Highwall Mining System Highwall Mining Method

Highwall Miner Applications

HIGHWALL MINING METHOD The self-contained and self propelled Cat highwall
mining system offers an innovative method for extracting
Feasibility Determination coal from exposed seams in a multitude of applications.
Highwall mining can produce exceptionally low cost
coal if conditions are right. Having the right geology and Whether you’re operating a trench, open cast or con-
environmental conditions is the key to success. Caterpillar tour mine, the Cat highwall mining system can extract
and its dealers can assist you with an in depth evaluation coal affordably and safely:
of the site. For a very high-level evaluation, you can start ● Open Cast — Highwall mining is used to mine coal from
by going to the Highwall Miner page on www.cat.com underneath the final highwall, when the strip limit is
and use the on-line site evaluation tool. reached due to economic reasons or surface conditions.
Extracting Coal Affordably and Safely ● Trench Mining — The unit mines coal from both sides
Highwall mining is a proven and versatile primary of a purpose-prepared trench; this mining method is
method for mining coal from exposed seams. used when an open pit is not an option.
The Cat HW300 highwall miner stands on the pit floor ● Contour Mining — In a mountainous area, the Cat
or on a bench, directly in front of the exposed seam and highwall mining system can follow a coal seam along
makes long parallel rectangular drives into the coal seam. the side of the hill.
Pillars of material are left in place between the entries to
support the over burden.
A remote-operated cutter module is pushed up to
300 m (1000 ft) into the seam by a string of push beams
(unmanned coal-conveying elements) that transport the
mined coal back to the entry of the drive onto a stock-
pile. The whole mining cyle is completed by a three- or
four-man crew, with no personnel going underground
at any time.

2 1

HIGHWALL MINER APPLICATIONS

1 Open Cast Pit Mining

2 Trench Mining (mining seams on both sides)

3 Contour Mining

6-2

PHB-Sec06-18.indd 2 6/21/18 2:40 PM

 Cutter Module Highwall Mining System
Power Head
Mobility
Operator Comfort

CUTTER MODULE MOBILITY

Proven Cutter Module Improved Maneuverability in Tight Spaces
Caterpillar offers four separate cutter modules for The Cat highwall mining system is an agile, self-propelled
the HW300: extra low seam, low seam, mid seam and machine that operates on contour benches as narrow as
high seam. 18 m (59 ft). It trams easily from entry to entry and dis-
charges coal in tight spaces. An optional right-angle
Recommended Seam Heights conveyor system discharges coal on the right or left side
Extra Low Seam 711 to 1549.4 mm 28 to 61 in on narrow benches. It can also discharge onto a stacking
Low Seam 762 to 1500 mm 30 to 59 in conveyor system, where coal is moved to the center of
Mid Seam 1200 to 3050 mm 47.2 to 120 in the bench for stockpiling large volumes.
High Seam 2400 to 4500 mm 94.5 to 177 in
Four heavy-duty, hydraulically-powered tracks articu- 6
The cutter modules are interchangeable and quickly late independently in two operating modes — mine mode
attach to the power head assembly. The cutting cycle is and tram mode — and can rotate the machine 360°,
fully automated, yet allows the operator to manually which improves maneuverability in congested areas.
adjust the machine function using an ampere reading as Mine mode is used for moving parallel to the highwall,
the coal seam varies. This proven technology allows the while tram mode is used when moving from pit to pit.
cutter module to accurately follow the coal seam and
produce a cleaner product. OPERATOR COMFORT
Advanced Technology Ergonomic Design for Comfort,
For even more accurate directional mining operation, Control and Productivity
Caterpillar offers an optional solid-state, fiber-optic, The Cat highwall mining system is equipped with a
gyro-based navigation and steering system. This pro- comfortable, climate controlled, pressurized cab that
vides operators with very precise cutter module location offers a full view of the mining operation and the high-
data in real time for enhanced cutter module steering and wall. A full suspension seat and two adjustable touch-
pillar width control. screen displays provide an ergonomic environment,
placing machine controls and system information at
An optional Gamma Detection system can be used to the operator’s fingertips.
guide the cutter module through the coal seam, leaving
predetermined amounts of coal in the roof and floor.
This system also allows the mining of coal in soft roof
and/or soft floor situations.

POWER HEAD
Heavy Duty Power Head Assembly
The power head drives the cutter module and push
beam string forward using two hydraulically-powered
sump cylinders with a 6.86 m (22.5 ft) stroke.
The pushing force of 133 tonnes (147 tons) propels
the cutter module to a depth of 300 m (1000 ft) and the
pulling force of 275 tonnes (303 tons) retracts it safely.
The new standard sump cylinders have higher sump-
and retract forces.*
*Applies to international customers only. Not available
in the USA.

6-3

PHB-Sec06-18.indd 3 6/21/18 2:40 PM

 Highwall Mining System Push Beams
Reel and Chain
Control System
Anchoring System

PUSH BEAMS CONTROL SYSTEM

Backbone of the Highwall Mining System Control System with Diagnostics
Cat push beams are 6 m (20 ft) long, rectangular, The Cat highwall mining system’s operation is con-
reinforced steel box structures joined together to form trolled by a Programmable Logic Controller, which
a string, which connects the highwall mining system to provides reliable performance for greater uptime. A com-
the cutter module. prehensive diagnostics system, including troubleshoot-
ing assistance, streamlines maintenance procedures.
The push beam string is the backbone of the machine;
pushing and pulling the cutter module in and out of the Electric Controls
coal seam. Motor Control Circuits (MCC) for the cutter mod-
The push beam conveys mined coal inside. The enclosed ule motors are housed on the surface in the Electrical
beam protects the coal from contamination and sup- Control Module (ECM). Underground electrical com-
ports the hose chain that supplies control and power to ponents are housed in flame-proof enclosures.
the cutter module.
ANCHORING SYSTEM
Other Cat push beam advantages include:
Maximum Stabilization even under
● A strong method of attachment that is secured and Toughest Conditions
disengaged quickly Two drills mounted on the front of the machine are
● A push beam connection that allows the string and used to drill into the pit floor up to 2.4 m (8 ft). High-
cutter module to navigate through coal seam rolls and strength pins are then inserted through the base frame
undulations into the pit floor to help stabilize the machine and to
maintain its accurate position, even under tough push-
● A simple design free of electrical and hydraulic con- ing and pulling conditions.
nections
● Push beams that can be stacked six high reducing stor-
age area in narrow work sites, even under tough push-
ing and pulling conditions.

REEL AND CHAIN

Storage and Protection of Cables and Hoses
A steel-armored hose chain stores and protects all
electric power cables, hydraulic and coolant lines, and
the control cable to the cutter module. The hose chain
is automatically unrolled and retracted on a reel during
mining.

6-4

PHB-Sec06-18.indd 4 6/21/18 2:40 PM

 Equipment Relocation Highwall Mining System
Safety
Support

EQUIPMENT RELOCATION ● Methane Sensor — A methane sensor is mounted near

the cutter drum. When the methane content in the air
Convenient Modularity for Quick Assembly reaches the warning level, an automatic warning sig-
For quick relocation over long distances, the Cat high- nal attends the crew. When the methane level reaches
wall mining system can be taken apart in modules. Rapid a pre-set maximum level, a warning signal attends
disassembly and reassembly is facilitated by convenient the crew, and all electric power to the cutter module
hydraulic and electrical connectors, and all modules are is automatically disconnected (Except to the methane
sized for transport using regular public roads. sensor itself). Settings depend on local regulations.
Depending on local conditions, the system can also ● Working safely at night is enhanced by a number of
be transported between sites and without disassembly LED Flood lights, as well as LED platform and inte-
by heavy haul trucks. rior lights. The platform and interior lights are backed-
up by a battery system to stay on for up to 10 minutes 6
SAFETY after a power outage.
Designed with Safety as the First Priority ● Hydraulic Controls — Underground hydraulic valves
The Cat highwall mining system is engineered and are provided with flame proof solenoids.
equipped with a priority on safe operation; safety fea-
tures include:
SUPPORT
● Elevated Cab with Cameras — For a complete view
Product Support
of the highwall mining system and mining opera-
tion, the FOPS certified operator cabin is elevated Parts and service support for the HW300 are never
on the machine and three magnetic base cameras are far away with the global Cat Dealer Network. You can
provided whose positions can be easily and quickly count on our dealers’ skill and knowledge for qual-
adjusted. ity maintenance and high parts availability. Since the
machine will be serviced on site, this requires a trained
● Above-ground Operation — Operation of the system is crew with a dedicated maintenance truck, stocked with
performed entirely on the surface with no crew mem- essential spares and consumables for the machine. Your
bers working underground. dealer is happy to discuss this and other support services
●
options.
Small-crew Size — The highwall mining system only
requires a three- to four-person crew for full operation. Training
● Remote Operation — In an emergency, the machine Caterpillar can arrange operational and technical
can be operated remotely using a laptop from as far training which covers every aspect of the HW300 Highwall
away as 61 m (200 ft). Miner.
● Anchoring System — Two drills mounted on the front Support Equipment
of the machine are used to drill into the pit floor up The highwall miner has the following support equip-
to 2.4 m (8 ft). High-strength pins are then inserted ment needs:
through the base frame into the pit floor to help stabi-
1. Two wheel loaders; one to load push beams during
lize the machine and to maintain its accurate position,
mining, one to manage the coal stock pile.
even under tough pushing and pulling conditions.
2. A stacker belt is recommended for managing the coal
as it comes off the machine.
3. Equipment requirements for keeping the seam exposed
will depend on the application.

6-5

PHB-Sec06-18.indd 5 6/21/18 2:40 PM