„NEW CUTTING SYSTEMS“ PROJECT

THE „ICACUTROC“ RESEARCH PROJECT:

THE AIM OF THE PROJECT WAS TO EXTEND THE RANGE OF
APPLICATIONS OF ROADHEADERS TO HARDER TYPES OF ROCK

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„NEW CUTTING SYSTEMS“ PROJECT

Figure: 7

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 „NEW CUTTING SYSTEMS“ PROJECT

INFLUENCE OF THE ROCK MASS CHARACTERISTIC

The RMR (Rock Mass Rating)

• Natural Fractures (Parting Planes) are a frequent Feature of a Rock Mass

• Any existing Parting Plane does not have to be generated by Pick Action
• Cutting is virtually a Parting Process
• The Excavation Process is only assisted by the Rock Mass Features above a
certain Intensity, Orientation and Development of the Parting Planes

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 „NEW CUTTING SYSTEMS“ PROJECT

INFLUENCE OF THE ROCK MASS CHARACTERISTIC

INFLUENCING FACTORS OF THE RMR (Rock Mass Rating)

VALUE RATING
UCS (MPa) (Strenght) 1 - >250 15 - 1
Block Size (m3) (Intensity of Parting) >0,6 - <0,03 20 - 1
Surface/Eveness rough - very smooth 30 - 0
Joint Conditions Aperture closed - >5mm 30 - 0
Wall / Fill hard/dry - soft filled/wet 30 - 0
very favourable - very
Orientation of Joint Sets -12 - 0
unfavourable

THE ACTUAL ROCK MASS RATING IS THE TOTAL FIGURE

OF ALL FOUR FACTORS

NOTE: ONLY A SUFFICIENT QUANTITY OF TESTS WILL GIVE AN ACCURATE READING

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 „NEW CUTTING SYSTEMS“ PROJECT

RMR (revised) AND HOW IT AFFECTS THE NCR

( HIGH SPEED CUTTING )

10
Balsareny Wujek
9
Borynia Bogdanka
8 Prosper (AM 105) Erzberg
NCReff / NCRtheor

7 Saudi Arabien (Site 1) Szieroszowice

Prosper (AM 85) Wujek
6
Blumenthal
5
4 NCReff/NCRtheor = 9,4302RMRrev-0,5614
3 R2 = 0,8256
2
1
0
0 10 20 30 40 50 60
RMR (revised)

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 „NEW CUTTING SYSTEMS“ PROJECT

RMR (revised) AND HOW IT AFFECTS THE NCR (NET CUTTING RATE)
( LOW SPEED CUTTING )

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9 NCReff/NCRtheor = 54,607RMRrev-1,0374
8 R2 = 0,9239
NCR eff / NCR theor

7
6
5
4
3 Erzberg
2 Stillwater
1 Pozzano
0
0 10 20 30 40 50 60
RMR (revised)

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 „NEW CUTTING SYSTEMS“ PROJECT

RMR (revised) AND HOW IT AFFECTS THE NCR

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8 NCReff/NCRtheor = 9,4302RMRrev-0,5614
R2 = 0,8256
7 High Cutting Speed
NCR eff / NCR theor

5 NCReff/NCRtheor = 54,607RMRrev-1,0374
R2 = 0,9239
4
Low Cutting Speed
3

0
0 10 20 30 40 50 60
RMR (revised)
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 „NEW CUTTING SYSTEMS“ PROJECT

FIELD TEST 4: STILLWATER, MONTANA in USA

• Roadway Development at Stillwater

Platin Ore Mine, Cross Section
4,9x3,7m
• Norite
• UCS 55 to 185 MPa
• Hard Minerals/Quartz 30%
• RMR 27-52
• CAI 2,7 to 4,2

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 „NEW CUTTING SYSTEMS“ PROJECT

THE TWO CUTTERHEADS COMPARED

Cutterhead GW57 Cutterhead GW87

CUMULATED TOOL CONSUMPTION CUMULATED TOOL CONSUMPTION

NEW TOOLS REPLACED NEW TOOLS REPLACED

5,00 1,60
1,40
4,00
1,20
3,00 1,00
0,80
2,00 0,60
TOOL/BCM TOOL/BCM
0,40
1,00
0,20
0,00 0,00
1 3 5 7 9 11 13 15 17 19 21 23 25 1 3 5 7 9 11 13 15 17 19 21 23 25
Day Day

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 „NEW CUTTING SYSTEMS“ PROJECT

FIELD TEST 3: POZZANO in ITALY

• Roadway Tunnel by IMPREGILO

• Limestone
• UCS 104 to 295 MPa
• Hard Minerals/Quartz 10-25%
• RMR 18-25
• CAI 1,1 to 2,2

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 „NEW CUTTING SYSTEMS“ PROJECT

TEST RESULTS 3: POZZANO in ITALY

After 600m3

CUTTING PICK VIBRATION

PERFORMANCE CONSUMPTION EMISSION

ACTUAL 35 m3/h 0,2 Picks/m3 0,5mm/sec

REQUESTED max.
min 20m3/h N.A.
by CUSTOMER 1,8mm/sec

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 „NEW CUTTING SYSTEMS“ PROJECT

THE TEST RESULTS COMPARED

ERZBERG STILLW ATER PO ZZANO
Porphyroid Norit Limestone

UCS [M PA] 85 - 205 55 - 185 104 - 294

UCS/TS 11,3 13,8 24

Hard M inerals [% ] 31 – 44 30 10 - 25

CAI 3,3 – 4,3 2,7 – 4,2 1,1 – 2,2

Block size of rock m ass [m³] 0,13 0,16 - 1 0,008 – 0,25

ROCK M ASS RATING 15 - 20 27 - 52 18 - 25

(Gehring revised)
Cutting rate [m³/h] 35 - 50 20 – 25 35

Tool consumption [pick/m³] 0,25 0,8 – 1,5 0,2

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 „NEW CUTTING SYSTEMS“ PROJECT

ECONOMIC COMPARISON OF EXCAVATION SYSTEMS

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 „NEW CUTTING SYSTEMS“ PROJECT

ECONOMIC COMPARISON OF EXCAVATION SYSTEMS

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 „NEW CUTTING SYSTEMS“ PROJECT

THE NEW ICUTROC BOLTERROADHEADER

DESIGN WITH INTEGRATED ROOFBOLTER AND AUTOMATED CUTTING

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 „NEW CUTTING SYSTEMS“ PROJECT

THE NEW ICUTROC BOLTERROADHEADER

DESIGN WITH INTEGRATED ROOFBOLTER AND AUTOMATED CUTTING

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 „NEW CUTTING SYSTEMS“ PROJECT

THE NEW ICUTROC BOLTERROADHEADER

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 „NEW CUTTING SYSTEMS“ PROJECT

THE NEW ICUTROC BOLTERROADHEADER

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 „NEW CUTTING SYSTEMS“ PROJECT

SYSTEM COMPARISON: ROADHEADER vs. D&B

2.000

1.800
Diagram forms an
example for specific
1.600 assumptions for a 20 m²
1.400
D&B roadway development
Cost per meter [USD/m]

Most likely tendency for

1.200
Roadheader
D&B
1.000
Most likely tendency for
800 Bolter Roadheader BOLTER ROADHEADER

600 ROADHEADER

400

200

0 Cutting rate [m³/h] and

50 m³/h 35 m³h 20m³/h tool consumption [1/m³]
0,2 tool/m³ 0,4 tool/m³ 0,6 tool/m³ as a function of rock properties

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 „NEW CUTTING SYSTEMS“ PROJECT

SYSTEM COMPARISON: ROADHEADER vs. D&B

14,00

Diagram forms an
12,00
Most likely tendency for
example for specific
Bolter Roadheader assumptions for a 20 m²
10,00 roadway development
Advance [m/day]

8,00 D&B
Most likely tendency for
Roadheader BOLTER ROADHEADER
6,00
ROADHEADER
D&B
4,00

2,00

0,00 Cutting rate [m³/h]

50m³/h 35m³/h 20m³/h and tool consumption [1/m³]
0,2 tool/m³ 0,4 tool/m³ 0,6 tool/m³ as a function of rock properties

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 „NEW CUTTING SYSTEMS“ PROJECT

„NEW CUTTING SYSTEMS“ PROJECT

Task 4: Grade development

Task 5: Tools for RSA

Task 6: Tools for ABM14

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 „NEW CUTTING SYSTEMS“ PROJECT

PROJECT TASKS
Task 6: Tools for ABM14

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 „NEW CUTTING SYSTEMS“ PROJECT

PROJECT TASKS

Task 9: Low speed cutting process -> Test in Potash at AKZO/Lousianna

Task 10: Electronic boom stabilisation

Task 11: Modelling of tool system

I-DEAS Master Series 5: Simulation 15-Apr-98 17:55:53

Database: r:\team\projects\Darbeit1.mf1 Units : MM
View : No stored View Display : No stored Option
Task : Meshing Model/Part Bin: E) Halter-Buchse komplett
Model: Fem1 Parent Part: Testbeispiel EF 58 BRD/ kon

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 „NEW CUTTING SYSTEMS“ PROJECT

PROJECT TASKS

Task 12: New cooling

New system

Present system

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