Basic E&Mcalculations for a coal mining project
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The document outlines methodology for calculating equipment capacities for coal mining operations, including estimates for machinery power requirements, operational cost analysis, and various mining technologies. It includes detailed formulas for pull calculations, friction assessments, and power requirements, emphasizing mechanized and hand section approaches. Various parameters affecting production, safety, and efficiency in mining operations are also discussed, alongside the necessary equipment and their deployment based on project needs.
Basic E&Mcalculations for a coal mining project
- 1. EQUIPMENT CAPACITIES CALCULATIONS IN PLANNING -A.V.REDDY
- 2. • Estimates capacity (KW/HP) of machines, Electric power, Power cost/ton of coal or OB , For OCs Capacities of shovels dumper combination, capital required for Plant and machinery etc, of New Projects to in corporate in Feasibility Reports. (FRs) • Estimates P&M for Revised Feasibility Reports of projects. • Estimates P&M requirement of completed projects and on going projects.
- 3. Technology adopted a) Hand section b) Mechanised mining a) Hand Section : Equipment required : Haulers (DH,EH), Pumps, Drill M/Cs, Main mechanical ventilator, Auxiliary fans connected Electricals
- 4. • Gradient (1:3.5 or 1:4) Approx= 57/gradient • Weight to be pulled Calculation : Pull = Pull due to rope(w) + Pull due tubs(W) (kgs) Pull due to rope= Resistance against gradient (w) + Rope rolling resistance(f) = w x Gradient (Sin O) + w/10 ( w is weight/mtr of rope) =w/3.5+ w/10 (10% weight of rope)
- 5. Pull due to tubs/(man riding cars) = Resistance against gradient (W) + Rolling resistance of tubs (F) = W x Gradient + W/40 (W/20) where W is the total weight of tubs = W / 3.5 + W/40 (W/20) Total Pull = w/3.5+w/10 +W / 3.5 + W/40 (W/20) Kgs Based on pull, rope is selected. Breaking load of rope as per IS 1570 =352 KN for 26 mm rope dia Factor of safety =9
- 6. Breaking Load = 350 x1000/9.81 Kgs =35678 Kgs Safe load =35678/9 =3964 kgs HP =Total Pull x speed(mps)/75 KW =Total pull x speed(mps)/102 Peripheral speed of rope= 3.14xN xD/60x1000 m/sec D is Drum Dia, in mm N is RPM
- 7. Total Length of Installation,L in mtrs. 2200 Max. Lift,H in mtrs 134 Distance between two chairs m 16 Max. Travelling Speed,V m/s 3 Man Riding Capacity,C Nos. 675 Weight of person,Mper in kgs 80 Weight of Chair,Mchair in kgs 13 Weight of Rope,Mrope in kg/m 1.6 Drive&Return wheel Dia,D in mtrs 1.5
- 8. Power required to raise mass of persons,Ppers in W = C x H x 9.81 x 80/3600 = 675x133.52x9.81x80/3600 =19647 W Power to overcome Frictions,PFriction Line Friction,PFriction1 Chair Spacing ,X chair in mtrs 16 Total Continuous Rope length,LRope in mtrs =2 x L + 3.14 x D = 2x 2200 + 3,14x1.5 = 4404.71 Total no. of chairs, X =L rope / Chair spacing = 4404.71/16 = 275.29 Total no.of persons on one side only,Y =275/2 = 134 PFricion1 = 0.09((Lrope x Mrope) +( Y*Mper) +X * Mchairs)) V = 5304 W
- 9. Friction included by vertical&horizontal curve stations, PFriction2 P Friction C= K*(Ppers +PFriction1 ) where K is a constant that increases with angle of deflection Angle of Deflection % Value of K 5°To10° 1 0.01 10°To20° 2 0.02 20°To30° 3.5 0.035 30°To40° 5 0.05
- 10. Three curve stations are there Sl.No Horizontal Angle Vertical Angle 1 33° 2.34° 2 37° 2.04° 3 33° 1.00° At 1st Station,PFrictionCH1 = 0.05 x (19647 +5304) = 1247.57 W PFrictionCV1 = 0.01 x (19647 +5304) = 249.51 At2nd Station,PFrictionCH2 = 1247.57w PFrictionCV2 = 249.51W At3rd Station,PFrictionCH3 = 1247.57W PFrictionCV3 = 249.51W Total PFriction2 = 3 * (1247.57+249.51) =4491W
- 11. Friction induced by Return sheeve Wheel,PFriction3 0.02x(Ppers +PFriction1 +PFriction2 ) 0.02x(19647.468+5304.0042+4491. 27) =588.854844 Therefore ,PFriction =(5304+4491+588) = 10384.12904 Total Power at the Driving Wheel,P Ppers +PFriction
- 12. Efficiency of the System 0.76 Therefore,Input Power 39515.25927 Taking5%extra,Required Power will be 41491.02223 Standard Available Power,KW 45 Rope Pull Calculation Power at Driving Wheel = 30 KW =30/0.746=40HP HP=2NT / 4500 So, T=HPX4500 / 2N = (40*4500*7)/ (2*22*19.1) = 1499.286054 = 15kN
- 13. Power = QxHx Sp.gravity/75x Efficiency HP = Qx Hx Sp.gravity/102 x Efficiency KW Q = Ltr/sec H = Head in mtrs Sp.gravity = 1.03 gms/cc one gallon =4.54 Ltrs Generally GPM of pump is taken Say 2250 LPM = 2250/4.54 = 495 GPM or 500 GPM
- 14. Generally in SCCL mines single, Double, multistage centrifugal pumps are being used for pumping water from under ground to surface. 7.5 HP to 500 HP. • Depending upon depth and sump capacity pumps are deployed.
- 15. Air Power in KW = Air Discharge (Cu.m/sec)x water gauge in mm/ 102 Fan efficiency = Air power in KW / brake shaft Power in KW Brake shaft power = Transmission efficiency x motor efficiency x Measured input power in KW Overall efficiency = Air power KW x100/ Measured power in KW
- 16. Auxiliary fans of 20 KW is deployed in galleries where the flow is less than requirement High water gauge fans of 90 KW (200 to 500mm water gauge) are deployed in Road header drivages. In SCCL mines1 to 3 lakh CFT/min i.e (3000 to 9000 Cu.m/min) are working with blade angle 14 to 22 deg For Adriyala shaft 15000Cu.m/min fan is required.
- 17. Mechanised mining : To increase the production and safety mechanised mining is adopted with following technologies. a) Long wall : Shearer is the deciding factor
- 18. 1 Determine the mining rate, TPH Assume Cutting height,H mtrs 3.0 Web depth,D mtrs 1.0 Max. cutting speed,Vs mt/min 12.0 Coal density(solid), T/Cu.m 1.5 TPM= H*D*Vs * T/min 54 TPH 3240
- 19. Drum Dia. mtrs 1.8 Web mtrs 1 Cutting speed, Vs mt/min 12.0 Density of coal (solid) T/m3 1.5 Q(Mining rate in tonnes per hour by one drum) TPH 1944 K is Specific energy consumption factor in HP-hr/Ton Normally K is 0.5 for hard coal and 0.25-0.35 for soft coal P(HP) = QK HP 972 There fore, for 3mtr extraction, the other drum requires only a power of (3-1.8)*1*12*1.5*0.5 HP 648 But, in practice, both drums will require equal power for bi- directional operation KW 725.112
- 20. • (Assumed 1TPH=1KG) • For 1000 TPH, • S1 = 1000 Kg. • S1 - Tension • gc1 – Gravitational resistance on slack side (weight component acting along the bottom for chain) • gc2 - Gravitational resistance on tension side • RC1 - Frictional resistance on slack side • RC2 - Frictional resistance on tension side • gc1 = qc x L x Sinø • Where qc = Wt. of chain/mt. • L = Length of chain in mt. • Ø = Inclination
- 21. • RC1 = qc x L x fc x Cosø • Where qc - Wt. of chain/mt. • L - Length of chain in mt. • fc - Frictional co-efficient of chain with pan • ~ 0.35 to 0.4 for soft chain • ~ 0.45 for shaking & watering • S2 = S1 + gc1 + RC1 or S1 + qcL (Sinø + fc Cosø) • (S1, S2 are in the opp. Direction) • S3 > S2 and there will be some loss • Thus S3 = 1.05 S2 • S4 = S3 – Gc2 + RC2
- 22. • Where • gc2 = (qc x L x Sinø) + (qy x L x Sinø) • RC2 = (qc x L x fc Cosø) + qy x L x fy x Cosø • qy = Q/3.6V (Q = TPH, V = Velocity m/s) • Fy = Frictional co-efficient of material conveyed • 0.45 to 0.8 for dry soft coal, • 0.8 for silica, rock etc, normally 0.7 • Now S4 = S3 – gc2 + RC2 • Or S4 = S3 – (qc L Sinø + qy L Sinø) + (qc L fc Cosø + qy L fy Cosø) • = S3 + qc L (fc Cosø – Sinø) + qy L (fy Cosø – Sinø) • Power (P) = (S4 – S1) KW • 102 • Motor Power - P/h h = 0.8 to 0.9
- 23. Based on shearer capacity AFC,BSL, Gate Belts, Trunk belts are designed. The supports are designed by taking load coming to supports / Sq.m area as per finite element method. The connected electricals are designed basing on the above capacities Power pack is designed on the design of support load.
- 24. In SCCL Long wall technologies produced 4 to 7 lakhs per annum BG technology the following equipment is deployed a) Jumbo Drills b) LHDs c) Hydraulic props d) Power pack SDL Low height are deployed in hand section mines to increase productivity, safety and decrease in man power
- 25. Based on production No. of LHD,SDL are deployed For CTX,811 Eimco LHDs annual production = 50,000 T For 912 Eimco LHDs = 60,000 T/ annum For Low height SDLs = 45,000 T/ annum Connected Electricals like GEBs, HT/LT switches, transformers are calculated on the No. of SDLs / LHDs deployed
- 26. a) Power to move load horizontally =2.72 x L x F x (C+46)/1000 kW b) Power to move empty belt = 9.81 x F x G x (C+46) x S/1000 kW c) Power to elevate load =2.72 x L x H/1000 kW Total Power P = (a) +( b) +(c)
- 27. Taking safety factor as 1.1 to 1.2 Total power requirement is calculated C = Centre distance in mtrs F = Friction factor (0.03) G = Inertia factor H = Change in elevation in mtrs L = Peak load in Tonnes/Hour S = Belt speed in mtrs/sec
- 28. L= B x D x S/1000 Tonnes/Hr L = Peak load B =Belt capacity Factor D = Material density Kg/Cu.m S = Belt speed in mtrs/sec • Selection of belt T = K x P/S kN P is power required, K = Belt Drive factor S = speed mtrs/sec = kN/1 m = kN/m Taking Factor of Safety as 10:1 for PVC F.S 7:1 for steel cordvalue from table can be used for selection PVC/ Steel cord
- 29. Based on coal production, OB removal and depth of the mine No. of shovels( Coal, OB), Dumpers, RBH Drills (Coal, OB), Dozers, Graders,Pumps and water sprinklers and other common equipment are calculated
- 30. Sl.No Particulars 3cu.mShovel along with 35T Dumper 1 No. of Annual working days 330 2 No. of duty shifts 3 3 Duration of shift in Hr 8 4 Total No. of Annual shift hrs 7920 5 Annual utilisation of shift hrs 61%
- 31. 6 Annual working hr 4831.2 7 Shovel bucket capacity (m3) 3 8 Material density - Tes/BCM 2.2 9 Swell Factor 0.732 10 Bucket fill factor 0.905 11 Swell cum fill factor 0.662
- 32. 12 Material quantity per shovel bucket (T) 4.3722 13 Pay load capacity of dumper (T) 31.5 14 No. of passes per dumper load 7.204 15 No. of passes adopted 7 16 Adopted Pay load capacity of dumper (T) 30.605 17 Bucket cycle time (Minutes) 0.6
- 33. 18 Loading time per dumper (Minutes) 4.2 19 Spotting time of dumper 0.5 20 Shovel time for loading dumper (Minutes) 4.7 21 Hourly shovel capacity Cum/hr 177.595 22 Factor for travelling positioning etc. 0.85 23 Annual shovel capacity (Cum) 729300 M.Cum 0.73
- 34. Sl.No DESCRIPTION 0.5 1 Shovel loading time for dumper ,min 4.70 2 Spotting for unloading ,min 0.5 3 Unloading time ,min 0.6 4 Travelling time ,up ,min 1.20 5 Travelling time, down, min 1.00
- 35. 6 Dumper cycle time. min 8.00 7 Dumper waiting time 1.40 8 Cycle time adopted 9.40 9 No. of trips per hour 6.382979 10 Dumper utilisation hours 2376 12 No. of trips per annum 15165.96
- 36. 13 Dumper capacity,Cu.m 14.43182 14 Corrected dumper capacity 14.03093 15 Annual Dumper capacity,M.cum 0.212793 16 Calculated capacity of shovel, M.cum 0.73 17 No.of Dumpers required per shovel 3.524559 18 Rounded no. 4
- 37. Assessment of volume of water to be pumped Q = A x H x Run off coefficient A = Catchment area in Sq.m H = Maximum daily precipitation in m Run off coefficients For mined out area = 0.60 Area beyond excavation =0.10 For internal dump area =0.15
- 38. Maximum capacity of pump is determined on operating time 20 Hrs for 10 days i.e 200 Hrs as per CMPDI In SCCL 20 Hrs for 6 days i.e 120 hrs Add 10% seepage for attaining total make up Peak pumping capacity = /120 No of pumps is determined from above depend on pump capacity Cu.m/Hr
- 39. For coal based on coal & OB No. of Drills is calculated Drilling pattern for coal = 5 x 5 x 6/5 Height of bench =5 m Spacing =5 m Burden =5 m Volume of coal exposed/ mtr drilling =30 Cu.m Annul working hrs =2112 Annual meterage = 42000 Volume of coal exposed by one drill =1.26 M.Cu.m Drill employed =150mm
- 40. For OB 250mm RBH drills are used Depending on OB removal/ year No. of drills calculated Drilling pattern =8 x 8 x 9/8 Volume of OB exposed /mtr of drilling =72 Cu.m Annual working Hrs =2112 Annual meterage = 40000 Volume of OB exposed M.Cu.m = 2.88
- 41. Road Length to be graded, Km 17 Road Width to be graded, Mtr 20 Area to be Graded, Sq.mtrs 340000 Speed of the Grader ,Mtrs / Hr 6100 Blade Length ,Mtrs 4.32 Blade overlap ,Mtrs 0.3
- 42. Width of Graded area/each pass ,Mtrs 4.32 SIN 600 3.74 Graded Area/hr,Sq,Mtrs((3.74-0.3)*6100) 20984 No of Hours required /day 16.20 No. of Graders available at GKOC 2 Working hours required / each Grader/Day 8.1 % of utilization on SSH 34
- 43. Dozers are 50% of shovel population Water Sprinklers 28 kL -2 Nos Common equipment Cranes 10T to 70/100T Diesel bouser Maintenance van Compact vibrator, Tyre handlers, Front end loaders, Fire tenders etc, are provided
- 44. Power calculations Connected load = kW Active load = Connected load x demand factor kW Demand factor = 0.6 to 0.9 kVA = Active load / Power factor Power factor = 0.8 No. of annual working hrs = say 3000 Energy consumption/annum = Active load x No.of hrs/annum Unit cost =2.80 x kWH Surcharge @ 0.06Rs/kWH Maximum demand/ kVA= Rs.250
- 45. SURVEY OFF NORMS FOR HEMM Sl. Equipment Existing(CMPDI) Proposed(SCCL) No. Hours Years Hours Years 1 10 Cu.m Rope Shovel 80000 22 100000 25 2 4.6-5 Cu.m Rope Shovel 36000 12 40000 15 3 5-10 Cu.m Hydraulic Excavators 20000 9 40000 15 4 2.2-3.5 Cu.m Hydraulic Excavators 20000 9 35000 15 5 85 T Rear Dumpers 22000 10 35000 15 6 35 T Rear Dumpers 12000 9 20000 15 7 Water Sprinklers 12000 9 25000 15 8 420&310HP Dozers 14000 9 20000 12 9 250mm RBH Drills 20000 9 35000 15 10 150mm RBH Drills 10000 9 25000 15 11 Motor Graders 10000 9 20000 15 12 Front End Loader 16000 9 25000 15