1. BOLTER MINER
Study Tour @ Russia
Team
Wise to resolve,
patient to perform…
Prepared by Venkat

2. Presentation Profile
• Objective
• Details of the Visit
• Russia – Mining Scenario
• Bolter Miner Details
• Mine visits – Salient Features
• Maintenance
• Things to be implementable
• Conclusions
• Pics of Bolter Miner

3. The Objective
• Background
– SCCL future depends only on the successful implementation of bulk
capacity Longwalls.
– Company is in advance stage of introduction of high capacity Longwalls
in few mines at first and on a large scale later.
– From past experience it is clear that the panel development is one of the
critical activity in Longwall success.
– Now, it is the time to change ourselves from age old Road headers to
Bolter miners to have rapid progress in roadway development including
safety.
• A team of three executives were selected to visit Russia to study,
observe and analyze the operation of Bolter miner in different mines
at different geo-mining conditions. The same can be compared with
and if possible can be implemented in our longwall mines.

4. Visit Particulars
• Total Period - 10th to 23rd April 2010
• Mines Visited - Four
• Surface visits include - Manufacturing plants

5. Training Schedule - 2010
DATE ACTIVITY
Mon 12th April Arr Novokuznetsk am, transfer to hotel, meeting at Joy Kuzbass office pm.
Tue 13th April Underground visit to Kotenskaya mine to see Joy Bolter miner development
Wed 14th April Underground visit to Raspadskaya mine to see Joy development and Longwall
Thur 15th April Underground visit to Raspadskaya Koksova mine to see 12CM30
Fri 16th April De-brief meeting at Novokuznetsk office
Sat 17th April Dep Novokuznetsk am, free time in Moscow.
Sun 18th April Sightseeing in Moscow
Mon 19th April Depart Moscow for Vorkuta, arrive Vorkuta 12.50
Tue 20th April Underground visit Vorgashorska mine to see Joy Bolter miner development.
Wed 21st April Meeting at Vorgashorska mine am.Depart Vorkuta 13.50 arrive Moscow 16.40
Thur 22nd April De-brief meeting in Mosow office
Fri 23rd April Depart Moscow for return home - EK 134,Moscow(DME) 1755

6. Russian Coal Industry
World Coal Reserves
• Fifth largest producer of coal in the
world.
• 2nd largest proved coal reserve in
world.
Russian production for last 15 years
350
300
250
200 O/C
U/G
150
100
50
0
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

7. Russia Coal Map

8. Svalbard, Norway
Arctic Ocean Bering
Barents Sea
Sea
Sweden
Joy/P&H
Moscow Vorkuta coal reserves
PECHORA BASIN
YAKUTIA BASIN
Moscow
Elga project
EAST
Joy/P&H SIBERIA
Kuzbass KUZNETSK
BASIN
BASIN
Kazakhstan China
Kuzbass coal reserves Japan
Mongolia
Russia Coal Market Overview

9. Top 10 Russian Mines by Production
Customer Name Production
Raspadskaya 10.6 MT
Zarechnaya 5.1 MT
Kirova 4.5 MT
Kotinskaya 3.9 MT
Salek 2.9 MT
Polosukhinskaya 2.8 MT
Alardinskaya 2.6 MT
Taldinskaya-Zap-1 2.5 MT
Taldinskaya-Zap-2 2.2 MT

10. Kuzbass Coal Market
Overview
Territory 95.5sq.km
Coal Reserves = 91.2b tonnes
Total Region Population = 3M
VORKUTA DONETSK -
- 9.2Mt 7.6Mt
FAR (4)
(3)
EAST -
32.5Mt (5) 4.8Mt -
URAL
EAST
SIBERIA -
73.6Mt
(2) 180.0Mt -
KUZBASS
(1)
KUZBASS 57 % OF TOTAL COAL PRODUCTION
KUZBASS 75.5 % OF COKING COAL PRODUCTION
No of U/G Mines = 58
No of Operating LW = 64
Joy Machines in Operation = 93 units

11. Bolter Miner
Details

12. CM + BM population - 2008
Total Population Apprx. 1600 units = 1400 CM and 200 BM

13. OEM suppliers of Bolter miner

14. Machine Type Vs Operation heights

15. Market Share of
various OEMs
World

16. Bolter Miners in Russia
SERIAL No & OE PLANT M/C TYPE CUSTOMER STATUS
JM 5601 PINXTON UK 12BM15 Yzhkuzbassugol Installed June 06
Ulyanovskaya Mine
JM 5602 PINXTON UK 12BM15 Yzhkuzbassugol Installed June 06
Ulyanovskaya Mine
JM 5606 FRANKLIN US 12CM15 WHBM Suek Kotenskaya Mine Intalled Sep 06
JM 6708 MOSS VALE AUS 12CM30D Raspadskaya Group Installed July 07
Muk 96
JM 6709 MOSS VALE AUS 12CM30D Raspadskaya Group Installed July 07
Muk 96
JM 6710 MOSS VALE AUS 12CM30D Suek Taldenskaya Mine Installed Sept 07
JM 6711 MOSS VALE AUS 12CM30D Suek Kotenskaya Mine Installed Oct 07
JM 6712 MOSS VALE AUS 12CM30D Suek Taldenskaya Mine Installed Jan 08
JM 6723 MOSS VALE AUS 12CM30B Vorkutaugol Installed Dec 08
Vorgasorskaya Mine 1005 m during Aug 09

17. Bolter Miners in Russia
SERIAL No & OE PLANT M/C TYPE CUSTOMER STATUS
JM 6727 MOSS VALE AUS 12CM30B Vorkutaugol Installed Apr 09
Vorgasorskaya Mine 1212 m during March
JM 6725 MOSS VALE AUS 12CM30D Raspadskaya group, Installed Nov 08
Koksova mine
JM 6726 MOSS VALE AUS 12CM30D Raspadskaya group, Installed Sept 09
Koksova mine
JM 6736 MOSS VALE AUS 12CM30B (5.4 width) Raspadskaya group, Installation Planned For
Raspadskaya mine June 2010
JM 6737 MOSS VALE AUS 12CM30B (5.4 width) Raspadskaya group, Installation Planned For
Raspadskaya mine June 2010
Totals
• 2 x 12BM15
•1 x 12CM15 WHBM
•11 x 12CM30

18. 12CM30 - Overview
• The Joy bolter miner system fully integrates the early installation of
high strength roof bolts close to the face with the latest JOY
continuous miner drivage system, incorporating the latest
improvements in machine design and roofbolting technology.
• Single pass machine
• Cutting range : 2.4 to 4.5 m
• Standard width : 5.2 m (Options, 4.8, 5.0 & 5.4m)
• Hydraulic cutter head extensions reduce the width by 600
mm(800mm with 5.4m head)

19. 12CM30B with HFX 280 Standard cut
dimensions

20. 12CM30B with HFX 280 deep cut
dimensions
Extreme Case, with undercut
Outbye Facing Rigs - Deep Undercut -

21. Mine Visits
Salient Features

22. Raspadskaya mine
• This is a Longwall mine currently producing 7 mil.tonnes of coal
per year from 5 nos longwalls.
• Mine contains two JOY machines 12CM15 and 12CM18 installed
in 1997 supported by JOY Shuttle cars.
• Bolting operations carried out by Joy WOMBAT hand held bolting
machines.
• Till now, 12 CM 18 machine has done about 18 Kms of drivage
and 12 CM 15 done 17 kms with no major overhauling except
failed components replacement/repair.
• The roadway dimensions are 5.2 M (wide) x 2.5 M (height) with 6
bolts at every 1 M length and 2.6 M to 2.8 M in to roof with resin
capsules.
• An advance rate of at least 6-8 M per shift of 6 hours is being
achieved.

23. Kotinskaya mine, SUEK (Siberian Coal and Energy Company)

24. Kotinskaya mine, SUEK (Siberian Coal and Energy Company)
• This is a longwall mine currently producing 5 mil. tonnes per year
from one longwall at 300 M depth with face dimensions 230 M X
4000 M and seam thickness 4.5 mtrs.
• This mine has two Bolter miners used for longwall gate road
development averaging 5 Kms of development per year per
Bolter Miner.
• Bolter Miners are operating at 12 deg dip gradient and 3 deg
cross gradient.
• The roadway dimensions are 5.5 m(wide) X 4.5 M (height) with 6
bolts in to roof at every 1 M length.

25. Raspadskaya – Koksovo mine
• This is a new longwall mine in development stage.
• The Bolter Miners (2 no.s of 12CM30) are used for all mine
development roadwaysworking on 13 deg to 16 deg gradient
cutting roadway of 5.2 M (wide) x 4.0 M (height) in a seam height
of 5.5 M leaving about 1.5 M coal in the floor and sand stone
roof.
• Current roadway visited where Bolter Miner was working is at
600 mtrs depth and is backed up by 20 T Shuttle car working in
these gradients with an average progress of 10m per day.
• Roof bolting goes up to 3.4 M in to roof and Rib bolting 1.8 M to
2.2 M is being done for side stability.

26. Vorgashorskaya Mine 2 (Vorkutaugol Group)
• This is a longwall mine with two sets of (Russian) longwalls
operating each set producing 1.5 MTPA with of 250 mtrs face
length with 1.2 to 1.3 km long.
• This is a shaft mine with 2 no.s of 12 CM 30 Bolter Miners, which
have been lowered in completely dismantled condition and
assembled in underground.
• This mine has got the privilege of driving 1200 mtrs of roadway
from one 12 CM 30 machine, during March 2010, which is
considered to be a record for Russian mine roadway
development.
• The roadway dimensions are 5.2 M(wide) x 3.6 M (height) and
the machine is able to cut a perfect rectangle with clean floor. 6
nos. bolts of 2.4 M deep @ every 0.5 M and rib bolting of 1.8 M
being practiced with “W” straps and wire netting in to roof and
ribs.

27. Vorgashorskaya Mine 2 (Vorkutaugol Group)
• Cable bolting up to 5 M in to roof being done at every alternate
row of standard bolting.
• This mine also currently have few Russian and Ukrainian Road
headers, with manual bolting and achieving a maximum of 9 M
per day.
• Each 12 CM 30 Bolter Miner on an average achieving 35 M
progress per day.
• In spite of driving > 16 Km of roadways the 12 CM 30 machines
are found to be as good as new machines devoid of any small
leakages.

28. Maintenance

29. Maintenance Practices
• Maintenance of equipment is being carried out in separate
maintenance shift of six working hours. After completion of
maintenance job the maintenance personnel start machinery for
production and handover the face to the production shift crew in
running condition.
• Planned preventive maintenance practice is being followed.
• Service contract is given to JOY for regular maintenance of the
equipment in one of the mine (Vorgashorskaya Mine).
• Other Mines, their own maintenance crew is carrying out the
maintenance job with the guidance of JOY.

30. Maintenance Practices
• Service Engineers of the JOY are closely monitoring the
performance and also recording the mean time between
failure (MTBF) i.e service lives of all the components of
the equipment for better guidance.
• Based on the recorded MTBF of components, floats of
Sub-Assemblies are being maintained right at the Pit
Stores.
• However, replacements of components are being done
only on failure for achieving optimum life of the
component.

31. Maintenance Practices
• Maintenance practices are being followed very
religiously.
• Machinery is being thoroughly cleaned with water before
taking up maintenance job. The best example is the
feeder chain of Hydraulic bolter is being thoroughly
cleaned with de-greaser to clear off the rock/coal dust
present in the lubricant from the chain before doing the
daily lubrication ,which results in longer service life of the
Seals.

32. What we learnt from the
Russia Trip …

33. Notable Points
• Bolter miner is a single pass, robust machine capable of
bolting both Roof & Sides.
• With the elimination of Gathering Arms, it is possible to
bolt the Roof at distance of 1.0m from the face and if
required first row of bolts can be fixed at a distance of
0.6m from the face by sumping the drum into the face.
• There is less number of hoses & Rotary gathering arm
thus eliminates the maintenance difficulty.

34. Notable Points
• The least progress from Bolter Miner is 300m, the
average progress is 600m and the best is 1200m per
month.
• Transport of work persons to the face on Man Riding
(Chair Lift/Chair Car/Diesel Monorail and Men transport
FSV) is a must, which will be useful for material transport
too.
• Very good ventilation (Quality & quantity) is a must to
avoid discomfort for maintenance of Diesel FSVs.

35. Notable Points
• Maintenance contract with OEM is worth trying with such
high capital intensive equipment.
• It is better not to try driving the machine in cross
gradients for better and faster progress.
• 4” x 4 “Wire mesh with 5mm dia rod is be procured
instead of 2”x 2” GI Chain link fence.
• 150 x150 x 6mm thick Bearing plates are to be replaced
with 300 x 300 x 10mm thick for effective Roof control.

36. Conclusions

37. Conclusions
• 12 CM 30 Bolter Miner is capable of Working in gradients of about 13
Degrees.
• First row bolts can be fixed at a distance of 1.0m from the face.
• Further shortened distance from the face can achieved for effective
roof control in weak roof condition.
• The average progress that can be achieved from the machine is
about 400m per month.
• Maintenance CONTRACT with the OEM is very much essential.

38. Few Pics of Bolter Miner

45. THANK ‘U’
Mail your comments to venkoos@gmail.com