AGA
Anglo Platinum Project Proposal 1
MINING MACHINE DEVELOPMENT
PROPOSAL
Prepared for:
Prepared by: John Gibson, partner, AG Associates and
Llewellen Anderson, partner, AG Associates
Anderson Gibson Associates
4840 NE 40th
Street, Seattle, WA, USA, 98105
[email protected] , +1 541 398 1713
[email protected] , +1 206 524 0248
December 21, 2010 Proposal number: RCTS 2010-101
TECHNO
LOGY
SERVIC
E
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Anglo Platinum Project Proposal 2
Executive Summary
Objective
The proposal projects will produce designs for an enlarged production RM and a
larger RM for excavating strike gullies. The ‘extra’ projects are normal steps in the
product development and will improve the efficiency and availability of the RM
family of machines.
Goals
Completion of detail design of an RM 1200 and an RM 2000 or RM 2000 XP.
Manufacturing cost estimates, operating costs and production rates will be
completed and benefits to the mine identified.
Improvements in excavation and availability rate of Reef Mole style machines by
testing of typical Platinum mine rocks, testing of alternate cutter types and design
studies of alternative power and vacuum systems.
Solution
AGA and it's associated companies in South Africa will assign qualified personnel to
carry out the identified tasks according to the project schedule and budget. The
projects may be completed in any sequence.
Major Project Milestones
Completion of design layouts and analysis for an RM type machine that cuts a1200
x 5000 mm opening including cost of manufacture and performance estimates
Completion of design layouts and analysis for an RM type machine that cuts a 2000
x 4000 mm opening including cost of manufacture and performance estimates
Discussion of machines for large openings
Coordination with test results from RM 950 excavation at Waterval mine
Collection and lab testing of representative rock types and summary of existing test
results
Preliminary design of alternate power and vacuum systems to better match mine
safety and environmental conditions
Additional studies of alternate RM system designs
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Anglo Platinum Project Proposal 3
Contents
1. Project description, machine series, technical basis of design, development and
manufacturing
2. RCTS organization and associated companies
3. Experience, RM 850, RM 950, VM 800
4. Stope mining machine, RM 1200
5. Gulley development machine, RM 2000, RM 2000XP
6. Main Shaft development machine
7. Additional tests and design studies of rock types, power/control and vacuum systems
8. Project Plan
9. Project Schedules and cost estimates
10. Project total cost estimate for engineering, travel and testing
11. Reference Information,
rock energy density graph, cutter spacing/penetration ratio graph, rolling cutter technology,
typical tunnel boring machines, size, weight, power and cost table, historical machine types,
& Web links
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Anglo Platinum Project Proposal 4
1. Project description
The primary goal of the project is to produce rugged machines manufactured in
South Africa that excavate the ore and the gullies found in the narrow reef
platinum mines.
This proposal describes the next phase of product development for the original Reef Mole
type machine. From this machine a family of machines suited to needs of Anglo Platinum will be
designed and developed.
Besides the structural design of the machines the proposal identifies several technical aspects
of the systems that would benefit from additional testing, specification or standards evaluation.
Descriptions for these programs, their schedules and costs follow.
The Reef Mole is designed and manufactured to the same standards as those
tunneling and raise boring machines that are used so successfully throughout the
mining and civil construction industries. All of the steel fabrication, hydraulic
and electrical design and manufacturing and assembly skills are found in local
industry.
RM production rates were estimated on a kW-hr / tone basis. Analysis of
penetration, thrust and boom swing rate results in production of ore and
determines the loads used to design the structural components.
These values fit with the ‘standards’ established from testing and performance from actual
tunneling projects. Testing of the RM 850 at Townlands mine confirmed the estimated values
and power consumption for the UG2 and surrounding rocks. See Reference 11.1.
Cutter wear for the testing was very small and analysis showed that the projected life of
cutters was comparable to expectations for roller cutters used in the tunneling and mining
industries.
The Patented Reef Mole machine concept brings together certain elements of
mechanical design in an excavating machine which results in an opening ideal
for narrow reef mining.
First, the opening produced has a flat footwall and hanging wall.
Secondly, it uses standard tungsten carbide inserted roller cutters that cut the reef and
surrounding rocks very easily and resist the abrasive material well.
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Thirdly, the use of hydraulic cylinders as the main power source on the machine to drive
the cutters through the rock means that the large forces for thrust and rolling are provided by a
strong element that can fit into the small opening. No gearboxes or electric motors are used on
the machine itself.
Fourthly, the RM configuration lends itself to mounting on tracks for mobility.
Particularly in a gulley size excavator where it would need to be moved to different locations.
And lastly, the rock cuttings are small and easily handled by a vacuum system, no
primary crushing is needed and the amount of waste rock produced is significantly reduced.
There will be many benefits realized from the cleanly cut footwall and hanging wall related to
rock support and equipment maintenance. Full day operation is possible and conditions will be
safer for personnel.
The following diagram shows the RM 950. Note the Front Gripper, sliding Rear Grippers,
Swing Cylinders, Swinging Boom, Cutter Head and Vacuum Shroud on the cutter head.
RM 950 narrow reef mining machine
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2. Rock Cutting Technology Service - RCTS
RCTS is a South African registered company. The four partners
bring years of experience in the design and manufacture of heavy
excavation equipment.
For many years, Mr. Anderson and Mr. Gibson were employed at a major manufacturer
of tunneling and mining equipment and have management, project engineering and underground
experience. This was during the formative years when the design and operation of tunneling and
raise boring machines matured and mechanization became standard in those industries. This
included participation in the development of new machine types such as the mobile miner and
box holers. The Reef Mole is covered under a South African patent held by their company
AG Associates, Seattle, Washington, USA. [email protected] , +1 541 398 1713 or
[email protected] , +1 206 524 0248
The goal of AGA is to be a technology company based in the USA. To form
partnerships with in-market companies to design and build excavation
equipment specifically for the production, safety and environmental needs of
narrow reef mines and to provide local aftermarket service and parts.
These machines will excavate the reefs and the openings for access and conveyance using
proven roller cutter technology. With the exception of a few specialty items like bearings, the
machines and cutters will be totally manufactured in-country by associated engineering and
manufacturing companies.
The original RM 850 and the rebuilt RM 950 were designed and manufactured
by AG &Associates (Seattle, USA), Scheffer Mechanical Technology (Witbank),
Megmet Engineering (Pretoria), Turnkey Hydraulics (Wadeville), Orbweb
Electrical/Electronics (Pretoria) and several hydraulic cylinder manufacturers.
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3. "On the ground" Experience
Besides the work experience described above, work on the RM projects has
involved design, testing, redesign and manufacture of the RM series of
machines.
This includes the RM 850, the RM 950 and the VM 800 which was built and tested in
Canada.
Our partnership in South Africa, RCTS and associated companies have persisted in solving
the problems encountered and found solutions which have been incorporated into the RM 950. It
is to begin testing at a mine near Rustenburg, SA in January 2012.
The RM 950 has been strengthened in the gripper and steering systems and equipped with
larger cutters to increase the opening size to 950 mm x 5000 mm. A test and panel excavation
plan is being developed with the mine. Operation of the machine during this project can allow
for incorporation of new information into the design of the next machines in the family.
The RM 950 is predicted to mine at a rate of 1 meter per hour and can operate at
least 10 hours or more each day if the operating crew is properly set up to sustain
the logistics of operation.
Each meter excavated yields about 18 tonnes of rock.
If the reef is 300 mm width then the dilution in a 950 mm cut is roughly 2 to 1. This
compares very favorably to an excavation width of 1800 mm, where the dilution is 5 to 1. This
means that if all the ore in a mine was produced mechanically then a monthly quota of
platinum would be produced by processing 1/2 the volume of material and with no primary
crushing.
Original testing of the RM 850 took place at Townlands mine in the same area.
Having to access the machine by vertical shaft and coordinate with blasting was very
limiting to the time the operating crew was able to spend on the machine. Operating crews
have to develop a strict regimen to coordinate the attention needed by the systems. Machines are
dependent on mine power supplies which can be unreliable. Servicing and repair of the machine
was difficult. Also, installation and removal of the machine was very difficult, time consuming
and expensive.
Manufacturing abnormalities encountered during testing demonstrated the importance of
strict quality control in materials and processes.
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Loading higher than the design loads proved too difficult for the machine
components to be operated at maximum capacity.
Most of the excavation was carried out at 60% of thrust and power capacity. Nevertheless,
reliability, advance rates and cutter life predictions were very favorable.
Roller cutters have been used in various rock types for years.
They work by pressing against a rock with great force and crushing the rock that they are
directly in contact with. The amounted penetrated is proportional to the load or thrust
applied. This action creates lateral tension cracks which want to propagate to the adjacent kerf
if it is close enough. You can imagine the variables related to rock strength, toughness, existing
cracks, cutter force, tip sharpness and even overburden stresses in some cases. In addition, the
cutter has to be forced through the rock as a boat through water. If you roll the cutter faster it
takes a greater amount of power. A certain amount of broken rock is yielded by this process
depending on the depth of penetration and the speed of rolling.
So much roller cutter testing has been done that there are standard charts for 'energy
density' and spacing to penetration ratios for roller type cutters. Examples of these charts
have been included in the 'References' section.
During testing of the RM 850, it was determined that the machine operated at a
level of 13 to 20 kW-hrs/tonne of rock excavated.
This level was significantly reduced with a new cutter design during testing. Some of the
testing proposed involves alternate cutter designs which can result in more efficient cutting so
that more tonnes are produced by each kilowatt of power used.
Factors related to penetration and power determine the specifications for a specific
machine and from them an estimate of performance or production can be calculated. From
the design forces and rates of operation the machine structure and energy systems can be
designed.
The most efficient performance has been found to occur when the spacing to penetration
ratio is approximately 20. The insert row spacing on the cutters averages 25 mm and the
design penetration rate is 2.0 to 3.0 mm per pass of the cutter head. The design cycle time for the
boom swing is 6 to 10 seconds.
The new RM 950 has been analyzed and designed for sustained daily operation at
these load and power levels. New machines in the RM family will continue to
improve based on the testing and analysis of the RM 950 during the coming year.
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In addition, the mine will develop the crew and support systems needed for the
machines to operate at a high utilization rate. These will include guidance and
rock bolting systems.
The following diagrams show how a typical mine area panel development using these
machines might look.
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Overall view of an inclined shaft and developed R & P panels
RM 950 developed R & P panel development
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Starting ‘Cubby’ for the RM 950
View of the Vacuum pumps, ore drop boxes and electrical panels
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4. Panel Mining machine, RM 1200
This machine would be a more powerful version of the RM 950. It would cut an
opening of 1200 mm X 5000 mm.
Additional cutters would be installed and the power and thrust increased so that the
excavation rate was the same as the RM 950.
This additional width is for the reef formation at Waterval mine.
The reef there has a thin seam of rock directly above it that is approximately 150 mm thick. It
is desirable to remove this layer with the machine but in doing so with a 950 mm machine some
portions of the lower reef are left behind. Cutting a wider opening recovers more ore with the
disadvantage of increasing dilution. It is most efficient to keep the machine cutting ahead rather
than trying the difficult and time consuming maneuver of undercutting the footwall in small
areas.
The layout, detail design and structural analysis of the machine will be completed to
include detail drawings to in-country standards. A price estimate for the machine
based on manufacturer’s quotations will also be provided.
A specification sheet for the proposed machine is shown on the next two pages.
The milestones, schedule and cost estimate for this project are given in Sections 8 & 9.
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Anglo Platinum Project Proposal 13
Reef Mining Machine RM1200
Condensed Specifications (Preliminary) December 13, 2010
Cutter Head: Cutting Height 1220 mm (48”) cut height
Gripper: Hydraulic actuated cylinders, 2 sets of 2, gripping
between hanging wall and foot wall
Gripping Force 222 kn. (50 000 lbs.) each
Rock Contact Pressure 22 bar (320 psi)
Cutters: Number 8
Type Multi-row with Tungsten Carbide inserts
Diameter 382 mm (15 ins)
Insert Spacing 33 - 37 mm (1.3 – 1.5 ins)
Rated Capacity 267 kN (60 000 lbs)
Swinging Boom:
Maximum Extended Length 2 500 mm (78.7 ins)
Extension 500 mm (19.7 ins)
Thrust Capability 2 224 kn. (500 000 lb.)
Swing Velocity 0 - 76 m/min (0 – 250 ft/min)
Angle of Swing 200 degrees
Support Frame: Length Approximately 2 500 mm (98 ins)
Width Approximately 2 500 mm (98 ins)
Pivot Sealed tapered roller bearings in EP grease
Main Gripper: Hydraulic actuated cylinder gripping between
hanging wall and foot wall.
Gripping Force 2 000 kn. (450 000 lbs.)
Rock Contact Pressure 172.5 bar (2 500 psi)
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Gripper Carriage:
Rear Grippers: Two pairs of hydraulic actuated cylinders gripping
against hanging wall footwall.
Gripping Force 1 112 kn. (250 000 lbs.) each
Rock Contact Pressure 172.5 bar (2 500 psi)
Steering and stabilizing: Pitch and roll steering is accomplished by
varying oil flow to the four rear gripper cylinders
thereby moving the support frame and boom in
whichever direction is required, pivoting about the
main gripper spherical mount. All cylinders are
fitted with linear transducers
Muck Removal:
From Face Vacuum system via suction nozzles strategically
mounted on the cutterhead.
From Machine Vacuum hose and rigid pipe that transfers the
cuttings, dust and fines to a water scrubber to
remove dust before discharging the coarser material
onto the mine conveying system
Power Pack:
Electric Motors Water cooled, double ended shaft. Total installed
power: 350 kW (470 hp)
Oil Pumps – swing cylinders High pressure, 345 bar (5 000 psi), high volume,
0 – 1 320 lit/min (350 gpm) variable displacement
pumps for boom swing and fast regrip.
– thrust cylinders Medium pressure, 104 bar (1 500 psi), low volume,
0 – 136 lit/min (36 gpm) variable displacement
pumps for thrust, gripper and steering control.
Required Services:
AC Electrical Power 420 kVA, 550 V, 50 Hz
Water for Oil Cooling 226 lit/min @ 7 bar (60 gpm @ 100 psi)
Ventilation Adequate flow across the stope face.
Weights: RM1200 assembly Approx. 22 Tonnes (48 000 lbs)
Power pack assembly Approx. 8 Tonnes (18 000 lbs)
Vacuum unit assembly Approx. 5 Tonnes (11 000 lbs).
Maximum modular component Approx. 8 Tonnes (18 000 lbs).
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5. Gulley Mining machines, RM 2000/2000XP
Two versions of this machine would be evaluated. They would cut an opening of
2000 mm X 4500/5000 mm.
The first version would have the same power as the RM 950.
The design excavation rate would be 1/2 M/hr. The power unit would be very similar to the
RM 950 unit. This machine would have an indexing cutter head with 6 cutters. It would require
2 swings to cut the full face area. It would be lighter and less expensive than a full power
version and would yield 5 Meters of advance in a 10 hour operating day. This may be adequate
for some mining plans. It would be mounted on tracks so it could be moved to other
locations.
The second version of this machine would have a design advance rate of 1 meter
per hour.
Additional cutters would be installed and the power and thrust increased to match the design
loading. The power unit would require higher power motors and a larger oil reservoir. It would
be mounted on tracks.
The layout, detail design and structural analysis of the machines will be completed
to include detail drawings to South African standards. A cost estimate based on
manufacturer’s quotations will also be provided.
Specification sheets for the proposed machines are shown on the next 4 pages.
The milestones, schedule and cost estimate for this project are given in Sections 8, 9 and 10.
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Anglo Platinum Project Proposal 16
Strike Gulley Machine RM2000
Condensed Specifications (Preliminary) December 12, 2010
Cutter Head: Cutting Height 2 010 mm (6’ 7”) cut height
Gripper: Hydraulic actuated cylinders, 2 sets of 2, gripping
between hanging wall and foot wall
Gripping Force 222 kn. (50 000 lbs.) each
Rock Contact Pressure 22 bar (320 psi)
Cutters: Number 7
Type Multi-row with Tungsten Carbide inserts
Diameter 382 mm (15 ins)
Insert Spacing 33 - 37 mm (1.3 – 1.5 ins)
Rated Capacity 267 kN (60 000 lbs)
Swinging Boom:
Maximum Extended Length 2 000 mm (78.7 ins)
Extension 500 mm (19.7 ins)
Thrust Capability 3 336 kn. (500 000 lb.)
Swing Velocity 0 - 76 m/min (0 – 250 ft/min)
Angle of Swing 200 degrees
Support Frame: Length Approximately 2 500 mm (98 ins)
Width Approximately 2 500 mm (98 ins)
Pivot Sealed tapered roller bearings in EP grease
Main Gripper: Hydraulic actuated cylinder gripping between
hanging wall and foot wall.
Gripping Force 2 000 kn. (450 000 lbs.)
Rock Contact Pressure 172.5 bar (2 500 psi)
Gripper Carriage:
Rear Grippers: Two pairs of hydraulic actuated cylinders gripping
against hanging wall footwall.
Gripping Force 1 112 kn. (250 000 lbs.) each
Rock Contact Pressure 172.5 bar (2 500 psi)
Steering and stabilizing: Pitch and roll steering is accomplished by
varying oil flow to the four rear gripper cylinders
thereby moving the support frame and boom in
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whichever direction is required, pivoting about the
main gripper spherical mount. All cylinders are
fitted with linear transducers
Muck Removal:
From Face Vacuum system via suction nozzles strategically
mounted on the cutterhead.
From Machine Vacuum hose and rigid pipe that transfers the
cuttings, dust and fines to a water scrubber to
remove dust before discharging the coarser material
onto the mine conveying system
Power Pack:
Electric Motors Water cooled, double ended shaft. Total installed
power: 350 kW (470 hp)
Oil Pumps – swing cylinders High pressure, 345 bar (5 000 psi), high volume,
0 – 1320 lit/min (350 gpm) variable displacement
pumps for boom swing and fast regrip.
– thrust cylinders Medium pressure, 104 bar (1 500 psi), low volume,
0 – 135 lit/min (36 gpm) variable displacement
pumps for thrust, gripper and steering control.
Required Services:
AC Electrical Power 420 kVA, 550 V, 50 Hz
Water for Oil Cooling 226 lit/min @ 7 bar (60 gpm @ 100 psi)
Ventilation Adequate flow across the stope face.
Weights: RM2000 assembly Approx. 14 Tonnes (32 000 lbs)
Power pack assembly Approx. 8 Tonnes (18 000 lbs)
Vacuum unit assembly Approx. 5 Tonnes (11 000 lbs).
Maximum modular component Approx. 10 Tonnes (22 000 lbs).
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Strike Gulley Machine RM2000XP
Condensed Specifications December 12, 2010
Cutter Head: Cutting Height 2 010 mm (6’ 7”) cut height
Gripper: Hydraulic actuated cylinders, 2 sets of 2, gripping
between hanging wall and foot wall
Gripping Force 222 kn. (50 000 lbs.) each
Rock Contact Pressure 22 bar (320 psi)
Cutters: Number 12
Type Multi-row with Tungsten Carbide inserts
Diameter 382 mm (15 ins)
Insert Spacing 33 - 37 mm (1.3 – 1.5 ins)
Rated Capacity 267 kN (60 000 lbs)
Swinging Boom:
Maximum Extended Length 2 000 mm (78.7 ins)
Extension 500 mm (19.7 ins)
Thrust Capability 3 336 kn. (750 000 lb.)
Swing Velocity 0 - 76 m/min (0 – 250 ft/min)
Angle of Swing 200 degrees
Support Frame: Length Approximately 2 500 mm (98 ins)
Width Approximately 2 500 mm (98 ins)
Pivot Sealed tapered roller bearings in EP grease
Main Gripper: Hydraulic actuated cylinder gripping between
hanging wall and foot wall.
Gripping Force 2 891 kn. (650 000 lbs.)
Rock Contact Pressure 172.5 bar (2 500 psi)
Gripper Carriage:
Rear Grippers: Two pairs of hydraulic actuated cylinders gripping
against hanging wall footwall.
Gripping Force 1 557 kn. (350 000 lbs.) each
Rock Contact Pressure 172.5 bar (2 500 psi)
Steering and stabilizing: Pitch and roll steering is accomplished by
varying oil flow to the four rear gripper cylinders
thereby moving the support frame and boom in
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whichever direction is required, pivoting about the
main gripper spherical mount. All cylinders are
fitted with linear transducers
Muck Removal:
From Face Vacuum system via suction nozzles strategically
mounted on the cutterhead.
From Machine Vacuum hose and rigid pipe that transfers the
cuttings, dust and fines to a water scrubber to
remove dust before discharging the coarser material
onto the mine conveying system
Power Pack:
Electric Motors Water cooled, double ended shaft. Total installed
power: 400 kW (536 hp)
Oil Pumps – swing cylinders High pressure, 345 bar (5 000 psi), high volume, 0
– 2 000 lit/min (530 gpm) variable displacement
pumps for boom swing and fast regrip.
– thrust cylinders Medium pressure, 104 bar (1 500 psi), low volume,
0 – 200 lit/min (53 gpm) variable displacement
pumps for thrust, gripper and steering control.
Required Services:
AC Electrical Power 550 kVA, 550 V, 50 Hz
Water for Oil Cooling 350 lit/min @ 7 bar (90 gpm @ 100 psi)
Ventilation Adequate flow across the stope face.
Weights: RM2000XP assembly Approx. 30 Tonnes (66 000 lbs)
Power pack assembly Approx. 10 Tonnes (22 000 lbs)
Vacuum unit assembly Approx. 5 Tonnes (11 000 lbs).
Maximum modular component Approx. 10 Tonnes (22 000 lbs).
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6. Main Shaft Mining Machine
Earlier, the advantages to narrow reef mining of the patented RM concept were
explained. In the large sizes of either inclined or vertical shafts the full face
machine types have been developed to do just this kind of work.
There are several companies which have built and tested these kinds of machines. See the
reference section web links for information on these.
For these reasons no work is being proposed to develop a machine larger than the
gulley excavation machine.
There are advantages to a partial face machine where the geology requires access to the face
for ground or water control.
An available option is to make two cuts with a smaller machine.
First a face would be advanced a certain distance and then the lower face would be advanced.
The design challenge in this is to provide an adequate gripping system for the machine when it is
removing the lower face. A ‘floating’ hang wall would be designed. This might also be used as a
starting ‘cubby’ for the production RMs.
The overall advance rate would be less than for a full face machine but the performance may
fit into a particular project.
If this is the case, AGA would perform a design study to further define an
approach to a system and make a proposal. Contact any of the listed AGA
representatives.
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7. Evaluation of additional tests or alternative designs
Certain areas of the RM system may yield better efficiency or cost reduction if
more were known about them or alternative approaches evaluated.
4 practical and current examples of these issues are:
Increase in production with a new insert pattern on the cutters. This was found in the RM 850
testing at Townlands mine. All current cutters are to this design.
A question has arisen as to whether the computer control hardware is adequately protected by
their enclosure and whether they should not be separate from the machine power unit. How
would they be remotely mounted?
When the machine is hidden away in it's excavation, what method is going to be used to enable
the operator to steer the machine so that it maximizes ore recovery?
A list of topics have been identified and study projects defined for each. Some of these are
only paper studies and others include designing, building and testing hardware. Individual cases
will be evaluated for their particular parameters. In all cases a report will be completed and
action recommended.
The following is the list of items. Their schedules, goals and costs are shown in
Sections 9 and 10.
Rock test results - Identify and collect all existing test data from prior testing of the
Waterval mine rock types. Compile results and predict RM performance.
Rock Testing. Alternate to 1. Collect suitable size samples from all rock types present
to do physical characteristic tests (200 mm ^ 3) and roller cutter tests ( 500 x 500 x 1000
mm). Contact and select a suitable test lab and contract for testing. Use cutters from the
RM 850 testing which include insert and integral disc designs. Design, manufacture and
test a wider spaced integral disc design. Evaluate test results and make recommendations
for RM and cutter designs.
Electronics cabinet design - Identify alternate classifications of electronic cabinet
environmental designs, compare to existing RM standards and identify practical
communication methods and more secure alternate locations for the electronic
equipment. Make recommendations for new designs.
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Machine guidance systems - Work with Waterval mine staff to develop a practical
position reference system so that the machine operator can remotely. Recommend a 'best'
approach and provide a set of specifications and costs.
Machine Communications - Identify a practical system for audio and visual
communication between the operator station and crew when they are in the area of the
machine. Recommend a system and provide specifications and costs.
High intensity power systems - Provide a practical design with specifications, costs
and advantages for a higher voltage electrical system and a higher pressure hydraulic
system that would yield improvements in efficiency or reduce weight and costs for RM
style machines.
Hydraulic reservoir study - Through testing on the RM 950, evaluate the performance
of the hydraulic oil reservoir. Identify alternative methods to cool and de-froth the oil.
Provide system specifications and costs with recommendations for reducing the volume
of oil held in the reservoir. This will yield a smaller power unit and make it easier to
handle.
Remote power unit study - Evaluate and design an oil transfer system which would
allow the power unit to remain in a gulley. Design a mining pattern which could be
accomplished with this system that satisfies the mine's requirements for support,
ventilation and safety. Provide defining documentation, specifications and costs for the
system.
Vacuum system evaluation - The vacuum system currently in use on the RM 950 will
be evaluated when in place underground to test it's capacity limits for length of
conveyance, air volume moved and volume of transported material. The factors
determining it's medium term maintenance and support will be identified and
improvements recommended. A list of alternate equipment types, hardware suppliers and
alternate types of units will be provided.
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8. Overall Project Plan and Schedule
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9. Project Schedules and costs
9.1 Project Management Schedule
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9.2 RM 1200 Design Schedule
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9.3 RM 2000 Design Schedule
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9.4 RM 2000XP Design Schedule
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9.5 Extra Studies for operational improvements
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10. Project Total Cost Estimate
10.1 Summary and Total Estimated Expenses
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11. Reference material and Web links
11.1 Graph of excavation power required to particle size, Ref: Colorado
School of Mines
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11.2 Graph showing the relative power consumption for roller type
cutters for various spacing to penetration ratios.
11.3 For information related to roller cutter technology, see the web
links listed below for the different types and their applications.
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11.4 Graphs showing specific characteristics of a range of excavation
machines.
The following graphs show established value trends for measured
values of the rock breaking parameters relating energy and the size of
the broken material.
They point out the position of the Reef Mole 850 test values in the
overall data set and of the average values for tunnel boring machines.
Graph 1 illustrates the band of values as a function of particle size.
The differences in the high and low values relate to the rock toughness
and compressive strength. This graph also shows values from the RM
850 testing at Townlands Mine.
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Graph 2 illustrates the values plotted from the data covering
manycompleted tunnel projects. The important factors to compare are
kW/cutter, cutter spacing in MM, the specific energy in kW-hr/tonne
of excavated rock, and the penetration per pass.
The RM 950 values are shown for comparison. Because of the use of
inserted cutters which are long lived and have a close spacing the effect
is to reduce the penetration per pass for a given cutter thrust force and
to require relatively more power for each cutter. Ie, the cutter rolling
force ratio is higher and the speed of rolling must increase to have an
economical production rate.
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11.5 For historical excavation machine types see the web link listed
below.
11.6 Web Links
See this on-line paper for a broad look at excavation technologies for
many types of machines.
http://cerena.ist.utl.pt/masysnet/books/SMEMiningEngineeringHandbook/2
2%20Section%2022%20Novel%20and%20Innovative%20Mining%20Methods
/C22_1.PDF
This site shows some very interesting mining and tunneling projects
http://www.oobject.com/category/20-interesting-boring-machines/
http://www.platinum.org.za/Pt2008/Papers/293-296_Harrison.pdf
http://www.patersoncooke.com/system_app/underground/UNDERG_hoisting.pdf
These are good industry websites for general and specific information.
http://www.tunnelingonline.com
http://www.world-tunnelling.com
These are academic references.
http://www.saimm.co.za
http://www.canadianinstitute.com/mining.htm
http:// www.mines.edu
And search Google or Bing with any of these terms to discover more
information.
Tunnel machine roller cutters, tunnel boring machines, raise boring
machines, tunnel projects, Chicago deep tunnel project, tunnel machine
guidance systems, rock tunneling
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