In situ studies on service life and pick consumption characteristics of shearer drums

Longwall shearers usually suffer from excessive pick and pickholder consumptions and severe wear of the backplate of the clearance ring section of shearer drums. In practice, most of the drums were seen to be withdrawn from the face due to the abovementioned problems, while vane picks and their holders were intact due to the improper lacing design of the clearance ring picks. However, few underground investigations and their results on the effect of lacing arrangement of clearance picks on the service life of shearer drums have been published. Nevertheless, the pick consumption characteristics of shearer drums were not investigated in detail, since these are fewer pick consumptions with shearers when compared to roadheaders. This paper is concerned with the comprehensive in situ trials on the effect of lacing of clearance ring picks on the lifespan of shearer drums, and the pick consumption characteristics of longwall shearers at Cayirhan Coal Mine in Turkey. The lifespan of shearer drums employed with shearers in this mine increased 70 per cent, while the consumption rate of clearance ring picks decreased three fold through using an alternative lacing for clearance picks, indicating the significance of utilizing proper design techniques for clearance ring picks for the service life of shearer drums. Statistical analyses carried out, using the raw pick consumption data, implied that the clearance ring picks experienced much higher loads than vane picks, revealing that special attention must be paid to designing clearance ring picks. An average maximum consumption value of 41 was determined for clearance ring picks, with corner-cutting picks having the most replacements, while it was 35 for vane picks, on three-day based pick replacements.

A statistical approach to predict the effect of confinement on the detonation velocity of commercial explosives

Commercial explosives behave non-ideally in rock blasting. A direct and convenient measure of non-ideality is the detonation velocity. In this study, an alternative model fitted to experimental unconfined detonation velocity data is proposed and the effect of confinement on the detonation velocity is modelled. Unconfined data of several explosives showing various levels of nonideality were successfully modelled. The effect of confinement on detonation velocity was modelled empirically based on field detonation velocity measurements. Confined detonation velocity is a function of the ideal detonation velocity, unconfined detonation velocity at a given blasthole diameter and rock stiffness. For a given explosive and charge diameter, as confinement increases detonation velocity increases. The confinement model is implemented in a simple engineering based non-ideal detonation model. A number of simulations are carried out and analysed to predict the explosive performance parameters for the adopted blasting conditions.

Influence of charge size distribution on net-power draw of tumbling mill based on DEM modelling

Modelling and optimization of the power draw of large SAG/AG mills is important due to the large power draw which modern mills require (5-10 MW). The cost of grinding is the single biggest cost within the entire process of mineral extraction. Traditionally, modelling of the mill power draw has been done using empirical models. Although these models are reliable, they cannot model mills and operating conditions which are not within the model database boundaries. Also, due to its static nature, the impact of the changing conditions within the mill on the power draw cannot be determined using such models. Despite advances in computing power, discrete element method (DEM) modelling of large mills with many thousands of particles could be a time consuming task. The speed of computation is determined principally by two parameters: number of particles involved and material properties. The computational time step is determined by the size of the smallest particle present in the model and material properties (stiffness). In the case of small particles, the computational time step will be short, whilst in the case of large particles; the computation time step will be larger. Hence, from the point of view of time required for modelling (which usually corresponds to time required for 3-4 mill revolutions), it will be advantageous that the smallest particles in the model are not unnecessarily too small. The objective of this work is to compare the net power draw of the mill whose charge is characterised by different size distributions, while preserving the constant mass of the charge and mill speed. (C) 2004 Elsevier Ltd. All rights reserved.

Influence of explosive energy on the strength of the rock fragments and SAG mill throughput

Extensive in-situ testings has shown that blast fragmentation influences the performance of downstream processes in a mine, and as a consequence, the profit of the whole operation can be greatly improved through optimised fragmentation. Other unit operations like excavation, crushing and grinding can all be assisted by altering the blast-induced fragmentation. Experimental studies have indicated that a change in blasting practice would not only influence fragmentation but fragment strength as well. The strength of the fragments produced in a blast is clearly important to the performance of the crushing and grinding circuit as it affects the energy required to break the feed to a target product size. In order to validate the effect of blasting on fragment strength several lumps of granite were blasted, under controlled conditions, using three very different explosive products. The resulting fragments were subjected to standard comminution ore characterisation tests. Obtained comminution parameters were then used to simulate the performance of a SAG mill. Modelling results indicate that changes in post blast residual rock fragment strength significantly influences the performance of the SAG mill, producing up to a 20% increase in throughput. (c) 2004 Elsevier Ltd. All rights reserved.

Relationship between ash content and R-70 self-heating rate of Callide Coal

Borecore samples from the Trap Gully pit at Callide have been assessed using the R-70 self-heating test. The highest R-70 self-heating rate value was 16.22 degrees C/h, which is consistent with the subbituminous rank of the coal. R-70 decreases significantly with increasing mineral matter content, as defined by the ash content of the coal. This effect is due to the mineral matter in the coal acting as a heat sink. A trendline equation has been fitted to the borecore data from the Trap Gully pit: R-70 = 0.0029 x ash(2) - 0.4889 x ash + 20.644, where all parameters are on a dry-basis. This relationship can be used to model the self-heating hazard of the pit, both vertically and laterally. (c) 2005 Elsevier B.V All rights reserved.

Effect of moisture content on the R-70 self-heating rate of Callide coal

Strip samples from the Boundary Hill pit at Callide have been tested in an adiabatic oven to assess the effect of moisture on the R-70 self-heating rate of coal. The two strip samples tested had R-70 self-heating rate values of 10.23 and 8.61 degrees C/h. As the moisture content of the coal was progressively increased, from the dry state of the test, the R-70 value decreased dramatically. At approximately 40-50% of the moisture holding capacity of the coal, the self-heating rate becomes measurable. Above this critical level of moisture content, the heat produced by oxidation is dissipated by moisture evaporation and coal self-heating is significantly delayed. (c) 2005 Elsevier B.V All rights reserved.

Comparison of the R-70 self-heating rate of New Zealand and Australian coals to Suggate rank parameter

Samples from New Zealand and Australia have been tested in an adiabatic oven to assess the effect of rank on the R-70 selfheating rate of coal. A non-linear relationship can be defined for coals from both countries using the revised Suggate rank (S-r) parameter. Subbituminous coals have the highest R-70 self-heating rate values, which are 20 times that of high volatile A bituminous coals on a dry mineral matter free basis (similar to 1 cf. 20 degrees C h(-1)). However, the moderating effects of moisture and mineral matter can reduce this difference to only 2-3 times for coal in-situ. (c) 2005 Elsevier B.V All rights reserved.

Robust bucket position tracking for a large hydraulic excavator

The device we study is the excavation arm of a large hydraulic mining shovel having a multi-loop kinematic form. We describe an iterative algorithm that allows the position of the bucket to be tracked from measurements of the linear actuator extensions. The important characteristic of this algorithm is that it is numerically well-behaved when the linkage is close to singular configurations. While we focus on a specific device, the algorithm is easy to adapt to other multi-loop linkages. (C) 2004 Elsevier Ltd. All rights reserved.

Assessing longwall support-roof interaction from shield leg pressure data

A concept has been developed where characteristic load cycles of longwall shields can describe most of the interaction between a longwall support and the roof. A characteristic load cycle is the change in support pressure with time from setting the support against the roof to the next release and movement of the support. The concept has been validated through the back-analysis of more than 500 000 individual load cycles in five longwall panels at four mines and seven geotechnical domains. The validation process depended upon the development of new software capable of both handling the large quantity of data emanating from a modern longwall and accurately delineating load cycles. Existing software was found not to be capable of delineating load cycles to a sufficient accuracy. Load-cycle analysis can now be used quantitatively to assess the adequacy of support capacity and the appropriateness of set pressure for the conditions under which a longwall is being operated. When linked to a description of geotechnical conditions, this has allowed the development of a database for support selection for greenfield sites. For existing sites, the load-cycle characteristic concept allows for a diagnosis of strata-support problem areas, enabling changes to be made to set pressure and mining strategies to manage better, or avoid, strata control problems. With further development of the software, there is the prospect of developing a system that is able to respond to changes in strata-support interaction in real time.