1. WORKING OF ICC-BWE-ROCK BREAKER
I. Satyanarayana,
M.Tech,MBA,MCA
Dy. Manager, Project Planning, SCCL,
isnindian@gmail.com,
visit at
www.slideshare.net/isnindian

2. 2

3. 3. In pit crusher conveyor technology
•The drilled & blasted OB is loaded by shovels and transported by dumpers
to Crushers. The crushed OB is then transported by a series of conveyors
into a spreader for dumping.
•Can be used in steep seams where laying of transport roads for the trucks
is difficult.
•While S.R indicates volumes, cut off ratio indicates depth and reflects in
dumper haulage cost, which increase with depth and may become
prohibitive where in alternative haulage system may have to thought off.
•Ideally suited where material has to be transported over a longer distance
& high lift.

4. 3.IN-PIT CRUSHER CONVEYOR TECHNOLOGY
• Haulage costs have been an area that have risen significantly with the
increase of diesel prices.
• One alternative to reduce haulage costs is to shorten the truck haul
distance by bringing the dump point into the pit using an in pit movable
crusher/ crushers and conveying the Over burden out of the pit can
reduce the haul cost.
• When the gradient is too steep, dumping the material within the mine is
not practicable as the dumped OB slides on to the coal face. In such
cases in pit crushing is preferred.
• The flow of material utilising an inpit movable crusher and conveyor
system starts with OB material being dumped into crushers by
dumpers. The material is crushed and fed on to horizontal transfer
belts within the pit or directly on to a major up slope belts taking the
material out of the pit. There may be one or more belts depending on
the pit Geometry and depth. The conveyed material is dumped as per
Video
the requirement and the dump design by using spreaders.

5. In pit crusher conveyor technology:
• Can be used in steep seams where laying of transport
roads for the trucks is difficult.
• Ideally suited for large capacity projects.
• Ideally suited where material has to be transported
over a large distance with huge lift.
• Requires huge capital.
• The transport cost will be much less than compared
to shovel dumper combination.
• Requires heavy equipment like crushers, conveyor
distribution point and spreaders.

6. Ramagundam OC-II with Inpit Crushing & Conveying Technology
Depth and gradients makes dumper haulage prohibitive due to high operating
cost. The alternate choice is ICC where material has to be transported over a
large distance & lift.
The drilled & blasted OB is loaded by shovels and transported by dumpers to
Crushers. The crushed OB is then transported by a series of conveyors into a
spreader for dumping.

7. Salient features of RG OC-II Project
No.of seams- 10
Gradient- 1 in 3.6 to 1 in 4
Depth planned- 400m
Capacity of the project- 4 MTPA
Technology- Shovel dumper combination with ICC technology
Life of the project- 27 years
Stripping Ratio- 7.73 Cum/T (107.46 Mt of coal and 808.46 M.Cum of OB)
Grade of the coal- ‘D’
OMS- 6.88 planned
Cost of production in Rs/T - 1606.94
Total Capital outlay of the project is estimated at Rs 896.32
Slope stability is a vital aspect in this project, as final highwalls will have a height
of up to 400 m which need to be planned as steep for better economics.
The 120m high dumps with crushed OB(low cohesion) will pose different
problems in dump stability which needs a comprehensive study on design,
maintenance, monitoring and stabilisation altogether.

8. IN-PIT CRUSHER CONVEYOR TECHNOLOGY

9. ICC at RG OC-II

10. Ramagundam OC-II Mine with Inpit Crushing & Conveying Technology
Compacted floor sloped 2-3°towards toe of the upper deck to direct the water to the
drain to avoid seepage into the dump. Better we provide lined drains/channels.

13. The spreader can rotate with an angle of 120 degrees.
In SCCLtd, the inpit crushing and conveying system introduced in RG OC II,
Ramagundam. The capacity of each crusher-conveyor system is 1200
cum/hour. There are 3 such systems in addition to coal conveying system in
RG OC II mine.

14. 4) Continuous Miner Technology:- Bucket Wheel Excavators
•Presently being used in Naveyali, Lignite Opencast mines,
having soft strata.
•The bucket wheel excavates the material without blasting
which is transported by a series of belt conveyors to
spreader.

15. 4. BUCKET WHEEL EXCAVATOR(BWE)

16. BUCKET WHEEL EXCAVATOR(BWE)
This machine is suitable for excavating soft and non sticky material in
large quantities.
Lignite deposits usually associated with soft over burden. Most lignite
mines in world use these BWEs for both OB and Lignite, as is the case
of “Nyveli Lignite Corporation” of India.
Semi hard material also be made suitable for BWEs by small blastings.
The BWE is a continuous excavating machine and capable of removing
of OB up to 1200 cum / per hour.
The excavation component of BWE is a large rotating wheel mounted on
an arm/boom.
On the outer edge of wheel is a series of scoops/ buckets as the wheel
turns, the Bucket removes soil
As the wheel turns, the bucket removes OB/Coal from the target areas
and carries it around to the back side of the wheel, where it falls on to a
conveyor which carries the material to the identified destination.
BWE are generally worked in combination with crusher & conveying
system.

19. Overview – 3D view

20. Structural Components of the
BWE – Side View
Hoist Unit for Bucket Maintenance Crane Counterweight Boom Maintenance Crane
Wheel Boom
Pylon Operator’s Cabin
Bucket Wheel Boom
E-House
Bucket Wheel
Slewing Platform
Discharge Boom Discharge Boom Slew
with Conveyor Arrangement
System Rotary Plate and Drive
Crawler Travel Crawler Undercarriage Main Ball Race

21. Equipments Installed on
BWE
Crawler Drive
Bucket wheel
Rotary Plate
Boom Conv. Systems
Slew Systems
Boom Hoist System

22. LIGNITE FIELDS OF INDIA
NLC is also the Nodal agency
4 for Exploration of Lignite
Deposits in India.
The Lignite Reserves in
various states of India was
2 proved and estimated by NLC.
3
Lignite Reserves (as of April 2009)
Sl. State In MT %
No.
1 Tamilnadu &
31818.42 81.7
Pondicherry
2 Rajasthan 4443.65 11.4
3 Gujarat 2662.25 6.8
1
4 Jammu & Kashmir 27.55 0.07
5
5 Kerala 9.65 0.02
6 West Bengal 1.15 0.003
Total 38963.17 100.0

23. LOCATION OF NEYVELI LIGNITE MINES (SATELLITE IMAGE)
Neyveli
Township
TPS-I & IE
TPS-II

24. Safety Department – Mine-II & Expn.
SALIENT FEATURES OF MINE – 2
Mines-2 Expansion Mine-2
Description ( 10.5 MTPA) (4.5MTPA) (15.00MTPA)
Overburden thickness 50-100 M 57-112 M 50-112 M
Lignite Thickness 4-24 M 6-22 M 4-24M
Stripping Ratio in m3 :t 1:5.2 1:5.88 1:5.5
Minerable Reserve in M.T 380.81 214.88 595.69
Land requirement in Ha. 5321.99 2031.63 7353.62
Over burden removal in
MCM /A 51 27 78
Lignite in MT /A 10.5 4.5 15

25. 0.0 Alluvial Clay
3.0
Sandstone, Clayey Sandstone ,
Sandy clay.
105.5
Semi – Confined Aquifer Sand
112.0
113.5 Carbonaceous Clay
Lignite – I Seam
133.8 – 137.0 Carbonaceous Clay
137.0 – 138.30 Lignite – II Seam
Confined Aquifer Sand
154.8
156.8 Clay
190.0 Confined Aquifer Sand

26. Safety Department – Mine-II & Expn.
MAJOR MINING EQUIPMENTS FOR MINE-II .
Mines-2 Mines-2
Description (10.5 MTPA ) (15.00MTPA)
1400 Lit. STANDARD BWEs 2 5
1400 Lit. STANDARD BWEs- BRIDGE TYPE 3 3
700 Lit. STANDARD BWEs 3 4
700 Lit. STANDARD BWEs- Bucket rever. Type 2 3
11000 TPH MTC 3 6
4700 TPH MTC/4420Cu.mPH 2 3
20000 TPH SPREADER 2 3
20000 TPH CRAWLER MOUNTED TRIPPER 2 3
11000 TPH SPREADER 2 2
11000 TPH CRAWLER MOUNTED TRIPPER 2 2
6000TPH STACKER 1 1
2800 TPH RECLAIMER 2 2
TRANSPORT CRAWLER 2 4

27. METHOD OF MINING
Opencast continuous mining system using
• Bucket Wheel Excavators
• Spreaders
• Conveyor Systems
Refilling Mine Advancing Side
NSBS
NSBS
SBS
SBS
TBS
TBS
Spoil Bank
MBS
MBS OB bench Avg. Height – 25 m
Spoil Bank BBS
Av. Height – 15 m
Spoil Bank BBS Lignite Bench
Maximum Height = 22 m

28. 1400 LITRE BRIDGE TYPE BWE
Rated Production : 2250 m3/hr
Outreach from BW boom to Discharge boom : 130 ± 12 metres
Maximum High Cut height : 30 metres
Service Weight : 3193 Tonnes

29. 1400 LITRE BWE
Rated Production : 2250 m3/hr
Outreach from BW boom to Discharge boom : 61.3 metres
Maximum High Cut height : 26 metres
Service Weight : 2170 Tonnes

30. 700 LITRE BWE WITH DEEP CUT FACILITY
Rated Production : 1100 m3/hr
Outreach from BW boom to Discharge boom : 63.8 metres
Maximum High Cut height : 18 metres
Service Weight : 1450 Tonnes

31. 11,000 TPH SPREADER
Theoretical design capacity : 11,000 Tonnes/hr
Outreach from Receiving boom to Discharge boom : 135 metres
Working Gradient : 1 : 20
Service Weight : 1450 Tonnes

32. BRIDGE TYPE 1400 LITRE BWE IN OPERATION

33. DUMPING OPERATION OF 20,000 TPH SPREADER

34. 700 LITRE BWE OPERATION IN LIGNITE BENCH

35. EXCAVATION WITH LOCAL DEPRESSURISATION
GROUND WATER PUMPING FROM MINES - 110 Mm3 / ANNUM
45 NUMBERS OF 1000 GPM PUMPS (20” DIA) ARE IN OPERATION

36. Rock breaker
Rock breaker technology can be applied for breaking of rock/coal/ore
even about 500 kg/sq.cm.
It can be used wherever it is not possible to go for blasting – near
vicinity of structures and habitations.

37. Technical Parameters of Mega –
Breaker
Make : INDECO
Model : 8500 UP
Weight : 4500 Kg
Dia of tool : 195 mm
HP : 120 HP
Striking rate : 350-450 Blows / Min
Pressure to
Breaker : 150-160 bar
Energy Class /
Blow : 10,000 joules

38. Working Parameters of Mega Breaker
Production / Hour : 190 – 200 tons
Production / Month : 55,000 tons
Diesel Consumption : 30 Lit./ Hr
Life of Moil point : 275-300 hours
Optimal Bench Ht. : 3 to 4 M

39. Advantages
Locked-up reserves can be mined easily
Reduction in Man power
Sump-deepening an easy affair
Digging of foundation pits adjoining the kiln /
valuable structures
More environmental friendly working &
maintaining better social relationship with
villagers
Effective working hours compared to
conventional working methods

40. Limitations
Floor-level will not be uniform as
compared to Surface Miner
Not suitable for mining huge reserves
Have to be dependent on a single
machine

41. Cost Particulars
Total Capital Investment = 330 Lakhs
Cost of consumables = 1.2 Lakhs
Cost / ton of Limestone (Rs./MT) :
Owning Cost = 17.77
Operating Cost = 12.25
Total Cost = 30.02
Cost of Conventional Mining (Rs./MT) :
Total Cost = 24.80