If you have ever worked in or near mining or underground construction, you know how critical haulage is. The ability to move materials efficiently can make or break your entire operation.
And many operations still use traditional systems, such as shuttle cars or locomotives. They’ve worked for decades, so why switch now? Well, that’s where continuous haulage system come in.
They’re not just for looks, since they match specific demands and provide real advantages when the numbers are right. So, in the post, we’ll take you through when you should consider moving on from the old ways to continuous haulage.
Consistent Production Demands
Continuous haulage systems is what you need, when, for your operation, it only makes sense to have a constant flowing of material with no stops or slowdowns. Traditional methods are batch-dependent: load, travel, dump, return. That pauses between loads. It chews up your production time. Continuous haulage passes material from face to conveyor or stockpile with minimal delay.
Now, consider a room-and-pillar mining arrangement. If the face moves faster, there’s a bottleneck in waiting for shuttle cars. With a sustained system, the cutting and the hauling take place at the same time. You’re not idling equipment or crew. Which means less wasted time and more tons moved per shift.
Additionally, the absence of start-stop cycles contributes to a more perfect rhythm. If you have a mine coming on stream with a plan for sustained operation — no idling, no masses of trucks standing by for loading — an integrated continuous haulage system can bring more consistency than traditional systems.
Tight Underground Spaces
Traditional Cars Need Space to Move. Shuttle cars, haulers and loaders have turning radii, backup patterns and safety clearances. More space, meaning, just to let them operate safely. That space is precious in cramped underground spaces.
Continuous-haulage systems, particularly flexible ones, can be looped through low seam or narrow entries without a lot of extra width. You can construct narrower roads and make the best use of limited development space. Some systems are designed to follow the continuous miner very closely, further shrinking the system’s footprint.
High Equipment Utilization
If your operation extends in long shifts with little time to decompress, you need gear that can keep pace. If you’re trying to get every bit of productivity out of your equipment, continuous haulage is a great option for your site. Because it doesn’t linger like a fleet of shuttle cars could, it keeps the entire production line flowing.
This may also add up to fewer machines. You could replace runs of cars back and forth with a single moving unit — possibly along with a moving belt — as such to eliminate much of the stop-and-go. The fewer the machines, the fewer the breakdowns, and less maintenance and simpler scheduling.
Reduced Ventilation And Fuel Requirement
Shuttle cars and trucks running on diesel push a lot of fumes below ground. Which means it’s more work for your ventilation system. And that comes along with more fuel use and more emissions control. Electric systems, and hauling solutions for mining more broadly, consume less fuel and require less ventilation and have lower emissions.
Some mines spend a large share of their budget on ventilation. The less diesel equipment you can use, the less airflow you need. That’s saving money on fans, ducting and electricity. It also enables you to comply with tougher air quality regulations without big equipment upgrades.
Long-Term Cost Planning
Continuous haulage systems are more expensive to buy upfront. No getting around that. But if you intend to run a site for years — or even decades — they can pay off over time. The fewer the moving parts, the less wear and tear, and the lower the cost of repair. And with a steady output you cut downtime and increase efficiency.
You’ll also save money on fuel, tires and maintenance crews. Common haulage gets more wear-and-tear from the constant driving, loading, dumping. Over time, those costs add up. In the case of continuous systems, because there is less stop-and-go motion, your equipment lasts longer.
Wrapping Up
So, how do you know when to choose a continuous haulage system? Basic: When the pockets are tight, the production is steady, or you want to cut down on fuel and maintenance. These systems don’t suit every mine, but in the right circumstances they make a lot of sense.
If you’re looking to keep things running smoothly, cut down on costs over time and generally have an easier time with underground buildings, they’re worth considering. You’ve just got to apply the method to the mine.
