Rope Shovels and Electric for Surface Mining

Rope Shovels

1. Shovels for Surface Mining Shovels are a game-changer in the mining industry, allowing for efficient and careful excavation of earth. In this presentation, we'll dive into the advantages and inner workings of these machines. by Dr. Anupam Kher

2. Shovels for Surface Mining

3. Shovels for Surface Mining Discontinuous/Cyclic Methods of Excavation, Loading and Transport Excavation and loading relates to excavating the bench material and loading them onto the transporting equipment. However, in some cases the excavator itself transports and dumps the bucket load (e.g. dragline, scraper). This operation may be accomplished in cyclic/discontinuous mode or in continuous mode. Like excavation and loading, transportation of the loaded material may also be accomplished either in discontinuous/cyclic mode or in continuous mode. In this operation, the transporting equipment transport the loaded material to the respective destinations – coal/ore to coal depot/ore stock pile, and overburden/waste to overburden/waste/spoil dumps .

4. Shovels for Surface Mining Development of Shovels The shovel is one of the oldest types of excavating equipment. With time, the machine grew in capacity , steam power was replaced by diesel fuel and finally by electricity in the larger units. The basic configuration has changed relatively less but the efficiency and sophistication have increased substantially (Martin et.al., 1982 ). The steam shovel was invented and patented by William Otis in 1839. The first machines were known as 'partial-swing', since the dipper arm could not rotate through 360 degrees. They were built on a railway chassis, on which the boiler and movement engines were mounted. The shovel arm and driving engines were mounted at one end of the chassis, which accounts for the limited swing .

5. Shovels for Surface Mining Development of Shovels The full-swing, revolving shovel was developed in England in 1884, and became the preferred format for these machines. Perhaps the most famous application of steam shovels is the digging of the Panama Canal

6. Shovels for Surface Mining Development of Shovels The full-swing, revolving shovel was developed in England in 1884, and became the preferred format for these machines. Perhaps the most famous application of steam shovels is the digging of the Panama Canal

7. Shovels for Surface Mining Development of Shovels Shovels were also used for construction, road and quarry work. Steam shovels became more and more popular in the 1920s with the publicly funded road building programs around North America . Thousands of miles of State Highways were built in this time period, together with new factories , docks , ports, buildings, and grain elevators. During the 1930s steam shovels lost out to the simpler, cheaper diesel-powered excavating shovels . Open-pit mines were electrified at this time that helped the development of electric rope shovels. Bucyrus constructed one of the most famous monsters - the Big Brutus , the largest power shovel ever built and the largest still in existence.

8. Shovels for Surface Mining

9. Shovels for Surface Mining

10. Shovels for Surface Mining Classification of Shovels

11. Shovels for Surface Mining Classification of Shovels Based on Movement - Crawler Mounted - Wheel Mounted - Tub Mounted - Mounted on a barge/ rail

12. Rope Shovels for Surface Mining Classification of Shovels

13. Rope Shovels for Surface Mining Classification of Shovels

14. Rope Shovels for Surface Mining Classification of Shovels Tub Mounted

15. Rope Shovels for Surface Mining Classification of Shovels Rail Barge Mounted

16. Rope Shovels for Surface Mining

17. Power Shovel A power shovel is a single bucket equipped machine, electrically or diesel operated for digging and loading earth, fragmented rock or coal/mineral. They may be classifies as: Rope shovel Hydraulic shovel

18. Rope shovel

19. Hydraulic Shovel

20. Working of a Shovel

21. Rope shovel

22. Rope shovel

23. Shovels for Surface Mining Rope Shovels The machine typically consists of a boom, bucket, and counterweight system mounted on a rotating platform called the revolving frame. The revolving frame is supported by crawlers, allowing the rope shovel to move around the mining site. One of the key features of a rope shovel is its massive bucket capacity. These buckets can range from several cubic meters to over 100 cubic meters, depending on the size and model of the shovel. This bucket is also known as dipper. The bucket, often equipped with teeth or cutting edges, is designed to penetrate the ground and gather the material for loading and transportation.

24. Shovels for Surface Mining Rope Shovels The operation of a rope shovel involves several essential components. The boom is the long, rigid arm that supports the bucket and enables it to reach and dig into the material. It can be raised, lowered, and swung to different positions, allowing the shovel to excavate at various angles. Generally inclination of the boom is 450 to the horizontal, but it can be varied if required. By manipulating the ropes, the shovel can dig into the ground, fill the bucket, and lift the material for loading onto haul trucks or other transport vehicles. Their flexibility and maneuverability allow them to work in various mining environments, including open-pit mines and surface coal mines.

25. Main parts of a rope shovel Bucket Revolving deck Counter weight A boom Hoist cable Crowd Cable Support cable A frame Saddle block Driving and Control panel Crawler Operator cabin Shovels for Surface Mining

26. Shovels for Surface Mining Rope Shovels

27. Shovels for Surface Mining Rope Shovels

28. Main motions of a shovel Hoist - pulling the bucket up through the bank (i.e. the bank of material being dug) Crowd - moving the dipper handle (arm) out or in to control the depth of cut and when positioning to dump Swing - rotating the shovel between digging and dumping Propel - moving the shovel unit to different locations or dig positions Shovels for Surface Mining

29. Factors affecting performance of power shovel Height of cut Angle of swing Material preparation Capacity of hauling unit Efficiency of operator Working environment Condition of shovel Shovels for Surface Mining

30. Availability and utilization time Where, Available Hours = Worked Hours + Idle Hours Total Scheduled Hours = Worked Hour + Breakdown Hours + Maintenance Hours + idle Hours

31. Advantages of Rope Shovels in Surface Mining 1 Productivity 📈 Rope shovels have a high production capacity, making them ideal for large-scale mining operations. 2 Precision 🔬 These shovels are capable of precise, controlled excavation, reducing waste and increasing accuracy. 3 Durability 💪 Designed for heavy-duty use, rope shovels can withstand tough mining conditions for extended periods of time. 4 Lower Costs 💰 Rope shovels are cost-effective due to their high productivity and low operating and maintenance costs.

32. Components of Rope Shovels Boom The long arm that carries the dipper and provides the shovel's reach. Cab The operator's station, which contains the controls for operating the shovel. Dipper The large bucket that scoops up earth and carries it away. Crawler Treads The treads on which the shovel moves within the mine.

33. Operating a Rope Shovel 1 Pre-Operation Inspection Check the oil, fuel, and hydraulic levels and make sure all components are functioning properly. 2 Starting the Engine After inspecting the machine, turn on the engine and wait for it to warm up. 3 Excavation Use the controls in the cab to maneuver the shovel and scoop up earth with the dipper. 4 Transporting Material Swing the shovel to dump the material into a truck or other transport vehicle.

34. Maintenance of Rope Shovels Cleaning Regularly remove debris and dirt from all machine components to prevent wear and tear and minimize downtime. Oil Changes Change oil and other fluids regularly to ensure optimal performance and lifespan of the machine. Replacing Parts Replace worn or damaged parts as soon as possible to avoid more expensive repairs and downtime later.

35. Innovations in Rope Shovel Technology Automation 💻 Advancements in automation technology have made it possible to operate rope shovels remotely, reducing the risk of human error and increasing safety. Electric-Powered 🌿 Electric-powered rope shovels use renewable energy sources and produce lower emissions, making them more environmentally friendly. Improved Hydraulics 🚛 New hydraulic systems allow for better control and faster operation, increasing productivity and efficiency.

36. Future of Rope Shovels in Mining Industry 1 Decreased Human Input The use of automation technology will continue to rise, leading to more remote-operated rope shovels. 2 Increased Sustainability Environmental concerns will drive the industry towards more electric-powered and low-emissions rope shovels. 3 Improved Efficiency Advancements in hydraulics and other technologies will lead to faster, more efficient rope shovels that can handle larger quantities of earth.

37. Latest Mining Electric Shovels Electric shovels are transforming the mining industry. Discover their features, benefits, and challenges, and explore the latest developments in this innovative technology. by anupam kher

38. Introduction The Basics Electric shovels are used for removing large amounts of rock and soil in mines. They're powered by massive electric motors and are connected to an external power source. The Advantages Electric shovels offer better energy efficiency, lower maintenance costs, and greater control and precision. They also generate less noise and air pollution than diesel shovels. The Uses Electric shovels are used for a wide range of mining activities, from surface mining to underground mining. They're ideal for mining large-scale deposits in open-pit mines.

39. Components and Technology 1 Drive System The drive system consists of electric motors, a motor controller, and a transformer. It's responsible for powering the shovel and controlling its speed and torque. 2 Bucket and Dipper The bucket and dipper are the main working tools of the shovel. They're made of high-strength steel and are designed to withstand the stress and wear of continuous use. 3 Control System The control system manages the shovel's various functions, including hoisting, swinging, and dumping. It's operated by an operator who sits in a cab and uses joysticks to control the shovel.

40. Performance and Productivity Higher Efficiency Electric shovels are faster and more efficient than diesel shovels. They're also more precise, with greater accuracy and control over the amount of material moved. Improved Safety The use of electric shovels reduces the risks associated with diesel engines, including fire, explosion, and air pollution. It also reduces the noise levels on-site, making it easier for workers to communicate with each other. Bigger Capacity Electric shovels can load more material at once than diesel shovels, which means they require less time and equipment to complete a task. This translates into significant time and cost savings for mining companies.

41. Case Studies 1 Primary Gold Mine A gold mine in Australia replaced its diesel shovel fleet with electric shovels, resulting in a 50% increase in productivity and a 30% reduction in fuel consumption. 2 Bingham Canyon Copper Mine The Bingham Canyon Copper Mine in Utah, USA, uses one of the largest electric shovels in the world, capable of moving 180,000 tons of material a day. It has helped the mine become one of the most profitable in the world. 3 Hibbing Taconite Mine The Hibbing Taconite Mine in Minnesota, USA, has been using electric shovels for over 25 years, making it one of the early adopters of this technology. It has reported significant improvements in productivity and efficiency.

42. Challenges and Limitations Power Infrastructure Electric shovels require a reliable, high-voltage power source. This can be a challenge in remote or underdeveloped mining areas. Costs Electric shovels are generally more expensive than diesel shovels. However, they offer significant long-term cost savings, which can offset the initial investment. Maintenance Electric shovels require specialized maintenance and repair services, which may not be readily available in all regions. Regular maintenance is essential for keeping the shovel running at optimal performance.

43. Future Trends and Developments 1 Automation Some mining companies are exploring the use of self-driving electric shovels, which can operate without human intervention. This could improve safety and efficiency. 2 Battery-powered Shovels New developments in battery technology could eventually make it possible to power electric shovels with batteries, instead of reliance on external power sources. This could allow for greater flexibility and mobility. 3 Advanced Analytics Advanced analytics and machine learning algorithms can help improve the performance and efficiency of electric shovels by predicting their maintenance needs and optimizing their operating parameters.