Kollu galeri açma makinelerinin seçim kriterleri ve Amasra havzasına uygulanması
Selection criteria of roadheaders and its application to Amasra coalfield
Yazar: CİHAN ERSOY
Danışman: DOÇ. DR. CEMAL BALCI
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / Maden Mühendisliği Ana Bilim Dalı
Derece: Yüksek Lisans, 2014
Konu: Maden Mühendisliği ve Madencilik = Mining Engineering and Mining

Özet:
Madencilik ve tünel kazılarında daha hızlı ve daha ekonomik yollarla hedefe ulaşma amacıyla çeşitli teknolojiler geliştirilmiştir. 1950'li yılların başında kömür madenciliğinde mekanize kazı gerçekleştirmek üzere geliştirilen kollu galeri açma makineleri günümüzde gelişen teknolojilerin de yardımıyla daha yaygın olarak kullanılmaya başlanmıştır. Kollu galeri açma makineleri kullanım yerine ve amacına uygun seçildiği takdirde hızlı bir kazının yanı sıra emniyetli, esnek, taşınabilir ve ekonomik kazı imkanı sağlamaktadır. Çeşitli sertlik değerine sahip formasyonlarda kullanılabilir olmaları, farklı kazı kesit ve boyutlarında çalışma imkanı sunan bu makineler maden ve tünelcilik projelerine zaman ve maliyet yönünden olumlu etki etmektedir. 
Türkiye'nin birincil taşkömürü bölgesi olan Amasra havzasında da mekanize kazı yöntemleri kullanılması adına çeşitli adımlar atılmıştır. Amasra-B lisans sahasında madencilik faaliyetleri yürütmekte olan Hattat Enerji ve Maden Ticaret A.Ş. firması da bu kapsamda Sandvik AM105 model kollu galeri açma makinesi satın almıştır.
Bu tez çalışması kapsamında ilk olarak kollu galeri açma makinesi yapısal bileşenleri ve makine seçimine etki eden temel performans kriterleri irdelenmiştir. Daha sonra, Amasra havzasında kollu galeri açma makinesi kullanılabilirliğini incelemek adına havza kayaçları için yapılan eski çalışmalar incelenmiştir. Ayrıca, firmanın derin kotlarda üretimini planladığı "Kalın Damar" isimli kömür damarından ve yan kayaçlarından blok numuneler alınarak İstanbul Teknik Üniversitesi Maden Mühendisliği Bölümü Kazı ve Mekanizasyon Laboratuvarları'nda bazı kesilebilirlik, fiziksel ve mekanik özellik deneyleri yapılmıştır.
Bu çalışmada, yaygın olarak kullanılan kollu galeri açma makinesi performans tahmin yöntemleri ile Amasra havzası kayaçlarına ait veriler kullanılarak performans tahminleri yapılmıştır. Son olarak, firmaya ait Sandvik AM105 model kollu galeri açma makinesinin arazide yapılan yerüstü test kazısı çalışmalarından performans verileri toplanarak daha önce yapılan performans tahminleriyle karşılaştırmalar yapılmıştır.
Bu tez çalışmasında görülmüştür ki, havza için daha önce yapılan jeoteknik rapor çalışmaları göz önüne alındığında kömür yan kayaçlarına ait tek eksenli basınç dayanımı değerleri ortalama 80 MPa, dolaylı (Brazilyan) çekme dayanımı değerleri ortalama 6 MPa ve Cerchar aşındırıcılık indeks değerleri 0,8 ile 3,1 arasındadır. Bu çalışmalarda havzadaki kayaçların tek eksenli basınç dayanım değerlerinin en düşük 20 MPa olduğu ve bölgesel olarak 156 MPa'a kadar çıkabildiği ortaya konmuştur.
Tez çalışması kapsamında yapılan laboratuvar deneylerine göre ise Amasra havzasında kumtaşı ve silttaşına ait tek eksenli basınç dayanımı değerlerinin 20 ile 90 MPa arasında, dolaylı (Brazilyan) çekme dayanımı değerlerinin 0,5 ile 3,5 MPa arasında ve Cerchar aşındırıcılık indeks değerlerinin 1,5 ile 2,5 arasında değiştiği görülmüştür. 
Yapılan performans tahminlerinde 300 kW kesici kafa gücüne sahip travers tip bir kollu galeri açma makinesi ile havzaya ait kömür yan kayaçlarında 19,26 - 672,58 m3/sa kazı hızlarına erişilebileceği öngörülmüştür. Firma tarafından test çalışması yapılan bölgenin kayaç özellikleri dikkate alınarak yapılan performans tahminlerinde ise 14,97 - 69,00 m3/sa kazı hızlarına erişilebileceği öngörülmüştür. Arazide yapılan yerüstü test çalışmasından alınan performans verilerinde 12,90 - 48,00 m3/sa kazı hızları elde edilmiştir.

Abstract:
Several technologies have been developed for mining and tunneling excavations in order to meet the goals of projects in faster and economical ways. Roadheaders, which were developed in 1950s for mechanized excavation in coal mining, have been more widely used nowadays as a result of improved technology. By a proper selection for purpose and location, roadheaders present secure, flexible, mobile and economic excavation as well as a rapid excavation. Roadheaders have a positive impact on timelines and costs of mining and tunneling projects due to their ability to excavate formations, with various strength values, in different cross sections and dimensions. 
In order to use mechanized excavation technologies in Turkey's primary hardcoal basin several attempts were made. Hattat Enerji ve Maden Ticaret A.Ş., the company carry out mining activities in Amasra-B license, has procured Sandvik AM105 type roadheader with this purpose.
In this thesis, primarily the main structure of roadheaders and performance criteria which affect the selection of roadheaders were analyzed. Secondly, in order to examine the usability of roadheaders in Amasra coalfield, previous studies on Amasra coalfield rocks were analyzed.
Moreover, block samples were taken from "Thick Seam" which is planned to be produced in deep levels by Hattat Enerji ve Maden Ticaret A.Ş., and its surrounding rocks. Cuttability, physical and mechanical properties tests were applied to these samples in Istanbul Technical University Mining Engineering Department Excavation Technology and Mining Machinery Laboratory.
Performance predictions were done with data of Amasra coalfield coals and rocks by commonly used roadheader performance prediction methods. Finally, performance data collected from surface test study of Sandvik AM105 type roadheader owned by company. Test study data were compared with previously done performance predictions.
In this thesis, it is seen from previous geotechnical report study results that uniaxial compressive strength of surrounding rocks of coal is averagely 80 MPa, Brazilyan tensile strength is averagely 6 MPa and Cerchar abrasivity index figure changes from 0,8 to 3,1. In these previous report studies it is observed that uniaxial compressive strength of Amasra coalfield rocks can be minimum 20 MPa and 156 MPa can be observed locally.
Laboratory tests done in scope of this thesis confirmed that uniaxial compressive strength of Amasra coalfied sandstone and siltstone varies between 20 MPa and 90 MPa, Brazilyan tensile strength varies between 0,5 MPa and 3,5 MPa and Cerchar abrasivity index figure varies from 1,5 to 2,5.
Laboratory tests also showed that specific energy required to excavate Amasra coalfield sandstones is averagely 4,5 - 5,74 kWh/m3 and 4,71 - 6,17 kWh/m3 for siltstones. Specific energy required for coal is found out as 0,70 - 2,08 kWh/m3.
There are several ways of predicting the performance of a roadheader. In this study, these methods were also explained. Full scale linear cutting test, small scale linear cutting test, empirical prediction methods, semi-theoretical approach and in-situ machine test are the principal methods.
In order to predict the performance, specific energy is the commonly used criteria as well as uniaxial compressive strength of rock. Roadheader specifications such as machine weight and cutterhead power are also considered in some prediction methods.
Main six prediction equations in this study belongs to Gehring, Rostami et al., Çopur et al., Thuro, Balcı et al. and Ocak et al. In Rostami et al. method, specific energy used is separately derived from both Brazilian tensile strength and static elasticity modulus according to Balcı et al regression analysis. Main difference of Çopur et al. method is that is developed for soft evaporitic rocks. In Ocak et al. method, RQD value assumption is 50% different than the assumption taken for this thesis study which is 80%.
Based on data obtained from test results and 300 kW cutterhead power; it is predicted that according to Gehring's method 35,53 - 70,07 m3/h, according to Rostami et al. method 19,31 - 51,18 m3/h, according to Çopur et al. method 98,11 - 672,58 m3/h, according to Thuro's method 39,14 - 67,43 m3/h, according to Balcı et al. method 19,26 - 40,72 m3/h and according to Ocak et al. method 68,65 - 186,93 m3/h instantaneous cutting rates in surrounding rock of coal can be achieved in Amasra coalfield. During the evaluation of these results, main differences of each prediction method shall be considered carefully. 
Considering rock properties of test field, performance prediction methods were also applied. Based on 80 MPa uniaxial compressive strength of test field rock unit (limestone) and 300 kW cutterhead power; it is predicted that according to Gehring's method 28,28 m3/h, according to Çopur et al. method 69,00 m3/h, according to Thuro's method 29,63 m3/h, according to Balcı et al. method 14,97 m3/h and according to Ocak et al. method 36,27 m3/h instantaneous cutting rates can be achieved. Based on these results, it can be said that Balcı et al. method gives the lower limit, Gehring, Thuro and Ocak et al. method give the medial limit and Çopur et al. method gives the upper limit of performance predictions.
Pick consumption rates were also analyzed for the given properties of Amasra coalfield rocks. Assuming that the average uniaxial compressive strength of rocks as 40 MPa and 3 CAI index, 0,2 pick/m3 consumption were predicted. This consumption may increase up to 0,6 pick/m3 when the uniaxial compressive strength is considered 80 MPa.
In the last phase of this thesis, in-situ machine test data were obtained. Hattat Enerji ve Maden Ticaret A.Ş. have realized a surface testing of Sandvik AM105 roadheader. In this test, a 56 meter length gallery from surface was headed with 30 m2 cross section, two different brands of same type point attack cutter picks were also tested.
In this in-situ machine test, 12,90 - 48,00 m3/h instantaneous cutting rates were achieved where the rock formation have averagely 80 MPa uniaxial compressive strength. Pick consumption rate with Brand-1 picks was 0,33 pick/m3 and 0,056 pick/m3 with Brand-2 picks. 
It is seen from in-situ machine tests that results are parallel to empirical predictions. Pick consumption rates of two different brand showed that Brand-2 picks are more suitable than Brand-1 picks for an excavation in such formation. Considering CAI index and previous empirical approach for pick consumption it can be said that consumption rate of Brand-1 picks are higher than expected, but consumption of Brand-2 is better than expected.
Machine utilisation during in-situ machine testing was also analyzed. It is observed that machine utilisation is 33%. This figure can be considered relatively low, on the other hand the low-experience of testing staff must be considered as well.
As a result of this thesis, it can be concluded that prediction model results for Amasra coalfield rocks were parallel to in-situ machine test results. However, it is a fact that Amasra coalfield rocks have a wide range of mechanical properties. Also, in-situ test location rocks are close to surface and the conditions in underground will be different.