Post on 19-Feb-2020
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Longwall Mining – An Overview
• Underground Retreat Mining Method
• Face Lengths up to 450m
• Panel Lengths > 6000m
• Production > 1mt per month
• Depths over 1000m
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Longwall Product Groups
Longwall Shearer:
• Coal cutting machine
• Required to cut coal and rock
• Controls cutting height and horizon control
• System designed to efficiently load AFC
Powered Roof Supports (PRS):
• Hydraulic support holds up the
mine roof
• Hydraulic ram ‘advances’ AFC after
each shearer pass
• Caving shield protects miners from
collapsing goafArmoured Face Conveyor:
• Chain conveyor for coal clearance
• High torque to overcome friction and weight of coal
• High wear component
• Acts as the interface between PRS and Shearer
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History of Longwall Mining
1900 1920 1940 1960 1980 2000 2020
Introduction of Belt
Conveyors onto the coal face
gives the first recognisable
mechanised conveyor
operation
Introduction of the first
Armoured Face Conveyor
(AFC) in the UK. Twin
outboard chain designs with
drive powers up to 40kWAFCs now established as
machine of choice for
longwall operations. Powers
up to 180kW and fluid
couplings introduced
Joy introduces patented BroadBand™ Chain
TTT Controlled Fill couplings
introduced to market allowing
for independent start of large
AFC motors. AFC size limits
changed significantly
Fully integrated Variable
Frequency Drives (VFD)
released to market
AFCs now available with
4800kW installed power
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Pressure to meet tightening cost
requirements of customers,
particularly in developing
markets.
Increasing size of equipment due
to production requirements,
equipment life and safety
standards.
Recent Times
In a hazardous industry,
significant focus has been placed
on improving operator safety and
reducing LTIs.
Safety
Demands for increased
production have driven much of
the design changes in coal
cutting and clearance.
Production Bigger is Better Cost
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Installed power of
4200kW, with
4800kW capable
Long life
components for
lower cost of
ownership
Pitch Steering and
ASA
Proximity Detection
for Powered Roof
Supports
Where are we now?
Pressure to meet tightening cost
requirements of customers,
particularly in developing
markets.
Increasing size of equipment due
to production requirements,
equipment life and safety
standards.
In a hazardous industry,
significant focus has been placed
on improving operator safety and
reducing LTIs.
Safety
Demands for increased
production have driven much of
the design changes in coal
cutting and clearance.
Production Bigger is Better Cost
7
Looking Forward
Automation
Fully Autonomous Operations
Remote, Live Equipment Diagnostics
Automated Failure Detection
Equipment Life
Longer and Wider Panels Expected
Equipment Reliability
Lowest Cost of Ownership
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Keeping up with the change
Automation
Fully Autonomous Operations
Remote, Live Equipment Diagnostics
Automated Failure Detection
Equipment Life
Longer and Wider Panels Expected
Equipment Reliability
Lowest Cost of Ownership
Cameras
Remote Visualisation
Marker Band Identification
Bed-height Detection
Panline Tilt-Sensors
Tension Sensing Chain Link
Chain Break Detection
Dumbell Break Detection
Proximity Sensing
Increase in Support Densities
Longer Life Components – Industry Leading Materials
Ranging Arm Product Development
OptiDrive Reduction in Chain Travel
Collision Avoidance
Exception Management
Maximise Equipment Availability
Longer OE Equipment Life
Innovative Overhaul Technologies
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Roundup
Recent Times:
- Focus on improving the safety of underground operations
- Equipment size increasing: are we ready for the next step change?
- Industry contraction has put significant pressure on costs
Where Are We Now:
- New innovations across the product groups giving higher performance and longer life
- Advances in technology allowing greater levels of automation than ever
Where Are We Going:
- Automation is key: overarching goal for manless operations and fully automated equipment
- Achieving lowest cost of ownership
Can We Get There:
- Investing in apprentices and younger skilled professionals: leveraging global network to give access to operations and customers
- Global supply network gives stability through political change
- Giving customers highest equipment availability and lowest cost per tonne