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Hydraulic Shovel: Working Principle, Capacity & Production Calculation in Mining | Indian Minerology

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Hydraulic Shovel: Working Principle, Capacity & Production Calculation in Mining

Hydraulic Shovel: Working Principle, Capacity & Production Calculation in Mining | Indian Minerology

Hydraulic shovel is one of the most important surface mining machinery used in opencast coal, limestone, and metal mines. It is mainly used for loading blasted material into dumpers with high productivity and accuracy.

What is a Hydraulic Shovel?

A hydraulic shovel is a heavy earth moving machine (HEMM) that uses hydraulic power to excavate, lift, and load material. It works on the principle of hydraulic pressure generated by pumps and cylinders.

Main Parts of Hydraulic Shovel

  • Boom
  • Arm (Dipper)
  • Bucket
  • Hydraulic Cylinders
  • Engine
  • Hydraulic Pump
  • Upper Structure
  • Track or Crawler

Working Principle of Hydraulic Shovel

The hydraulic shovel works on Pascal’s Law. Hydraulic oil is pressurized by a pump and supplied to cylinders. The movement of boom, arm, and bucket is controlled using hydraulic valves.

Steps of working:

  1. Bucket penetrates blasted material
  2. Material is filled in bucket
  3. Boom lifts the bucket
  4. Upper structure swings
  5. Material is dumped into dumper

Types of Hydraulic Shovel

  • Front Shovel (Face Shovel)
  • Backhoe (Back Actor)

Hydraulic Shovel Capacity

Hydraulic shovel capacity depends on bucket size and material density.

Bucket Capacity: 2 m³ to 45 m³
Common Models: CAT, Komatsu, Liebherr, Hitachi

Hydraulic Shovel Production Calculation

Formula:

Hourly Production (m³/hr) = Bucket Capacity × Fill Factor × Cycles per Hour

Where:

  • Bucket Capacity = m³
  • Fill Factor = 0.8 to 1.1
  • Cycle Time = seconds

Cycles per Hour:

Cycles per Hour = 3600 / Cycle Time

Example Calculation

Bucket Capacity = 10 m³
Fill Factor = 0.9
Cycle Time = 30 seconds

Cycles per Hour = 3600 / 30 = 120
Hourly Production = 10 × 0.9 × 120 = 1080 m³/hr

Advantages of Hydraulic Shovel

  • High productivity
  • Better digging force
  • Accurate loading
  • Low cycle time
  • Suitable for hard rock mining

Limitations

  • High initial cost
  • Requires skilled operator
  • High maintenance cost

Safety Precautions

  • Regular hydraulic hose inspection
  • Proper bench height
  • Safe dumper positioning
  • Operator training as per DGMS rules

Uses of Hydraulic Shovel in Mining

  • Coal mining
  • Iron ore mining
  • Limestone mining
  • Copper and metal mines

Frequently Asked Questions (FAQs)

Q1. Hydraulic shovel and backhoe difference?

Hydraulic shovel works above ground level, while backhoe works below ground level.

Q2. Which shovel is best for opencast mining?

Front shovel is best for large opencast mines.

Conclusion

Hydraulic shovel is the backbone of surface mining operations. Proper selection, operation, and maintenance can significantly improve mine productivity and reduce cost.

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