Development of a Continuous Mining System for Semi-Steep Potash Seams

Jrgen Chon
RWTH Aachen University, Institute of Mining Engineering I (BBK I)
Per N. Martens
RWTH Aachen University, Institute of Mining Engineering I (BBK I)
Ludger Rattmann
RWTH Aachen University, Institute of Mining Engineering I (BBK I)
Franz X. Spachtholz
K+S AG, Germany
Thomas Jacob
K+S AG, Germany

Abstract
For tabular semi-steep deposits almost no standardized mining method is available. Due to the
ambition of a more sustainable utilization of deposits such as semi-steep potash deposits, alternative
mining concepts are getting more and more into the focus of the German potash mining industry.
Recently a project as part of a strategic research initiative to analyze potential applications for cutting
technology in German potash mines is launched in this context.
The following paper deals with the development of mining concepts for cutting technology in semisteep deposits as a part of this initiative. The major problem in deposits with an inclination (dip) of
20 to 60 is a dip that is too steep for the straight forward use of mobile equipment or regular belt
conveyors on the one hand and on the other hand not sufficiently steep enough for gravity flow. Thus,
if one would intend to use mobile equipment, the core challenge is to find a suitable mine design
trying to reduce the inclination in the roadways to an acceptable level. In order to do so, different
alternative mine designs are developed and discussed.
The most suitable mine design is identified by means of a benchmarking analysis comparing new
continuous mining concepts and the commonly applied drilling and blasting method. In addition, 3D
models of these new mining concepts are presented. Furthermore, a performance matrix for different
cutting machines is developed in order to compare several cutting rates under various conditions.
Finally, a case study is carried out to apply the new mining concept to a representative mining area.

Biography
Jrgen Chon graduated from RWTH Aachen University in 2008 with a diploma degree in Mining
Engineering. His diploma thesis dealt with technical and economical optimization of alternative
mining methods for continuous miner in a German rock salt mine. He is currently working as a junior
researcher at the Institute of Mining Engineering I (BBK I) since 2008. He is involved in various
environmental projects on tailings disposal and mine backfill in German potash mines. His core
responsibility focuses on a research project in cooperation with K+S AG, which comprises feasibility
studies on the applicability of cutting technology in various areas of German potash mining, e.g. mine
development, extraction and mining methods.

Paper

Introduction
Continuous cutting technology represents one of the most efficient extraction methods in underground
mining operations. There is a wide range of continuous underground mining equipment for mechanical
extraction, e.g. shearer, borer miner, roadheader, continuous miner and bolter miner. Internationally, in
hard coal and potash mining cutting technology is considered to be state of the art.
However, whereas drilling and blasting is still the most widely applied extraction method in German
potash mining, applications of cutting technology come increasingly into focus due to technological
advancements and consequently increases in productivity.
The development of a continuous mining system for semi-steep potash seams is part of a strategic
research project, which currently is being conducted by the Institute of Mining Engineering I (BBK I)
at RWTH Aachen University in cooperation with K+S AG. It comprises feasibility studies on the
applicability of cutting technology in various areas of German potash mining, e.g. mine development,
extraction and mining concepts in general. Within the project, both framework conditions for the
application of cutting technology as well as mining concepts under various deposit conditions are
being developed.
The strategic research project for the applicability of cutting technology in German potash mines
comprises:

International benchmarking on state of the art of cutting technology, haulage systems and
mining methods in potash mining
Detailed process and cost analyses of current mining operations
Analysis of basic conditions for the applicability of cutting technology in potash mining
Analysis of possible applications and mine development concepts
o Cutting technology for extraction of semi-steep deposits
o Rapid development of mine roadways
o Combined extraction methods (cutting technology combined with drilling and
blasting)
Development of 3D models for the new mining concepts
Roadmaps, Recommendations, Outlook

The results of the strategic research project studies are going to be the basis for the implementation of
cutting technology in German potash mines.

Development of a Mining Concept for Semi-Steep Deposits

Approach. The primary objective of the studies conducted is the development of mining concepts
using cutting technology for mine development and extraction as an alternative to the currently applied
drilling and blasting technology. With particular emphasis on the deposit characteristics, mining
concepts are developed along the process chain (cutting, loading and hauling) as well as potential
solutions provided for related processes (e.g. mine development, mine ventilation, roof support, etc.).
Currently, the following mining methods are mainly used in international potash mining:

Room and Pillar Mining

Stope and Pillar Mining
Sublevel Stoping
Cut and Fill Mining

Shrinkage Stoping
Longwall Mining
Solution Mining

For tabular deposits with an inclination from 0 to 20 (flat) and for inclined deposits from 60 upwards
(steep), a choice of these standard mining methods can be applied. At an inclination range from 20 to
60 (semi-steep) almost no standard mining method can be applied because the minimum inclination
for gravity flow starts at 60 and the maximum inclination for mobile equipment and belt conveyors is
considered to be 20. Figure 1 provides an overview for tabular deposits and possible mining methods
depending on the inclination.
90
60
Standard Cases
Cut and
Fill

Exceptional
Cases
R&P
Longwall

20

Standard Cases
0

Figure 1: Mining methods for tabular deposits depending on the inclination [1]

Within the scope of this project the challenge is to develop mining concepts for semi-steep deposits
with an inclination ranging from 20 up to 60. Therefore, in a first step, the main aim is to reduce the
inclination in roadways down to a value which is acceptable for extraction machines as well as for
mobile equipment and belt conveyors from a technical and economic point of view. Accordingly, the
geometric relations have to be presented first.
Figure 2 illustrates the angular relationships between an inclined roadway and an inclined deposit. The
angle represents the real inclination of the roadway. The dip angle represents the real inclination of
the deposit and angle (dip-adjustment-angle - DAA) is the angle between the strike and the roadway.
For a given deposit the DAA depends on the inclination of the deposit and the maximum inclination of
the roadway. Hence, the DAA is a major parameter for the panel layout. To depict an inclined
roadway in an inclined deposit into a mine map the angle relationship = arcsin (sin () / sin ()) is
applied. With the help of the DAA it is possible to develop panel layouts under various dip conditions.

= Dip angle (roadways in deposit) [/degree]

= Inclination of the deposit [/degree]
= Dip adjustment angle for roadways in deposit level [/degree]

sin () = c/x
sin () = h/c
sin () = h/x

sin () = h / sin () / h / sin () = arcsin (sin () / sin ())

Figure 2: Principal drawing for used mine maps [1]

Figure 3 shows a theoretical example of a panel layout in a semi-steep deposit (average inclination
25). The general mining direction is downwards. Access to the panel is provided by an entry drift,
which is developed at a DAA of 33.5 within the deposit and which leads to an inclination of the
roadway of 13.5. At the end of this entry drift the actual panel layout starts. Within the panel the
inclination of the mains is reduced to 8.5 by means of a DAA of 20.5. For layout purposes and in
order to stay within the panel, the direction of the mains changes every 500 m. Fully-loaded standard
mobile haulage equipment can operate economically up to this dip of the mains. The main extraction
takes place in horizontal rooms/stopes with a length of approx. 500 m, starting from the mains. The
development of the mains and the mineral extraction in the horizontal rooms/stopes are carried out
simultaneously. The mineral is extracted by means of a continuous miner and is then transported to a
feeder breaker by means of dump trucks.

Entry Drift
(3-Drift-System)

33.5
2,000 m
500 m

500 m

Feeder Breaker and

Conveyor Belt
20.5
Main Development Drift
(3-Drift-System)

Direction of Mining

1,000 m

Rooms/
Stopes

20.5

Inclination of the Deposit: 25

Inclination Development Drifts (in deposit): 8.5 = 15% = 20.5
Inclination Entry Drift: 13.5 = = 33.5

Figure 3: Mining concept for a semi-steep deposit (principal drawing) [1]

It is also possible to modify this layout depending on the deposit conditions and concession boundaries
for best-possible deposit utilization. Figure 4 shows different variations of possible panel layouts with
either horizontal/diagonal rooms/stopes and dipping main drifts or diagonal/horizontal rooms/stopes
and horizontal main drifts. The rooms/stopes are being developed between development drifts
(2-drift-systems), which have the same inclination and the same development direction.
Horizontal Rooms/Stopes

Horizontal Rooms/Stopes

Main Development Drift

(3- Drift- System)
Main Development Drift
(3- Drift- System)

400m
Development Drift
(2- Drift- System)

Rooms/Stopes

Development Drift
(2- Drift- System)

Rooms/Stopes

Diagonal Rooms/Stopes

Diagonal Rooms/Stopes

Main Development Drift

(3- Drift- System)

Development Drift
(2- Drift- System)

Development Drift
(2- Drift- System)

Main Development Drift

(3- Drift- System)
Rooms/Stopes

400
m
Rooms/Stopes

Figure 4: Variations for panel layouts (principal drawings) [1]

An alternative option to mineral transport within the potash seam would be the development of a
separate horizontal haulage level underneath the deposit, thus necessitating the integration of ore
passes between the seam and the haulage level. However, the roadways required would most probably
have to be developed in surrounding rock, which usually would be uneconomical.
In a next step and in order to facilitate the general comprehension for different mine design
alternatives some of the most suitable concepts are visualized (3D models). Figure 5 shows a mining
concept in which the rooms/stopes are being developed in horizontal direction. Consequently, the
parallel main development drifts have to be developed within the deposit staggered at different
elevations. The arrangement, development direction and number of cross-cuts between the parallel
main development drifts may vary due to rock mechanical considerations.

Plan View

Figure 5: Mining concept for a semi-steep deposits (3D view) [1]

Example: Semi-Steep Panel of a Pilot Potash Mine

In a further step the aforementioned considerations are applied to planning of a specific future semisteep mining area at a given mining operation. The future panel is located at the south-east border of
Rapid
Minefield,
Development
the
mine
which is delimited by two geological faults (see Figure 6).

Saltdome

Panel

Figure 6: Pilot potash mine (mine map) [2]

Geological information is used to create a 3D-model in Surpac of the future mining area. This
model is linked up with the existing mine models of the operation (see Figure 7).

Deposit

Panel

Figure 7: 3D model of the panel in Surpac [1]

Based on this model preliminary mining concepts are compared. After identifying the optimum
location for the entry drift and after a detailed planning of the roadheading sequence for these drifts, a
mining concept, optimized according to the framework conditions as mentioned below, is developed.
The mining concept includes the roadheading sequence for the panel mains and the extraction of the
rooms/pillars as well as a comparison to the drilling and blasting method. Furthermore, cost models
are part of the investigation. The major framework conditions are as follows:

Inclination: 20 to 33
Average thickness: 5 m
Rock Strength: 25 to 30 MPa
Arch shaped main drifts, reinforced with rock bolts (0.25 bolts/m)
Maximum depth: 1,200 m
Required minimum thickness of the overlying rock salt layer is 35 m
Max. 20 % of the pillars height may consist of carnallitic rock
No entry area in the west of the panel (hazard of spontaneous gas release)
Max. inclination of 13.5 (24 %) for main development drifts
Max. inclination of 15.5 (28 %) for drifts/stopes in working areas
Restrictions due to mining climate regulations (KlimaBergV)
Isolated operation requires a large volume of fresh air
Extraction rate: 5,000 to 6,000 t/d

Entry Drift System. Accessing the panel from the north is not possible because of gas release-related
hazards in conjunction with an insufficient thickness of the protective rock salt layer in the roof.
Hence, the operation has to start in the southern part of the mine. Access to the panel is achieved via a
3-drift-system within the potash seam with a vertical offset of the drifts ranging from 10 to 15 m. It is
not deemed feasible to develop three parallel drifts at the same level due to rock mechanical
considerations as the footwall layers consists of carnallitic rock and the roof of anhydrite rock (see
Figure 8).
Drilling +
Blasting

1m

Continuous Miner
+ Roadheader

6 m

5m

37,4 m

2,9 m

An

hyd

rit-F
orm

atio

46,3 m

8m

6 m
37,4 m

rna

llitit
-Fo
rm

2,9 m

atio

n
5m

Ca

20 m

6 m
37,4 m

2,9 m

20 m

25,0

46 %

Figure 8: Entry drift (3-drift-system / side view) [1]

The entry drift is developed in north-easterly direction with a total length of 720 m and a dip angle of
13.5. The cross-section of a single drift amounts to 46.3 m. The entry point into the panel lies at a
depth of -850 m. A plan view of the entry drift is shown in Figure 9.

Figure 9: Entry drift (plan view) [1]

Mining Concept. Several concepts and alternatives for mining the panel are investigated. After
considering the advantages and disadvantages and a resulting comparison of possible mining methods
regarding the parameters flexibility, productivity, mining costs (investment and operating costs) and
the possibility of selective mining, the room and pillar mining method is chosen and adapted. Figure
10 shows a conceptual, qualitative comparison where red boxes indicate a nonfulfillment of a
parameter, yellow color indicates difficulties to match the required parameter and green color means
full achievement of the parameter.
Comparison of Mining Methods
Mining Method

Flexibility

Productivity

Inclination 20-33 Investment Costs

Operating Costs

Selective Mining

Room and Pillar

Longwall Mining
Cut and Fill Mining

Figure 10: Comparison of possible mining methods for the panel [1]

Figure 11 shows two variations for the panel layout as described before. The horizontal direction of
the main drifts (3-drift-system / green) can be considered as the main advantage of Alternative 1.
Disadvantageous effects are the more acute angles between the main development drift and an
additional 2-drift-system (also in terms of rock mechanics) and between the rooms/stopes and the
cross-cuts. The mining panel extends in eastern direction. Due to this, mine ventilation and
infrastructure would also become more complicated. In the case of diagonal rooms/stopes less acute
angles arise in the main development drifts and cross-cuts. As a result Alternative 2 is chosen, also
because of better deposit utilization and better access to future panels in the North-East.
Alternative 2

Alternative 1
Depth: -1.300 m

Einfallen
BF13
No Entry
Area

Depth: -1.300 m

Contour Lines

EinfallenLines
BF13
Contour

No Entry Area

Concession
Boundary

Entry Drift
(3-Drift-System)

Concession
Boundary

Entry Drift
(3-Drift-System)

Figure 11: Panel layouts (principal drawings) [1]

Equipment Selection. Since the main development drifts (long lasting drifts) have to be arch shaped a
continuous miner (CM) in combination with a roadheader (RH) is selected as possible mining
equipment. Due to the cutting geometry of the CM which leads to rectangular drift profiles, an
additional RH is required to cut the arch. Therefore, a combination of both machines has to be taken
into consideration. For developing the rooms/stopes a continuous miner is used solely since an arch
shaped cross-section is not required. The selected machines are shown in Figure 12.
RH (11.3 m)

5m

1m

CM (35 m)

7m

8m

Drift Cross-Section
MB 770 (~35 m2)
Technical Data
Cutting Height:
Cutting Width:
Installed Cutting Power:
Cuttable Rock Strenght:
Negotiable Gradients:
Incline/Decline:
Max. Cross Gradient:

Recutting with MT 520 (~11.3 m2)

4.9 5.5 m
6.6 7.2 m
400 kW
up to 35 MPa
+- 20 gon (18)
+- 8 gon (7)

Technical Data
Cutting Height max.:
Cutting Width max.:
Installed Cutting Power:
Cuttable Rock Strenght:
Negotiable Gradients:
Incline/Decline:
Max. Cross Gradient:

7.1 m
10.3 m
315 kW
up to 35 MPa
+- 20 gon (18)
+- 8 gon (7)

Figure 12: Equipment selection [3]

Creating a Performance Matrix. The manufacturers usually give an overview of the theoretic cutting
performance of their machines. In order to create a realistic value of the net cutting performance a
performance matrix is developed. In this respect the terms gross cutting performance and net
cutting performance, availability as well as utilization are defined.
The gross cutting performance, as specified by the manufacturer, is a performance figure, which can
be achieved under optimal conditions in a test setup. It has little in common with the performance
achieved during operation. With the aim of achieving a net cutting performance value input parameters
and basic factors (as shown below) are an integral part of the matrix. Neither the cutting cycle nor the
overall roadheading cycle is taken into account in the gross cutting performance, e.g. the auxiliary
process time due to movement and alignment of the machine, the raising and lowering of the boom,
etc.. The compressive strength of the mineral, floor condition and mining depth have great influence
on the net cutting performance. Since mining machines under given conditions have to work with an
inclination, the inclination is considered as a factor of influence on the cutting performance.
Considering all these factors of influence, the net cutting performance of the machines is considerably
lower than what is specified by the manufacturer. Another important factor to be considered is
machine idle time associated with change time of haulage equipment. Work organization (particularly
in terms of haulage) and the movement of the machine are other input parameters. The input
parameters are entered into the performance matrix with values ranging from 0 to 1. To determine the
inclination and rock strength parameter, empirical values are used for evaluation. Experience in rock
salt mining has shown that at rock strength in the range of 20 MPa the cutting performance decreases
by 3 % per MPa (case example). Hence, the loss of cutting performance at a rock strength of 30 MPa
is 30 %, which results in a factor of 0.7 (70 %). It is assumed that the cutting performance decreases
per percent of inclination. All other parameters are expressed by their percentage (e.g. 1 = 100 %;
0.93 = 93 %; etc.). These factors are multiplied by the gross cutting performance to determine the
approximate cutting performance during operation.

The following figure shows a Sandvik Continuous Miner type MB 770. The gross cutting performance
is given with approx. 388 t/h by the manufacturer. Applying parameters and basic factors into the
performance matrix results in an approximate cutting performance of 153 t/h during operation at an
inclination of 15 % (8.5) and a rock strength of 25 MPa.
Performance Matrix for a Continuous Miner MB 770
Gross Cutting Performance

388,55

[t/h]

Cutting Cycle

0,83

(0,1]

Availability

0,90

(0,1]

Utilization

0,90

(0,1]

Inclination

15,00

[%]

Haulage System

0,85

(0,1]

Working Organisation

0,95

(0,1]

Input Parameters

Net Cutting Performance 1 :

322,50

[t/h]

Net Cutting Performance 2 :

290,25

[t/h]

Net Cutting Performance 3 :

261,22

[t/h]

Net Cutting Performance 4 :

224,65

[t/h]

Net Cutting Performance 5 :

190,95

[t/h]

Net Cutting Performance 6 :

181,41

[t/h]

Basic Factors
Rock Strength

25,00

Floor Condition

1,00

Depth

1,00

[MPa]

Net Cutting Performance:

153,29 [t/h]

Figure 13: Performance matrix for a continuous miner MB 770 (case example) [1]

Result. Based on the calculated performance data and the specification of the roadheading sequence,
the development of the entry drift of the panel is going to take 0.6 years using cutting technology
(continuous miner and roadheader) and 0.8 years using drilling and blasting technology. Cost models
indicate that development of the main drifts using drilling and blasting technology is about 45 %
cheaper than cutting technology. For the extraction in the rooms/stopes cutting technology is 40 %
cheaper as compared to the conventional method. Hence, it is recommended to use drilling and
blasting technology for the development of the mains and cutting technology for extraction in the
rooms/stopes.

Outlook
Cutting technology is widely applied in international potash mining. Both standardized and specially
developed machines are in use. In conjunction with a suitable mining method these machines are able
to achieve high production rates and will therefore continue to remain an integral part of potash
mining. Further improvements regarding cutting machines are expected in the near future, e.g. by the
use of high voltage, modified haulage systems as well as automation possibilities. Also a combination
of the cutting technology and the conventional drill and blast method is possible.

References
[1]

Martens, P. N.; Rattmann, L.; Chon, J. (2011). Potentials of Cutting Technology in German
Potash Mining Feasibility Studies. Unpublished manuscripts, Final Reports, Institute of
Mining Engineering I (BBK I), RWTH Aachen University, Germany.

[2]

K+S AG (2011). Unpublished presentation.

[3]

Sandvik Mining and Construction GmbH (2011). Retrieved from http://www.miningand

construction.sandvik.com/
10