Green digital mining methods using automated mobile platform systems

Abstract

This invention relates to the field of mining, and particularly to mineral deposits at medium depths of 20 to 100 meters. The invention is a novel mining method based on excavating narrower mining trenches, enabling direct contact with the ore layer via a novel mobile mechanism called a "mining platform." This mobile mining platform moves along these trenches, receiving ore recovered from each ore layer and lifting it to the surface. This recovery is performed by a longwall system. This novel mining method, through the use of a novel mobile platform and an improved longwall mining system, allows for direct mining of ore without the removal of waste material, even when ore is present in multiple ore layers. With custom-sized mining panels that require no post-mining repairs and without the use of explosives, this novel mining method overcomes all the limitations and environmental drawbacks associated with other conventional methods. Digital technology is integrated into all levels of the method. A digital system (APC / AI) installed in the control room receives and processes data from other control systems and makes relevant decisions, while ensuring optimal operational performance, good control over ore quality, and improved equipment reliability. Data is transmitted from the field by sensors, scanners, and ore analyzers integrated at various equipment levels using the latest technologies. The entire production system is electrically powered and equipped with a control system based on online sensors and analyzers. By using clean energy (wind, solar, etc.) to power the equipment, this mining method meets the standards of green mines. With its improved performance, significantly reduced operating costs, full integration of new digital and artificial intelligence technologies, green energy supply, and compliance with environmental requirements, this new method is considered to represent the future of green and intelligent mining at medium depths.

Description

Technical Field

[0001] This invention relates to the field of mining, and particularly to medium-depth mineral deposits, including those constrained by thin seams.

[0002] More specifically, this invention is a novel mining method that overcomes the limitations and shortcomings encountered in traditional mining methods. Based on excavating narrower trenches, this novel mining method allows for the direct extraction of ore without the need to remove or drain waste. This makes it possible to achieve optimal operational performance indicators (KPIs) for mining operations.

[0003] This invention is particularly applicable to the mining field, especially to medium-depth (20 to 100 meters) deposits, even if these deposits occur in multiple ore layers (layers).

[0004] By achieving digitalization at all levels (Mining 5.0) and addressing all aspects of sustainable development, thereby proposing a green mine (zero negative environmental impact), this mining invention will make mining operators highly competitive in the following key metrics:

[0005] ●Production performance

[0006] ●Efficiency

[0007] ● Operating costs (OPEX)

[0008] ●Operational flexibility

[0009] ●Energy consumption

[0010] ● Mine repair after mining. Background Technology

[0011] Mining is the process of extracting geological and valuable materials from the earth. Materials obtained through mining include metals, gemstones, coal, phosphates, limestone, clay, gravel, and many other materials that cannot be produced through agricultural or industrial processes. These materials can only be obtained through properly regulated and economically profitable mining.

[0012] There are three main mining methods for obtaining various materials.

[0013] The choice of mining method is based on its economic profitability and production capacity. The three main methods are as follows:

[0014] Open-pit mining (open pit):

[0015] This is a mining method that involves removing the soil and overlying rock above the deposit to access the ore (the material being extracted). This method is used for deposits (coal, phosphate, limestone, etc.) where the ore layer is close to the surface.

[0016] Underground mining:

[0017] This is a mining method that extracts ore underground. The entrance from the surface to the underground mine can be formed through horizontal or vertical tunnels (also known as runways, shafts, or ramps). Underground mining is used when the ore body is too deep to be exploitably extracted from the surface (coal, manganese, gold, etc.).

[0018] Slope mining (High Wall System):

[0019] This is an evolution of open-pit mining methods. It combines underground and open-pit mining techniques. It is primarily used in coal mines. It involves excavating a wide trench next to the panel to be mined, and then laterally mining the ore layer in the panel through a small cross-section, while retaining ore pillars to ensure ground stability and support, thereby preventing roof collapse.

[0020] Other specific mining methods also exist, such as sedimentary or placer mining methods based on water / sand and ore mixtures (gold, diamonds, copper, etc.), and the so-called in-situ recovery method, which has been the primary method for uranium extraction for many years, involving the injection of circulating fluids with added reagents (whether alkaline, moderately acidic, or acidic).

[0021] Every mining method has its advantages and limitations. The choice of a given mining method essentially depends on its techno-economic performance.

[0022] The main factor in deciding which method to choose over another is the economic aspect, particularly the operating costs of mining (“OPEX”).

[0023] Purpose of the invention

[0024] The main objectives of this invention are summarized as follows:

[0025] ● Highly efficient mining with significantly reduced operating costs

[0026] ● Selective and flexible mining with improved grade management

[0027] ● Green mining with no negative impact on the environment

[0028] ● Efficient, automated, and digitalized mining

[0029] ● Mining with significantly reduced energy consumption

[0030] This invention proposes a novel mining method based on a mechanized longwall mining system and a mobile platform comprising a vertical transport device consisting of a bucket elevator and a belt conveyor. The platform system may also include a disc screen capable of separating ore particles, recovering only high-quality ore while rejecting waste rock. The production line of this invention can achieve an hourly capacity of 6000 cubic meters.

[0031] This invention further proposes a novel, compact mining method whose mine layout meets the geological constraints and data of the ore deposit, and features mining panels of uniform, customized dimensions. Mining production is selective; unlike open-pit mining methods, the extraction of various grades (ore layers) is automatic and instantaneous, requiring no planning or equipment relocation.

[0032] This invention provides a novel mining method consisting of systems and equipment entirely powered by electricity. These production systems and equipment produce no carbon dioxide (CO2), generate no noise, and do not cause terrain degradation after mining. With its clean energy supply source, this new method meets green standards.

[0033] This invention also aims to propose a digital, automated mining method with remote control, while utilizing new digital technologies (5.0) and artificial intelligence. This mining method operates with a significantly reduced workforce, ensuring supervision and monitoring only for correct operations.

[0034] This invention also aims to propose a mining method with significantly reduced energy consumption. Electricity consumption depends on the hardness of the ore being extracted, and is estimated to be approximately 1 kWh / m³. 3 Up to 2kWh / m 3 . Summary of the Invention

[0035] This invention is a novel mining method based on optimizing the mine layout of the mining panel and excavating a central trench with reduced width. Within these trenches located at the center of the panel, a mobile platform is integrated, which approaches each ore layer and moves horizontally along the central trench.

[0036] Ore extraction is performed by two longwall systems installed on the right and left sides of the mobile platform. These two systems work together to mechanically mine the ore across the entire face width and transport it directly to the mobile platform, which then lifts it to the surface. This transport is performed vertically by a bucket elevator integrated into the mobile platform.

[0037] The main concept of this mining invention is to directly mine the ore layer without removing or emptying the overlying rock layer or interburden waste.

[0038] This invention provides continuous, flexible, and selective mining with dual extraction on two mining faces separated by a mining trench. This dual continuous mining method is achieved by the following main extraction and transport systems:

[0039] ● Longwall mining system, each system consists of three pieces of equipment: twin-drum shear, armored face conveyor (AFC) and hydraulic roof support system.

[0040] ● A mobile platform with a metal structure, installed at the mining trench level, includes functional equipment such as bucket elevators, belt conveyors, and auxiliary equipment, and may also include screening machines depending on the type of ore being mined. The platform also houses power supply equipment, control and command systems, buildings, and meeting rooms on its surface.

[0041] This new mining method operates entirely on electricity. The production equipment produces no carbon dioxide (CO2), generates no noise, and does not degrade the terrain after mining. With its clean energy supply, this new method meets green standards.

[0042] Digital technologies are integrated into all levels of this approach. A digital system (APC / AI) installed in the control room receives and processes all data from other control systems and makes relevant decisions to ensure optimal equipment performance and output, as well as good control over ore quality and improved equipment reliability. Data is transmitted from the field by sensors and analyzers. All production and handling systems are equipped with control systems based on online sensors and analyzers.

[0043] Therefore, all equipment control and command are performed remotely in automated mode. The operations team has been significantly reduced and is stationed in the control room and offices located above the mobile platform. Operators only descend underground for inspections or emergency interventions. The descent and ascent of personnel and materials are performed by cranes integrated into the mobile platform. Attached Figure Description

[0044] The invention and its various advantages and benefits will be readily understood with the aid of the following accompanying drawings and details:

[0045] Figure 1 Explanation: Implementation of the method

[0046] Figure 1 The various stages of implementing this method are illustrated, from its research and setup to the mining phase. Therefore, the implementation of this novel mining method involves three stages, summarized as follows:

[0047] Phase 1: Mine Layout and Panel Preparation

[0048] This is the research and ground preparation phase, which includes mine layout, defining the overall mining plan, defining panel dimensions, working face width, and trench width. It also includes marking and excavating trenches. This phase is carried out through the following steps:

[0049] ● Define the dimensions of the mine panel and working face (3D, 3G).

[0050] ● Excavation trenches (5), engineering trenches (7) and edge trenches (6).

[0051] Phase 2: Engineering Phase and Installation of Mining Equipment

[0052] This is the engineering phase. It includes various items for installing the platform (1) equipment and the longwall mining equipment (2). The longwall equipment (2) is installed at the engineering trench (7) level, facing the ore layer to be mined. The platform components are assembled at the mining trench (5) level, particularly at the starting point facing the longwall equipment (2). The steps of this phase are as follows:

[0053] ● Assembly and installation of platform equipment components and sub-assemblies

[0054] ● Assembly and installation of longwall equipment.

[0055] Phase 3: Mining Start

[0056] This phase includes starting up the longwall mining equipment and mobile platform, and commencing mining. It is carried out in two steps:

[0057] ● No-load and load testing of platforms and longwall equipment.

[0058] ● Mining was initiated in the first panel (which has two longwall faces), and then operations were transferred to other panels after inspection and equipment relocation.

[0059] Figure 2 Explanation: The principle of the method

[0060] Figure 2 An overall description of the method during the mining phase is given. It shows the pre-mining panel and working face (3D, 3G), the post-caving panel (4D, 4G), the mined and caving panel (8), and the panel reserved for future mining (9).

[0061] The figure also shows the mining trench (5) that divides the panel along the longitudinal direction, the engineering trench (7) located in front of and behind the panel, and the so-called separation trench (6) located at the two edges of the panel.

[0062] Figure 2The diagram also shows a mobile platform system (1) introduced at the level of the mining trench (5) and two longwall mining systems (2). It further explains the direction of mine advance, as well as the right-side mining face (3D) and left-side mining face (3G) of the panel.

[0063] Figure 3 Explanation: Device and System Identification

[0064] Figure 3 Details of the mobile platform and longwall unit system and equipment are shown, as well as a cross-section through the geology of the deposit, showing the various ore layers to be extracted.

[0065] The figure shows that the mobile platform (1) consists of a metal structure, a translation system (1H) for platform propulsion, a bucket elevator (1A), a disc screen (1B), screening ore conveyors (1C) and (1I) that feed directly into the adjacent mobile conveyor (1J), waste conveyors (1D) and (1E) that feed into the adjacent mobile waste conveyor (1K), guide wheels (1F), and lateral skids (1G) installed on both sides of the platform (1) to ensure platform stability.

[0066] Figure 3 It is further shown that the longwall mining system (2) consists of a double-drum shear (2A) for continuous mining, a traction mechanism (2D), an armored face conveyor (2B), and a hydraulic roof support (2C) for roof support and propulsion of the longwall mechanism.

[0067] The figure also shows a geological cross-section of the ore, showing details of the individual ore layers (11), the overlying rock waste (10), and the interbedded rock layers (12) that separate the individual ore layers.

[0068] Figure 4 Description: Details of the equipment and system

[0069] Figure 4 Details of the various compartments of the platform located on the ground surface are given, and the vertical arrangement of the long wall unit (2) relative to the platform (1) is described, as well as details of the auxiliary equipment integrated in the mobile platform (1).

[0070] The figure also shows Figure 3 The diagram shows the conveyor transport system, along with details of the control room (1N) housing the main automation and digital systems. These command and digital systems consist of a highly advanced centralized digital system (APC), fed by the following other systems:

[0071] ●The overall process command and control system (DCS) for this method.

[0072] ● Geological and mineral reserves monitoring system (SMS)

[0073] ● Status-based maintenance monitoring system (CMS)

[0074] ●Power Management System (PMS)

[0075] The control room also includes automated and digital cabinets, ergonomic screen display systems capable of displaying operational data and performance indicators (KPIs), meeting rooms, and offices.

[0076] The figure also shows that the mobile platform (1) includes an electrical room, which includes a substation powered by a cable reel system and consisting of a transformer, a speed drive and a switchboard.

[0077] It further shows that the mobile platform (1) accommodates auxiliary equipment, utilities, cranes (1M) and stabilizing skids (1K) for trench walls and platform.

[0078] The figure also shows that the longwall system (2) is arranged vertically on top of each other and consists of a shear (2A), a hydraulic support (2C) and an armored face conveyor (2B), and these armored face conveyors are aligned with the bucket elevators to ensure that the mined ore is supplied to them.

[0079] Figure 5 Explanation: Digital System

[0080] Figure 5 A detailed explanation of the overall architecture of the digitalization and control-command system for the entire mining equipment of this novel mining method is given.

[0081] It provides a comprehensive digital chart from lower (on-site) levels to higher levels, covering data processing, command and control, display of performance indicators, and self-improvement of mining production system parameters. The chart shows the integration of digital technologies at each level of this new mining method:

[0082] On-site level (lower level): Equipment

[0083] This level of digitization is hardware-based. It is installed on functional and auxiliary equipment. It consists of sensors, junction boxes (JBs), and remote input / output modules (RIOs).

[0084] sensor:

[0085] All devices are equipped with powerful sensors and analyzers that measure physical parameters and report relevant information. These sensors can be categorized according to the type of data they report:

[0086] ● Ore grade and quantity sensors: mounted on the platform wall and longwall shears (X-ray, gamma ray, etc.) and volume scanners.

[0087] ●Equipment operation sensors: Installed on all equipment, including position controllers, rotation controllers, encoders, GPS, speed sensors, liquid level sensors, etc.

[0088] ● Maintenance and equipment health sensors: Installed on all equipment, including temperature probes and controllers, vibration analyzers, oil analyzers, etc.

[0089] ● Energy sensors: In addition to electricity meters, supplementary sensors are installed on all power-consuming equipment (motors, lighting fixtures, etc.).

[0090] ●Safety sensors: Installed on all equipment, including smoke detectors, gas detectors, etc.

[0091] ● Cameras: Installed at all key points of the equipment, such as the mining point and the ore discharge point.

[0092] Junction Box (JB):

[0093] As shown in the figure, the sensor is connected to a junction box (JB) that provides protection, simplifies wiring, and ensures cable identification.

[0094] Remote Input / Output Module (RIO):

[0095] These are analog and digital remote input / output (RIO) modules connected to JB. They receive input signals and transmit outputs to various device actuators in the form of commands.

[0096] Server hierarchy: Server room

[0097] This digitization occurs at the server room level, which hosts the process database and control system (DCS, SMS, CMS, PCS) and features control redundancy, with one main controller and one auxiliary controller (Controller 1, Controller 2). This control level manages and oversees all operations of the entire system using this novel approach.

[0098] Higher level: Control room

[0099] This level of digitization is software-based. It consists of two levels:

[0100] The higher level includes highly advanced digital systems, namely APC (Advanced Process Control), and artificial intelligence, namely AI (Artificial Intelligence). This level of digitization relies on databases and machine learning algorithms designed to optimize performance and provide improved, dynamic supervision of the process using this new approach.

[0101] The higher level of overall operation control of the method and equipment includes the following four control systems:

[0102] ●SMS: Inventory Management System, which connects to the server room. It enables the location, management, and tracking of ore layer data in terms of grade and quantity.

[0103] ●DCS: Distributed Control System, which connects to the server room. It provides control, command, and supervision of various systems and equipment used in mining operations.

[0104] ●CMS: Status Monitoring System, which is also connected to the server room. It provides monitoring of the maintenance and health status of the equipment used in the method.

[0105] ●PCS: Power Control System, which is also connected to the server room and is capable of monitoring the energy consumption of various equipment in the mining method.

[0106] Data processed by the command system (SMS, DCS, CMS, PCS) is transmitted to the advanced system (APC / AI), which provides dynamic processing of various mining parameters for the novel method, aiming to:

[0107] ●Optimize equipment output

[0108] ● Achieve optimal performance metrics (KPIs)

[0109] ● Improve final ore quality by reducing variability and increasing flexibility.

[0110] ● Optimize equipment energy consumption Detailed Implementation

[0111] The core of the new method is to mine the ore layer directly and continuously through trenches and with the help of a mobile extraction and transport system, directing the process from the surface without having to drain the overlying rock and interbedded rock waste.

[0112] The new method involves excavating trenches to accommodate a mobile platform and access to various ore layers. Mining in this new method is carried out using two longwall systems on two parallel working faces, and its reliability and performance have been proven in underground mines.

[0113] As shown in the figure, this invention is based on a mobile platform equipped with vertical and horizontal transport systems, a screening system, and auxiliary equipment. This platform moves along the mining trench, receiving ore extracted from both sides by the longwall unit and lifting it to the surface. The mobile platform system and the longwall system are enhanced in this new method with the latest digital and artificial intelligence technologies, making command and supervision automatic, remote, and autonomous.

[0114] In this new method, operators provide supervision only from the control room and descend to the underground levels only for inspection or in the event of an emergency intervention. The descent of operators and materials is performed by a crane integrated into the platform.

[0115] In practice, following geological studies, the application of the new method is carried out through geotechnical engineering studies and mine layout that allows for surface preparation. Once these surface and preparation studies are finalized, dimensional determination studies are conducted on the longwall mining equipment, and the dimensions of the mining platform and its vertical and horizontal transport equipment are determined.

[0116] Mine layout and surface preparation:

[0117] This section presents the overall scheme of the mining method described. In practice, before engineering begins to implement the method, a preliminary study is conducted to optimize the layout, dividing the mining area into several adjacent panels of the same size, separated by trench openings. The purpose of this study is to determine the panel sizes, the width of the working face, and the dimensions of the various trenches.

[0118] Panel and mining face:

[0119] In this new method, the panel size is determined based on the mean time between failures (MTBF) of the longwall machine and the length of the longwall face. Two engineering trenches are located at the front and rear ends of the panel, used for the assembly and disassembly of the longwall machine, for maintenance, or for relocation to adjacent panels.

[0120] The mean time between failures (T) is approximately 2 years, after which the sub-assemblies of the longwall unit are disassembled and overhauled under regular maintenance. The width of the longwall face (l / 2) corresponds to the length of the longwall machine. During the 2-year operation, the machine will travel an average distance (L), which is determined based on the ore properties and hardness. In this method, this length corresponds to the average length of the panel.

[0121] ●Mean Interval Between Failures (T) = Approximately 2 years

[0122] ●Disk length (L): The distance traveled during period T.

[0123] ● Working face width (l / 2) = Length of longwall machine.

[0124] The mining panel calculation in this new method is as follows:

[0125] ● Length (L) = The distance the machine travels during cycle T.

[0126] ●Panel width = (2 × working surface width (l)).

[0127] Typically, for large-scale production with a capacity exceeding 5000 cubic meters per hour, long-walled machines with a length of approximately 500 meters are used, and the panel size can be limited to the following dimensions:

[0128] ● Panel length L: 5000 meters

[0129] ● Panel width l: (2×500) meters.

[0130] For an average hourly production capacity of 1000 cubic meters, the panel size can be limited to the following dimensions:

[0131] ● Panel length L: 2000 meters

[0132] ● Panel width l: (2×100) meters.

[0133] trench

[0134] The size of the trench to be excavated depends on the size of the equipment to be accommodated, the size of the panel, the depth of the last ore layer, and the production capacity to be achieved.

[0135] Mining trench (5):

[0136] The dimensions of the mining trench (5) are determined based on the width of the moving platform (1), the length of the mining panel, and the depth of the final ore layer to be mined:

[0137] ●Trench width (5) = Width of mobile platform (1) + 0.6 meters

[0138] ●Trench length (5) = Length of mining panel (L)

[0139] ●Trench depth (5) = Depth of the last ore layer + 5 meters.

[0140] The width of the mobile platform is related to production capacity, production nature, whether screening is involved, and the number of production lines.

[0141] Typically, a width of 12 meters is sufficient for a platform that includes a single production line with screening, therefore a minimum width of 12.6 meters is required for the mining trench.

[0142] Engineering trench (7):

[0143] As described above, the trench provides the assembly, installation, and disassembly required for movement to other working faces. The dimensions of the engineering trench (7) are determined based on the dimensions of the sub-assemblies of the longwall machine (2), the panel width, and the depth of the last ore layer to be mined:

[0144] ●Trench width (7) = 12.6 meters.

[0145] ●Trench length (7) = Width of mining panel (l)

[0146] ●Trench depth (7) = Depth of the last ore layer.

[0147] At the end of panel mining, the trench (7) located at the end of the panel is able to remove the longwall equipment (2) and the platform (1).

[0148] After a panel is mined, the platform is divided into 12-meter sections on each side and withdrawn into the engineering trench for relocation and installation in the next mining trench.

[0149] Isolation or edge trench (6):

[0150] The trench is located at both edges of the panel and is used solely to separate the panel being mined from other panels to ensure controlled and immediate collapse. The length of the separation trench (6) corresponds to the length of the panel. The depth of the separation trench (6) corresponds to the depth of the last ore layer. However, the width must be kept to a minimum possible:

[0151] ●Trench length (6) = Width of mining panel (l)

[0152] ●Trench depth (6) = Depth of the last ore layer.

[0153] ●Trench width (6) = 0.2 meters to 0.3 meters

[0154] Based on current trenching technology, a width of 0.2 to 0.3 meters at medium depth is technically feasible.

[0155] Characteristics of the trench:

[0156] The marking and positioning of these trenches must be carried out by surveyors. The excavation of these trenches must be carried out using specialized machinery, such as trenchers, milling machines, rock cutters, or open-pit mining machines.

[0157] In these excavation projects, the use of explosives or materials that reduce the hardness and stability of the ground and trench walls should be avoided.

[0158] After excavation, the two sidewalls must have the following characteristics:

[0159] ● Surface flatness: ±200mm

[0160] ● Parallelism of the two surfaces: ±200mm

[0161] If the ground walls are unstable after trench excavation, stabilization techniques known in the art are required to stabilize them.

[0162] The bottom of the mining trench (5) must have acceptable strength and load-bearing capacity to support the weight of the mobile platform.

[0163] Production system and main equipment

[0164] This part of the invention is based on two basic systems: a longwall mining system and a mobile platform system.

[0165] Longwall systems:

[0166] The new method utilizes a longwall mining system. This system is widely used in underground mines, particularly coal mines. It is a mining system that has proven its performance, low cost, and reputation in coal mines in recent years.

[0167] This new method uses two parallel longwall units simultaneously on two frontal surfaces on both sides of the mobile platform.

[0168] Main equipment of longwall units:

[0169] This new method uses three basic components of long-walled units:

[0170] ●Double drum shearing machine

[0171] ● Armored Face Conveyor (AFC)

[0172] ●Hydraulic roof support

[0173] In addition to advancements in digital technology installed in these devices, the shearing machines used in this new method are equipped with online material analyzers and scanners, which analyze and transmit ore quality data to a digital system (APC / AI) before mining to determine the grade to be produced. All equipment on the machine is equipped with the latest generation of sensors and analyzers.

[0174] Advantages of using long-walled elements:

[0175] This new method employs a longwall recovery system to benefit from the following advantages:

[0176] ● Mobility, remote control, and automated roof support

[0177] ● Improved performance of continuous mining

[0178] ● Reduced particle size of extracted ore (0 to 90 mm)

[0179] ●Use of electricity

[0180] Mobile platform system:

[0181] The mobile platform system represents the core of this new method invention. Without this mechanism, the method cannot be applied. The platform serves as a means of establishing a connection between underground mineral layers and the surface. It includes the following equipment and systems:

[0182] ● A metal structure (chassis) called the mobile platform (1), which supports and houses the entire operating system, auxiliary equipment, and command equipment.

[0183] ● Two bucket elevators (1A) integrated into the mobile platform (1)

[0184] ● Ensure the mobility of the platform (1) through a translation system (1H).

[0185] ● Rotary disc screening system (1B), optional

[0186] ● Belt conveyors (1C), (1J), (1D) and (1E)

[0187] ● Two cranes (1M)

[0188] ● Roller Guide System (1F)

[0189] ●Stable Skid (1G)

[0190] ● Power supply station and electrical room (1L)

[0191] ● Control and command room including command systems (SMS, DCS, CMS, and PCS) and centralized advanced digital systems (APC / AI).

[0192] As described above, the mobile platform includes at least two bucket elevators that vertically transport the ore to the surface and feed it to a screening machine or conveyor, depending on the selected option. Depending on the application and ore type, the mobile platform can operate in two options:

[0193] ●Option 1: Screening the ore

[0194] ●Option 2: Do not screen the ore.

[0195] Option 1 involves a rotary disc screening system (1B) that can be mounted on top of a mobile platform (1) and can be directly fed by two bucket elevators (1A) to provide screening of the ore before it is delivered to the processing plant, thus avoiding the transport of waste.

[0196] Option 2 includes transporting the ore directly to the processing plant via a mobile belt conveyor installed next to the platform.

[0197] Method operation mode

[0198] As explained in the descriptions of the various figures, after startup, mining operations in the mining panel are carried out on the two faces of the platform (the right face and the left face).

[0199] In practice, the number of longwall units installed is twice the number of ore layers. Two longwall units (one machine per front) are installed facing each ore layer. The installed longwall units must be arranged vertically, one above the other.

[0200] Two longwall units (2) installed at the same level have an automatic synchronization function and must operate in parallel to mine ore from the same seam to ensure the same production grade. These mining systems (2A) are fed to an armored face conveyor (2B), which transports the extracted ore to a bucket elevator (1A) on a moving platform (1). These elevators lift the ore to the surface.

[0201] Extraction is carried out in a single pass by a pair of longwall units installed at the same level. Mining begins at the first (uppermost) ore layer and proceeds downwards, alternating between the various installed pairs of longwall units.

[0202] Once the first ore layer has been passed through, a pair of longwall units for that layer stops, and the next pair (at the second layer) begins. Control is automatic and remote. These operations are repeated alternately until the last ore layer.

[0203] During longwall unit mining, the platform is fixed in translation (in braking mode), but the bucket elevator remains operational, allowing the mined ore to be lifted to the surface.

[0204] The mobile mining platform (1), introduced into the mining trench (5), receives ore from two armored face conveyors integrated into two mining systems (2) on both sides, and lifts it to the surface via a bucket elevator, feeding it to a disc screen or belt conveyor (where screening is not required in this application). The ore passing through the screen is conveyed by a belt conveyor (1C) to a feed conveyor (1I), which feeds it to a mobile, tracked belt conveyor (1J), enabling the transport of the screened ore to a link conveyor, which then feeds it to the post-screened ore stockpile at the processing plant. Screening waste (waste) is conveyed to conveyors (1E) and (1K), allowing the waste to be discharged and stored behind the platform for backfilling the trench or mined and collapsed areas, while avoiding removal from the site.

[0205] After the last ore layer is mined, all pairs of longwall units are stopped, which allows the platform and the system of all pairs of longwall units to step approximately 200 mm to 500 mm, which can be further improved.

[0206] This stepping propulsion of the mobile platform is ensured by a translation system mounted on the bottom of the platform. Propulsion of all longwall systems is achieved by a ramming system mounted on hydraulic supports. The propulsion of the longwall units must be simultaneous, synchronized, and well-controlled.

[0207] The mobility of the entire system is ensured by a cable reel mounted on the platform, which must have a cable length capacity corresponding to the total travel of the platform and the longwall machinery. This cable reel is fed by a medium-voltage power grid, which powers the platform's electrical room. This electrical room powers the entire suite of functions and auxiliary equipment for the platform and the longwall unit.

[0208] Following this advancement of the platform and all longwall units, a new extraction cycle is triggered and mining resumes, always starting from the first ore layer.

[0209] After each advance, the right and left skids of the platform press against the two trench walls, thus ensuring the stability and verticality of the platform and the bucket elevator.

[0210] After propulsion, waste from the overlying rock strata and interbedded rock layers above the top plate falls into the voids created behind the hydraulic supports. The voids created on the surface are filled with waste rejected by the disc screening system.

[0211] These operations continue automatically until the current mining area is fully recovered.

[0212] After the current panel is mined, and following inspections and regular maintenance to ensure the reliability of these devices in the next mining cycle, the longwall equipment and platforms are moved and installed in adjacent panels.

[0213] Maintenance of the entire platform and longwall equipment is scheduled at the end of each panel's mining operations (approximately every 2 years of operation). Inspection and maintenance operations must be carried out by experts (preferably the manufacturers of these machines) under a maintenance contract.

[0214] Advantages and benefits of the new method:

[0215] Compared to traditional mining methods (open-pit, underground, slope, etc.), the new method offers several advantages in terms of both operation and sustainability. These advantages can be summarized as follows:

[0216] Improved efficiency and operational performance (mining efficiency):

[0217] ●Increased single-line production capacity (over 6000m) 3 / h)

[0218] ● Overall equipment efficiency is expected to improve by 90% to 95%.

[0219] ●The number of operational workers has been significantly reduced (from 9 to 12 people).

[0220] ● Production costs (OPEX) have been significantly reduced, estimated at 60 MAD / m 3 Up to 80 MAD / m 3 The value depends on the hardness of the ore and the thickness of the ore layer.

[0221] ● Energy consumption is significantly reduced (1kWh / m 3 Up to 2kWh / m 3 ).

[0222] It offers excellent production flexibility for different grades, allowing waste (tailings) to be discharged into the voids created within the mine (mining flexibility).

[0223] No negative environmental impact (mining sustainability):

[0224] ● Zero CO2 emissions

[0225] ● Zero noise disturbance related to the use of explosives

[0226] ● Zero waste rock and overlying rock strata after mining

[0227] Fully integrate digital technologies at all levels (Mining 5.0)

[0228] Note: These figures are based on estimates and calculations of medium-hardness ore rocks with an average mechanical strength of approximately 10 MPa to 25 MPa in terms of Young's modulus (longitudinal elastic modulus).

Claims

1. A mining method, characterized in that, The method includes marking and excavating three trenches with a depth greater than the depth of the last ore layer, the three trenches being defined as follows: – Mining trench (5), which is located in the center of the disk in the longitudinal direction and divides the disk into two fronts; –Disc isolation trench (6), which is located on the side of the disc area; – Engineering trench (7), which is located upstream and in front of the panel area.

2. The mining method according to claim 1, characterized in that, The method includes arranging the mine shafts into panels of the same size, wherein: – The length is related to the mean time between failures (T) of the device; – The width is equal to the width of the two front faces plus the width of the groove (5).

3. The mining method according to any one of the preceding claims, characterized in that, The groove has a finely machined, straight, well-aligned and parallel positive surface (wall) (parallelism and flatness of the surface: ±200mm).

4. A mining system, characterized in that, The system includes a vertical ore handling device with a metal structure, referred to as a mining platform, further... Includes the following equipment: – Two bucket elevators integrated into a mobile platform; –A translation system that ensures the mobility of the platform; - Belt conveyor; –Auxiliary and auxiliary equipment; – Control and command room, which includes a centralized digital system (APC / AI) and other process control systems (SMS, DCS, CMS, PCS). – Electrical room; -office; The platform can include a screening system depending on the properties of the ore.

5. The mining system according to claim 4, characterized in that, The system includes a mining device called a longwall unit (2), which has a twin-drum shear or cutter, an armored face conveyor (AFC), and a hydraulic roof support and propulsion system, wherein the longwall system is arranged vertically on top of the other.

6. The mining system according to claims 4 and 5, characterized in that, The system includes a mobile platform (1) comprising two bucket elevators (1A), each bucket elevator having multiple feed points corresponding to the number of ore layers to be mined. The two bucket elevators, integrated at the mobile platform level, are capable of vertically transporting the ore to the surface and feeding it to a screening machine or conveyor according to a selected option.

7. The mining system according to claim 4, characterized in that, The system includes a translation mechanism (1H) supporting the platform chassis, enabling the platform system (1) to advance for a new mining cycle, wherein the translation system (1H) can be constructed according to one of the following three options: -track; –Motorized tracks; – Motor tires.

8. The mining system according to claims 2 and 4, characterized in that, The system includes a mobile platform (1) capable of operating according to two options: –Option 1: Screen the ore; –Option 2: No screening is required; the sample is directly fed into the moving conveyor.

9. The mining system according to claim 4, characterized in that, The system includes a mobile platform (1) that is stabilized in a stationary state after translation stops and before the start of the mining cycle by means of the following device: - Braking device installed at the translation system (1H) level; - A stabilizing skid with a hydraulic cylinder is mounted on two sides (right and left) of the mobile platform to provide its stability.

10. The mining system according to claim 4, characterized in that, The system and equipment operate solely on electrical power, wherein an overhead power line aligned with the trench (7) in front of the mining panel (3G / 3D) supplies power to the substation at the electrical room (1L) level via an electrical cabinet and cable reel system, the cable length capacity of which corresponds to the total travel of the mobile platform.

11. The mining system according to claims 4 and 5, characterized in that, The system includes reliable sensors installed at the equipment level, wherein sensors of the ore analyzer and scanner type capture and transmit reliable information about the grade and quantity of ore in each ore layer, and wherein other sensors are installed on all said equipment to report a full set of operation, maintenance, safety and energy consumption data.

12. The mining system according to any one of the preceding claims, characterized in that, The system includes a highly advanced centralized digital system (APC / AI) installed in the control room. This centralized digital system relies on databases and machine learning algorithms to optimize performance and provide improved, dynamic monitoring of the process, thereby achieving optimal performance indicators for the novel mining method. The centralized digital hierarchy is fed by command and control systems (DCS, SMS, CMS, PCS) installed in the control room and server room, which control and monitor all operational aspects of the novel mining method.

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