Electromech Engineers Shaft / Tunnel Mucking System

 
Electromech Engineers has developed a unique and cost effective bulk material handling system for extraction and disposal of overburden generated during construction of tunnels. This system can very efficiently remove overburden generated  during construction of deep shafts which access tunnels as well as the overburden generated during the tunneling operation itself. Several such systems designed and manufactured by Electromech Engineers are operational at various construction sites.

The figure below shows a typical Shaft / Tunnel Mucking System.

 

Schematic Figure of Shaft / Tunnel Mucking System developed by Electromech Engineers.
Usually tunnels run to many kilometers and are located anywhere between 50 to 200 meters below surface. Such tunnels are typically constructed by accessing the tunneling zone at many locations simultaneously through vertical shafts. The topography of the surface above the tunnel normally is never at the same elevation for the entire length of the tunnel. As a result the shaft depths vary from point to point.

 
Briefly the system consists of -
  1. A high speed, high lift winch located at ground level.
  2. A support structure complete with columns and gantry girder and rails.
  3. A motorized trolley atop the gantry girder.
  4. A lower block from which a self dumping bucket is suspended.
  5. A heavy duty, side self dumping rectangular or square cross section bucket.
  6. A self dumping station where the laden bucket is emptied of the overburden into dumpers for onward transportation to dump site.
  7. All the associated electricals.
 

The entire shaft / tunnel mucking system operates as described below -

  1. After every blast / drilling operation carried out to extend the shaft / tunnel, the overburden generated needs to be removed immediately in order to proceed further.
  2. Once the affected area is approachable, the empty bucket is lowered to the appropriate elevation.
  3. The bucket is then filled with the generated overburden, either by payloaders or manually depending on the space available below for movement of men and machines.
  4. The laden bucket is then automatically hoisted to a pre-determined height above the surface using the winch and the hoisting arrangement.
  5. The laden bucket is then automatically traversed longitudinally to a pre-determined distance using the trolley.
  6. The laden bucket is then lowered at the dumping station.
  7. The door locks are now released and the bucket further lowered using the winch, emptying the overburden into dump trucks standing below.
  8. After the bucket is empty, the bucket is hoisted, the doors locked and is then automatically traversed to the centerline of the shaft and the whole cycle is repeated once more.
 

The whole system is custom built. The technical parameters taken into consideration are as follow -

  1. Shaft diameter
  2. Depth of shaft
  3. Expected bulk density of overburden
  4. Quantum of overburden to be removed per cycle, dependent upon the dump truck capacity. This would also determine the bucket size and consequently the winch capacity, trolley capacity and structural design of the support structure.
  5. Total overburden to be removed and total time available for such removal.
  6. Based on points 4 and 5 the time cycle desired can be broken into -
    1. Lowering time
    2. Loading time
    3. Hoisting time
    4. Traversing time
    5. Location of dump station and dumping time
    6. Bucket straightening and door locking time
    7. Traversing time back to the center line of the shaft to recommence the cycle.
  7. Based on 6.i and 6.iii the hoisting speed is optimized. Based on 6.iv and 6.vii the trolley traverse speed is optimized.
  8. Based on 4 and 7, motors, gearboxes, brakes and other mechanical and electrical items are selected.

Electromech Engineers has designed and installed systems to handle loads upto 15,000 kg per cycle, elevating the laden bucket to lifts upto 135 m.

Electromech Engineers will work with the client to evolve an efficient and cost effective system to suit every need.  

 

Please contact us with your requirements and we will be happy to give you a quote for our products.
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