Bucket-wheel excavator - AbsoluteAstronomy.com

Bucket-wheel excavators are heavy equipment used in surface mining

Surface mining

Surface mining , is a type of mining in which soil and rock overlying the mineral deposit are removed...

Mechanical engineering

Mechanical engineering is a discipline of engineering that applies the principles of physics and materials science for analysis, design, manufacturing, and maintenance of mechanical systems. It is the branch of engineering that involves the production and usage of heat and mechanical power for the...

/civil engineering

Civil engineering

Civil engineering is a professional engineering discipline that deals with the design, construction, and maintenance of the physical and naturally built environment, including works like roads, bridges, canals, dams, and buildings...

. The primary function of BWEs is to act as a continuous digging machine in large-scale open pit mining operations. What sets BWEs apart from other large-scale mining equipment, such as bucket chain excavators, is their use of a large wheel consisting of a continuous pattern of buckets used to scoop material as the wheel turns. They are among the largest vehicles ever constructed, and the biggest bucket-wheel excavator ever built, Bagger 293, is the largest terrestrial (land) vehicle in human history according to the Guinness Book of World Records.

History

Bucket-wheel excavators have been used in mining for the past century, with some of the first being manufactured in the 1920s. They are used in conjunction with many other pieces of mining machinery (conveyer belts, spreaders, crushing stations

Crusher

A crusher is a machine designed to reduce large rocks into smaller rocks, gravel, or rock dust. Crushers may be used to reduce the size, or change the form, of waste materials so they can be more easily disposed of or recycled, or to reduce the size of a solid mix of raw materials , so that pieces...

, heap-leach systems

Heap leaching

Heap leaching is an industrial mining process to extract precious metals, copper, uranium, and other compounds from ore.The process has ancient origins; one of the classical methods for the manufacture of copperas was to heap up iron pyrite and collect the leachate from the heap, which was then...

, etc.) to move and mine massive amounts of overburden

Overburden

Overburden is the material that lies above an area of economic or scientific interest in mining and archaeology; most commonly the rock, soil, and ecosystem that lies above a coal seam or ore body. It is also known as 'waste' or 'spoil'...

(waste). While the overall concepts that go into a BWE have not changed much, their size has grown drastically. BWEs built since the 1990s, such as the Bagger 293, have reached sizes as large as 96 metres (314.9 feet) tall, 225 metres (738.2 feet) long, and as heavy as 14,200 tons (31.3 million lb). The bucket-wheel itself can be over 70 feet in diameter with as many as 20 buckets, each of which can hold over 15 cubic metres of material. BWEs have also advanced with respect to the extreme conditions in which they are now capable of operating. Many BWEs have been designed to operate in climates with temperatures as low as -45°C (-49°F). Developers are now moving their focus toward automation and the use of electrical power.

Structure

A bucket wheel excavator (BWE) consists of a superstructure

Superstructure

A superstructure is an upward extension of an existing structure above a baseline. This term is applied to various kinds of physical structures such as buildings, bridges, or ships...

to which several more components are fixed.

The bucket wheel from which the machines get their name is a large, round wheel with a configuration of scoops which is fixed to a boom and is capable of rotating. Material picked up by the cutting wheel is transferred back along the boom. In early cell-type bucket wheels, the material was transferred through a chute leading from each bucket, while newer cell-less and semi-cell designs use a stationary chute through which all of the buckets discharge.

A discharge boom receives material through the superstructure from the cutting boom and carries it away from the machine, frequently to an external conveyor system.

A counterweight

Counterweight

A counterweight is an equivalent counterbalancing weight that balances a load.-Uses:A counterweight is often used in traction lifts , cranes and funfair rides...

boom balances the cutting boom and is cantilevered either on the lower part of the superstructure (in the case of compact BWEs) or the upper part (in the case of mid-size C-frame BWEs). In the larger BWEs, all three booms are supported by cables running across towers at the top of the superstructure.

Beneath the superstructure lay the movement systems. On older models these would be rails for the machine to travel along, but newer BWEs are frequently equipped with crawlers, which grant them increased flexibility of motion.

To allow it to complete its duties, the superstructure of a BWE is capable of rotating about a vertical axis (slewing). The cutting boom can be tilted up and down (hoisting). The speeds of these operations are on the orders of 30 m/min and 5 m/min, respectively. Slewing is driven by large gears, while hoisting generally makes use of a cable system.

Size

The scale of BWEs varies drastically and is dependent on the intended application. Compact BWEs designed by ThyssenKrupp

ThyssenKrupp

ThyssenKrupp AG is a German multinational conglomerate corporation headquartered in Duisburg Essen, Germany. The corporation consists of 670 companies worldwide. While ThyssenKrupp is one of the world's largest steel producers, the company also provides components and systems for the automotive...

may have boom lengths as small as 6m, weigh 50 tons, and move 100 fm3/hr of earth. Their larger models reach boom lengths of 80m, weigh 13,000 tons, and move 12,500 fm3/hr. The largest BWE ever constructed is TAKRAF's Bagger 293, which weighs 14,200 tons and is capable of moving 240,000 cubic metres of overburden every day. Excavations of 380,000 cubic metres per day have been recorded. The BWEs used in the United States tend to be smaller than those constructed in Germany.

Bucket chain excavators

Bucket chain excavators (BCEs) are similar in structure and function to BWEs. However, instead of the buckets being placed in a ring, they are strung out in a manner reminiscent of a trencher

Trencher (machine)

A trencher is a piece of construction equipment used to dig trenches, typically for laying pipes or cables, or for drainage. Trenchers may range in size from walk-behind models, to attachments for a skid loader or tractor, to very heavy tracked heavy equipment.-Types:Trenchers come in different...

. They remove material from below their plane of movement, which is useful if the pit floor is unstable or underwater. TAKRAF's BCEs travel on rails rather than crawlers.

Operation

BWEs are used for continuous overburden removal in surface mining applications. They use their cutting wheels to strip away a section of earth (the working block) dictated by the size of the excavator. Through hoisting, the working block can include area both above and below the level of the machine (the bench level). By slewing, the excavator can reach through a horizontal range.

The overburden is then delivered to the discharge boom, which transfers the cut earth to another machine for transfer to a spreader. This may be a fixed belt conveyor system or a mobile conveyor with crawlers similar to those found on the BWE. Mobile conveyors permanently attached to the excavator takes the burden of directing the material off of the operator. The overburden can also be transferred directly to cross-pit spreader

Spreader

Spreader can refer to:* Broadcast spreader, an agricultural machinery or lawn care tool designed to spread seed, fertilizer, lime, sand, ice melt, etc.* Spreader , a kind of maintenance of way equipment designed to spread or shape ballast profiles....

, which reaches across the pit and scatters overburden at the dumping ground.

Automation

Automation of the BWEs requires integrating many sensors and electrical components such as GPS, data acquisition

Data acquisition

Data acquisition is the process of sampling signals that measure real world physical conditions and converting the resulting samples into digital numeric values that can be manipulated by a computer. Data acquisition systems typically convert analog waveforms into digital values for processing...

systems, and online monitoring capabilities. The goal of these systems is to take away some of the work from the operators in order to achieve higher mining speeds. Project managers and operators are now able to track crucial data regarding the BWEs and other machinery in the mining operations via the Internet. Sensors can detect how much material is being scooped onto the conveyor belt, and the automation system can then vary the speed on the conveyor belts in order to feed a continuous amount of material.

Applications

Bucket wheel excavators and bucket chain excavators take jobs that were previously accomplished by rope shovels

Steam shovel

A steam shovel is a large steam-powered excavating machine designed for lifting and moving material such as rock and soil. It is the earliest type of power shovel or excavator. They played a major role in public works in the 19th and early 20th century, being key to the construction of railroads...

and draglines. They have been replaced in most applications by hydraulic excavators, but still remain in use for very large-scale operations, where they can be used for the transfer of loose materials or the excavation of soft to semi-hard overburden.

Lignite mining

The primary application of BWEs is in lignite

Lignite

Lignite, often referred to as brown coal, or Rosebud coal by Northern Pacific Railroad,is a soft brown fuel with characteristics that put it somewhere between coal and peat...

(brown coal) mining, where they are used for soft rock overburden removal in the absence of blasting. They are useful in this capacity for their ability to continuously deliver large volumes of materials to processors, which is especially important given the continuous demand for lignite.

Because of the great demand for lignite, lignite mining has also been one of the areas of greatest development for BWEs. The additions of automated systems and greater maneuverability, as well as components designed for the specific application, have increased the reliability and efficiency with which BWEs deliver materials.

Materials handling

Bucket wheel technology is used extensively in bulk materials handling. Bucket wheel reclaimer

Reclaimer

A reclaimer is a large machine used in bulk material handling applications. A reclaimer's function is to recover bulk material such as ores and cereals from a stockpile...

s are used to pick up material that has been positioned by a stacker for transport to a processing plant. Stacker/reclaimers, which combine tasks to reduce the number of required machines, also use bucket wheels to carry out their tasks.

In shipyards, bucket wheels are used for the continuous loading and unloading of ships, where they pick up material from the yard for transfer to the delivery system. Bucket chains can be used to unload material from a ship's hold. TAKRAF's continuous ship unloader is capable of removing to 95% of the material from a ship's hold, owing to a flexibly-configured digging attachment.

Heap leaching

An extension of their other uses, BWEs are used in heap leaching

Heap leaching

processes. Heap leaching entails of constructing stacks of crushed ore, through which a solvent is passed to extract valuable materials. The construction and removal of the heaps are an obvious application of stacking and reclaiming technology.

Manufacturers and market

Few companies are willing or able to manufacture the massive, expensive gears required for BWEs. Unex, Czech Republic, still has the original casting forms, and is still able to manufacture BWEs. However, these machines were built to last indefinitely under continuous heavy use, and strip mining is now ecologically unpopular, so there is little demand for new machines. The manufacturers of BWEs and similar mining systems now receive some revenue from maintenance and refurbishing projects, but also produce large steel parts for other purposes. Current use of bucket-wheel excavators is mainly focused in the area of lignite (brown coal) mining for the production of electricity, mostly in Germany and East/Southeastern Europe. Unex has also made a BWE for extraction of diamonds from the Siberian permafrost.

External links

The source of this article is wikipedia, the free encyclopedia. The text of this article is licensed under the GFDL.

History

Structure

Size

Bucket chain excavators

Operation

Automation

Applications

Lignite mining

Materials handling

Heap leaching

Manufacturers and market

See also

External links