''West and East Europe in global High Added Value

manufacturing - facts of today and challenges of tomorrow''

October 24-25th 2011, Wrocław

WS6 - Future Mining Session

Novel underground mining methods with the

use of hydraulic powered roof support and

continuous mining in KGHM copper mines.

Henryk Karaś, Corporate Adviser, KGHM, Chairman of ETP SMR

Herbert Wirth, President, CEO, KGHM Polish Copper

Content of the presentation.

1. Testing the use of hydraulic powered roof support in

underground conditions in KGHM copper mines – the

first experiences dating from 70s-80s in XX century.

2. Development of rock fragmentation and continuous

mining technology in world mining.

3. Current KGHM projects on the use of continuous mining

in underground operations.

4. General idea, advantages of continuous mining,

expected results.

In 1973 the KGHM decided to test the use of hydraulic

powered roof support (HPRS) in its Pilot Plant located

at the Lubin Copper Mine. The main reason was finding

solutions for cleaner extraction and lowering losses of

copper ore during the underground winning operations.

Short history on the use of hydraulic powered roof

support (HPRS) in underground conditions of KGHM.

The first tests with the use of HPRS „Hemscheidt” units in

room&pillar mining method, Lubin copper mine, 1974-1975.

Two phase room&pillar mining method with

the use of four HPRS Hemscheidt units

One phase room&pillar ming method with

the use of four HPRS Hemscheidt units

Typical set of HPRS Hemscheidt consisting

of 2 pairs of linked double units.

Tests in shortwall mining method with the use of HPRS

„Hemscheidt” units, Lubin mine, KGHM, 1976-1979.

Shortwall (20 m wide) mining with the use of HPRS

Hemscheidt units – single units along wall face.

Typical HPRS „Hemscheidt” units.

Shortwall (2 x 20 m wide) mining with the use of

HPRS Hemscheidt single units along wall face.

Basic cycle of exploitation in shortwall mining method

with the use of HPRS units,

Phase 1 – after drilling the face of the wall pillar, before charging the explosives.

Phase 2 – after blasting operation of the wall pillar.

Phase 3 – short wall during mucking operation, before drilling and advancement of roof

support.

Phase 4 – after drilling the face of short wall and the advancement of roof support.

The idea of shortwall mining method with „Fazos-70” HPRS

units tested in low seam deposit in Sieroszowice mine.

Protecting barriers installed before HPRS units Made in Poland „Fazos-70” HPRS units

Industrial Performance Testing carried out in 1981-1987

The tests on use of hydraulic powered roof support (HPRS) carried out

in underground conditions were stopped in 1987.

The main reasons were:

1. Problems with advancing the hydraulic support during mining

operations and effective triggering off the natural roof caving behind

HPRS line.

2. Problems with protecting the hydraulic installations inside HPRS

units caused by blasting operations. Protecting barriers installed before

HPRS units did not always fulfill their role. That mostly lowered the rate of

face advance.

3. High costs of using HPRS units in underground operations when

compared with the traditional room&pillar mining method prevailing at all

KGHM copper mines.

4. Financial crisis approaching Polish economy in the middle of 80s.

Results and conclusions from the first tests.

Reserve area - EXTENSION

GŁOGÓW

KGHM – one of the biggest resources of copper ore in the world.

Current area of mining

activity

10

When going down to onto the level 1500 m in mining

operations new solution in underground operations

became more challenging and acute at KGHM.

• Minimising ore dilution and copper ore losses in low seam copper ore deposits ;

• Eliminate human exposure in deep underground conditions (hot rock temperature, humidity, gas and diesel fuel emissions, dust, noise, rock burst hazards)

• Most of of underground mining operations from remote places.

• Implement automated communication and data transfer systems in mining operations.

Traditional the room&pillar mining method

used at KGHM mines with rock blasting.

1

2 3

4

5

6 7

8

Traditional

Drill/Blast

Process

Cycle

Room&pillar method with roof subsidience

Room&pillar method with hydraulic backfill

New approach in continuous mining in

underground mining operations at KGHM.

1. Drill & Blast – the current method.

• Inherently dangerous;

• Cyclic;

• Slower ?.

2. Rock Cutting – the way of the future.

• Continuous operation (non-cyclic mining);

• Easier to automate;

• Easier to respond to geology;

• Faster ? and safer.

Source : Dr Xing Li , Ian Gipps , CSIRO Exploration & Mining, 2008 Narrow Vein Mining Conference

Development of technologies in hard rock

fragmentation and continuous mining.

The basic principle of rock fragmentation

is to break bindings between the grains

and disintegrate the rock. This can be

done by using:

mechanical tools;

laser to heat and melt the rock or

pulsated laser to resonate and break it into

pieces;

microwave induced heat and thermal

stresses,

shocks such as plasma explosion;

erosion method such as water jet. Basic rock excavation mechanisms (Maurer, 1980).

Source: http://www.nap.edu/openbook.php?record_id=2349&page=63

1.Some of the concepts to develop mechanical excavation systems for hard rock

mines have been progressed since 90. XX c. to prototype machines which generally

were capable of excavating very hard, and often abrasive rocks (picks and discs).

2.The real battle is the abrasion wear of the cutting tools.

3. Thus the focus of the research in this area has been to develop cutting tools

that require low cutting forces when cutting hard rock formations.

Source: “A state-of-the-art review of mechanical rock excavation Technologies”,

by A. Ramezanzadeh, M. Hood. IJMEI, vol1, No 1, 2010

Recent innovations in rock excavation.

Mechanical excavation in

mining machine types. source: Aker Wirth GmbH, (www.wirth–

europe.com).

KGHM

TBM - Tunnel Boring Machine

MTM - Mobile Tunneling Machine

Rock Cutting – Possibilities.

1.Roadheaders & picks

1.1 Tungsten carbide picks

1.2 Diamond composites.

2.Mini cutters

2.1 Problems with handling forces on

bearings.

3.Oscillating Disc Cutters (ODCs)

3.1Several attempts over many years.

The two types of cutter heads (Sandvik MT720).

Source: CRCMining 2004-2005 Annual Report, Oscillating Disc Cutter technology, Oscillating Disc Cutter

Source: “A state-of-the-art review of mechanical rock excavation Technologies”,by A. Ramezanzadeh, M. Hood. IJMEI,

vol1, No 1, 2010

Recent innovations in rock excavation - undercutting discs.

Undercutting discs – making use of

lower tensile strength of rock (b) as

opposed to compressive strength (a).

This idea is getting more and more

approval among mining machine

producers.

Two types of Mobile Tunnelling Machine with undercutting discs.

(a) (b)

Recent innovations in hard rock excavation (picks): TSDC picks vs

Tungsten Carbide (TC) ones in comparison of wear development.

1.Reduced wear rates &

longer life

2.The ability to cut hard rock

(>300 MPa)

3.Faster cutting

Advantages of TSDC.

Thermally stable diamond

composite (TSDC).

Source : CSIRO SMART*CUT Technology, 2008 Narrow Vein Mining Conference

Tungsten Carbide (TC)

new

after

30 cuts 100 cuts

New solution in Mass Mining Technology – KGHM.

Tail entry chain conveyor

Powered sectional support

Long wall shearing machine

Armoured flexible conveyor

Longwall mining allows the most effective underground coal extraction today

for thin hardcoal beds between 1,5 to 2,3 m. Most of copper deposits on the

KGHM licence area are flat, high copper grade and and have similar height.

Coming back to the idea of continuous mining and longwall mining system

owing to development of effective rock fragmentation tools for very hard rock .

Solution in Mass Mining Technology - KGHM

Powered sectional support (HPRS)

Longwall shearing machine

Armoured flexible conveyor

Source: https://mining.cat.com/cda/layout?m=435165, Longwall mining systems

Longwall plowing machine

20

Summary of future solutions to implement the

new Mass Mining Technology at KGHM mines.

• No drilling and charging in Near-Face operations;

• Possibility of adaptation of longwall equipment in hard

rock applications (compressive strength 100-150 MPa),

• Roadheaders and continuous miners for hard rock

applications for underground drifts, longwall and room&

pillar mining methods.

• Opportunity to develop techniques for selective mining

operations underground.

Target : Automated continuous mining – an intelligent

and remote controlled robotic technology.

Lithological profile of

the Lubin-Głogów

copper ore deposit.

sandstone

dolomite

shale (Kupferschiefer),

Safe and effective underground mining operations should make use of the development of IT and ES technologies.

source: prof. Pekka Särkkä, Helsinki Technical University, 2008

Stages of Intelligent MineTM ,

project, Finland (1998-2002)

Level of

development

at KGHM

22

Experience of KGHM company with continuous

mining technologies.

• Salt extraction area

2000 – to date Polkowice/Sieroszowice Mine

• Mine development area

2010- to date

• Copper ore extraction area

first tests 2002-2005

Roadheader MH 620 (SANDVIK) at the Lubin Mine

SANDVIK’s Narrow Reef Miner ARM 1100, tests at the

Polkowice/Sieroszowice Mine

2009, KGHM signed the cooperation agreement with

Bucyrus (now Caterpillar, USA) based on patented

Bucyrus Activated Cutting Technology (ACT).

Continuous miner CAT CM210 for low

seam mining in range 0.71-1.52 m

CAT Gliding plow miner for extremely thin seams in the range 1.0 m – 2.3 m

Target : Designing and construction ACT Mining Complex consisting of an

ACT Mining Machine, AFC conveyor, hydraulic roof support together with

power supply.

KGHM’s expectations to construction of longwall

continuous mining and HPRS performance.

1. Remote operation should allow highest safety and maximum

productivity in extraction of low seam copper deposit.

2. The shear/plow system and shield supports can be positioned

exactly where they are needed (roof condition, faults etc.).

3. System is self-correcting for over- or underpush, thereby

maintaining a straight face regardless of floor or roof conditions.

4. Optimum use of installed power for maximum cutting depth for

every area of the longwall face.

5. Automated systems should allow access to extended reserves in

low copper ore seams to achieve a higher percentage of recovery.

6. ACT units should withstand the danger of seismic events (rock

burst) in the production area of KGHM copper mines.

Performance Trials to be carried out at the KGHM Mine (2012) in order to

prove the suitability of the prototype ACT Complex for use in the production.

KGHM: mechanical excavation method in

roadheading and room&pillar system.

Continuous miner (Joy, 14CM series)

Roadheader MH 620 (SANDVIK)

Conception of room&pillar method with

continuous mining and backfilling.

Two wing

operation

Objectives:

Lowering air cooling

costs

Haulage independence

Backfill improves safety

but rise operating costs

New conveyor is ready before

previous step is worked out

Source: K.Barrek, M. Czechowski, A.Ziąber, KGHM, Work Package 10, SMIFU project.

Mining of deep low seam deposits of copper ore (reserve

resources) in KGHM – picks or undercutting discs ?

Lithology

Reserve copper deposits in KGHM

Bytom

Odrzański Gaworzyce Głogów

Radwanice

Zachód Retków Average

Density

Mg/m3

[%]

Carbonates 52,3 83,95 28,53 87,43 8,67 28,14 2,6

Shale 10,25 14,45 12,41 12,57 13,66 12,75 2,5

Sandstone 37,45 1,61 59,07 0 77,67 59,11 2,3

Source: K.Barrek, M. Czechowski, A.Ziąber, KGHM, Work Package 10, SMIFU project.

KGHM’s contribution to the EU consortium to develop

a common vision for future deep mining in Europe.

The invisible, zero-impact

mine

„Fully automated mining method for deep metal mines in

Europe based on continuous mining with near-to-face

processing and waste backfilling”.

Countries which could support that initiative are: Sweden, Germany, Finland, other ?

Conclusions.

1. There is a need for new and modern vision of future deep

mining in Europe based on novel technical approach and zero

impact on environment.

2. International and interdisciplinary cooperation in EU is

necessary, both in the technical and socio-economical area to

design and implement that idea.

3. Europe 2020 programme should be a chance to increase funds

for RTD in the area of securing access to many deep laying

mineral deposits in Europe.

4. Active role of KGHM as a representative of extractive industry

should be valuable input in implementation of novel mining

solutions.