Continuous Miner Technology

The continuous miner technology (CMT) is being adopted extensively in

underground coal mines of India as Mass Production Technology (MPT).
This technology potentially eliminates the two-unit operating, namely
the drilling and blasting.
This elimination helps for better strata control and avoids the drillers
working in unsafe conditions, may be under the loose coal roof. This
CMT improves the quality of the coal extracted and increases the
output per man shift (OMS) by reducing the deployment of face crew.
It also reduces the accident as it is operated by remote and workforce
exposure to faces is limited. The method also helps for better roof and
side control, thus preventing side and roof fall danger.
With the changing time now, continuous miners of different heights are
available, which helps for optimum use of technology to mine out
varying in-situ height of coal seam.

Deployment of Continuous Miner in Under Ground

India is the second-largest coal producer globally, where 93.7 percent of coal
is produced from opencast mining, and the rest of the coal is produced from
underground coal mining. With the high rate of extraction from opencast
mining and the increase in the number of new open cast mining fields, it is
essential to depend on underground coal in the future.
The reason for shifting to Mass Production Technology for underground coal
for some companies may be the high stripping ratio, shortage of free land,
and severe quality issues. Underground mining can only bridge the demand
and supply gap with decent quality and quantity, provided proper technique
is used for mass production from underground mines.
CMT is one of the best underground coal mining methods over conventional
or partial mechanised ones with a high rate of safe extraction. Its high
productivity, the highest level of safety, eliminating blasting vibration,
eliminating the occurrence of noxious gases generated after blasting and
restricting the deployment of the workforce directly under the exposed roof
attracts the operator to choose the method.
Moreover, it is a proven method practised in different fields which can even
produce 2000 tonnes to 2500 tonnes of coal daily with an extraction ratio of
65-70% .
The state-of-the-art technology of the continuous miner (CM) deployment is
a unique method to extract coal seam lying at greater depth with higher
seam thickness, minimising the loss of coal in terms of insitu pillars and
continuous production rate.
Therefore, an in-depth study has been taken up in this research for this
deployment of a continuous miner. CMT was commissioned for the first time
in India in May 2002 at Anjan Hill mine in Chirimiri, SECL. Later the success of
this technology prompted other coal companies in India to adopt the CMT.
At present, 35 nos. of Continuous Miners (CM) have been deployed in 24 UG
mines of CIL with total production capacity of about 17.171 Mty.
As per UG Vision Plan, CIL has envisaged a plan for commissioning of another
121 Nos. of CMs with capacity of about 45.12 Mty by 2034-35.
The basic advantages of working with continuous miner are as follows:
• The technology is safe , productive and compatible with our Indian mining methods .
• Hazard of blasting is totally eliminated.
• Excellent dust treatment arrangement is provided with the package.
• All operation of the CM are by remote control
• High O.M.S. can be achieved as the system is fully mechanized .
• Less exposure of persons in the district.
• High rate of extraction can be achieved if the roof is stable . 1500 to 2000 TPD can be achieved
during depillaring operation .With good organistion of system it can reach up to 3000 t/day
• Continuous monitoring of CH4 in the face .
• Stable roof condition , by using stiff and high strength resin bolting and monitoring technique .
• Highest standard of safety of the persons deployed in the CM panel .
• Better strata control compared to the conventional blasting method of development &
depillaring.
• The production in this case is higher which should be matched by suitable out-bye transport
system.
• Loading usually done by shuttle car followed by haulage transport system thus it is much faster.
Condition Favourable for the Deployment of Continuous Miner
The deployment of standard height CM is dictated by a host of factors such
as
(1) gallery width (not less than 5.5 m), height (not less than 3 m) for the
standard height CM,
(2) ground pressure in the range 184–200 kPa ; however, the ground
pressure of higher value can also be considered in hard floor condition
depending upon the bearing strength of the floor.
(3) Power (1.1 kVA),
(4) adequate ventilation system (sufficient to remove the coal dust
constraints of visibility and other noxious gases),
(5) transport system -preferably belt conveyor,
(6) pumping arrangements, and
(7) adequate filtered water for dust suppression and roof bolting.
• Continuous Mining System consists of following sub-systems:
• Continuous Miner
• Transportation
• Support
• Feeder Braker
• Load Center
Continuous Miner Sub-system:
• Continuous miners
• Though there are many variations in design, continuous miners
mostly consist of five main elements:
• A central body to carry all other components mounted on some type of drive
mechanism to provide mobility (most commonly caterpillar tracks).
• A "cutting head" usually rotating drum(s) and/or chains with cutting picks
attached
• A loading mechanism to pick up cut coal and deliver it into the central part of
the machine
• A conveying system, usually a chain conveyor running in a steel trough from
front to rear of the miner
• A rear jib section capable of a degree of vertical and horizontal movement to
enable the coal to be delivered into a transport or loaded at a desired point.

Continuous miners _ Introduction _ underground COAL

• Cutting Head: The design and power of the cutting head (drum,
borer, etc.) are crucial for efficient coal extraction.
• Gathering Head: This component collects the cut coal and feeds it
onto the conveyor system.
• Conveyor System: Transports the coal away from the mining face.
• Traction System: Crawlers or other systems enable the miner to move
and position itself at the face.
• Dust Collection: Continuous miners generate dust, so effective dust
collection systems are essential for worker health and safety.
• Roof Bolting Integration: Modern continuous miners can integrate
roof bolting equipment, providing simultaneous roof support during
mining operations.
The "ideal" continuous miner would:
• Be able to cut the full face in one pass
• Be easily moveable between locations without dismantling parts
• Be able to excavate right angle turns with a minimum radius
• Have roof and rib bolters fixed to the machine in a location where
each row of the designed support pattern can be installed without
moving the miner and be installed close to the cut face if
necessary (Bolter Miner)
• Have adequate space alongside to allow good ventilation of the
face area for efficient removal of gas and dust.
• Allow strata supports to be safely installed while coal cutting
continues
Many of these ideals have been achieved to varying degrees of
satisfaction (the last being an area of minimal success), but matching
development rates with longwall retreat rates is still a major problem
for many mines.
Increasing numbers of development units to attain longwall continuity
is expensive and provides extra strain on all other service functions
(personnel, ventilation, materials handling, power and water supplies,
gas drainage, etc, etc.) and is not usually a satisfactory solution.
• Some continuous miners (at one time almost all) could not cut the full
roadway width in one pass but had to be moved backwards and
forwards and from side to side in order to cut the full profile. This
often results in a very rough rib line (bad for stability and ventilation
flow) and delays the ability to install support into/under freshly
exposed roof for a period.
• The advantages of the ability to cut the full profile in one pass was
recognized early, but was not easy to achieve. Cutting forward in a
straight line could be readily accommodated, but it is necessary to be
able to turn corners, mostly at right angles, and to be able to retreat
the cutting machine from one roadway to relocate at frequent
intervals.
• These factors have proved major stumbling blocks to many
developments. In machines which covered the full face, steering in
the vertical plane could also be a major difficulty.
• The term "continuous" as applied to development machines has been
one of the biggest misnomers used for mining equipment because, on
development, they are usually anything but continuously cutting.
• The main delays mostly occur while roof support is installed and often
waiting for shuttle cars to return from their discharge point for
reloading.
• When actually cutting, cutting rates are usually more than adequate,
but when averaged over a shift cutting rates are often poor and this is
one of the reasons many mines have difficulty developing at rates
adequate to prevent long delays on longwall production.
• As a result, development is an area receiving major attention in
recent times. Many of the difficulties have been overcome and most
modern continuous miners are "full face" machines. They also have
roof bolting equipment mounted on the miner in locations allowing
roof bolts to be installed reasonably close to the face.
Types of Continuous Miners
Continuous miners for coal can be broadly classified by their cutting mechanism
and size, with types including ripper-type, borer-type, and oscillating head ripper
miners. Specific models vary by manufacturer and are designed for different seam
heights and mining applications.
Classification based on Cutting Mechanism:
-Ripper-type:
These miners use a rotating drum with cutting teeth to rip coal from the face. They
are commonly used for mining in a variety of seam heights and conditions.
-Borer-type:
These machines use a rotating auger or borer head to cut the coal. They are often
preferred for their ability to work in low coal seams and under difficult roof
conditions.
-Auger machines
-Oscillating head ripper miner:
This type of miner combines the cutting action of a ripper head with an oscillating
motion to improve cutting efficiency and reduce dust.
Joy Ripper Miner:
One of the earliest continuous miners produced and one that is still in
demand in limited areas is the Joy Ripper Miner. While it was made in
various models in the past, primarily depending upon seam height. This
machine consists of a ripper head fitted with five multi-bit chains, a
main chassis, and a loading unit. The ripper head is attached to the
main chassis through a flexible hydraulic mechanism and can be swung
to either side and upward to a cutting height of 3 m as well as made to
advance forward 60 cm , independent of the main chassis. The coal cut
by the ripper head together with that loaded by the two eccentric arms
is delivered to the conveyor. The rear conveyor can swing 45° to either
side of the machine.
Operation:
• With its head in the retracted position, the machine is moved forward on its
crawlers until the cutting bits are just touching the face in the center of the room.
• The head is then swung to its limit to the right and lowered until the bits are
about to touch the floor.
• Then with the cutting chains running, it is hydraulically advanced 60 cm into the
coal and is gradually raised vertically, taking out the coal above as it rises, until
the desired roof line in the coal is reached [a maximum of 3 m].
• The head is then retracted, taking out any loose coal left at the roof level.
• Thus, a block of coal 106 cm wide and 60 cm deep is removed from the seam.
• The head is again lowered, swung about 1 m to the left and again sumped
forward 60 cm in the seam.
• This operation is repeated across the whole width of the room.
• Thus, from one stationary position in the middle of the room or entry, the
machine can advance the entry 60 cm over a total width of approximately 6.1 m.
Boring Miner:
As an alternative to the ripper machine, boring-type machines, were
introduced almost at the same time.
A borer type continuous miner for coal, often referred to simply as a
continuous miner, is a large machine used in underground coal mines to
extract coal from the seam in a continuous process. It utilizes a rotating
cutting drum equipped with teeth to break away coal and a conveyor system
to transport the broken coal away from the face. These machines are crucial
for efficient coal extraction in room and pillar mining operations.
These machines have rotating arms equipped with bits that bore out the
coal, hence the name.
The arms, which revolve relatively slowly, produce a much coarser product
that that of the ripper miner, minimizing gas and dust problems.
Since cutting is accomplished by advancing the machine on its cats, it is very
difficult to roof bolt and cut simultaneously with it.
The greatest disadvantage of the machine is its great bulk; it occupies almost
the entire entry.
Key Features and Benefits of Borer Miner:
• Continuous Operation: Borer miners cut and deliver material to the rear of the
machine in one continuous operation, increasing efficiency and productivity.
• Versatility: They are designed to handle various mining applications, including
driving entries, creating mine rooms, and extracting pillars.
• Speed and Efficiency: Borer miners can advance at high speeds, keeping pace
with haulage equipment.
• Specific Models:
• Sandvik MF320: A crawler-mounted borer miner with a cutting width of 4,800 - 5,100 mm
and a cutting height of 2,840 - 3,150 mm, according to DirectIndustry. [3, 5]
• Sandvik MF420: The world's heaviest and most powerful continuous miner, known for its
ability to cut and deliver material to the rear of the machine, says IndiaMART. [1]
• Onboard Roof Bolting: Some models, like the MF320, come with onboard roof
bolting rigs for safer operations.
• Optional Remote Control: Radio remote control is available for increased
flexibility and safety.
• DESCRIPTION
• Sandvik MF320 is a crawler-mounted borer miner built to drive
entries, headings and mine rooms with exceptional speed.
• The miner is designed to cut and deliver material to the rear of the
machine in a single operation and is ideal for potash, trona and salt
mining.
• Features Low maintenance costs Operates with high availability,
which keeps maintenance costs as low as possible.
• Optional radio remote control Radio remote control is available for
more visibility, safety and flexibility.
• Safer operations Comes with onboard roof bolting rigs, which creates
a safer operation and environment.
Specifications
• Cutting height 2,840 - 3,150 mm
• Cutting width 4,800 - 5,100 mm
• Cutter motor power 2 x 370 kW
• Dimension (L x W x H) 12400 x 5100 x 3150
• Profile area 15 m²
• Machine weight 160,000 kg
• Installed power 990 kW
• Electric supply voltage 3,300 V /50 Hz
Advantages Long-lasting components for low cost of ownership and more
uptime Operates with high availability, resulting in low maintenance costs
Radio remote control available for better visibility and flexibility On-board
Sandvik roof bolting rigs ensure safe operation
• Auger Miner:
One of the major mechanical design problems in the past has been packaging these
mining machines into low-seam models. The result has been that, for a particular
model, the high-pedestal mounting for thicker seams has resulted in a very good
machine but the low-coal models have been far less satisfactory.
There was basically, only one thin-seam miner that could mine in the 71 to 91-cm
range.
In operation,
- the auger miner is positioned at the side of the heading with both augers at floor
level.
- The rib-side auger is raised and the machine is sumped into the face.
- The rib-side auger is then lowered and the other auger is raised, and the machine
is hauled across the face.
- A gathering conveyor, consisting of a single-strand chain with cast-steel flights,
gathers the loose coal from between the augers and delivers it to the rear of the
machine where it is discharged into a bridge conveyor.
This is an obsolete machine now for underground use
Milling-Head Miner:
Basically, the machine is a ripper. A number of disks or wheels/drums are
located on arms and disks rotate in vertical plane.
• While the machine can be equipped with a full-face head about 4.6 m
wide, usually the width of the head is less so that two passes are required
to mine the full width of the entry.
Usual mode of operation is to push the machine into the face on its cats
while the head is in an elevated position and the disks are rotating. The
milling machine sumps into the top and shears downward. Loading arms
located under the head load the coal.
• More recently the same bit attack has been accomplished with a rigid head
In this type the bits are spirally wound on a fixed shaft so that each bit cuts
an infinite number of vertical planes during a single revolution,
accomplishing the same purpose without oscillating and with subsequently
fewer maintenance problems.
• This machine is cheaper as well as requiring less maintenance, and
produces a coarser product.
Key Features and Functionality:
• Rotating Cutting Drum:
• The core of the continuous miner is a large, rotating drum fitted with teeth
(often tungsten carbide) that cut or rip the coal from the mine face.
• Conveyor System:
• A conveyor system is integrated into the miner to transport the cut coal
away from the cutting head and towards a shuttle car or other haulage
system.
• Haulage Integration:
• Continuous miners work in conjunction with other equipment, such as
shuttle cars, LHDs (load-haul-dump machines), and conveyors, to move the
coal out of the mine.
• Advancements:
• Modern continuous miners are often remote-controlled, and some are
even robotic, allowing for operation in difficult and dangerous conditions.
There is a host of manufacturers of the continuous miner, they are Joy Global
Inc, model no 12CM15 having around 11.03 m length and height minimum
1.05m. and width 2.77m. JA Engineering, South Africa, Sandvik, Caterpillar,
Chines CM. Performance and acceptance-wise in India, Joy and Caterpillar
CM have been top-rated. A brief comparison of the global CM is presented in
Table.
The safety features incorporated with the continuous miner are
• the tram safety switch, which has to be pressed throughout the tramming
unless CM will be stopped,
• besides the other safety devices such as
• the main isolation switch,
• dust controller,
• emergency stop,
• water interlocking,
• methane sensors.:The methane sensor is fixed on the cutter frame, and this sensor
can directly monitor the methane concentration and display it to the video display
unit (VDU) and trip the machine if it crosses the set limit.
Continuous Miner Cutter head Design
A continuous miner's cutter head, a rotating drum with cutting bits, is crucial
for breaking rock or coal. Its design involves the drum's diameter, bit lacing
patterns, and cutting horsepower, all tailored to geological conditions and
desired cutting depth. The cutter head's design directly impacts the
machine's ability to effectively extract material and minimize wear.
Key Design Considerations:
• Drum Diameter and Width: The drum's diameter and width determine the cutting
range and the volume of material that can be cut per pass.
• Bit Lacing Pattern: The arrangement of cutting bits on the drum is crucial for efficient
cutting and is influenced by the hardness and type of material being mined.
• Cutting Horsepower: The power delivered to the cutter head determines its ability
to penetrate and break the material.
• Material of Construction: The cutter head is made from robust materials to
withstand the forces and abrasion during cutting.
• Modular Design: Some designs feature modular cutter heads, allowing for easier
maintenance and replacement of worn components.
• Dust Suppression: Modern designs include features to minimize dust generation
during cutting, often incorporating water sprays and dust collection systems.
14CM10_Komatsu
JOY12HM
2. Transport Sub-system:

• With virtually all main coal haulage systems within the seam being by
conveyors which start from a more or less fixed point, some
arrangement is needed to bridge the gap from the coal cutting
machine to that point.
• For other mining systems, a more flexible arrangement is required as
coal has to be transported from other roadways back to a fixed point,
with frequent changes of the mining location.
Face Transportation:
A more flexible arrangement is required as coal has to be transported
from other roadways back to a fixed point, with frequent changes of
the mining location.
Transportation of coal cut by CM up to gate belt conveyor is done by
either the following
- Shuttle Car
- Ram Car/Haulers
- Continuous Haulage System

[Link]
Shuttle Cars
• By far the most common method of transport at present is the use of "shuttle
cars".
• Shuttle cars are electric powered, rubber tyred vehicles - essentially a large
trough with a scraper conveyor running along the floor, a driver's position
mounted to one side and a jib section at one end of the conveyor which can be
raised for discharging the load. They are four wheel steered, four wheel driven
vehicles with power supplied by a trailing cable reeled onto and off a cable reeler
mounted opposite the driver's position.
• It is normal for two cars to be used in one mining section with one car being
loaded by the continuous miner at the face while the second car is discharging its
load at the conveyor. Whilst being loaded, the scraper conveyor in the shuttle car
is run in short bursts to drag the load towards the opposite end of the car until
the car is full. That car then heads out to the conveyor discharge point, passing
the other car at a shunting position on the way.
• On reaching the conveyor, the unloading jib section is raised to enable coal to be
discharged into the "breaker feeder" or directly onto the conveyor (depending on
the mine's relevant equipment and practices) and the scraper conveyor is run
until the car is empty. This car will then return to the mining machine or to the
passing shunt to await the other car.
Shuttle cars have proved to provide a robust, flexible and generally reliable
haulage system and are still very popular. They do suffer from a number of
disadvantages:
• Trailing cables are prone to damage as a result of being run over, squashed
against the ribs or other equipment or jammed and pulled apart and can
be a safety hazard as well as a common source of downtime.

• Trailing cables essentially restrict the number of cars servicing a miner to

two, without a risk of tying the cables in knots.

• The haulage is intermittent (unless a car is used as a temporary bunker

behind the continuous miner).

• The distance between the mining face and the conveyor discharge point is
limited by the length of the trailing cable, unless other special
arrangements are adopted.
Development in shuttle cars:
• Battery powered shuttle cars were developed to avoid trailing cables and
provide more flexibility; some success and certainly more flexible, but
batteries are bulky and heavy and require time to charge up and cool
before use – this entails a charging station and battery changing
equipment. All of this can be just as troublesome and hazardous as using
cables, so is only beneficial if the extra flexibility is required.

• Diesel powered shuttle cars were similarly developed to avoid the use of
trailing cables and provide more flexibility; certainly more flexible than
either cable or battery powered cars and haulers and are unrestricted in
respect to distance between loading and discharge points. Their biggest
drawback is the production of diesel fumes and heat in the face area which
can create unpleasant conditions even with good ventilation.
Shuttle Cars in Indian Mines
The shuttle car (Fig.) can take the load from CM and unload it to the
feeder breaker. As the cable length is fixed as per the IER 2010 , there
may be some limitations.
However, one can also have an option for the diesel-operated machines
(called ram car), which could be plying in any direction with unlimited
distance.
However, its deployment depends upon the degree of gassiness of the
coal seam. The vital specification of an electrically operated shuttle car
is given in Table 3.
Shuttle car Operations:
• Generally, two numbers of Shuttle cars / Ram Cars are provided with a
Continuous Miner machine. The shuttle car is an 1100 volt.
• The machine is fitted with an automatic cable reel which is hydraulically
operated. The reel will take 200m of type 11 cable (16mm2 conductor size)
when wound in the pure state.
• Normal practice is to work on a length of 160m to allow for any cross-
lapping that might take place. The safe working load is 13.6 tonnes with a
volumetric capacity of 8.8m3 when fitted with 300mm sideboards.
• The machine has a 910mm twin outboard chain discharge conveyor which
can be raised or lowered hydraulically.
• The shuttle car is a multi motor machine minimising the use of hydraulics
to give greater reliability and longer life for components. All electrics are
approved for use in India by DGMS.
• Head and tail lights are provided at both ends of the machine, when power
is on the lamps are illuminated and switch automatically from white to red
or red to white whenever the machine direction is changed.
JOY 10SC32C shuttle car
• The JOY 10SC32C shuttle car is a high production machine designed for mid
seam applications. The 10SC32C shuttle car is a global design that
incorporates the latest design features and has a maximum rated capacity
of 20 metric tonnes.
• The side-saddle arrangement reduces operator fatigue, improves visibility,
and ensures a better ergonomical layout.
• New features such as, non-handed wheel units, heavy duty drive system,
cam style spooling device, 105mm pitch conveyor chain, stick steering,
revised swing out hydraulic module, light weight covers are all designed to
increase safety and reliability while ensuring lowest cost per tonne.
• This machine is a variable speed tyre mounted machine which can work in
gradient less than 1 in 7 along the line of advance. If gradient is greater
than 1 in 7, differential gear is needed.
 Ram Car/Haulers
• Ram Cars are driven by diesel engines which can negotiate a
maximum gradient of 1 in 4, both in the direction of travel and cross
gradient. It has a volumetric capacity of 15 m3 with a maximum
payload of 20 tonnes.
• "ram cars" or "haulers" in place of shuttle cars: these are articulated
vehicles with one end carrying the power system and the driver
position, the other end consisting of a large tray or bin with a push
plate to eject the load. The push plate is operated by a hydraulic
cylinder. Ram cars or haulers are operated similarly to shuttle cars
except the cars have to be turned between the loading and discharge
locations, loading and unloading being at the same end of the vehicle.
Ram cars/haulers are usually diesel or battery powered
 Difference between shuttle car and ram car

In the context of underground mining, the primary difference between

a shuttle car and a ram car (or ram hauler) lies in their material
transport and operational characteristics. Shuttle cars are designed for
short-distance haulage, collecting material at the face and transporting
it to a fixed discharge point, often a feeder-breaker or conveyor. Ram
cars, on the other hand, are capable of longer, more flexible travel
distances, allowing for loading and unloading at different locations
within the mine.
Shuttle Car:
• Function: Primarily used for short-distance haulage of mined material from the cutting
face to a fixed discharge point.
• Operation: Typically travels a short distance, dumps its load, and returns to the face to
repeat the cycle.
• Maneuverability: Designed for tight spaces and maneuverability in underground mines.
• Power: Often electrically powered, with a cable for power supply.
• Discharge: Usually discharges into a feeder-breaker, which crushes large lumps and feeds
the material onto a conveyor belt.

Ram Car (or Ram Hauler):

• Function: Similar to shuttle cars, but with greater flexibility in haulage distance and
discharge locations.
• Operation: Can load and unload at different locations within the mine, potentially
requiring turning between loading and discharge points.
• Maneuverability: May have more limited maneuverability compared to shuttle cars due
to their size and potentially require more space for turning.
• Power: Can be diesel or battery powered.
• Discharge: Can discharge at various points within the mine, not necessarily limited to a
feeder-breaker.
Key Differences Summarized:
• Haulage Distance: Shuttle cars are for short, repetitive hauls, while
ram cars offer more flexibility for longer distances.
• Discharge Point: Shuttle cars typically discharge at a fixed point (e.g.,
feeder-breaker), while ram cars can discharge at various locations.
• Maneuverability: Shuttle cars are designed for tight spaces, while ram
cars may require more space for maneuvering.
• Power Source: Both can be electrically powered, but ram cars may
also utilize diesel or other power sources.

While both shuttle cars and ram cars are used for underground
material haulage, their operational differences make them suitable for
different mining layouts and material transport strategies.
Transfer of coal on belt conveyor or feeder breaker:
With all the car or hauler arrangements, some facility is needed to load
efficiently at the panel conveyor. At least a "boot end" is required, a
trough arrangement with a top opening slightly narrower than the
conveyor belt.
The return roller for the conveyor is at the end of the boot nearest the
face, so the belt runs under the opening in the top of the boot to carry
the coal away.
The coal can be loaded on top of the boot, the pile reducing at the rate
that the belt can remove the coal.
Care is therefore required to ensure that loading is not too fast
otherwise spillage will occur.
The belt will be fully loaded whilst there is coal left in the boot.
• Continuous Haulage System
[Link] conveyor trains (FCT);
• various types have been produced including both floor mounted and
roof mounted continuous conveyor systems with both systems
offering some degree of operational flexibility. The discharge end of
the flexible conveyor runs above the end section of the main
conveyor to enable the flexible conveyor to discharge onto the panel
conveyor as the flexible conveyor follows the continuous miner
through the development sequence, The face end of the flexible
conveyor is attached to the rear of the continuous miner or is self
propelled and kept at that position. With such an arrangement the
flexible conveyor is always in place between the miner and the main
conveyor, providing continuous haulage.
• The main disadvantage to date is the high capital cost of such systems
and the high maintenance costs associated with the flexible belting.
The flexible conveyor trains, at this stage, cannot handle right angle
bends and necessitate formation of diamond shaped pillars, which
may in some circumstances be prone to crushing on pillar ends
and/or result in larger intersections than otherwise preferred. Some
mines also consider that the angled cut-throughs that result do not
suit most other aspects of mining. Both roof and floor mounted
flexible conveyor systems were trialed in Australian mines during the
late 1980's with limited success. However, there is now a resurgence
of interest in these systems as mines seek to improve gate road
development rates,
b. The Continuous Haulage System with tube belt:
It will serve as a permanent connection between the continuous
mining machine and the permanently installed underground material
handling system of the mine.
The Continuous Haulage System follows the continuous mining
machine throughout the entire cutting process. During this
mining process the continuous miner is cutting the material out
of the mining face and transporting it via on-board loading
devices and conveyors to the back of the machine where it is
discharged into a Hopper Car.
This Hopper Car, as an integral part of the Continuous Haulage
System, loads the conveyor system which transfers the material
at its discharge end onto the permanently installed
underground material handling system, which in the case of a
coal mine will typically be the section conveyor.
During the retreating operation of the continuous miner, the
Continuous Haulage Systems also backs up out of the mined
area always maintaining the connection of the material flow
between the miner and the section belt conveyor system.

71
c. FLEXIVEYOR
The customizable Flexiveyor works in conjunction with any mining machine to provide a
safe, automated, and continuous flow of ore.
The Flexiveyor is designed to continuously convey ore and tram around corners as sharp as
50⁰ with minimal operator supervision.
The Miner Follower system allows the Flexiveyor to automatically follow any mining
machine through all corners of the mine, all while maintaining a throughput rate of up to
1200 tons of ore per hour.
Available in multiple configurations, the Flexiveyor is custom to contain an endless number
of individual conveyor cars.
The tried and tested Standard Flexiveyor is the ideal haulage solution in conventional
mining environments.
The Low-Profile Flexiveyor brings the same continuous haulage power to mines with
limited access.
The compact Narrow Flexiveyor integrates seamlessly into mines with restricted entry ways
and work areas.
With greater ground clearance, the Straddle-Over Flexiveyor is ideal for narrow mines with
reduced access or with unstable ground conditions.
• Bridge conveyor systems:
• various types have been produced including both chain type conveyors
and conventional conveyor belt systems. Bridge sections are typically short
(6m on conveyor bridges and 16m on chain type bridge systems) and are
self propelled. The conveyor bridge systems are now fitted with PLC
(Programmable Logic Controller) controls which enable the entire system
to be operated by one person whereas the chain type require an operator
on each bridge section. Again angled cut-throughs are preferred (70o) to
facilitate transition between adjacent roadways.
• Depending upon seam (and hence mining) height the discharge end of
these systems can either run over or beside the main conveyor to enable
the bridge conveyor to discharge on the panel conveyor as the bridge
conveyor follows the continuous miner through the development
sequence. Both bridge systems provide a continuous haulage system
similar to the flexible conveyor train systems while both have only recently
been introduced into Australian mines (although a chain type bridge
system was operated in one Australian mine during the 1990's with limited
success)
3. Bolter/Quad bolter
This machine is used for vertical and side bolting up to 90 degrees in
the sidewall, as four rigs for the bolt are attached to the machine called
quad bolter.
The detailed specification of this machine is given in Table. Quad bolter
is used to support the green roof after cutting the coal by CM. The
quad bolter has a temporary roof support unit (TRS), which can be
quickly erected and removed on the green roof. The load-bearing
capacity of the TRS is approximately 215 kN.
The Joy Quadbolter
• The Joy Continuous Miner package consists of a Multi mast bolter (Quad
bolter) with associated accessories. The Quad bolter is a track mounted
high capacity “place change” Roof bolter.
• It features four HFX (Hardy Frame eXtreme) bolting units. The HFX is a
patented, semi-automatic, wear resistant bolter that minimizes
maintenance and downtime.
• The Quad bolter (Fig) is available in either wet or dry drill models and
capable of operating in heights from 2.3 to 4.6m.
• The dual boom design provides extensive reach and flexibility for rapid roof
and rib bolting. These features allow the Quad bolter to maximize
productivity via simultaneous drilling and installation.
• The Quadbolter features a proven cat track system. This provides excellent
tractive effort, low ground pressure and a robust base even in difficult floor
conditions.
• To improve safety, the Quadbolter is equipped with a temporary roof
support system (ATRS) and a protective canopy for its operators.
• The Quad boom is unique in offering 3D parallel hold.
• The dual tripod cylinders are connected in such a way with matched
volumes to provide automatic parallel hold. Parallel holding applies
to all boom movements, boom swing, boom lift/lower i.e. to each
individual movement or to all movements simultaneously. This means
fast positioning bolt to bolt without juggling controls.
• This feature provides a real benefit when bolting through straps or
mesh.
• The hydraulic proportional control over boom movements
complements this design with smooth and accurate operation.
• Parallel holding is obtained by maintaining the geometrical uniformity
between the triangles that are formed by the rear and the front boom
cylinders respectively.
The Quad Bolter machine has important feature which has allowed:
• the unique dual bolter per boom configuration
• large work area described in the operator platform section
• and a telescopic boom that is far more spatially efficient and provides more
boom extension than conventional, bulky boom sump geometry.
The two rear boom cylinders are at the same time both lift and swing
cylinders.
Consequently, there is no need for any separate, bulky swing cylinder.
This cylinder arrangement also means that the lifting force is
distributed over two cylinders.
In addition, all play in the boom movements is eliminated since both
cylinders work all movements.
• Bolter Miner
• This is drilling set with a complete handling chain, which is mounted
on a movable rail located above the Continuous Miner turntable. The
machine is designed to work in road headings of arch and rectangular
cross-sections. During operation the rail moves over the shearer arm,
allowing for drilling and bolting works in the area that does not
require human intervention, which ensures safety to users. All drill rig
functions are hydraulic, and it is controlled from the operator panel
located on the shearer.
4. Feeder breaker
A feeder breaker is used to receive the coal from the shuttle car or ram
car and send it to the central belt after crushing in the desired size. It is
a crawler-mounted machine having a belt conveyor in the middle of the
machine (Fig.). A crusher is fitted with a water spraying system that
breaks the coal lumps to - 200 mm (Table)
It is crawler mounted machine to size and feed the coal brought by
shuttle cars on to the conveyor at a consistent rate to control spillage of
coal and also to a protect belt conveyor from damage.
It is an electrically operated machine fitted with a chain conveyor and a
Breaker which is kept in operation while shuttle car discharges its load
on it (Fig.).
General description of the STAMLER FEEDER BREAKER MODEL BF14B-3-7C :
The Feeder-Breaker consists of three (3) basic elements namely:
(i) The intake or receiving hopper
(ii) The onboard conveyor system
(iii) The breaker shaft
All Hoppers are of robust design and construction to facilitate optimum interfacing with whatever haulage
equipment the mining operation uses allowing maximum rates of discharge and minimum turnaround time of
that haulage equipment at the tipping points.
The Hydraulically Powered Drag Chain Conveyor system provides "positive feed" into the breaker from the
hopper and after "breaking" or size reduction of oversized input material, the conveyor system ratios the
material onto the mine belt at the correct rate. The conveyor system is reversible and all conveyor chains are
covered.
The Breaker is mechanically driven through a speed reducer and chain transmission. A flywheel arrangement
incorporated in the breaker drive produces sufficient inertia and mechanical pick force to fracture the hardest
material. Fines generation is minimal due to the unique "splitting" action of the breaker shaft picks on the
material. Breaker drive protection is achieved by a simple shear pin arrangement. This single pin configuration
is easily replaced in 3 to 5 minutes by experienced personnel.
Tramming is achieved through hydraulically powered crawler track units. The crawlers are mounted on
hydraulic cylinders which provide variable ground clearance and levelling of the machine at the belt end.
The Main Machine Frame provides the mounting for all components. Heavy structural shapes, abrasion
resistant wear plates and heavy duty components provide maximum integrity and frame strength.
The Hydraulic System uses full flow pressure filtration and incorporates a heat exchanger to cool the hydraulic
oil.
Lubrication is achieved through a centralised manifold mounted on the feeder breaker.
5 Load centre
The load centre is a type of step-down transformer. The incoming
voltage in the machine is 3.3 kV, and it can reduce the voltage to 1.1 kV.
This machine has ten drives for a separate power supply to the
individual machine (Fig.).
A load center in a continuous miner section of a mine serves as a
distribution point for electrical power, providing a safe and controlled
way to power the continuous miner and other equipment. It steps
down high-voltage electricity from the main power supply to a lower
voltage suitable for mining equipment, while also incorporating safety
features like ground fault protection and short circuit protection
LOAD CENTRE
Purpose:
• Power Distribution: Load centers receive high-voltage power (e.g., 4160V
or 6600V) from the mine's main power distribution system.
• Voltage Transformation: They then transform this high voltage to a lower,
usable voltage for the continuous miner and other equipment (e.g., 1000V,
550V, or 480V).
• Safety Features: Load centers are equipped with various safety
mechanisms to protect personnel and equipment from electrical hazards.
These include:
• Ground fault protection: Detects ground faults (leakage of current to ground) and
quickly de-energizes the circuit.
• Short circuit protection: Protects against excessive current flow due to short circuits.
• Overload protection: Prevents damage to equipment from overcurrent conditions.
• Control and Monitoring: Load centers often include control and
monitoring systems to allow operators to manage power distribution and
track electrical parameters
Key Components:
• High-Voltage Isolator/Circuit Breaker: Disconnects the load center
from the main power supply.
• Transformer: Transforms the high voltage to the desired utilization
voltage.
• Low-Voltage Circuit Breakers/Fuses: Protect individual circuits
connected to the load center.
• Ground Fault Detection and Protection System: Detects ground
faults and trips the appropriate circuit breakers.
• Control and Monitoring System: Provides control and monitoring
capabilities for the load center.
Types of Load Centers:
• Fixed Load Centers: Permanently installed in a specific location in the
mine.
• Mobile Load Centers: Mounted on skids, wheels, or other platforms
for easy relocation as the continuous miner moves. [1, 4, 5]

Importance in Continuous Miner Operations:

Continuous miners require a reliable and safe power supply to operate
effectively. Load centers are crucial for ensuring that the continuous
miner and associated equipment (e.g., shuttle cars, roof bolters)
receive the necessary power while maintaining a safe working
environment. They are an essential part of the infrastructure required
for continuous miner operations in underground coal mines.
In a load centre, the following safety devices are merged
1. Transformer secondary 1100V earth fault protection
2. 1100V, 1200A circuit breaker with short circuit tripping
function
3. 1100V test switch
4. 5KVA, 120V lighting transformer with four switched outlets
5. Individual pilot circuit control all outgoing motor drive
sockets
6. Individual overload protection, all 1100V motor drive
The load centre where all the cables are connected to supply the
power to all machines. The specifications of the cable are given in
Table
 CODE OF PRACTICE FOR CONTINUOUS MINER OPERATION

• Read operators manual before operating.

• Do not operate without proper training.
• Do not make any type of temporary trailing cable connections on the machine.
• Be certain all electrical power has been disconnected before performing any
adjustment, repair and parts replacement.
• Never work in the electrical cables or perform any service or maintenance
work, unless electrical power to the machine has been physically disconnected.
• Do not alter, remove or by pass any emergency stop devices.
• Shut off the machine and relieve hydraulic pressure before disconnecting any
hydraulic line or fitting.
• Never work under any part of this machine that is supported only by a hydraulic
cylinder.
• Perform welding or burning operations only in a safe and approved area and in
accordance with existing laws and safe practices.
• Never work under unsupported roof. CM operator and cable man shall stand in
a safe position behind the machine out of the way of shuttle cars.
• The cutting sequence shall be followed as per the permission granted by
DGMS.
• As soon as the required distance is cut, the machine is trammed to a safe
position.
• When the Continuous Miner has to be trammed all activities in the section,
with the exception of roof bolting, will be stopped to assist the cable handling.
• Operators must ensure the cable and hoses are clear from the machine.
• The machine operators continue coiling the cable while the machine starts
cutting.
• In the event of a breakdown of the Continuous Miner while cutting the face,
the operator shall ensure:
• Machine is trammed back to safe position.
• Should the machine not be able to tram back, the area will be made safe by dressing
down and installing approved temporary support jacks or permanent supports if
possible.
 CODE OF PRACTICE FOR QUAD BOLTER

• Ensure that all the necessary pre-start checks have been performed.
• Ensure all emergency stops are in unlatched position.
• Move the main breaker switch on the isolator enclosure to the ON position.
• Turn on the power supply to the machine.
• Confirm power is on to the machine by looking at the phase location indicator in the isolator
enclosure.
• Power up the electrical system by rotating the pumps switch to the ON position.
• Check stator indicator panel to ensure all required LEDs are showing green.
• Start the machine pump.
• Start the pump motor. Rotate the pump switch counter clockwise to the START position. After the
pump has started the switch must be released to spring-return to the RUN position.
• Pressure the emergency / park break system to release the emergency / park brakes, by pushing the
button on the break release valve. The pressure gauge in the operator compartment must read 68.96
bar (1000 psi)
• Check that all personnel are clear of the machine.
 CODE OF PRACTICE FOR SHUTTLE CAR

• Carefully read and follow all safety signs and wear all relevant personal protective
equipment.
• Inspect and clear all roadways.
• Check for the proper operation of the brakes, steering, lights and pre start alarm.
• Ensure all guards, covers and safety signs / cables are in place.
• Connect the trailing cable to the correct power source. Make certain the cable is
securely fastened and proper overload protection is provided for the cable.
• Locate the machine brakes and place them in the ON position.
• Switch the light to the ALL ON position. It is recommended for safety that the lights
to be turned ON before starting the shuttle car.
• Ensure that the tractor foot switch is in the NEUTRAL position. The shuttle car will
not start with the foot switch pressed. Ensure that the conveyor switch is in the
OFF position.
 CODE OF PRACTICE FOR LOAD CENTRE

• The assembly should be installed on a flat level surface and in a location that will restrict
damage by passing machine.
• Earth termination points are provided in each enclosure. Each enclosure must be
effectively earthed before connecting the incoming supply.
• Incoming supply cables should be terminated as per the cable coupler manufacturer
instructions. Connect the 3300V supply to an incoming cable coupler on the AW2000 /
INE10 circuit breaker.
• Main outgoing cables should be terminated as per the cable coupler manufacturer
instructions supplied with the adaptor.
• Auxiliary cables should be terminated as per the gland manufacturer instructions. Type
SW814 bolter plugs and sockets are used on the left hand side plate for the remote
control. A compassion gland is available for the blue terminal chamber to provide a
remote. TS supply type F81 bolted plugs and sockets are used on the rear of the
incoming circuit for the lighting supply.
• Any cable entry that is unused must be blanked off with an appropriate flameproof cover.
 CODE OF PRACTICE FOR FEEDER BREAKER

• Always disconnect power and lock out the power supply before entering or
performing maintenance on the equipment (board).
• Personnel must be fully trained to operate the equipment.
• Awareness of the entire machine. ALL STOP switches to be properly identified and
located and all concerned must know how to properly operate them.
• Capabilities and limitations of the equipment shall be known to all concerned for
most efficient and safe operation of the equipment.
• Follow the instructions associated with the operation of the machine.
• Inspect the machine daily for signs of damage, unusual wear, fluid leaks or faulty
operation.
• Never remove any safety covers or devices from the machine while operating.
• Don’t allow sitting anybody on the machine including the operator.
• Read and thoroughly understand the maintenance procedures before performing
them.
• Never perform maintenance while the machine is moving or operating.
• Before performing maintenance or repair work on the equipment, contact with
manufacturers service manual and follow the recommended practices.
• Keep your head, hands, legs, feet and loose clothing away from rotating and moving
parts.
• Pay attention to warning labels on the machine.
• The equipment should never be turned more than is necessary to avoid damages to the
cables, hoses or to the operator.
• Always use the proper tools for the proper job.
• Provide supports for items supported by the hydraulic cylinders and relieve all trapped
pressures before performing any service work to the hydraulic components.
• Does not change the pressure setting of any hydraulic valves when trouble shooting a
hydraulic system for leaks, use a piece of card board or other material as a detector rather
than your hand.
• Take cautions when draining hot fluids from the machine.
• Perform weld repairs outside or in a safe and approved area and in accordance with
existing laws and safe practices.
• Remove stripper and solvent with soap and water and allow time to disperse for at-least
15 minutes before welding or heating.