Sub-Underground coal mining methods

and fuel technology

Dept.-Mining Engineering
Sem.-3rd Sem.
Group-A
Module-3 (Longwall Methods)
Prepared by: Asikul Islam
Name of the Institute: Asansol Polytechnic
 LONGWALL METHODS

On completion of the topic we would able to learn –

• General description
• Elements of longwall face
• Factor effect to select longwall methods
• Advancing and Retreating method of longwall mining
• Advantages and disadvantages of those methods
• Factor effect the direction of face advancing.
• Factor effecting face layout.
• Procedure to establish the design of a new longwall face or district.
• Development of panel and face.
• Machinery use in longwall mining.
• Simple Layout of an longwall panel
 LONGWALL METHODS(CONTD…)

LONGWALL MINING METHOD:

 Longwall method of working consists in laying out long faces ( 60- 200m long )
from which all coal in working section of the coal seam is removed by a series of
operations , maintaining a continuous line of advance in one direction and leaving
behind the void( called goaf). The roof over the goaf is partially or completely
supported by walls of stone ( called pack walls), sand or other material like crushed
stone to prevent collapse of roof and only a small strip 3 to 6 m wide and parallel to
the face is supported by timber or steel props , bars or chocks in a systemic manner
. Alternatively the roof over the goaf is allowed to cave in but the roadways are
secured by pack walls and chocks if they have to be used ( as in long wall
advancing method)
 ELEMENTS OF A LONGWALL FACE
A long wall face comprises the following elements –
1. The Face: A long front from which the coal is
won .
2. Tail Gate: The roadway usually used for the Rib
Dip
supplies of material and return air. It is also known
Stable
as supply gate.
3. Main Gate: The roadway used for transport of Tail Gate/Supply Gate
coal out-bye and for the intake of air. It is also known
as Mother gate.
Break
4. Goaf Line : The line at which the roof is intended line Face
to cave .
Goaf
5. Span : The width of the workings from the goaf Direction of advance
line supports to the face.
6. Stable: A portion at the ends of a face specially
prepared to accommodate the machine to cut the
Main Gate /Mother Gate
face.
7. Buttock: The portion of the face at its end from
where cutting starts . Stable

8.Face Conveyor: The conveyor installed to the Basic Elements of longwall face
face.
9. Stage Loader: The conveyor which receives coal
from the face conveyor for its transport out-bye.
10.Face supports : The supports use on the face
11.Breaking row supports: The supports at the goaf
edge
 APPLICABILITY CONDITION OF LONGWALL MINING METHOD
Longwall mining can be applied in the following condition-
1. Thin seam (as thin as 0.7m)
2. Seam with dirt bands
3. Gassy seams which required meticulous planning of ventilation
4. Seam which are to be mechanised for large planned output
5. Seam with tough roof which can be induced to bend gradually and settle on packs
or seam with weak friable roof which may caved in goaf.
6. Seam having cleats: Parallel to face is suitable for plough face.
 ADVANTAGE & DISADVANTAGE OF LONGWALL MINING

ADVANTAGE OF LONGWALL MINING:

 High recovery
 Lower Operation cost (next to the block caving)
 Continuous production/No cyclic operation
 Ventilation of working is rendered easier with simple and direct air routes
 Dirt's bands in the seam can be use full in purpose of the goaf.
 It output /production is more as compared to bord and pillar method
 In this way only few roads are formed and is to be maintained
 All the seam section is extracted in one operation .
 Enabling the maximum percentage of extraction.
 Easier to supervise and
 Easier to trained the main power
 Can work under weak roof as well as bad geological condition.
 Lower dilution
 Safer ; worker are all the time under the power support and supported roof bracing.
 ADVANTAGE & DISADVANTAGE OF LONGWALL MINING

DISADVANTAGE OF LONGWALL MINING:

 High capital investment
 High subsidence
 Chances of ventilation short circuit through the goaf.
 Small problem=Big production losses
 Dust control difficult
 Overloading Conveyor system
 FACTOR WHICH INFLUENCE THE LAYOUT OF LONGWALL FACE
The factors which influence the layout of the longwall face are follows-
 Seam thickness and the consistency of the thickness: thinner seam normally practice
advancing face, thicker seam normally practice the retreating face, Choice of power
support, shears machine may be double drum may be single drum based on this,
Variant seam make problem to take decision regarding support , machines etc.
 Roof and floor:In soft and friable roof the shield support may be the choice. In strong
and difficult to caves roof blasting of roof may be necessary or in some situations full
stowing of goaf may become necessary similarly with soft floor the base area of the
support must be large enough to prevent floor penetrations.
 Dip of the seam: Flat seam - Face may be advance in any direction .Steep seam-
advance in the strike direction or at an angle to dip. For stowing face advance will be
in rise direction.
 Cleat of the seam: plough face give good results if they are parallel to the cleat but
cutter loader work well on end faces
 Presence of contiguous working: In order to avoid adverse interaction from pillar left
in the overlaying working, if any the gate road in lower seam must be sited in the
destress zone. Where this is not possible the face is so sited as to be parallel to the bord
in the upper seam working
 Geological constraints: In geological disturbed area with fault and dykes etc, the
layout is largely determined by the geology of the seam and often advancing face may
not be practiced. In disturbed area retreat face can be worked , positioned in suitable
way to take account of faults , surface damage, old working etc.
 DIRECTION OF FACE ADVANCE

• The direction of advance of the face is influence by-

the physic - mechanical property of the roof rock,
dip of the seam and
direction of cleat etc.
• Roof falls are more common if the face is parallel to the main cleat and less frequent
when it is laid at right angle to the main cleats i.e on end or at an angle to the line of
main cleats . .
• Also coal cutter work at their best efficiency if the face are on end whereas plough work
more efficiently if the face is parallel to the main cleats.it the seam is too steep , the
face is laid at an angle to the main dip so as to have required gradient along the face for
the efficient operation.
• There are three possible direction of face advance 1) on the strike 2) to the rise and 3) to
the dip.
• The last alternative is possible only when the gradient of the seam is slight or nearly
flat.
• The alternative 2) i.e the face advance to the rise is possible if the dip of the seam is up
to 25 degree .
• Where hydraulic sand stowing is done for goaf control the face must not advance to the
dip. It may advance to the rise or on the strike
 LENGTH OF LONGWALL FACE
The optimum length of a face, whether advancing or retreating, depends upon the
following consideration
1. Output desirable
2. Capacity of coal cutting and loading machines
3. Ventilation at the face
4. Capacity available for face mechanization
5. Geological disturbances
6. Rate of stowing
7. Development work
8. The length of a longwall face varies from 60m to 200m. The maximum face length is
restricted in some countries by mining Regulations; e.g. in Germany the maximum
length is 250m. In India Adriyala mining project in SCCL length of L/W face is
250m and panel length 3km
 TYPE OF LONGWALL MINING METHOD

Basically longwall mining methods are two types based on the direction of the advance
face. They are-
1. Longwall Advancing
2. Longwall Retreating
Longwall Advancing:
 In longwall advancing extraction of the coal commence form the vicinity of the shaft
and advance towards the boundary of the coal mine. Or panel
 Approach to the face is by parallel roads formed at a specified distance apart which is
equal to the length of the face.
Tail Gate

Dip
Goaf Coal

Rib Main Gate

 TYPE OF LONGWALL MINING METHOD (CONTD..)

Longwall retreating:
 In longwall retreating pairs of heading are driven in the solid coal at and interval equal to
the predetermined length of face up to the fine or panel boundary.
 The coal is extracted and retreat towards the shaft hence it is called longwall retreating
method
 Roof of the goaf is allowed to caved in or stowed best on the situation of the mine area
and geological situation.
Tail Gate

Coal
Goaf

Main Gate
 ADVANCING AND RETREATING LONGWALLS

Comparison of Advancing and Retreating Longwalls

The advantages of retreating longwalls compared to advancing are:
• Gate road formation is remote from face operations (less congestion at face ends, less
supplies into longwall face area, face not held up waiting for gate road preparation or
vice versa, no problems of dust production from gate road workings affecting longwall
personnel).
• No gate roadway side packs required, so less supplies overall
• Longwall block is surrounded by roadways before the longwall starts so knowledge of
strata conditions is much better
• Gas drainage of adjacent blocks can be carried out starting during development; with
longwall advancing the drilling can only be done behind the face after longwall
extraction, allowing less drainage time before the next block commences production
• With retreat longwall mining, additional gate roads or bleeder roadways behind the goaf
area can be developed for ventilation by the development unit if required. Such
additional roadways are much more difficult to mine with an advancing longwall
• There are more options for ventilation/gas control using additional roadways at the limit
of the block
• Advancing longwall gate roads typically require extensive maintenance to maintain the
roadway cross-section (roof and floor brushing) during the life of the longwall block,
whereas retreat longwall gate roads are allowed to collapse behind the retreating face
 ADVANCING AND RETREATING LONGWALLS(CONTD..)

The only real advantages of advancing longwalls are:

• Production can begin earlier as the mine does not have to wait for the gate roads to be
developed before longwall production can commence (provided development rates are
adequate this should only apply for the first longwall in a mine)
• It provides an opportunity for disposal of stone which has to be excavated into gate side
packs (this benefit is probably more than offset by the costs involved in pack
construction)
RETRATING OVER ADVANCING IN SHORT
• Reserve are proven on development
• Gate road development is separate
• Water easier to control
• Recovering equipment easier
• Easier ventilation
 VARIANT OF LONGWALL FACE LAYOUT
•
• Long wall face may be single unit of .

double unit faces.

• In the double unit face lay out the
central gate is used for transport of coal F
Face Conveyor
Goaf
Dirn a Dip
from both the faces : a common Of c
face Gate belt
conveyor serve the both faces. For the e
supply of the material the respective
gates at the flank of each faces are
used. Diagrammatic Illustration Single unit long wall face

• The advantage of the double unit faces

Dirn.
are: 1. The cost on haulage is Of F
A Sand stowed goaf
reduced.2. Loss of coal is reduced Face
C
adv Main Gate Balt
which otherwise would occur if coal is E

to be left between two faces

• Following are the disadvantage of the Dirn F
a Face Conv.
. Of
double unit face 1. Ventilation of faces face c
adv e Sand Stowed goaf
may create difficulties as in the case of
dip face descensional ventilation and in
the case of the rise face ascensional
Diagrammatic illustration of a double unit long wall face with
ventilation will be necessary. 2. The stowing
central gate may need heavy repair
 VARIANT OF LONGWALL FACE LAYOUT(CONTD..)

• In the past however double unit • .

faces have been worked in many Cave line Dip

collieries abroad and even in

India. Where the seam were
comparatively level and mining Dirn. f Face Conv.
Of Goaf
condition permitted , it has been adv
a
c
possible to layout double unit e Main Gate belt conv.
face up to 457 m long with 229 m
face on either side of the main
F
gate. a
Goaf
Dirn c
• Where hydraulic sand stowing of of adv e
the goaf is done as in India the
dip side face lead the rise side
face . This arrangement facilities
the drainage of water from the
rise side goaf but on caving faces Diagrammatic illustration of a longwall face with caving
or face where pneumatic stowing
is done , the rise side face may
lead the dip side face
 PROCEDURE TO ESTABLISH THE DESIGN OF A NEW LONGWALL FACE
The procedure to establish the design of a new longwall face or district is outlined below:
1. Establish the appropriate objective for the new district or face in terms of; ( a) Output
(b) product and ( c) timing.
2. Accumulate information on different parameters affecting design of layouts particularly
on - ( a) General geology ( b) Depth of cover ( c) surface restrictions ( d) Old workings
( e) water ( f) Gas ( g) Liability to spontaneous combustion ( h) Total thickness of seam
3. Decide thickness of seam to be extracted both for production and for development of
roads.
4. Establish the workable reserves in the area and seams to be worked .
5. Decide on the size and output per face
6. From (4) and (5) decide how many faces are required at any time and whether they all
will be in one seam or will require multi-seam working.
7. Decide on the method of development and risk reduction .
8 . Decide whether some form of protection for the development roadways is necessary by
setting the development in distressed area or by ensuring the the initial working a distressed
area in the to site the long term trunk roads.
 PROCEDURE TO ESTABLISH THE DESIGN OF A NEW LONGWALL FACE

9. Decide whether face roadway will require rib side protection.

10. In cases of previous working in the area check each alternative layout for effects of
old workings. If other seams are to be worked in the area , consider each alternative
layout as a part of multi-seam system.
11. Produce a detailed layout for five years , with a sketched layout for the remaining
life of the area . In sitting the position of the faces , avoid as far as practicable high
stress conditions for both face and roadways.
12. If the geology is uncertain and likely to have a major effect on results , the layout
should be tested by means of ' Geosimplan ' on atleast three possible geologies and
where practicable one alternative layout .
13. Prepare a detailed estimate of output, OMS and cost and compare with the
objective set for one representative year.
 FACE DESIGN FOLDER SHOULD CONTAIN

The completed face design folder should contain the following

1. The final specification sheet which gives the followings- ( a) face details : face length, seam
section and the section of the face extracted; (b) details of powder loader ( c) coal clearances and
material handling : A.F.C , stage loader and gate conveyor. ( d) support system: face support type
and power pack , main gate road head support , tail gate road head support ;( e) stable hole width,
height and method of work ;( f) Roadways- main gate size support , main gate goaf side packs, (
g) electrical and (h) special requirements
2. Manpower and machine data sheet .
3. A plan showing coal clearance scheme.
4. A plan showing man riding and material handling schemes.
5. Calculation of the horse power required for the face conveyor and gate conveyors together with
the safety factors of the gate conveyor chain .
6. Specification of the required electrical equipment.
7. A schematic arrangement of the electrical equipment .
8. A face profile drawing showing a section of the face equipment and the planned prop free front
distance.
9. A schematic drawing showing the proposed dust suppression equipment and also specifying the
drum and pick speeds.
10. Support plan for the face and gate ends.
11.Geological assessment of the area to be worked.
12.A hydraulic schematic drawing for the face as a whole
13. Cross section of gate roads support conveyors, haulage track , pipes , cables etc.
 DEVELOPMENT OF PANELS AND FACES
In the longwall advancing system, the development drivages are comparatively less ; all that is needed to
keep the gate roads sufficiently advanced so that face operation can proceed uninterrupted.
But with retreat mining , development drivages assume much greater importance. As a rough guide,
the speed of each development heading shoud be 1.5 time the planned rate of face advance.
This speed of drivage will have to increased when one heading machine drives both roads and face line,
or where multi-entry system ( employing fewer machines than the number of entries) are used.
Position of development roadways
1. Roof of the seam in the roof of the roadway
2. Floor of the seam in the floor of the seam
3. Position in between (a) and (b)
Shape and size of the development roadways- 1.Rectangular 2. Arched 3. Circular
Method of drivage of roadway
The gate roads for longwall advancing faces are driven by 1. blasting off the solid or 2. by undercutting
the face with a coal cutter, drilling, blasting and hand loading of coal. Each gate must have its own
equipment.
Drivages are retreat working from major part of the mining system and generally, and the following
methods are used for the drivages :
1. Drill - blast - and load 2. Cut- drill- blast - and load 3. Cut and load by mechanical means, e.g., road
headers, dint headers , etc. Blasting of the solid is cheap in capital cost but the rate of advance is slow
compared to the other methods of drivages. This system is however, very popular in the Indian coal
mines . In coal headings two rounds of blasting per shift , i.e .,a progress of about 2.4 m per shift is
easily possible. Mechanical loading, the progress can be increased considerably. In some Indians coal
mines road headers or dint headers have found applications
 DEVELOPMENT OF PANELS AND FACES)CONTD…)

• Construction of longwall face

• Installation of longwall face equipment.
Procedure of the installation of longwall face equipment
The steps involved in the installation of longwall face equipment are-
1- transport of face equipment from the surface to the unloading station
2- unloading of the equipment
3-Its transport and positioning on the face
The unloading station was established at the face end in the tail gate. At the unloading
station two chock shields were used to unload the equipment and load them on the face
trolley which was moved along the face with the aid of a 35 h.p direct hauler installed
at the face end. Figure show the layout of the unloading station in the next slide.
The AFC drive head , stage loader and jump breaker were transported to the site
through the main gate road and the power pack pumps , transformers and gate end
boxes were positioned and powered behind them . Once the AFC head end unit and
stage loader tail end were aligned the building of AFC was started. Simultaneously two
tail gate supports were loaded and positioned in the unloading station and hydraulic
power was connected to them. A girder frame with lifting sling was erected and then
the lowering of remaining chock shields was started.
 DEVELOPMENT OF PANELS AND FACES)CONTD…)
Procedure of the installation of longwall
face equipment
The two main gate end supports were the • .
first to be positioned. The placement of
chock shields advanced and the extension of
AFC was continued till the tail gate end of
the face was reached
The chock shiels were transported by a Gyro
Mining Transport (GMT) car up to the
unloading station and then they were
transferred to the GMT face trolley. The
direct hauler at the unloading station was
used to lower the chock shields. The
positioning of the chock shield required their
tilting by 90 degree, from the face trolley.
Using a special clevis and a long chain the
chock shields was pulled out from the face
trolley by using its own hydraulic pusher
ram. By a few advance and retreat action of
the pusher ram the chock shield tilted by 90
degree and positioned itself adjacent the
previous chock shield.
 LAYOUT OF LONGWALL MINING
Dip

Main Gate
• .
3
2

11 8 10 9 4

1.2km

Face Adv.

150m 6

7
Tail Gate

1.AFC 2. STL (Stage Loader) 3. Gate Belt .4 Power support

5. Main Belt 6. Serer( DERD) 7. Track Line 8. Set of gate end
9. Water Tank-2 no's 10. Power pack -2 no's 11. Transformer
 LAYOUT OF LONGWALL MINING(CONTD..)

 The figure which is shown in the previous slide is a complete layout of an longwall retracting
with caving face having dimension 1200m x150m. Now a days width of face may be go up
to 300 m and length of heading 1200m. which is most common practice in Indian coal mine.
First of all two road way is fully developed . Development work is done by road header or
dint header .After development the two road this road way is connected where AFC , Shearer
and power support are installed called longwall face. After completion of the face and road
way development the whole hydraulic power support , shearer machine AFC, Hydraulic prop
, stage loader gate belt are transported and installed at the face and main gate in a sequence.
Haulage line is installed up to face at the tail gate to supply the required material during the
time of development. Power support AFC ,Shearer are installed at face. Stage loader gate belt
and the transformer, different power supply unit like gate end box and switch gear to operate
shearer stage loader, lump breaker, gate belt conv. and water tank are kept in the main gate
side beside the gate belt conveyor.
 Dip , strike direction and direction of face advance has been shown in the figure.
 Intake air and return air direction has been shown in the figure . Intake air goes through the
main gate and it clear the dust of face and provide the comfort to the worker who are working
there and finally it mixed with the return circuit through the tail gate .
 Shearer cut the coal at the face and AFC convey the coal up to the stage loader at main gate.
Stage loader convey the coal up to the gate belt conveyor . Gate belt conveyor convey it up to
the main belt . And finally coal is transported up to the surface through the main belt circuit
or through other belt has been design according to the mining purpose.
 30 m of both gate road from the face have to supported by hydraulic prop and girder as per
CMR
 LAYOUT OF LONGWALL MINING(CONTD..)
• Numerical on Long Wall production:
Let coal seam thickness =3m,
face length =150m,
Web=0.6m ,
gradient -1 in 7 ,
Shift per day-4 , and cut shift per day -3 ,
sp. Gravity of coal=1.3 ,
now the production per cut =3x150x0.6x1.3=351 ton,
Cut distribution per shift is- 1 cut in maintenance shift and 3 cut in each rest three
shift so total cut per day =10,
So production per day=351x10=3510 ton
Cut sequence in longwall face: Middle to tail gate , tail gate to middle, middle to Main
gate , main gate to Middle
Half sumped inclined method-,
 LAYOUT OF LONGWALL MINING(CONTD..)

• Population of machinery/ summery of Machinery used –

1. Gate belt 800 mm ,150 HP – 1
2. AFC = 150 hp x 2( 2 no's motor) –
3. PAN = 100 no's with length ( 1.5m each)
4. Stage Loader = 150 HP
5. SEARER ( DERD) = 150 HP × 2(for two motor)
6. Power support ( 480 T Cap ) - 150 Nos
7. Main belt - 150 HP
8. Power Pack- 2 No ( 150 hp× 2)
9. Water tank- 2 No
10. Track line
11. GATE END BOX - needed for the following purpose Gate belt-1 no's , searer- 2
no's, p/ pack – 2 no's , STL - 1 no's , lighting – 1 no's,
12. Trans Switch
13. Water Spray Line
14. Open circuit H/ Prop- 120nos ,Girder – 60 no's
15. AUDIO visual system AND LOCKOUT
 LONGWAL FACE MACHINERIRS
Shearer(DERD)
A double-ended ranging-drum. Shearer for example, consists of four major components: electric
motors, gearheads, haulage unit (power pack), andcutting drums.
The electric motor ranging from 300 to 1000 horsepower (223-750kw) is the power source for the
shearer. It provides power to run the hydraulic pumps in the haulage unit and the gearheads for the
cutting drum. The large capacity shearers are generally equipped with two electric motors: one for
the haulage unit and one gearhead and the other for the other gearhead and other ancillary
equipment. The motors can be remotely controlled. There are two gearheads, one on the left- and the
other on the right-hand side of the shearer. Each gearhead consists of a gearhead gearbox and a
ranging arm.
The cutting drum is laced with spiral vanes on which the cutting bits are mounted. Its diameter
ranges from 34 to 72 in. (0.86-1.83 m) with rotational speeds from 30 to 105 rpm. The trends are
toward fewer but larger bits and slower drum speed for better cutting efficiency and less coal dust
production. The drums are also equipped with power cowls to increase the coal loading efficiency.
The power cowl is usually located behind the cutting drum. For that reason, it can be rotated a full
180°.
The electric motor, haulage unit, and gearhead boxes combine to form the shearer's body which is
mounted on the underframe. The underframe has four sliding shoes. The face-side shoes are fitted
and ride on the face-side top guide of the face conveyor pan, and the other two gob-side sliding
shoes are fitted on a guide tube to prevent derailment. The tramming speed of the shearer ranges
from 19 to 46 ft/min (5.8-14.0 m/min).
In addition, the shearer is equipped with auxiliary hydraulic pumps and control valves for operating
the ranging arms and power cowls, water spraying devices, cable, chain anchorage and tensioners,
and so on.
LONGWAL FACE MACHINERIRS(CONTD..)
 LONGWAL FACE MACHINERIRS(CONTD..)
• Types of Shearer:
Since its first appearance in 1954, the
shearer has undergone continuous
changes both in capability and structure.
It is now the major cutting machine in
longwall coalfaces. There are two types
of shearers, single- and double drum. In
the earlier models, the drum in the single-
drum shearer is mounted on the shearer's
body and cannot be adjusted for height.
Therefore it is not suitable for areas where
there are constant changes in seam thickness
and floor undulation. Thus the single ended
fixed-drum shearer is used mostly for thin
seams. Single drum is two type 1. single
ended fixed drum. 2. single ended ranging
drum .Both are obsolete.
Double drum are two type 1. Single ended
double ranging drum shearer 2. Double
ended ranging drum shearer . DERDS are
two types 1.Ranging arms shearer 2.
Modern multimotor shearer.
 LONGWAL FACE MACHINERIRS(CONTD..)

Application of SERDS Application of DERDS

• SERDS are commonly used for the
seam of thickness 1.5m to 4m
• Inclination up to 20 degree
• Strong floor
• Cavable roof
• Medium to hard seams
• DERDS are commonly used for the
seam of thickness 1.5m to 6m
• Inclination up to 20 degree
• Strong floor
• Cavable roof
• Medium to hard seams
 LONGWAL FACE MACHINERIRS(CONTD..)
Plow Unit
• The plow unit consists of the plow head, haulage chain, gearhead gearbox,guide, chain
protection device, and electric motor and control. The bits mounted on the plow head
are mostly knife-shaped. The plow head is equivalent to the cutting drum in the shearer,
but it contains no motorized equipment.
• Through the pulling force of the haulage chain, the plow moves along and plows the
coal face back and forth. In comparison with the shearer, the plow is simpler and easier
to operate; the operator's position is fixed; it produces larger coal lumps and less
airborne dust; and its loading efficiency is high. The plow unit and the face conveyor
integrate as a unit, although a separate electric motor and gearhead gearbox installed at
both face ends is used to drive them. The plow head is driven along and plows the coal
face back and forth by a round-link continuous chain. Each time, the plowing depth is
from 2 to 7 in. (50-180 mm). To prevent the sideway sliding of the plowing unit and the
face conveyor, there are anchorages at both face ends. At the head entry, two units of
the face-end powered supports are equipped with hydraulic anchors. The electric motor
and gearhead gearbox for the plow head is located on the face end supports.
• There are two types of plow – 1. Hook plow 2. Sliding plow
LONGWAL FACE MACHINERIRS(CONTD..)
 LONGWAL FACE MACHINERIRS(CONTD..)
AFC
In longwall coal mining, the coal cut down by the shearer or the plow is transported by the
armored face chain conveyor (AFC), which is laid across the full face width, to the head-
entry T-junction, where it is transferred to the entry belt conveyor through the mobile stage
loader. The armored face chain conveyor has a large carrying capacity. It is structurally very
strong, bendable like a snake, and low in body height. It serves not only as a guide rail for
the shearer or the plow, but also as the pivot for support advance. If the conveyor is
equipped with a ramp plate, it can also load the coal left on the mine floor. The main
component of AFC are- 1. Drive unit 2. Return Unit 3. line pan 4. Chain Assembly 5.
Ancillary equipment(Ramp plate)
 LONGWAL FACE MACHINERIRS(CONTD..)

Drive head: The drive head consists mainly of the drive frames, drive units, including
the electric motor, gearbox, fluid coupling, and chain sprockets. The electric motors
range from 100 to 170 hp (75-125 kw) with rotational speeds from 1450 to 1480 rpm.
The gearboxes are basically of the same type but vary in design. Fluid coupling is
always used between the electric motor and the gearbox.
A- overall view B- Cutaway view
 LONGWAL FACE MACHINERIRS(CONTD..)
BEAM STAGE LOADER
• When the coal is transported by the AFC along the longwall face it reaches the beam stage
loader at the end of the face. The beam stage loader is simply a chain conveyor that
transport coal from the AFC to the main belt conveyor. Also incorporated into the beam
stage loader is a small crusher to reduce the particle size of the coal for easier
transportation. There are two discharge configurations for the beam stage loader :
• End discharge :
This configuration allows the AFC to overlap the beam stage loader so that coal falls
down onto it. This configuration is used for coal that is very slabby.
• Side Discharge :
Most modern design AFC utilises a side discharge arrangement to push the coal directly
onto the beam stage loader. This design is most suited to coal with large lumps. This
design can also transport a higher capacity of coal. The picture opposite shows a side
disgharge design beam stage loader.
• Once the coal is transported onto the belt conveyor it is then transported to the surface for
processing.
LONGWAL FACE MACHINERIRS(CONTD..)
 LONGWAL FACE MACHINERIRS(CONTD..)

Power support
Hydraulic powered roof supports are self advancing structures which are
interconnected along the length of the longwall face. Each unit along the line is also
connected to each pan of the AFC. The function of the powered supports are to:
• To control strata deformation, fracture and movement around the coal face,
• To maintain a safe and coal producing working environment,
• To limit the amount of roof to floor convergence,
• To prevent broken rock from entering the work area, and
• To secure and advance all plant on the coal face including the roof supports.
Each support structure consist of a roof canopy connected to a base via a shield and
leminscate linkages. Side shields mounted to the canopy prevents excessive debris
falling into the work space during support advancement. The hydraulic legs of a each
type of support are inclined or splayed at an angle. This is to prevent the legs from
buckling under the immense loads that they support. The most common types of
supports used are :
• Chock shield supports
• Shield Supports
 LONGWAL FACE MACHINERIRS(CONTD..)
SETTING PRESSURES
The initial force applied to the strata is known as “setting pressure”. Once this
pressure level is achieved the hydraulic supply is removed but the pressure is retained
in the support legs by means of a non return valve. A guaranteed setting pressure, also
known as Positive Setting Pressure, insures the preset full pump pressure is being
maintained on each support unit along the face. This is achieved by the incorporation
of Positive Set Circuit in the hydraulic circuit of the support system
YIELD LOADS
The term “yield load” refers to the maximum resisting force of the support and is
determined by a preset yield valve in the leg of the powered support. The yield valve
generally releases the fluid from the support leg circuit at a constant pressure and in such a
manner to insure that, even during yield, the fine control of convergence is still achieved.
In general the setting load of the supports is 80% of the yield load.
Support capacities in india vary and are dependent upon geological and geo -
environmental factors. In general the support capacities can be between 650 tonnes to over
1100 tones. For example uses a 630 tonne yield load 4 leg chock shield support for a depth
of cover up to 240 metres. Another examples uses a 950 tonne yield 2 leg support for a
depth of cover of 130 metres.
 LONGWAL FACE MACHINERIRS(CONTD..)

SUPPORT ADVANCEMENT
As the shearer traverses along the coal face the supports are advanced to enable the shearer
to cut a fresh web of coal when it returns. There are two methods of advancing powered
supports, these are:

Conventional Method of Advancement

In the conventional method the supports are stood up to the conveyor before the shearer cuts
a web of coal. After the shearer passes the support an extension bar from within the canopy
of the support is extended. This gives support to the newly exposed roof until the conveyor
and the support are advanced to their new position.

Immediate Forward Support (IFS) Method of Advancement

In the IFS method the supports are stood back from the conveyor before the shearer passes.
This is to allow the support to be advanced once the shearer has passed it to offer immediate
forward support. The conveyor is then advanced afterwards.
 LONGWAL FACE MACHINERIRS(CONTD..)
SUPPORT CONTROL SYSTEM
The various functions of the powered supports are controlled by an electro-hydraulic
control system. The simplest method utilises a control valve mounted on each support
which is used to operate the functions of that support (lowering and raising legs, support
advancement and conveyor push). This method is termed “unit control” and has a major
disadvantage in that the operator is located in the powered support whilst it is moving. For
this reason this method has been superseeded by more sophisticated systems.
The “adjacent control” method, as the name suggests, allows the operator to control the
powered supports from the adjacent unit by using a similar type of control valve. This
allows the operator to remain within a support which is set to the roof. This system can be
extended so that not only does the adjacent support lower, advance and set to the roof, but
once this is completed a signal is transmitted to the next support so that it too can be
operated with the operator at the one location. This can be continued for any number of
supports but is restricted to a comfortable seeing distance of around 8 to 10 supports. On
completion of the advance cycle of this group of supports the operator will walk through to
the start of the next group and continue advancement. The type of system is termed “batch
control” or “bank control”.
It is also possible to remove the operator from the face completely and allow them to
control the supports from a console at the face end. However, in most cases the operation is
still carried out on the face because of mining considerations and the requirement to operate
supports in conjunction with other face equipment.
 SOME OPERATIONAL PROBLEM

Operational problem in longwall mining/Difficulties in operation

 O ring or hose burst
 Solidification of Power support
 AFC Creeping ( To over come it Power support is be moved in the alternative way)
 Broken material is dropped down from roof that means gap place in between
canopy and face or in-between two power support. To over come it flat bamboo is
use to it
HYDRAULIC POWER SUPPORT
HYDRAULIC POWER SUPPORT
 POWER PACK

Purpose of Power Pack:

1. The main purpose of Power Pack to set the hydraulic supports.
2. Setting load expressed in tones per square meter or tones per square feet
3. Loading is determined by the hydraulic pressure applied to the support, the size and
number or support legs and the area over the support.
4. Nominal setting pressure of the support is determined by the setting of the unloading
valves of the power pack.
5. Setting load is the resistance offered by the power supports to the roof strata .
Hydraulic Power Pack:
1. Flow up to 200 litres per minute per pump and pressure of 400 bars available.
2. Necessary motor capacity for the complete power pack are from 10- 110 KN
3. High pressure setting hose pipe have a minimum size of 25 mm and inter shield
hoses 10 mm.
4. The 25 mm hoses being 4 ply steel wound and the 10 mm has two ply, which are
commonly available in the world market.
Note: the fluid which is used in the powered support system is 5 to 10 %
emulsion(ANVOL-C) and 90 to 95% water
 LONG WALL RETRATING WITH STOWING
• .
Barrier
Figure in this slide depicts a
typical layout of longwall Dip
retreating face with caving. The
longwall retreating with hydraulic
stowing on a double unit face is Goaf/Caving
also described in another figure in
the next slide. The rise face AB AFC
is so advanced during retreat as to
be somewhat outbye the face CD.
This prevents stowing water of
face AB from flowing to the face Dirn. Adv.

CD. Pairs of roadways P1, P2, P3

are driven to the panel barrier and
the cross-connecting dip galleries Next Panel
Solid
in each pair are on the apparent coal
dip to have obtuse angle bends on
stowing pipe range at the
junctions. Each face is served by
two intake airways and on Limit of Retreating

roadway of the pair P3 will serve

as return when a retreating face is
Opened to the dip of P3.

Longwall retreating face with caving

 LONG WALL RETRATING WITH STOWING(CONTD…)
Haulage
M. Belt

To Shaft Limit of retreating Stowing Range

P1 A

A P
F Goaf/Stowing A
C N
E
L
Gate Belt B
B C
A
R
R
A
Goaf/Stow I
F
ing E
C
R

P3 D

Stowing Range for next

panel

Dip
 REFERENCES

• Principles and practices of modern coal mining by R.D Singh

• Elements of Mining technology by D.J. Deshmukh
• Wikipedia
• www.MINEPORTAL.in
• Mining machinery –I, Mining Machinery-II by M. Kumara Swamy.
 .

THANK YOU