mining face.
 Entries are unmanned, unsupported, and unventilated.
 CIMFR adopting Highwall Miner in SCCL at
Ramagundum Opencast Mine and Tata Steel is
adopting for Quarry SEB and AB In West Borkaro.
Design, Key features & Components
 Interchangeable Cutter Head Module.
 Programmable Logic Controller.
 Pushbeams.
 Reel and Chain.
 Tracks.
 Anchoring System.
 Right Angle Conveyor.
 Generator.
Highwall Miner
A Terex™ Highwall Miner
Installation
 Complete unit can be assembled in 2 days and
dismantle in 3 days.
 Machine equipped with Bench Anchoring System.
 2 Machine mounted drills are located in front of
the Highwall Miner.
 Capable of drilling 2.5m holes in the pit floor.
 2 High strength rods of Dia. 15cm is then
inserted in the pit floor.
 During mining and retract cycle anchoring system
supports and stabilizes the Highwall miner.
Methods of Working
 Seam is penetrated by a Continuous Miner propelled by a
Hydraulic Pushbeam Transfer Mechanism (PTM).
 Cycle includes pushing forward, raising and lowering of
the Cutter head boom to cut entire length of coal.
 Pushbeams of 6.1m is placed between the cutter head
and power head as depth of penetration increases.
Maximum penetration upto 300m.
 Using Video imaging and gamma detector, the Cutter head
moves inside the seam and cuts only coal.
 Unwanted material and other debris is left inside, which
supports the strata.
Methods of Working
 Unwanted material and other debris is left inside, which
supports the strata.
 All functioning is controlled from a touch screen panel
located in operators cabin.
 Coal is transported via conveyor system and washed by
the unit itself before discharging onto stockpile.
 Recovery is much better than any other operation.
 Can be used in closed mines, But large capital is required
for its purchase and operation.
 Power from Generator of 2000hp, 1500 KW, 995 Volt,
Enclosed in super silent container of 6.1m.
Highwall Miner Working (Video)
Considerations in its Application
GROUND CONTROL:
 Roof Strength: Very good roof and strong to bear the load
of overlying strata.
 Web Pillars: Mostly thickness of 70% of the seam height is
projected.
 Barrier Pillars: Each pillar after 10 to 20 drives is left and
load assumed on pillar is taken as Load of the overlying
strata above pillar plus on each side half the load of
overlying strata above the drives to the Next Barrier Pillar.
 Dip: Seam dipping from 2-15 degrees. Almost impossible
to apply the system into steeper dipping coal seams.
Considerations in its Application
RECOVERY RATES:
 Less recovery as coal is left to maintain the Highwall Stability.
 Low seam under low overburden have recovery rate around 70%,
while high seam under low overburden have recovery rate around
15%.
FAULTS:
 Mining through faults always avoided, and safe distance at least
the width of barrier web pillar should be kept from faults.
UNDERGROUND MINES:
 Highwall through abandoned Underground areas must be
avoided.
Considerations in its Application
PRODUCTION RATES:
 Production rates in favorable conditions and well maintained
locations with avg. penetration of 70 to 95% lead to annual
production of 0.5 to 1.5 Million Tons of Coal. But changes
from site to site and also affected by local circumstances.
SEAM UNDULATIONS:
 Strong seam undulations are more difficult to follow by cutter
head.
INTEGRATION IN MINE PLANNING:
 Highwall Mining system saves cost of making benches from
spoil. Miner should be planned to proceed with least
interruption.
Safety in Highwall Mining
 Although, all operating personnel are surface located in the pit, Coal cutting
occurs in an Underground Environment, But still there are few hazards:
 Highwall Hazard
- Resulting from crushing of Pillar or Failures associated with insitu structures.
- Avoided by developing 2 Zones i.e. General Safety Zone and Vertical Drop
Zone.
Safety in Highwall Mining
 Roof Span Collapse Hazard
- Continuous in Operation and System Results in Unsupported Opening, So
Successful and Safe Operation can be Achieved with Rapid Entry and
Retraction. Otherwise CHM Could Readily be Buried in Rock.
 Explosion Hazards
- Operations Occurs in Underground Environment, So Methane Explosion can
Occur. To Minimize the Explosion Flame Proof Enclosure of Machinery and
Instrumentation Entering the Highwall Drives. Methane Monitoring Equipments
Installed in Operators Cabin.
Ground Control of Highwall Mining
 While designing layout, Engineer must specify
 Web Pillar Width
 No. of Web Pillar between Barrier Pillars.
 Barrier Pillar Width.
 Coal Pillar Strength
SP = SI [0.64 + 0.54 W / H], Where:
SP = Web or Barrier Pillar Strength
SI = Insitu Coal Strength
W = Web or Barrier Pillar Width
H = Mining Height
 Coal Pillar Stress
SWP = SV (WWP + WE) / WWP, Where:
SV = Insitu Vertical Stress
WWP = Web Pillar Width
WE = Highwall Miner Hole Width.
Ground Control of Highwall Mining
 Finally, the Stability Factor For Web Pillars against
Strength Failure is Simply:
 
SFWP = Web Pillar Strength(SP) / Web Pillar
Stress (SWP).
Typical Highwall Miner
Holes and Web Pillars.

Note: Barrier Pillar or “Skip Hole”

indicated by arrow.
Site of Massive Web
Pillar Collapse resulting
in Highwall Slope
Failure.
Note: Photograph is taken from
adjacent spoil pile. Highwall is
about 150 feet high. A 110 ton Coal
Haulage truck is buried in Rockfall
Debris.
Advantages
 Cost
 Flexibility
 Applicability
 Safety
 Coal Recovery
 Productivity
 Environmental Impacts
Limitations
 Method is not suitable in steeper
gradient.
 Penetration depth has got its limit
depending upon the dip of the seam.
 Requires skilled and qualified personnel.
 Added to that it is not an end of the
mining rather underground mining can
extent farther from the highwall.
Highwall Mining in India & Conclusion

It is logical to prioritize Highwall Mining in sites with the

following parameters:
 Strong roof 
 Straight seams
 Dip angle < 6 degrees
 Seam Height < 3.5 metres
 Coal of high value or superior grades
 Where open cast pits have to be closed
 
Highwall Mining in India & Conclusion

Recently, a high level delegation of coal companies visited USA and

also the manufacturers of the Highwall mining machines. Two
companies of Coal India Limited and the Singareni Collieries have
shown their inclination towards Highwall mining and are set to
introduce this technology in selected mines.

Experts believe that there will be lot of scope for introduction of this
technology in Indian mines in coming years and there could be
additional production of 10 to 15 million tones per annum with these
new machines. 
Thank You