HIGH-INTENSITY
High coal recovery, high annual capacity, high operation-cost savings – an inside look at the features and components of the Bucyrus highwall mining system.

Highwall Miner Features/Components

cutterheads
Interchangeable Electric Cutterhead Modules

The Bucyrus Highwall Miner is equipped with interchangeable electric cutterhead modules to facilitate mining of varying coal seams heights from 28 inches (71.1 cm) to 15 feet (4.6 m). Low seam cutterhead modules can mine seams from 28-64 inches (71.1 - 162.3 cm), while medium and high seam modules can mine up to 15 feet (4.6 m).

The cutterhead module attaches to the powerhead assembly in the center of the machine. Two hydraulically powered cylinders provide 380,000 pounds (172.4 metric tons) of force to cut into the coal seam - reaching depths over 1,000 feet (304.8 m).

The cutting cycle of the electric cutterhead is fully automated. As the coal seam varies, the machine operator is able to adjust the machine function while in automatic mode. This proven technology allows the cutterhead to accurately follow the coal seam and produce a cleaner product.

control center
Programmable Logic Controller (PLC)

The cutting cycle of the electric cutterhead is fully automated through the use of a Programmable Logic Controller (PLC).  The machine operator has the ability to manually adjust the mining operation through the PLC as coal seams vary in height.  This proven technology allows the cutterhead to accurately follow the coal seam and efficiently produce a cleaner product.

pushbeam system
Pushbeams

One of the strengths of the Bucyrus Highwall Miner is its powerful pushbeam technology.  As the cutterhead pushes into the coal seam, the Loader Operator loads a pushbeam from the storage location on to the Pushbeam Transfer Mechanism (PTM) every 20 feet (6.1 m).  The pushbeams are fully-enclosed, consisting of a pair of 18-inch (45.7 cm) diameter augers that equal the length of the pushbeam.  This fully-enclosed design facilitates mining through tough roof conditions, eliminating the addition of external ash dilution.  The design further allows the system to mine seams with soft floor conditions due to its low ground-bearing pressure.  Being hinged at each end allows the string of pushbeams and cutterheads to be navigated through rolls and undulations within the coal seam.

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Reel and Chain

All electric power cables, hydraulic lines, control cables, water lines, and methane sensor cables are stored in the armored hose chain that is wrapped around the hose reel assembly.  During the mining process, the hose chain is automatically unrolled as the pushbeams are added every 20 feet.  In the retract mode, when the pushbeams are being removed, the hose chain is automatically rolled back up on the reel.

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Tracks

The Bucyrus Highwall Miner utilizes four heavy-duty hydraulically powered tracks that can articulate 90 degrees.  The machine has 360 degree mobility for precise placement at the work site.  The tramming system allows the Bucyrus Highwall Miner to operate on contour benches as narrow as 42 feet (12.8 m), facilitating easy tramming from entry to entry, or when relocating the highwall miner to a new pit.

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Anchoring System

During the mining and retract cycles, the onboard anchoring system provides stability to the Bucyrus Highwall Miner.  Two machine mounted drills, located on the front of the machine, are capable of drilling up to 96 inches (2.44 m) into the pit floor.  Two high-strength pins, measuring 6 feet (1.83 m) feet in length, are inserted through the base frame of the highwall miner and into the pit floor.

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Right Angle Conveyor

The Right Angle Conveyor can be mounted on the left or right side of the Bucyrus Highwall Miner, for the purpose of discharging mined coal.  This configuration permits the highwall miner to work on bench widths as narrow as 42 feet (12.8 m).  The Right Angle Conveyor system is able to discharge its contents on to a stacking conveyor system, whereby the coal can be transported to a central location for stock piling purposes.

mobile generator
Generator

The Bucyrus Highwall Mining System can be powered from either high-line power or by utilizing the Bucyrus Highwall Miner Electric Generator.  This mobile 2,000 hp generator, 16-cylinder diesel, 995-volt system is housed in a 20 foot super silenced container.  The mobile generator is mounted on crawlers for high-maneuverability in rough terrain.

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Advantages
  • Penetration depths over 1000 feet are possible.
  • Rigid push-beam design with PLC controlled sump forces allows for more consistent and accurate cutting depths.
  • Modular design allows system to be easily moved from pit to pit.
  • Current systems are successfully mining 40,000 to 100,000 plus tons per month depending on coal seam height.
  • Three to four man crews keep labor costs low.
  • Up to 70% of in place coal can be recovered using the Bucyrus Highwall Mining System.
  • Enclosed push-beam conveyor eliminates external ash dilution from the roof.
  • Ability to operate on contour benches as narrow as 42 feet.
  • Technical support assuring Bucyrus Highwall Mining availability is provided.
  • Assistance in designing mine plans for highwall mining can be provided.