Equipment for Surface Coal Mines

Process Overview

What this application covers

Surface (opencast or strip) coal mines extract coal from shallow seams after stripping the overburden above them. Equipment includes large draglines, shovels, hydraulic excavators, and bulldozers for overburden and coal removal; haul trucks and in-pit crushing-and-conveying systems for material transport; and surface coal preparation or sizing at the pit-top. Surface mining equipment is selected for productivity (cost per ton moved) and matched to the mine plan and stripping ratio.

Process Flow

Step by step

01

Overburden drilling and blasting

Blastholes are drilled and charged to fracture overburden.

02

Overburden removal

Draglines, shovels, or excavators move overburden to spoil piles or trucks.

03

Coal extraction

Smaller shovels or excavators load exposed coal into haul trucks or feeder-breakers.

04

Haulage

Off-highway haul trucks transport coal to the pit-top or to an in-pit crusher.

05

In-pit crushing and conveying

A crusher in or near the pit feeds an overland conveyor to surface, reducing truck haulage.

06

Pit-top sizing and stockpiling

Coal is crushed, screened, stockpiled, and either dispatched directly or fed to a washing plant.

Buying Notes

Technical Buying Considerations

Surface mining equipment selection is driven by the mine plan: stripping ratio, bench geometry, haulage distances, and target production rate. Capital choices between truck-and-shovel and in-pit crushing-and-conveying are made early and lock in the rest of the equipment fleet for years.

Process equipment

Required Equipment

Mining drill bit / cutter

Mining Drill Bits

Rock drill bits and cutter heads for coal mining roof bolting, surface blasthole drilling, and continuous miner cutting drums.

Consumable Coal, sandstone, shale, mudstone roof and floor rocks

Coal crusher

Coal Crushers

Primary and secondary crushers for reducing run-of-mine coal to handleable, screenable, or preparation-ready sizes.

50–3,000 tph Run-of-mine coal, washed coal, middlings

Coal feeder

Coal Feeders

Apron, belt, vibrating, and reciprocating feeders for metered coal extraction from hoppers and silos.

20–4,000 tph Raw coal, washed coal, fines, blends

Belt conveyor system

Coal Conveyor Systems

Belt conveyor systems for moving raw coal, washed coal, and rejects between mining, preparation, and load-out points.

200–6,000 tph Raw coal, washed coal, middlings, rejects, coal fines

Vibrating screen

Vibrating Screens

Vibrating screens for sizing, dewatering, and media recovery in coal preparation plants and handling circuits.

50–1,500 tph per deck Raw coal, washed coal, dense medium, slurry

Related Guides

What Equipment Is Used in Coal Mining

A practical reference covering the equipment used in surface and underground coal mining, from extraction to dispatch.

Coal Handling Equipment Guide

A reference guide to the equipment used in moving and storing coal between mining, processing, and end-use.

Frequently Asked

FAQ

What is the difference between truck-and-shovel and in-pit crushing-and-conveying?

Truck-and-shovel uses haul trucks to transport coal and overburden — flexible and proven but with high diesel costs and tire wear. In-pit crushing-and-conveying (IPCC) installs a semi-mobile crusher in or near the pit and feeds an overland conveyor, reducing truck fleet size but adding crusher and conveyor capital cost.

Where are draglines used in surface coal mining?

Draglines are used for overburden stripping in shallow, flat-lying seams with thick overburden, where they cast overburden directly into mined-out areas. They are not used for coal extraction itself; the exposed coal is dug by smaller shovels or excavators.

How does stripping ratio affect equipment selection?

A high stripping ratio (more overburden per ton of coal) shifts the equipment investment toward overburden machines (draglines, large shovels). A low stripping ratio shifts investment toward coal extraction and haulage equipment. The economic stripping ratio defines the boundary of the mine.

What pit-top equipment do surface coal mines need?

Pit-top equipment typically includes a primary crusher sized for the largest expected lump, a sizing screen, surge stockpile facilities, and conveyors to dispatch or to a washing plant. Dust control at transfer points and on stockpiles is integral.