BOLTER MINER Study Tour @ Russia

Wise to resolve,

patient to perform…

Team

Prepared by Venkat

Presentation Profile

• Objective

• Details of the Visit

• Russia – Mining Scenario

• Bolter Miner Details

• Mine visits – Salient Features• Mine visits – Salient Features

• Maintenance

• Things to be implementable

• Conclusions

• Pics of Bolter Miner

The Objective

• Background– SCCL future depends only on the successful implementation of bulk

capacity Longwalls.

– Company is in advance stage of introduction of high capacity Longwalls

in few mines at first and on a large scale later.

– From past experience it is clear that the panel development is one of the

critical activity in Longwall success.critical activity in Longwall success.

– Now, it is the time to change ourselves from age old Road headers to

Bolter miners to have rapid progress in roadway development including

safety.

• A team of three executives were selected to visit Russia to study,observe and analyze the operation of Bolter miner in different minesat different geo-mining conditions. The same can be compared withand if possible can be implemented in our longwall mines.

Visit Particulars

• Total Period - 10th to 23rd April 2010

• Mines Visited - Four

• Surface visits include - Manufacturing plants • Surface visits include - Manufacturing plants

Training Schedule - 2010

DATE ACTIVITY

Mon 12th April Arr Novokuznetsk am, transfer to hotel, meeting at Joy Kuzbass office pm.

Tue 13th April Underground visit to Kotenskaya mine to see Joy Bolter miner development

Wed 14th April Underground visit to Raspadskaya mine to see Joy development and Longwall

Thur 15th April Underground visit to Raspadskaya Koksova mine to see 12CM30

Fri 16th April De-brief meeting at Novokuznetsk office Fri 16th April De-brief meeting at Novokuznetsk office

Sat 17th April Dep Novokuznetsk am, free time in Moscow.

Sun 18th April Sightseeing in Moscow

Mon 19th April Depart Moscow for Vorkuta, arrive Vorkuta 12.50

Tue 20th April Underground visit Vorgashorska mine to see Joy Bolter miner development.

Wed 21st April Meeting at Vorgashorska mine am.Depart Vorkuta 13.50 arrive Moscow 16.40

Thur 22nd April De-brief meeting in Mosow office

Fri 23rd April Depart Moscow for return home - EK 134,Moscow(DME) 1755

Russian Coal Industry

• Fifth largest producer of coal in the

world.

• 2nd largest proved coal reserve in

world.

World Coal Reserves

Russian production for last 15 years

0

50

100

150

200

250

300

350

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

O/C

U/G

Russia Coal Map

Svalbard, Norway

Sweden

Arctic Ocean Bering

SeaBarents

Sea

Joy/P&HMoscow Vorkuta coal reserves

PECHORA BASINPECHORA BASIN

YAKUTIA BASINYAKUTIA BASIN

Russia Coal Market Overview

Kazakhstan

Mongolia

ChinaJapan

Moscow

Joy/P&HKuzbass

Kuzbass coal reserves

YAKUTIA BASINYAKUTIA BASIN

EAST EAST SIBERIASIBERIABASINBASINKUZNETSKKUZNETSK

BASINBASIN

Elga project

Top 10 Russian Mines by Production

Customer Name Production

Raspadskaya 10.6 MT

Zarechnaya 5.1 MT

Kirova 4.5 MT

Kotinskaya 3.9 MTKotinskaya 3.9 MT

Salek 2.9 MT

Polosukhinskaya 2.8 MT

Alardinskaya 2.6 MT

Taldinskaya-Zap-1 2.5 MT

Taldinskaya-Zap-2 2.2 MT

EAST

SIBERIA -

73.6Mt

FAR

EAST -

32.5Mt (5)

VORKUTA

- 9.2Mt

(3)

DONETSK -

7.6Mt

(4)

4.8Mt -

URAL

Kuzbass Coal Market Overview

Territory 95.5sq.km

Coal Reserves = 91.2b tonnes

Total Region Population = 3M

180.0Mt -

KUZBASS

(1)

73.6Mt

(2)

� KUZBASS 57 % OF TOTAL COAL PRODUCTION

� KUZBASS 75.5 % OF COKING COAL PRODUCTION

No of U/G Mines = 58

No of Operating LW = 64

Joy Machines in Operation = 93 units

Bolter Miner

DetailsDetails

CM + BM population - 2008

Total Population Apprx. 1600 units = 1400 CM and 200 BM

OEM suppliers of Bolter miner

Machine Type Vs Operation heights

Market Share of

various OEMs

World

SERIAL No & OE PLANT M/C TYPE CUSTOMER STATUS

JM 5601 PINXTON UK 12BM15 Yzhkuzbassugol

Ulyanovskaya Mine

Installed June 06

JM 5602 PINXTON UK 12BM15 Yzhkuzbassugol

Ulyanovskaya Mine

Installed June 06

JM 5606 FRANKLIN US 12CM15 WHBM Suek Kotenskaya Mine Intalled Sep 06

Bolter Miners in Russia

JM 5606 FRANKLIN US 12CM15 WHBM Suek Kotenskaya Mine Intalled Sep 06

JM 6708 MOSS VALE AUS 12CM30D Raspadskaya Group

Muk 96

Installed July 07

JM 6709 MOSS VALE AUS 12CM30D Raspadskaya Group

Muk 96

Installed July 07

JM 6710 MOSS VALE AUS 12CM30D Suek Taldenskaya Mine Installed Sept 07

JM 6711 MOSS VALE AUS 12CM30D Suek Kotenskaya Mine Installed Oct 07

JM 6712 MOSS VALE AUS 12CM30D Suek Taldenskaya Mine Installed Jan 08

JM 6723 MOSS VALE AUS 12CM30B Vorkutaugol

Vorgasorskaya Mine

Installed Dec 08

1005 m during Aug 09

SERIAL No & OE PLANT M/C TYPE CUSTOMER STATUS

JM 6727 MOSS VALE AUS 12CM30B Vorkutaugol

Vorgasorskaya Mine

Installed Apr 09

1212 m during March

JM 6725 MOSS VALE AUS 12CM30D Raspadskaya group,

Koksova mine

Installed Nov 08

JM 6726 MOSS VALE AUS 12CM30D Raspadskaya group,

Koksova mine

Installed Sept 09

JM 6736 MOSS VALE AUS 12CM30B (5.4 width) Raspadskaya group, Installation Planned For

Bolter Miners in Russia

JM 6736 MOSS VALE AUS 12CM30B (5.4 width) Raspadskaya group,

Raspadskaya mine

Installation Planned For

June 2010

JM 6737 MOSS VALE AUS 12CM30B (5.4 width) Raspadskaya group,

Raspadskaya mine

Installation Planned For

June 2010

Totals

• 2 x 12BM15

•1 x 12CM15 WHBM

•11 x 12CM30

12CM30 - Overview

• The Joy bolter miner system fully integrates the early installation ofhigh strength roof bolts close to the face with the latest JOYcontinuous miner drivage system, incorporating the latestimprovements in machine design and roofbolting technology.

• Single pass machine

• Cutting range : 2.4 to 4.5 m

• Standard width : 5.2 m (Options, 4.8, 5.0 & 5.4m)• Standard width : 5.2 m (Options, 4.8, 5.0 & 5.4m)

• Hydraulic cutter head extensions reduce the width by 600mm(800mm with 5.4m head)

12CM30B with HFX 280 Standard cut

dimensions

Outbye Facing Rigs - Deep Undercut -

Extreme Case, with undercut

12CM30B with HFX 280 deep cut

dimensions

Mine Visits

Salient FeaturesSalient Features

Raspadskaya mine

• This is a Longwall mine currently producing 7 mil.tonnes of coalper year from 5 nos longwalls.

• Mine contains two JOY machines 12CM15 and 12CM18 installedin 1997 supported by JOY Shuttle cars.

• Bolting operations carried out by Joy WOMBAT hand held boltingmachines.machines.

• Till now, 12 CM 18 machine has done about 18 Kms of drivageand 12 CM 15 done 17 kms with no major overhauling exceptfailed components replacement/repair.

• The roadway dimensions are 5.2 M (wide) x 2.5 M (height) with 6bolts at every 1 M length and 2.6 M to 2.8 M in to roof with resincapsules.

• An advance rate of at least 6-8 M per shift of 6 hours is beingachieved.

Kotinskaya mine, SUEK (Siberian Coal and Energy Company)

Kotinskaya mine, SUEK (Siberian Coal and Energy Company)

• This is a longwall mine currently producing 5 mil. tonnes per yearfrom one longwall at 300 M depth with face dimensions 230 M X4000 M and seam thickness 4.5 mtrs.

• This mine has two Bolter miners used for longwall gate roaddevelopment averaging 5 Kms of development per year perdevelopment averaging 5 Kms of development per year perBolter Miner.

• Bolter Miners are operating at 12 deg dip gradient and 3 degcross gradient.

• The roadway dimensions are 5.5 m(wide) X 4.5 M (height) with 6bolts in to roof at every 1 M length.

Raspadskaya – Koksovo mine

• This is a new longwall mine in development stage.

• The Bolter Miners (2 no.s of 12CM30) are used for all minedevelopment roadwaysworking on 13 deg to 16 deg gradientcutting roadway of 5.2 M (wide) x 4.0 M (height) in a seam heightof 5.5 M leaving about 1.5 M coal in the floor and sand stoneof 5.5 M leaving about 1.5 M coal in the floor and sand stoneroof.

• Current roadway visited where Bolter Miner was working is at600 mtrs depth and is backed up by 20 T Shuttle car working inthese gradients with an average progress of 10m per day.

• Roof bolting goes up to 3.4 M in to roof and Rib bolting 1.8 M to2.2 M is being done for side stability.

Vorgashorskaya Mine 2 (Vorkutaugol Group)

• This is a longwall mine with two sets of (Russian) longwallsoperating each set producing 1.5 MTPA with of 250 mtrs facelength with 1.2 to 1.3 km long.

• This is a shaft mine with 2 no.s of 12 CM 30 Bolter Miners, whichhave been lowered in completely dismantled condition andassembled in underground.

• This mine has got the privilege of driving 1200 mtrs of roadwayfrom one 12 CM 30 machine, during March 2010, which isconsidered to be a record for Russian mine roadwaydevelopment.

• The roadway dimensions are 5.2 M(wide) x 3.6 M (height) andthe machine is able to cut a perfect rectangle with clean floor. 6nos. bolts of 2.4 M deep @ every 0.5 M and rib bolting of 1.8 Mbeing practiced with “W” straps and wire netting in to roof andribs.

Vorgashorskaya Mine 2 (Vorkutaugol Group)

• Cable bolting up to 5 M in to roof being done at every alternaterow of standard bolting.

• This mine also currently have few Russian and Ukrainian Roadheaders, with manual bolting and achieving a maximum of 9 Mper day.per day.

• Each 12 CM 30 Bolter Miner on an average achieving 35 Mprogress per day.

• In spite of driving > 16 Km of roadways the 12 CM 30 machinesare found to be as good as new machines devoid of any smallleakages.

MaintenanceMaintenance

• Maintenance of equipment is being carried out in separatemaintenance shift of six working hours. After completion ofmaintenance job the maintenance personnel start machinery forproduction and handover the face to the production shift crew inrunning condition.

Maintenance Practices

• Planned preventive maintenance practice is being followed.

• Service contract is given to JOY for regular maintenance of theequipment in one of the mine (Vorgashorskaya Mine).

• Other Mines, their own maintenance crew is carrying out themaintenance job with the guidance of JOY.

• Service Engineers of the JOY are closely monitoring the

performance and also recording the mean time between

failure (MTBF) i.e service lives of all the components of

the equipment for better guidance.

Maintenance Practices

• Based on the recorded MTBF of components, floats of

Sub-Assemblies are being maintained right at the Pit

Stores.

• However, replacements of components are being done

only on failure for achieving optimum life of the

component.

• Maintenance practices are being followed very

religiously.

• Machinery is being thoroughly cleaned with water before

Maintenance Practices

taking up maintenance job. The best example is the

feeder chain of Hydraulic bolter is being thoroughly

cleaned with de-greaser to clear off the rock/coal dust

present in the lubricant from the chain before doing the

daily lubrication ,which results in longer service life of the

Seals.

What we learnt from the What we learnt from the Russia Trip …

Notable Points

• Bolter miner is a single pass, robust machine capable of

bolting both Roof & Sides.

• With the elimination of Gathering Arms, it is possible to

bolt the Roof at distance of 1.0m from the face and ifbolt the Roof at distance of 1.0m from the face and if

required first row of bolts can be fixed at a distance of

0.6m from the face by sumping the drum into the face.

• There is less number of hoses & Rotary gathering arm

thus eliminates the maintenance difficulty.

Notable Points

• The least progress from Bolter Miner is 300m, the

average progress is 600m and the best is 1200m per

month.

• Transport of work persons to the face on Man Riding• Transport of work persons to the face on Man Riding

(Chair Lift/Chair Car/Diesel Monorail and Men transport

FSV) is a must, which will be useful for material transport

too.

• Very good ventilation (Quality & quantity) is a must to

avoid discomfort for maintenance of Diesel FSVs.

Notable Points

• Maintenance contract with OEM is worth trying with such

high capital intensive equipment.

• It is better not to try driving the machine in cross

gradients for better and faster progress.gradients for better and faster progress.

• 4” x 4 “Wire mesh with 5mm dia rod is be procured

instead of 2”x 2” GI Chain link fence.

• 150 x150 x 6mm thick Bearing plates are to be replaced

with 300 x 300 x 10mm thick for effective Roof control.

ConclusionsConclusions

• 12 CM 30 Bolter Miner is capable of Working in gradients of about 13Degrees.

• First row bolts can be fixed at a distance of 1.0m from the face.

Conclusions

• Further shortened distance from the face can achieved for effectiveroof control in weak roof condition.

• The average progress that can be achieved from the machine isabout 400m per month.

• Maintenance CONTRACT with the OEM is very much essential.

Few Pics of Bolter MinerFew Pics of Bolter Miner

THANK ‘U’THANK ‘U’

Mail your comments to venkoos@gmail.com