LONGWALL COAL MINING
today with such record-breaking in mind , according to Eickhoff , with comparatively high prices for both coking and thermal coal giving these buyers the confidence to acquire new and productive longwall equipment .
Eickhoff explained : “ The coal price is so high at the moment that people are saying , ‘ if I can pay off a new shearer in a matter of weeks thanks to the increased productivity state-ofthe-art shearing equipment offers , why should I refurbish a 10-year-old machine instead ?’ ( Even though refurbishing and overhauling is daily business for all global Eickhoff subsidiaries ).”
This sentiment shift – as well as a continued move towards improving safety at the face – has helped the company continue to win orders for key projects in Australia for its SL 750 and SL 900 shearers , as well as secure business from China and all over the world .
On the latter country , Eickhoff said the company was benefitting from government-led plans to consolidate the fragmented coal mining sector .
“ A lot of small Chinese coal manufacturers are being integrated into much bigger entities ,” Eickhoff said . “ For us , that is a very nice development that has seen us book orders from new customers looking for highly productive technology .”
These same customers out of China are ordering shearers able to automate a high degree of longwall processes , according to Eickhoff , who said the country ’ s miners are gaining on the heels of automation leaders in Australia .
“ The big mines in Australia are leading the race , but China is following close behind ,” Eickhoff said . “ They are investing heavily in the technologies necessary to automate their longwall operations .”
In terms of achieving that magical 100 % automation mark , Eickhoff is convinced that some of the company ’ s major customers will reach that milestone shortly .
Chinese Joy
Komatsu has also been making inroads into China , and recently launched a product specifically for this market in the form of the Joy MATS6 shearer .
The Joy MATS6 Tier II comes with the reliability attributes of existing Joy machines thanks to components manufactured under rigorous Joy quality processes . Because the machines are assembled in China with many Chinese-made components , a MATS6 shearer can be built and delivered relatively quickly , according to Komatsu .
Advanced control systems protect the machine from mechanical and thermal overload , while similarly advanced diagnostics enable faster troubleshooting .
In addition , by incorporating the tie-rod chassis connection , the MATS6 can be assembled faster , both in the workshop and underground , and its modular design allows more material to pass under the machine body .
Comprised of three high-tensile fabrications with a slim main section , the MATS6 has no under-frame . This design allows quicker adaptation to different mining scenarios , more efficient rebuilds and easier maintenance , Komatsu says .
Coming with longer lasting components , the MATS6 can mine larger panels reliably between rebuilds or even mine multiple panels without a rebuild . Additionally , the machine ’ s longer machine chassis life can provide a higher return on initial investment , Komatsu says .
The machine weighs 115 t , has a cutting height of 2.5-6 m , a maximum total power of 2,495 kW , cutting power of 2 x 900 kW and 1,200 kN of haulage pull .
And , in line with Eickhoff ’ s China longwall automation insights , Joy ’ s latest shearer pitch steering technology is offered as an option on the MATS6 , providing access to fully automated cutting sequences , including gate end turnarounds and optimal drum positioning for highly efficient cycle times and consistency .
Komatsu is also including – as standard – Radio Motion Monitoring , Landmark , and REST Api , all of which enable remote operation to help keep workers out of harm ’ s way .
Within its powered roof support ( PRS ) offering , Komatsu has also launched the multifunctional Joy Compak Next Gen hydraulic control system , helping , it says , improve the performance of customers ’ PRS and facilitate the shearer cutting rate with exceptional cycle time performance .
Engineered to be durable and reliable in rugged environments , the Joy Compak system features corrosion-resistant materials on valve block assemblies , components and the main
Coming with longer lasting components , the Joy MATS6 can mine larger panels reliably between rebuilds or even mine multiple panels without a rebuild , according to Komatsu
body . With a reduced number of components to lessen wear and tear , the spool valve in the system is engineered to handle higher flow rates , to help reduce the risk of part failure and promote extended life , Komatsu said . Providing flexibility to suit the individual needs of operations , the Joy Compak Next Gen hydraulic system can be conveniently upgraded or retrofitted to any PRS system ( regardless of manufacturer ).
The high-performance valve technology of the Compak hydraulic control system helps improve cycle times by up to 12 % compared with the previous model . Designed with operators in mind , the hydraulic system ’ s overall size is reduced by up to 27 % and weight by up to 30 %, the company says , making it easier to position , while improving accessibility . Hosing position has also been conveniently located for improved access .
The reliable hydraulic valve system helps control modern automated longwall PRS from the Faceboss electronic control system using solenoid control or through manual control with the solenoid push button override function .
Seals play a crucial role in the functionality of the hydraulic spools that operate PRS functions , and Komatsu ’ s seal technology helps prevent leakage in hydraulic spools , it says . A simplified , standardised hydraulic circuit design helps provide a reduction in the number of spool valves without impacting performance of the Compak hydraulic system . This design minimises fitting and connecting hoses , helping reduce potential leak points .
Komatsu says the system can easily expand ( over 16 functions ) to increase functional requirements to suit the operation ’ s needs . For example , a standard 10-spool valve can be expanded through separate two- and four-spool
12 International Mining | AUGUST 2022