Continuous Method of Surface Mining:

Bucket Wheel Excavator

Prof. K. Pathak
A view of continuous surface mining with BWE
Learning Outcome

After successful completion of this unit the you will be able to

• classify the continuous mining methods applied in surface
mining
• classify different types of BWE and specify under what conditions
bucket wheel excavators are applicable and what are their
advantages and disadvantages compared to cyclic methods
• identify the most appropriate method of extracting a block from
the full block and the half block method of operation of bucket
wheel excavator comparing their respective applicability, merits
and demerits
• sketch a working layout of a BWE and explain development of
ramp cut and box cut in bucket wheel excavator application
• estimate the productivity of a bucket wheel excavator and
system productivity for given site specific conditions
A surface mining operation in which there is no time gap between excavation
and transportation is considered as continuous surface mining.
 Classification of Continuous Surface Mining Methods

• With drilling and blasting

• Without drilling and blasting
Normally loose and low compressive strength rock mass are excavated by
continuous mining.

The methods vary depending on the types of machines used. E.g

➢ Mining with Bucket Wheel Excavator
➢ Mining with bucket chain excavator
➢ Mining with Continuous Surface Miner
➢ Other methods: Dredging (for under water mining)
Advantages over Cyclic Methods

• Use of continuous transporting by conveyor belt eliminates fleet of trucks, diesel consumption
and men power required
• Large production rate can be maintained
• Eliminates the downtimes due to poor haul road conditions in bad weathers
• Eliminates or reduces crushing needs as continuous mining produces smaller rock pieces
• Safer as less persons and less moving vehicles
• For a given production rate the bucket wheel excavator is more energy efficient compared to
the power shovel as its service weight is less
Disadvantages Compared to Cyclic Methods

• Less flexible as conveyor roots are fixed

• More time in system commissioning
• Highly dependent on the geo mining conditions
• More demands on reliability calls for more investment on monitoring
and maintenance

Bucket capacity Max output Cutting Height Service Weight

(m3) m3/h (m) (T)

Power shovel 2400 21 2600

24

BWE 2400 35 2000

1.4
Types of BWE and their Applicability
BWEs are can be classified on the
following basis:
Travelling System:
Capacity:
i) Low (up to 630 m3/h) i) Rail mounted.
ii) Medium (630 to 2500 ii) Crawler mounted.
m3/h) Discharging System:
i) Without telescope discharge
iii) High (2500.5000 m3/h)
boom.
iv) Extra high(>5000 m3/h)
ii) With telescope discharge boom
Digging force: iii) Direct casting type.
i) Normal Digging force (4.5-7 iv) Conveyor loading/conveyor
fridge loading type.
kg t/)
Length: Dia Ratio:
ii) High digging force(8.5-14 kg
t/) i) Compact B.W.E (L/D
Kind of Digging: 1.9~2)
i) High digging (*0.51) ii) Semi compact B.W.E ( L/D
2.8 ~3)
ii) High and deep digging.
iii) Full size B.W.E (L/D 4.2~4)
Advancing the wheel towards the face:
i) With Crowding.
ii) Without Crowding.
BWE is the most efficient when
• excavating soft strata and no blasting is required,
• large scale excavation,
• higher bench height to match with the size of the machine.
• Compressive strength up to 100 kg/cm3 can be negotiated.

Deployment is normally for

• high cut, i.e. above the crawler level,
• parallel cuts with parallel horizontal slices (terraces)from top to bottom
of the face,
• For compact ground with horizontal stratification, vertical cut (dropping
cut) along the whole cross section,
• Normally conveyor system of transport using round the pit or across the
pit system,
• All benches are with similar system
• Working with less manpower, as fleet of trucks are eliminated men
power required is less .
 Cutting boom
Hoist rope

Electrical
controls Bucket
BW Boom Hoist
mechanism

Operator Cabin

Counter balance
Boom
Conveyor belt Bucket Wheel
Super
Structure Bucket Wheel
Discharge boom Boom
Hoist mechanism
Discharge
Boom Crawler (3x2)

Under Carriage
CL – Distance between leading edge of crawler
and the center of rotation of the BWE.
CW – Distance between the outside edge of a
crawler and the BWE centre line of advance.
D – Digging wheel diameter measured at
cutting lips
D1 – Digging wheel diameter without buckets,
at wheel rim
DB – Discharge boom length
DD – Lowest elevation of the discharge chute
DM – Highest elevation of the discharge chute
E – Distance between the load boom pivot
point and the center of rotation of the BWE
HD – Maximum depth of cut below crawler
level
HM – Maximum elevation the digging wheel
center
LB – Length of the load boom
LBW – Width of the load boom
Y – Elevation of the load boom pivot point

kh & kd – Lowest and highest load boom inclination angles

I & r – Horizontal wheel free angles
I & r – Vertical wheel free angles
I & r – Maximum discharge boom slew angles
k – Minimum angle permitted between load and discharge booms
Best conditions for deployment are:

• Flat to slightly inclined seam.

• Thick seam.
• Thick OB.
• Higher tonnage per hour.
• Longer life.
• Reliable power supply.
• Hard and tough new fragmented blasted rock with no boulder. (uniform ground)
• Wide radius of excavation to 90m high and deep cut.
• Disposal of one or OB to a considerable distance above or below its working level.
A BWE can be used to form three distinctly different types of cuts:
• Terrace Cut
• Dropping Cut
• Combination Cut

From Bulk Solid Handling, Trans Tech Publication

A Bucket Wheel Excavator (BWE) is being used to create a drop cut in
a lignite mine. The following operational parameters are provided:
• Cutting height (H) = 15 meters
• Cutting width (W) = 20 meters
• Cutting depth per pass (D) = 2 meters
• Wheel rotation speed = 4 RPM
• Number of buckets on the wheel = 16
• Bucket capacity = 0.5 m³
• Operating efficiency = 85%
Calculate:
1.The volume of material cut per pass.
2.The hourly production rate of the BWE in cubic meters.
 Step 1: Volume of material cut per pass
The volume of material cut per pass is
calculated as:
Vpass=H×W×D
Vpass=15×20×2=600 m3

Step 2: Volume handled by the buckets per pass

• Each bucket takes material equal to its capacity.
• Total volume handled by the wheel in one complete
rotation:
Vwheel=16×0.5=8 m3

Step 3: Production Rate Calculation

The hourly production rate (Q) is:
Q=Number of buckets per rotation×Bucket capacity×Wheel rotation per hour×
Operating efficiency
Q=16×0.5×(4×60)×0.85
Q=1632m3/hr Answer:
1.Volume of material cut per pass = 600 m³
2.Hourly production rate = 1632 m³/hr
A BWE is operating in a terrace cut configuration in an open-pit coal mine. The
following data is given:
• Cutting height (H) = 10 meters
• Cutting width (W) = 25 meters
• Depth of cut per terrace = 3 meters
• Bucket capacity = 0.75 m³
• Wheel speed = 3 RPM
• Number of buckets on the wheel = 18
• Operating efficiency = 90%
Calculate:
1.The volume of material removed in one terrace cut.
2.The total volume of material removed in 1 hour.

Step 1: Volume of material cut per terrace

Step 2: Production Rate Calculation
Total volume handled by the wheel per rotation
Answer:
1.Volume of material cut per terrace = 750 m³
2.Hourly production rate = 2187 m³/hr
• A 1400l bucket wheel excavator has theoretical capacity of handling loose soil
at the rate of 5460 m3/h

• The crawler mounted machine has a 31m long bucket wheel boom and 35m
long discharge boom and can operate up to the maximum inclination of 1:20.

✓ Operating Block width: 40m

✓ Maximum block height: 27m
✓ No. of slices: 4
✓ Height of slices: 6.9/ 6.9/6.9/6.3m
✓ Maximum slice increment: 7m
✓ Highwall slope angle: 650
✓ Lateral slope angle: 65 0
✓ Slew angle when operating maximum block width: 75 0+420
✓ The machine can change its direction of working through 180 0 without
any special mining preparations.
Full Block and the Half Block Method of Operation of BWE
applicability, merits and demerits
Working Layout of a BWE
A bucket wheel excavator is having wheel boom
linear slewing speed of 125m/min. There are 9
buckets on the wheel rotating at 24 rpm while
cutting. Determine the width of a cut
Solution:
The width of the elementary cut by the bucket ,
b, depends on the linear speed of the wheel
boom at bucket tip,vbm, the bucket wheel
speed , nwh (rpm) and the number of buckets
on the wheel, nbt by the relation:
b=vbm/nbt.nwh, m
Thus by given conditions,
b= 0.58m
Working Layout of a BWE
Working Layout of a BWE
BWE with a dragline and a Cross –pit-
Conveyor (XPC)
Principles of Developing Surface Mining Layout for Bucket Wheel
Excavator (BWE) Operations
Designing a surface mining layout for Bucket Wheel Excavator (BWE)
operations requires careful consideration of the geological, technical,
operational, and economic factors involved in large-scale material extraction.
BWEs are highly efficient for continuous mining of large volumes of
overburden or ore, especially in coal, lignite, and other soft-rock mines.
The layout must ensure optimal positioning of the BWE, smooth material
flow, and minimal downtime to maximize efficiency and minimize operational
costs. Objectives of BWE-Based Mining Layout
1.Maximizing Excavation Efficiency – Ensure high
excavation rates with minimal operational
interruptions.
2.Optimizing Material Flow – Design haulage and
dumping systems to minimize delays and increase
throughput.
3.Minimizing Equipment Downtime – Ensure
smooth relocation and flexible operation.
4.Ensuring Safety and Stability – Design bench and
slope angles for safe excavation and operator
security.
5.Reducing Environmental Impact – Optimize land
reclamation and minimize disturbed land area.
Key Principles of BWE-Based Mining
Layout Design
1. Geological and Geotechnical Considerations
The geological structure of the deposit determines the
positioning and orientation of the mining layout. Key factors
include:
•Ore body thickness and depth – Determines the number
and size of benches.
•Dip and strike of the deposit – Affects the direction of
excavation.
•Rock strength and stability – Determines the bench height
and slope angle.
•Faults and fractures – Influence excavation stability and
positioning of equipment.
•Groundwater conditions – Requires effective dewatering to
prevent slope instability.

2. Bench and Slope Design

Bench Height:Typical bench height for BWE = 10–20meters.Determined by
bucket wheel size and reach.
Bench Width:Must allow room for the BWE and support vehicles.Typical
width = 30–50 meters depending on equipment size and maneuverability.
Bench Slope Angle:Optimized for material stability and ease of
access.Range = 30° to 45° depending on material hardness and cohesion.
Inter-Bench Slope:Ensures drainage and safety of adjacent benches.
3. BWE Positioning and Operation Strategy 4. Conveyor and Material Handling System
• Parallel Operation: Design
• Continuous Conveyor System:
• BWE operates parallel to the face to maximize
• Direct integration of conveyor with BWE
contact area with material. for real-time material removal.
• Reduces turning time and increases cutting • Reduces downtime associated with
efficiency. haulage interruptions.
• Angle of Attack: • Typical belt width = 1.5–2 meters
• Ideal angle = 60° to 90° to ensure deep and depending on material size.
• Conveyor Angle:
consistent cutting.
• Optimal range = 12°–18° to ensure
• Steep angles improve productivity but may smooth flow without rollback.
require increased stability measures. • Intermediate Transfer Points:
• Advance Direction: • Ensure smooth transition between
• Best to work against the dip to avoid conveyor segments.
undercutting instability. • Include buffer stockpiles to prevent
overload.
• Advance in a linear or radial pattern depending
• Dumping and Stacking:
on deposit shape. • Coordinate with mobile stacking
systems (e.g., spreaders) or stockpiles.
• Minimize rehandling and transport
distance.
5. Mobility and Flexibility of BWE
•Crawler Tracks:
6. Safety and Stability Measures
• High-torque, low-speed drive for
•Slope Stability Monitoring:
consistent maneuverability.
• Use ground radar and laser-based
• Must accommodate variations in terrain
systems to detect slope instability.
without loss of stability. • Install pit dewatering systems to reduce
•Turn Radius:
hydrostatic pressure.
• Designed to allow pivoting and
•BWE Operational Limits:
realignment along the face.
• Avoid excavation at slope overhangs.
• Wide platforms and low center of gravity
• Keep BWE at least 5–10 meters from
reduce tipping risk. the edge of the bench.
•Relocation Strategy:
•Operator Visibility:
• Scheduled relocation based on face
• Install high-definition cameras and
advancement rate.
radar-based proximity detection.
• Ensure conveyor extension capacity
matches excavation advance rate.
7. Environmental and Reclamation Considerations
•Progressive Backfilling:
• Begin backfilling immediately after mining a section.
• Use overburden to reclaim excavated areas.
•Dust and Noise Control:
• Install water spray systems on BWE and conveyors.
• Enclose conveyors to minimize dust spread.
•Revegetation:
• Plan early-stage revegetation of reclaimed land.
 Layout Configurations for BWE-Based Mining

1. Straight-Line Layout 2. Radial Layout

Suitable for deposits with minimal dip. •BWE works in a circular or semi-circular pattern.
BWE advances in a straight line along the ore •Conveyor pivots to accommodate changing
body. position.
Conveyor system follows a straight or slightly Advantages:
curved path. •Increased flexibility with irregular deposits.
Advantages: •Allows quick adjustment of working face.
High efficiency and low maintenance. Disadvantages:
Simple conveyor routing. •Complex conveyor design and higher
Disadvantages: maintenance.
Limited adaptability to variable geology.

3. Chevron Layout
•BWE operates in a V-shape or zigzag pattern.
•Allows parallel operation of multiple BWEs.
•Multiple conveyor transfer points.
Advantages:
•High excavation rates and increased face exposure.
•Improved efficiency for deep deposits.
Disadvantages:
•Complex operational coordination.
•High conveyor maintenance costs.
Factors Influencing Layout Selection

Factor Impact Design Consideration

Defines working face
Deposit Shape Straight vs. radial layout
orientation
Affects slope angles and Adjust slope and bench
Geological Structure
bench height design
Defines bench
Increase bench width for
BWE Size and Capacity dimensions and
larger BWEs
conveyor design
Affects operational Limit to <5 km for
Conveyor Length
efficiency efficiency
Affects equipment
Mobility Requirements Provide crawler flexibility
relocation strategy
Limits excavation area Use closed conveyor
Environmental Limits
and noise/dust spread belts and water sprays

Operator and equipment Ensure minimum setback

Safety Constraints
stability and bench integrity
Performance Indicators for Effective Layout Design
1.Excavation Rate: ≥90% of rated BWE capacity.
2.Downtime: ≤10% due to equipment failure or layout
issues.
3.Material Handling Efficiency: >95% throughput at
conveyor transfer points.
4.Conveyor Utilization: ≥85% operating efficiency.
5.Relocation Frequency: ≤2 relocations per month.

Designing a mining layout for Bucket Wheel Excavator (BWE) operations requires a
balance between geological characteristics, equipment capacity, and material
handling efficiency. An optimized layout enhances equipment utilization, minimizes
downtime, and improves safety. The choice of a straight-line, radial, or chevron layout
depends on deposit geometry, operational flexibility, and production targets. Proper slope
stability, conveyor design, and real-time monitoring further enhance overall operational
efficiency and environmental sustainability.
Test Yourself

• Can you classify the continuous mining methods applied in

surface mining ?
• Can you classify different types of BWE and specify under what
conditions bucket wheel excavators are applicable and what are
their advantages and disadvantages compared to cyclic
methods ?
• Can you identify the most appropriate method of extracting
a block from the full block and the half block method of
operation of bucket wheel excavator comparing their respective
applicability, merits and demerits ?
Development of ramp cut and box cut
Bucket Wheel Excavators (BWE) are designed for continuous excavation in surface
mining operations, especially in large deposits such as coal, lignite, and soft rock.
During initial mine development or when opening up new mining areas, two essential
cuts are developed: Ramp Cut and Box Cut. These cuts enable proper access, material
flow, and operational efficiency for the BWE.

1. Ramp Cut by BWE

A ramp cut is developed to provide access for the BWE and other mining equipment to different working levels or benches within
the pit. It serves as the main entry and exit route for equipment, facilitating material transport and operational movement.
Process of Developing a Ramp Cut:

1.Initial Setup:
1. The BWE is positioned at the upper edge of the deposit or a predefined working level.
2. The excavation direction is determined based on the dip and strike of the ore body.
2.Progressive Excavation:
1. The BWE starts cutting at a downward angle to form an inclined path.
2. The excavation is continuous, with the material being transferred to a conveyor or haulage system.
3.Slope and Gradient Control:
1. The ramp gradient is typically between 8% and 12% to allow safe and efficient movement of haul trucks and other
vehicles.
2. Bench width is designed to accommodate two-way traffic where needed.
4.Conveyor and Material Transport:
1. Conveyors are laid along the ramp for continuous material transport.
2. The BWE advances systematically, extending the ramp length and depth as needed.
5.Stabilization and Maintenance:
1. The sides of the ramp are trimmed to maintain slope stability.
2. Regular maintenance of the ramp surface ensures safe and efficient vehicle movement.
Key Considerations for Ramp Cut:
• Ensure that the gradient is within operational limits for both BWE and
haulage vehicles.
• Maintain adequate drainage to avoid water accumulation and erosion.
• Design the ramp width to allow for two-way traffic if necessary.
• The ramp should allow easy access to both the working face and waste
dump areas.

Advantages of Proper Ramp Design:

➢ Efficient material transport from working face to conveyor.

➢ Reduced wear and tear on haulage equipment due to optimal gradient.
➢ Increased operational efficiency and flexibility for BWE relocation.
Box Cut by BWE
A box cut is developed to provide the initial opening into a deposit. It establishes the starting point
for excavation and sets up the operational space for continuous mining. The box cut allows the
BWE to position itself for systematic excavation of the deposit.
Process of Developing a Box Cut:
1.Site Preparation:
1. Geological and geotechnical surveys are conducted to identify the best location.
2. Surface preparation involves removing vegetation and loose overburden.
2.Initial Cut:
1. The BWE is positioned at the target elevation.
2. Cutting begins at the center or along one edge of the designated box cut area.
3.Face Advancement:
1. The BWE cuts a rectangular or square section (box-shaped).
2. Material is transferred via conveyor to a stockpile or waste dump.
3. Cutting depth and width are defined based on the BWE's capacity and boom reach.
4.Bench Formation:
1. Once the initial cut is made, the BWE creates working benches.
2. Benches are aligned to ensure proper positioning of the conveyor and equipment.
5.Access and Mobility:
1. The box cut creates enough operational space for the BWE to maneuver.
2. Ramps are connected to the box cut to enable equipment access.
Key Considerations for Box Cut:
➢ Maintain face height and slope stability to prevent equipment instability.
➢ Ensure proper drainage to avoid water accumulation at the base of the cut.
➢ Design the box cut dimensions based on the capacity and reach of the BWE.
➢ Plan the location to allow for easy access to both the ore body and waste handling
system.

Advantages of Proper Box Cut Design:

➢ Provides a stable starting point for continuous mining.

➢ Facilitates proper positioning of the conveyor system.
➢ Allows efficient formation of working benches.
➢ Improves maneuverability and operational flexibility for the BWE.
Differences Between Ramp Cut and Box Cut

Parameter Ramp Cut Box Cut

Provides access to the
Establishes the starting
Purpose working face and
point for mining
operational levels
Gradient Typically between 8%–12% Flat or slightly sloped
Rectangular or square
Cut Shape Inclined path
shape
Direction of Cutting Downward, along the slope Horizontal or vertical face
Material transferred along
Material handled through
Material Handling the ramp via conveyor or
direct conveyor or stacking
trucks
Facilitates equipment Creates the initial mining
Operational Objective
movement and haulage face for BWE
Combined Strategy of Ramp and Box Cut
• The box cut is usually developed first to establish the working face.
• The ramp cut is then developed to create access for material transport and
equipment movement.
• Together, the ramp and box cut form the foundation for continuous
mining.
Example:
1. Box Cut: Opened up at the edge of the deposit to establish the working
face.
2. Ramp Cut: Developed along the side of the box cut to create access for the
BWE and haulage vehicles.
3. Systematic Excavation: The BWE progresses systematically from the box cut
while the ramp cut supports material transport and relocation.

❖ The box cut creates the initial working face and establishes operational space
for the BWE.
❖ The ramp cut ensures efficient movement of equipment and material from the
working face to the processing or dumping area.
❖ A well-designed box cut and ramp cut combination enhances BWE efficiency,
reduces downtime, and improves overall mining productivity.
❖ Proper slope, gradient, and equipment positioning ensure safety, operational
stability, and long-term performance.
Estimation the productivity
Productivity Estimation of a Bucket Wheel Excavator (BWE)
The productivity of a Bucket Wheel Excavator (BWE) depends on several operational, technical, and
geological factors. The key parameters involved in estimating the productivity are:
• Bucket capacity
• Number of buckets on the wheel
• Wheel speed
• Cutting depth
• Material density
• Operational efficiency

The basic equation for estimating the productivity of a BWE is:

Q=Bc×Nb×Sw×Fc×E
Where:
• Q = Productivity of the BWE (in m³/hr)
• Bc = Bucket capacity (in m³)
• Nb = Number of buckets on the wheel
• Sw = Wheel speed (in rpm)
• Fc = Cutting coefficient (fraction of bucket fill)
• E = Operational efficiency (fraction of effective working time)
Expanded Formula (Including Material Density):
The estimated weight-based productivity can be calculated by incorporating material density:
Qw=Q×ρ
Where:
• Qw = Weight-based productivity (in tons/hr)
• ρ = Material density (in tons/m³)
Effect of Cutting Width and Depth:
If the width and depth of cut are known, the equation becomes:
Q=Wc×Dc×Hw×Fc×Sw×E
Where:
•Wc = Cutting width (in meters)
•Dc = Cutting depth (in meters)
•Hw = Height of cut (in meters)

Factors Affecting Productivity

The actual productivity of the BWE can vary due to:

• Material Hardness – Harder material reduces

cutting efficiency.
• Wheel Slip – Reduced traction lowers bucket fill.
• Cutting Angle and Depth – Incorrect depth
reduces efficiency.
• Maintenance and Downtime – Reduced
operational efficiency lowers throughput. Strategies to Improve BWE Productivity
• Weather Conditions – Wet or frozen material • Optimize bucket fill factor by adjusting cutting angle
reduces fill efficiency. and speed.
• Ensure continuous material flow to avoid conveyor
bottlenecks.
• Minimize idle time through predictive maintenance
and automation.
• Use real-time data to adjust wheel speed and cutting
depth.
• Reduce wheel slip using advanced traction and
stability control.
Practice questions

Numerical Problem
Problem Statement:
A Bucket Wheel Excavator (BWE) is operating in a lignite mine.
The following data is provided:
• Bucket capacity (B_c): 1.2 m³
• Number of buckets on the wheel (N_b): 12
• Wheel speed (S_w): 3 rpm
• Cutting coefficient (F_c): 0.85
• Operational efficiency (E): 0.80
• Material density (ρ): 1.5 tons/m³
Objective:
1.Estimate the hourly volumetric productivity of the BWE.
2.Estimate the hourly weight-based productivity of the BWE.

Check Results:
Volumetric Productivity = 29.38 m³/hr
Weight-Based Productivity = 44.07 tons/hr
• The BWE can handle 29.38 m³ of material per hour at full operational efficiency.
• Considering the material density of 1.5 tons/m³, the BWE can move approximately 44.07 tons/hr of material.
• This result is reasonable for a medium to large BWE working under optimal conditions.