International Journal of Mining Science and Technology 23 (2013) 33–40

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International Journal of Mining Science and Technology

journal homepage: www.elsevier.com/locate/ijmst

Rock excavation using surface miners: An overview of some design

and operational aspects
Prakash Amar a,⇑, Murthy Vemavarapu Mallika Sita Ramachandra b, Singh Kalendra Bahadur a
a
Central Institute of Mining & Fuel Research, Dhanbad 826015, India
b
Indian School of Mines, Dhanbad 826004, India

a r t i c l e i n f o a b s t r a c t

Article history: Surface miner, a continuous mining machine, is being manufactured in India and abroad owing to
Received 14 May 2012 enhanced demand of production in various mining industries like coal, limestone, gypsum, bauxite etc.
Received in revised form 26 June 2012 Different types of surface miners are manufactured today based on cutting drum placement and design
Accepted 28 July 2012
specifications. Selective mining without drilling and blasting, high production and small size products are
Available online 7 February 2013
some of the prominent attractive features obtained with these moving marvels. This machine can be used
with good efficiency in soft to medium hard rock (100–120 MPa). This paper synthesizes the different
Keywords:
applications, equipment models, features offered, operating methods, cutting performance assessment
Surface miner
Cutting performance
models as well as typical production performance of surface miner in coal and limestone mines of India.
Compressive strength Engine hour metre reading, diesel and pick consumptions are linearly influenced by production. The
Operating methods emphasis for future research is also brought out.
Ó 2013 Published by Elsevier B.V. on behalf of China University of Mining & Technology.

1. Introduction Australia and Bosnia apart from India. Surface miners are becoming
popular day by day because of continuous and versatile selective
Technology depends on the type of mining operations prevail- mining, bulk production capability, reliability and cost-
ing in the country. In India, open cast mining is much more popular effectiveness.
than underground mining ever since nationalisation. Production of
coal from surface mining was increased by 2.67 times by 2004–
2. Surface miners and their development
2005 as shown in Fig. 1 [1]. The ratio of production from surface
and underground mines was 89:11 till 2009–2010. However, the
The earliest continuous surface miner used for excavating and
increase in overall production may be contributed mainly to OC
loading soft and loose material is the elevating grader. However,
mines. By and large, this increase is attributable to new proven
they are unsuitable for stiff material and cannot negotiate boulders
technologies employed. The surface miners are machines made
[6]. The first surface miner (of Wirtgen make, Germany) was sold in
for an efficient, continuous mining operation. Application of sur-
1983 to make on roads in gypsum mine in South Africa. However, it
face miner in different coal, limestone, gypsum, lignite, salt, phos-
took another 10 years to make this technology mines too. By the
phate, bauxite and iron ore projects is common and established
year 2008 more than 40 surface miners are employed in limestone
today. No drilling-blasting, selective mining, less dilution, no fur-
mines and around 50 in coal mines in India. The first break through
ther crushing and fragmentation etc., are the attractive qualities
of surface miner (Wirtgen make-2100SM) in Indian coal mine was
of the surface miner technology. Out of current global population
in 1999 at Lakhanpur open cast mine in Mahanadi Coalfields Lim-
of nearly 300 surface miners in productive use around the world,
ited (MCL). Two L&T surface miners each are deployed in Lingaraj
some 105 operating machines are in India [2–4]. The surface miner
open cast mine of MCL and Gevra opencast project of Korba Coal-
is a proven and versatile machine with cutting capability in soft
field, South Eastern Coalfield Limited. About 19 Wirtgen surface
and medium hard rock with compressive strengths ranging up to
miners of various sizes and capacities have been deployed in differ-
120 MPa [5]. Determination of various rock mechanical properties
ent collieries of MCL, CCL and SCCL. More than 100 surface miners
shall have a bearing in the selection and application of surface
are being used in coal and limestone mines of India [7]. The surface
miner. Presently, there are a number of projects utilising this tech-
miner (Wirtgen make-1900SM) was used for the first time in India
nology around various parts of globe, especially in USA, Russia,
in 1994 at a limestone quarry of GACL. This machine proved the
ability of excavating and sizing the soft limestone without blasting.
⇑ Corresponding author. Tel.: +91 9431315038. In the same year M/s Madras Cements purchased the first new
E-mail address: amar_cmri@yahoo.co.in (A. Prakash). Wirtgen surface miner 2100SM. Since then surface miners have be-

2095-2686/$ - see front matter Ó 2013 Published by Elsevier B.V. on behalf of China University of Mining & Technology.
http://dx.doi.org/10.1016/j.ijmst.2013.01.006
34 A. Prakash et al. / International Journal of Mining Science and Technology 23 (2013) 33–40

500 of the deposit, reduced processing after mining required, primary

crushing stage can be omitted and gentle loading of trucks due
400 to sized material, low investment costs in comparison to the range
Production (MT)

of equipment necessary for conventional mining, low operating

300 costs due to less equipment and less personnel, cut steep and sta-
ble surfaces and embankments (better exploitation), precise cut-
200
ting of designed profiles (slopes, surfaces) and improved safety.
100 Surface miners can maintain the surface of existing haul roads
in virgin rock or in opencast mines. It facilitates higher overall tra-
0 vel speed for haulage vehicles due to better road surfaces.
1974-75 1979-80 1984-85 1989-90 1994-95 1999-00 2004-05 2009-10
Underground 63.64 64.5 73.4 81.85 112.42 126.07 132 59.48
2.2. Types
Surface 24.77 39.5 74.011 127.65 197.89 292.19 353 472.52

Fig. 1. Trend of surface and underground production of coal in India [1]. (a) Milling type: This type of surface miner includes Wirtgen or
Bitelli machines, Easi-Miner from Huron, Man Takraf surface
miner, L&T surface miner and Vermeer Terrain Leveller. In
come the standard mining machines in all soft to medium hard most of these machines, the cutting drum is positioned
limestone mines and being used by various Indian mining compa- below the machine in between the front and rear crawlers.
nies such as: The Vermeer cutting drum is at the end of the machine; it
is also wider than the machine and uses top-down cutting
Gujarat Ambuja: 7 Wirtgen surface miners which allows the cutter teeth to gain penetration without
Madras Cements: 5 Wirtgen surface miners using machine’s tractive effort. In Man Takraf surface miner
India Cement: 3 Wirtgen surface miners (MTS250 and 1250) the cutting drum is fixed in front of the
MPL: 2 Wirtgen surface miners machine. The milling type miner can cut rocks with com-
pressive strength in the range of 80–100 MPa and has been
2.1. Applications and advantages claimed to be able to negotiate rocks of 140–150 MPa com-
pressive strength, with reduced production though.
The application of surface miners simplifies the operation (b) Bucket wheel type: This type of surface miner, based origi-
(ground breaking, crushing and loading are combined in one single nally on Satterwhite machine, is marketed by Thyssenkrupp
operation), maintenance and supervision-due to the one-machine Fordertechnik. In this machine (KSM2000), 4 parallel bucket
concept. The application procedure for a mining permit is faster wheels are mounted on a main frame without boom. The
than for a blasting operation. Surface miner eliminates primary machine has a theoretical output of approximately 1000–
crushing as the output size is <80 mm, and thus energy is saved, 1400 bank cubic m/h in material of average uniaxial com-
which otherwise would have been required for the primary crush- pressive strength of 20–30 MPa.
ing process. Surface miner produces a smooth, clean and even floor (c) Ranging-shearer-drum type: This type of surface miner is
facilitating the movement of the hauling equipment, minimizing based on underground drum type continuous miner, repre-
wear and tear of the tyres and chassis of the hauling equipment. sented by Voest Alpine’s VASM-2 and Rahco’s CME-12. The
As a result, operating costs are reduced considerably. Surface miner ranging-shearer-drum type miners can cut rocks up to
application dominates in limestone mines, though it is applicable 120 MPa, though their economic range of operation is
in production of various ore/mineral as given in Fig. 2 (up to Octo- 80 MPa.
ber, 2008).
Use of surface miner is simplified mining technology and pos- Continuous miners can cut and load stronger formations like
sesses several advantages, namely, selective mining, improved pro- coal, shale, soft sandstone and limestone, gypsum, chalk etc., which
ductivity, ability to work close to the habitat/agricultural fields, cannot be excavated by bucket-wheel excavators, or ripped by doz-
environment-friendly, reduced noise emission, reduced fugitive er rippers. Amongst the three types, milling type machine domi-
dust emission, total elimination of ground vibration, no drilling nates the market globally.
and blasting, no fly rocks, no secondary blasting/breaking of boul-
ders, stable, clean surfaces and benches, improved overall avail- 2.3. Cutting system
ability of the system, reduced operating cost, leading to easier
coordination and process planning during planning, dispatching The milling type of miner, shown in Fig. 3, consists of a rotating
and maintenance; enhanced ROM-quality, improved exploitation wide cutting or milling drum, which has spiral ridges carrying con-
ical picks with tungsten carbide inserts. The pick flight can be var-
140 129 ied to suit the type of material cut. The drum spirals are in the form
120 of twin helix so that the cut material is pushed towards the drum
100 centre where it is loaded on a loading conveyor. The conveyor sys-
Surface miners

tem comprises a wide primary conveyor which picks up the cut

80
and comminuted material at the cutting drum, as well as a dis-
60 50 charge conveyor to discharge the material onto trucks (Fig. 4).
40 The discharge conveyor can be adjusted in height and slewed to
17 22 22
20 both sides. The conveying speed can be infinitely varied.
6 2 1 2 2 5 1 4 3 1 4
The drum or the machine frame carrying the drum can be
0
pushed up or down between the tracks by hydraulic cylinders for
Gypsum
Limestone

Mudstone

Iron ore
Shale

Granite
Pegmatite
Kimberlite
Phosphate
Sandstone
Lignite
Coal

Salt
Bauxite

Oilshale

Tuff

controlling the milling depth from as low as 10–610 mm.

There is provision for tilting the drum or the entire machine to
give a sloping cut up to 7°. The drum chamber is sealed by a
Fig. 2. Application of surface miners in mining of different minerals/ore. hydraulically actuated scraper blade behind the cutting drum to
 A. Prakash et al. / International Journal of Mining Science and Technology 23 (2013) 33–40 35

Fig. 3. Working principle of surface miner.

Continuous
cutting
Crushed
aggregate

Precise cutting
depth
Direct
loading

Clean, level and

stable surface

Fig. 4. Transfer of cut material by conveyor system.

clean cutting surface. The cutting drum rotates in an up-cutting
direction. The cutting tools are mounted in tool holders welded
onto the body of the drum. The tools used, i.e., number, arrange-
ment and type of tools, depend on the machine’s momentary use
and on the properties of the material being cut.
2.4. Design features
2.4.1. Diesel engine
The surface miners are diesel powered. The engine’s power is
transmitted via a robust belt drive to the drum, ensuring an effec-
tive power transmission. Moreover, other systems (e.g., track and
belt drive) are hydraulically driven.
2.4.2. Central cutting drum with mechanical drive
The cutting drum is located in the centre of the machine (most
cases), between the four crawler tracks. It is located close to the
centre of gravity. The entire machine weight and installed power
can thus be converted into cutting force. This allows cutting of
harder materials with good results and ensures at the same time
stability of the machine (Fig. 5).
The cutting drum speed can be varied by interchanging the belt
pulleys. The usual range of drum speeds, which can be realised
with these changings vary from 60 to 100 r/min. The belt pulleys
are tensioned automatically by a hydraulic cylinder. This is an en-
ergy effective, low maintenance system, minimizing operating and
maintenance costs.
2.4.3. Automatic adjustment of cutting depth
The cutting depth is regulated by an automatic levelling system
mounted on the machine. The pre-selected cutting depth is main-
tained either automatically or can be adjusted manually. The con-
trol system can be connected with:
(a) Cable sensors scanning the distance to a reference plate slid-
ing on the surface.
(b) Non-contact ultrasonic sensors measuring the distance to
the side plate or the surface.
36 A. Prakash et al. / International Journal of Mining Science and Technology 23 (2013) 33–40

2.5. Machine specifications

There are many companies in the world which are manufactur-

ing surface miners, e.g., Wirtgen (SM Series), Huron Manufacturing
Co (Easi-Miner), Takraf, L&T, Vermeer etc.; specification of some of
their products are given in Tables 1–3.

2.6. Maintenance and breakdowns

It is imperative to provide proper maintenance for smooth and

regular operation as well as to minimize the number of break-
downs of surface miner. Some common maintenance works, expe-
rienced in Indian coal and limestone mines are regular washing of
Fig. 5. Central cutting drum with mechanical drive. machine by water; change of radiator coolant, engine oil, PTO gear
box oil, milling drum oil, advance drive gear oil and track gear oil;
change/service of PTO filter, diesel filter, water filter, coolant filter,
hydraulic filter, air filter and water filter; maintenance of radiator
Table 1 water leakage and track tensioning work. Production hampers due
Specification of Wirtgen surface miners.
to the machine breakdown. Some of the common breakdowns ob-
Name of Wirtgen served during operation of surface miners are thermostat valve re-
company moval due to overheat of radiator; failing of tension pulley bearing;
Model 2200SM 2500SM 3700SM 4200SM breaking of travelling pump seal; water pump pulley bush; picks
Cutting width 2.20 2.50 3.70 4.20 and pick holders breakage; puncture of brake hose, track motor
(m)
hose; damage of scrapper door, track roller; damage of radiator
Cutting depth 0.35 0.60 0.60 0.80
(m) bolt, radiator and oil collar; breakage of milling drum drive shaft
Drum diameter 1.14 1.40 1.40 1.86 coupling, milling drum pulley belt; engine breakdown and damage
(m) of steering cylinder key, guide column cylinder.
Fuel 150 191.5 284 284
consumption
(L/h) 3. Operating methods
Operating speed 0–25 0–20 0–20
(m/min)
The operating methods are classified into three categories based
Travel speed 0–5 0–3.9 0–2.5 0–2.5
(km/min) on the machine travel mode illustrated as follows:
Engine (HP) 800 1050 1600 1600
Weight (t) 51.0 103.0 176.0 191.4 3.1. Empty travel back method
No. of tools 76 Depends on Depends on Depends on
Spacing (mm) 38 application application application
Cutting drum Mechanical The surface miner cuts the material from one end of the pit. The
drive cutting drum is raised and moved back to the starting end without
Number of 4 turning after the completion of the full cut. The material is not cut
tracks
during the backward movement i.e., it travels back empty. After
Track drive Hydraulic
system
coming back to initial point, the machine is set for a new cut in
Drum speed (r/ 60–100 adjacent strip (Fig. 6). This method is generally adopted for a mine
min) having field length less than 200 m, so that the turning time be-
comes more than the empty travel time. It is also applicable in
bad pit-end condition and the machine is not able to turn there
or the pit width is not sufficient to allow the turning of machine
(c) Automatic control of transversal slope: The machine is at the end of a cut.
equipped with a slope sensor to control transversal slope
of the cutting surface. It can be used to create defined slopes, 3.2. Turn back method
for water drainages for example, on the cutting surface.
(d) Multiplex sensors working with sensors on one or both sides A surface miner cut from one end of the area and after the com-
of the machine, thus levelling uneven surfaces in longitudi- pletion of cut the cutting drum is raised and the machine turns
nal and transversal direction. (Fig. 7). This method is generally adopted for a mine having field
(e) Laser sensors working with a transmitter and receiver. length more than 200 m, so that the time consumption in turning

Table 2
Specifications of Takraf, L&T and Bitelli surface miners [8].

Name of company Takraf L&T Bitelli

Model MTS 180 MTS 300 MTS 500 MTS 800 MTS 1250 MTS 2000 KSM 223 KSM 303 KSM 304 SF202 M
Drum width (m) 3.3 4.0 4.9 5.6 6.5 7.4 2.2 3.0 3.0 2.0
Cutting depth (m) 0.70 0.875 1.05 1.225 1.40 1.575 0.35 0.35 0.40 0.25
Operating speed (m/min) NA NA NA NA NA NA 83 83 20 NA
Rated capacity (m3/h) 180 300 500 800 1250 2000 NA NA NA NA
Machine power (kW) 500 750 1650 2000 2500 2500 597 597 895 515
 A. Prakash et al. / International Journal of Mining Science and Technology 23 (2013) 33–40 37

Table 3 A
Specification of Vermeer surface miners [8].

Name of company Vermeer

Model T855 T955 T1055 T1255
Drum width (m) 2.5 3.4 3.4 3.7
Cutting depth (m) 0.812 0.812 0.812 0.610
Operating weight (t) 40.8 56.7 61.2 99.8
Max. cutting speed (m/min) 28 20 16 12
Machine power (kW) 281 309 317 447

Fig. 8. Continuous mining method.

As a rule of thumb, the turning radius is 12 cutting width

(when cutting harder rock, the cutting depth has to be reduced).

3.5. Working length

Fig. 6. Empty travel back method [9].
The productivity of a Surface Miner depends on the length of
the available working area. Longer cuts will enhance the productiv-
ity, because only a smaller amount of time is spent in manoeuvring
from one cut to the next. The forward speed depends on a number
of factors:

 cutting depth
 material hardness, structure and orientation
 type of machine and installed engine power

In standard applications, the appropriate minimum cutting field

Fig. 7. Turn back method. length should be in the range of:

 100 m (hard material, low forward speed)

is lesser than empty travel time. This method is widely used and  300 m (softer material, high forward speed).
gives more production.

3.6. Types of loading

3.3. Continuous mining method
Surface miner operates on an even field and continuously cuts
the material. The machine moves with cutting the material and
near the pit end, it takes turn with a gentle angle without raising
the cutting drum, so that there is no discontinuity in cutting oper-
ation. The cut area gets an oval shape (Fig. 8). The mining area is
developed by cutting slice by slice. For each slice the cutting depth
only needs to be set once on the surface miner.
After the completion of an elliptical movement, adjacent cut is
taken. This continues till the elliptical turning gets sharp angle.
Then machine goes for turn back method. This can be avoided by
overlapping elliptical movement, but the productivity reduces at
the overlapping area.
3.4. Block operation with ramp cutting
While cutting the block down to its planned level, the surface
miner cuts its own ramp. After completing the cut of the first block,
the next block can be started adjacent to the first one. Since turning
on narrow benches is difficult and time consuming, two alternative
operations can be recommended:
3.6.1. Conveyor loading
Machine is set by lowering its cutting drum at a predetermined
depth, and then starts excavation with its forward movement and
the material excavated is transported to the discharge conveyor via
primary conveyor. Discharge conveyor is mounted on a discharge
boom that can slew in either side and also the height of the boom
can be adjusted as per requirement. The cutting drum is followed
by a scraper plate, which gathers material left on the floor. This re-
sults in clean and smooth floor without any undulation.
3.6.2. Windrowing
The conveyor loading arrangement of the machine is not under-
utilised. The scraper plate behind the drum is modified and a door
is provided which allows the cut material to heap behind the ma-
chine in a row. Cut material can be loaded later to a dumper by
loading equipment like front end loader.
The production capacities of conveyor loading and windrowing
modes are shown in Table 4.
4. Theory

a. Turning the machine on an appropriate area outside the 4.1. Cutting performance
ramp.
b. Reverse the machine after finishing one cut and reposition The working performance by different types of surface miners
the surface miner at the adjacent cut. in different rock formations is given in Table 5. Surface miner
38 A. Prakash et al. / International Journal of Mining Science and Technology 23 (2013) 33–40

Table 4
Production capacity of surface miner in different working modes (m3).

Method of working Windrowing Conveyor loading mode

   
Empty travel back method W60 W60
SLd L L Sd L tc te
v þv e v þLt þ L
Planned Production ¼ 1000 Planned Production ¼
h i 1000 
Turn back method SLd W60
W60
L
v þtt
Sd 1 tc tt
Planned Production ¼ 1000 v þLt þ L
Planned Production ¼
1000 
Continuous mining method Planned Production ¼ Sv dW60
1000 W60
Sd 1 tc
v þLt
Planned Production ¼ 1000

Note: L is the length of face, m; d the predetermined depth of cut, mm; v the machine speed during cutting, m/min; ve the machine speed during empty travel, m/min; te = L/
ve, the empty travel back time, min; W the working hours available in shift, h; S the width of cutting drum, m; tc the truck changing time, min; Lt = (truck capacity (m3)  fill
factor)/(S  d  swell factor/1000), the length of cut to fill one truck, m; and tt the machine turning time, min.

Table 6
can cut oil-shale seams more exactly than rippers (2–7 cm) with Production performance of few surface miners in Indian coal mines [11].
deviations about 1 cm [10]. The production performance of a few Sl No. Company No. of machines Av. daily production
surface miners used in Indian coal mines (Central Coalfields Lim- (t/day)
ited (CCL), South Eastern Coalfields Limited (SECL), Mahanadi Coal- 1 CCL 5 4526
fields Limited (MCL) and Singareni Collieries Company Limited 2 SECL 6 4535
(SCCL)) in the year 2007–2008 is shown in Table 6. 3 MCL 19 6637
4 SCCL 1 6335

4.2. Cutting performance assessment models

Table 7
The performance, the cutting tool consumption and the eco- Cutting rate with respect to rock strength.
nomic operation of surface miner is significantly affected by the
Type Strength (MPa) Cutting rate (t/h)
mechanical properties of the rock to be cut. The main properties
of rock affecting the cutting performance are: 2200SM Up to 50 750–300
2500SM Up to 80 81 to 100 1550–220
220–65
 Uniaxial compressive strength, MPa; and tensile strength, MPa 3700SM Up to 80 81 to 100 2550–365
 Abrasivity 365–100
 Structure of the rock (i.e., frequency and direction of geological 4200SM Up to 70 3400–475
discontinuities).

In general, surface miners are capable of cutting rocks with a The production rate of the surface miner can be estimated as
strength range lying in between 10 and 80 MPa. Under certain cir- [14]:
cumstances (e.g., highly fractured material) even harder material  
can be cut economically. The cutting efficiency decreases with CI
L¼ 1 kMc ð2Þ
increasing strength of the rock (Table 7). 100
Kramadibrata and Shimada have shown a functional relation-
where L is the production or cutting performance, bcm/h; Mc the
ship between Voest Alpine Rock Cuttability Index (RCI) and various
rated capacity of machine, bcm/h; CI the cuttability index; and k a
intact rock, rock mass and machine parameters as given [12,13]:
factor for consideration of influence of specific cutting condition
RCI ¼ fN=ðL rC Þgaf fðc d=rC Þ; ðrt =rC Þ; ðd=dÞ; ðEy=rC Þ; ðF=d rC Þg and a function of pick lacing, pick shape etc., varies from 0.5 to
1.0 [11].
ð1Þ
CI ¼ Is þ J v þ Aw þ J s þ M ð3Þ
where N is the rated machine power, kW; L the Production rate, m3/
h; rC the UCS of rock sample, MPa; c the specific weight, kN/m3; d where Is is the point load index rating; Jv the volumetric joint count
the discontinuity spacing, m; Ey the Young’s modulus, MPa; F the rating; Aw the abrasivity rating; Js the direction of cutting with re-
Schimazek’s abrasivity factor, N/mm; and rt the tensile strength spect to major joint direction rating; and M the machine power
of rock sample, MPa. rating.

Table 5
Working performance of a few surface miners.

Sl Mine Type Condition Performance

1 Limestone mine, 2100SM Material: limestone Density: 2.2 t/m3 UCS: 30– Truck capacity: 28–30 t Cutting performance: av. 870 t/h Effective
Pannedam, India [7] 2500SM 50 MPa Structure: massive without visible fractures production: 613 t/h Gradation: 90% of the material 100 mm
2 Bauxite mine [7] 2100SM Material: bauxite Density: 2.2 t/m3 UCS: 30–125 MPa Truck capacity: 16 t Cutting performance: av. 250 t/h Gradation: 90%
2200SM Structure: massive without visible fractures of the material 100 mm
3 Frija ore deposit 2500SM Cutting performance: av. 500 t/h Effective production: 360 t/h
Guinea [7]
4 Limestone, Southern 2100SM Material: limestone Density: 2.24 t/m3 UCS: 43– Truck capacity: 25 t Effective production: 111.85 t/h
India [6] 48 MPa
5 Coal, Eastern India 2100SM Material: coal Density: 1.68 t/m3 UCS: 15–25 MPa Truck capacity: 10 t Effective production: 175 t/h
[7]
 A. Prakash et al. / International Journal of Mining Science and Technology 23 (2013) 33–40 39

Table 8
Surface miner performance analysis in different mines (ton/month).

Sl No. Details Coal mines Limestone mines

Production EHMR Diesel consumption Pick consumption Production EHMR Diesel consumption Pick
(m3/day) (h) (L) (m3/day) (h) (L) consumption
1 Minimum 1293 8.90 445.00 0.00 3829 21.50 4239.00 13.00
2 Maximum 7270 21.50 2179.00 23.00 64,812 440.78 27,690.00 306.00
3 Mean 4995 15.83 1291.13 8.37 32,364 208.43 13,315.61 99.05
4 Standard 2210 4.79 620.63 9.33 15,855 101.72 6371.06 90.34
deviation
5 Range 5976 12.60 1734.00 23.00 60,983 419.28 23,451.00 293.00
6 Sum 39,964 126.67 10,329.00 67.00 187,7160 12,089.01 479,362.00 3467.00
7 No. of data 8 8 8 8 58 58 36 35

8000 25 25
Production (m /day)

7000 20 20
Pick consumption

Pick consumption
y = 0.006x - 26
3

6000 15 15 y = 0.006x- 26
R 2 = 0.79 R 2 = 0.79
5000 10 10
y = 297x+817
2
4000 R = 0.83 5 5

3000 0 0
10 12 14 16 18 20 22 24 3000 4000 5000 6000 7000 8000 3000 4000 5000 6000 7000 8000
EHMR Production (m3/day) Production (m3/day)

(a) EHMR (b) Picks consumption (c) Diesel consumption

Fig. 9. Relation between production per day of coal and EHMR, picks consumption and diesel consumption.

Lack of information like machine cutting speed, cutting drum 5. Factors influencing production
specifications and percent of silica are the limiting factors of the
Eq. (2) for calculation of production. Considering the various Apart from the maintenance and breakdown of the surface
parameters relating the intact rock, rock mass and machine design miner, various other factors influencing the production are poor
and operating parameters an index, CISM (cuttability index of sur- availability of transport vehicle; road preparation; poor road con-
face miner) was developed by Murthy et al. [9]. The index CISM can dition, dusty road and slow movement of vehicles; heavy rainfall;
be determined from the following equation: traffic problem, narrow transport road; shortage of cutting mate-
rial; blasting at other site; lack of space for cutting at places; siding
MF problems; steep gradient of ramp and poor lighting. Drum design
CISM ¼ ð4Þ
RMF  IRF must match the rock/rock mass properties for optimising produc-
The term RMF represents rock mass factor and is represented by tion. This requires further investigations.
field P-wave velocity in the rock mass measured in km/s. the term
IRF represents Intact Rock Factor and is given by,
6. Results and discussion
IRF ¼ LVP  SiO2 ð5Þ
The performance details of surface miner has been carried out
where LVP is the laboratory P-wave velocity in rock, km/s; and SiO2 in different coal (Gevra-South Eastern Coalfields Limited and Ling-
the Silica content in rock mass, %. araj-Mahanadi Coalfields Limited) and limestone mines (Sanghi,
The term MF represents machine design/operating parameters Madras Cement Limited and India Cements), as given in Table 8.
and is represented by, The production performance related to pick consumption, Engine
Hour Metre Reading (EHMR) and fuel consumption have been
MF ¼ EP  CS  CA studied for different surface miners in Indian coal and limestone
mines presenting different situations. EHMR is a sum of cutting
where EP is the total engine power, kW; CS the cutting speed, m/s;
hours, maintenance hours and empty travel hours.
and CA the total cutting area engaged in cutting rock at any point of
EHMR, pick and diesel consumption are influenced by and line-
time. This can be calculated from the following equation,
arly related to coal production rate as shown in Fig. 9 respectively.
pD The pick consumption varies from 0 to 23 for daily production
CA ¼ W ð6Þ varying from 1293 to 7270 m3. The average pick consumption is
6
around 8 for 4995 m3/day coal production. The average diesel con-
where D is the drum diameter, m; and W the drum width, m. sumption for each m3 of coal production is 0.26 l.
It is assumed that at any time only 1/6th of the circumferential EHMR, pick and diesel consumption are also linearly related to
length of drum gets engaged in cutting the rock. The equation limestone production rate as clearly depicted in Fig. 10 respec-
established for machine performance prediction is: tively. The pick consumption in limestone mines varies from 13
to 306 for monthly production varying from 3829 to 64812 t. The
NTPH ¼ b0ðCISMÞb1 ð7Þ average pick consumption is around 99 for 32364 t/month lime-
stone production. The average diesel consumption for every ton
where NTPH is the production, t/h; and b0 and b1 are constants. of limestone production is 0.41 l. It is imperative to correlate the
40 A. Prakash et al. / International Journal of Mining Science and Technology 23 (2013) 33–40
80000
70000
Production (t/month)
60000
50000
40000
30000 y =148x+1543
20000 R 2 = 0.90
10000
0 100 200 300 400
EHMR
(a) EHMR
Fig. 10. Relation between production per month of limestone and EHMR, picks consumption and diesel consumption.
drum design with rock properties to minimize breakdown espe-
cially in terms of production and pick consumption.
The use of surface miner has several merits in mining for rock
strength up to 120 MPa and its application is enormous in lime-
stone and coal mines. The milling type surface miner is better
among other types. Pick consumption is a common factor of ma-
chine breakdown. EHMR, pick and diesel consumption are linearly
related to coal as well as limestone production. Higher the coal/
limestone production higher is the pick consumption. The relation
between pick consumption and production of coal showed coeffi-
cient of determination of 0.79. The maximum coal production
per day by surface miner in Indian mines is 7270 m3 with an aver-
age production of 4995 m3. Average production per pick consump-
tion is 1387 m3. Diesel consumption per cubic metre of production
is 0.26 L. Engine hour metre reading is positively correlated with
coal production. The regression analysis between pick consump-
tion and production of limestone is 0.82. Maximum production
of limestone per month is 64812 t with an average production of
32364 t. Average production of limestone per pick consumption
comes to 530 t. Diesel consumption per ton of production is
0.41 L. The pick consumption is comparatively higher in limestone
mines than coal mines. Pick consumption can be reduced if ma-
chine is operated with respect to rock and rock mass properties.
7. Conclusions
Surface miner, a mechanical rock cutter, has wide application in
open cast mining in rocks and minerals of soft to medium hard-
ness, though it can be operated in harder formation with lower
efficiency. Having several attractive advantages, these machines
with wide range applications are being used. Higher the produc-
tion higher is the pick consumption. Cutting performance of these
machines as discussed in limestone and coal mining found to vary
linearly with EHMR. Similar conditions are observed for diesel and
pick consumption. Performance prediction models, based on few
parameters on machine performance, intact and rock mass proper-
ties, are found to have limited applicability and need further
refinement. Additional research is imperative for suitable drum de-
sign, lacing pattern and pick spacing in relation to intact rock and
rock mass parameters for enhancing production with minimum
breakdown of picks of this wonderful machine.
350
30000
300
Diesel consumed (l)
25000
Pick consumption
y= 0.403x- 169
250 y= 0.005x- 70 2
20000 R = 0.87
200 R 2 = 0.82
15000
150
100 10000
50 5000
500 0 20000 40000 60000 0 20000 40000 60000
Production (t/month) Production (t/month)
(b) Picks consumption (c) Diesel consumption
Acknowledgments
The work presented in this paper forms a part of the Ph.D. work
of the first author in progress at Indian School of Mines, Dhanbad
and thus the authors acknowledge the support of Department of
Mining Engineering, ISM for making use of different facilities.
The authors also thank the director, Central Institute of Mining
and Fuel Research, Dhanbad, for permitting to publish the paper.
The views expressed in this paper are those of authors and not nec-
essarily of the organizations they represent.
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