7th BALKANMINE CONGRESS Proceedings, Prijedor 2017

DOI: 10.7251/BMC170701015M

AUTOMATIZATION OF COAL TRANSPORT ROUTES FROM

PREPARATORY SITES

Bogdan MAKOVEK1, Ivan POHOREC1, Boris SOTLER1, Simon LEDNIK1

1
Mining, Premogovnik Velenje d.d., Velenje, bogdan.makovsek@rlv.si, ivan.pohorec@rlv.si,
boris.sotler@rlv.si simon.lednik@rlv.si

ABSTRACT

In Velenje Coal Mine we construct annually up to 6000 m of new roadways for the production process
needs. Almost all roadways are made in coal seam with a conventional method, by cutting the profile
in phases and installing combined steel arched and wood support system.
The roadways are constructed with GPK PV machines, which were developed with partners and
adapted to our specific conditions. We have also developed a new PL PV-08 steel arches feeder, which
significantly contributes to the humanization and safety in the work process. On almost each
preparatory site we have installed HTZ coal crusher, which was developed with our own knowledge. It
is located on the double-chain conveyor directly behind the road header.
Crushing of coal at the preparatory site is crucial for the implementation of automatization. Crushed
coal can be transported via conveyor paths with reduced risk of causing failures to the transportation
lines. Coal is crushed on first or second double-chain conveyor and transported further on the
conveyor system. With the introduction of crushing and automatization of coal transport routes from
preparatory sites, we reduced the cost of the roadway construction process, thus less workforce is
needed.

Key words: preparatory sites, crushing unit, automatization

1. INTRODUCTION

In Premogovnik Velenje, we make annually up to seven km of new roadways. In order to

manage the economic viability of roadways, the highest level of humanization of work and
the highest level of occupational safety and health, the level of technological perfection
should be kept at the highest level in the field of roadways.
For high-quality and quick production of coal mine facilities we need modern machinery and
suitable machinery for working in the coal mine.
In addition to cutting machines, coal crushing and material manipulation (transport), in the
Velenje Coal mine during the process of coal mine production, great emphasis is placed on
the development and automation of coal transportation with transport systems to the main
transport system and from there to the surface.

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In the development, manufacture and installation of the coal mine facilities of all machined
elements, the work was done by experts within the company in cooperation with external
domestic and foreign experts.

2. EQUIPMENT FOR THE PRODUCTION OF COAL ROADWAYS AND VARIOUS

EQUIPMENT CONFIGURATIONS

2.1 Advance loading machine gpk pv

In addition to an experienced work team, reliable, suitable and condition-specific equipment

is also required for the efficient and reliable production of coal mine roadways. The advance
loading machine is one of the key elements in the production of coal mine roadways.
On the basis of many years of experience, we first approached the Premogovnik Velenje for
the development of a new advance loading machine. The new GPK PV is a product of the
development of Premogovnik Velenje with business partners. The electrical equipment of the
GPK PV machine was developed together with Bartec. The hydraulic steering system is the
fruit of the development of the experts of Premogovnik Velenje. The steel basic construction
was made by the Russian business partner GPK.
The GPK PV is adapted to the conditions in the Velenje coal mine and has proved to be very
useful, efficient and versatile as such. It has a higher capacity, is more durable, stronger,
easier to operate and more agile than its predecessor. There are 9 machines in Velenje Coal
Mine, and we sold some of them to the mines around the world, where they are very satisfied
with their versatility.

Figure 1: GPK-PV

BASIC TECHNICAL DATA OF THE MACHINE GPK-PV:

The GPK-PV is an electro-hydraulically driven console machine. The machine is used for the
production of roadways, cross-sections to 22 m2 below the inclination max. 25o. Suitable for
cutting materials up to approx. 70 N / mm2. Along with the advanced machine it is also
permissible to dissembling broken steel arches when rebuilding the coal mine roadways.

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Progress: in the slope range from 5 to 12 2.6 m/min;

in the slope line up to 8.3 m/min
Production of coal: up to 1.42 t/min
Profile shape: round, rectangular and trapezoidal

Dimensions off profiles:

Height: 1.8 - 4.6 m
Width: 2.6 - 4.7 m
Profile cross-section: to 22 m2
Track slope: max. 12o

Working body:
Design: cutting arm with head, gear and electric motor, telescopic movement
Engine power - Installations: 75 kW; 500 V, 1475 RPM
Engine type: 4KTCR 280 S-4, IMB5
Telescope stroke: 500 mm
Cutting heads: 60 rpm
Cutting arm displacement: hydraulic

Loading part:
Design: plug with loading levers, one central conveyor chain transporter
Plunger tip stroke: 0.5 m
Chain: 16 x 64; L = 16265 mm
Power: EM 22 kW, 500 V, 1475 rpm
Plate width: 2060 - 2600 mm

Travel mechanism:
Design: steel track
Shifting speed: from 2.6 m/min to 8.3 m/min
Track length: 5070 mm (complete with stand)
Hydraulics:
Working pressure: 160 bar
Pump capacity: 158 l/min
Capacity of the tank: ~ 350 l oil VG 46

Machine data:
Name: GPK-PV
Length: 10500 mm
Track width: 177 mm
Plug width: max. 2600 mm
Machine height: 2150 mm (cutting head)
Machine weight: 27000 kg
Specific pressure on the ground: 9 N / cm2
Length of chain conveyor: 7000 mm
Operating voltage: 500 V; 5%, 50 Hz

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2.2 The pl 08 pv arch feeding machine

As part of the development of equipment for the production of coal mine roadways and the
urgency to maximize the level of humanization, we approached the development and
production of a manipulator arch feeding machine, which significantly facilitated the work
on the preparation site. The manipulator of the steel arch support is used for the transport,
manipulation of the steel arch support and other materials that are needed for the roadway
construction. This segment of work on the preparation site is considered to be one of the
harder ones, but the introduction of the arc feeder significantly facilitated the transmission of
heavy loads.
The PL 08 PV is the product of the development of Premogovnik Velenje in cooperation with
the business partner DBSS - Sovi and Bartec. Partner DBSS - Sovi produced a steel part,
and Bartec took part in the development of the steering system. Ideal technical solutions and
design are the work of the experts of Premogovnik Velenje.
The basic components are a supporting structure with running units on two parallel steel rails,
a hand with gripper and a hydraulic device with a control pump, proportional hand controls
and hydraulic cylinders as working elements. A hydraulic shunting cat powered by a pump
from the feeder is used for driving. In the case of a dual propulsion engine that is above 12,
the second drive - shunting cat is fed from the common control valve, and the shunting cat has
its own aggregate - drive. One PL 08 PV is also equipped with remote electro-hydraulic
control.

Figure 2: PL 08 PV arch feeding machine

BASIC TECHNICAL DATA OF THE MACHINE:

Rated force when lifting gripper: F = 10 kN
Length with shunting cat: 8530 mm
Wheelbase 1500 mm between the steel rails
Rotating the bearing head: 35o
Lift the handle above the horizontal position: + 20o
Raise the handle under horizontal position: - 60 o
Maximum slope of progression: 15o
Working pressure of the hydraulic pump: P = 240 bar
Working pressure of the working part: P = 140 bar
Pump capacity: Q = 140l / min
Capacity of the tank: ~ 200 l of hydraulic oil VG 46

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Machine dimensions without braking and shunting cat:

Length: 6600 mm
Width: 1838 mm
Height: 906 mm
Machine weight: ~ 4500 kg
Operating voltage: 500 V; 50 Hz
Installed power: P = 22 kW

Brake unit:
Length along with 890 mm mounting bracket
Width: 375 mm
Height: 497 mm
Mass: M = 205 kg
Static braking force: Fmax = 48 kN
Brake start time: t = 0.3 sec

Drive unit:
Towing force: Rv = 15 kN
Hold force: Fd = 40 kN
Max. transport speed: vmax = 0.6 m/s
Weight: m = 740 kg
Working pressure: P = 110 bar
Flow: Q = 80 l/min

2.3 Ast 800 rubber conveyor belt

AST 800 rubber conveyor is part of electro-mechanic equipment used for mechanized
production of coal mine roadways in Velenje coal mine. An 800 mm rubber belt conveyor is
intended for the transport of coal from preparatory sites. The transporter consists of a basic
steel part, a drive train and a conveyor belt. The drive consists of: two electric motors, a
VOITH 422 hydrodynamic coupling, brakes and two gearboxes. In conjunction with the
mobile crushing unit, the conveyor can also be equipped with a system for continuous strip
lengthening.

BASIC TECHNICAL DATA AST 800:

Transporter with STAN AST 800 mm
Maximum operating length: l = 800 m
AST 800 drive electric motors: P= 2x45 kW
Transporting speed: v = 2.1 m/s
Width of the rubber conveyor: w = 800 mm
Conveyor belt angle (average): -1.8

Transporter capacity:
Cross-sectional area: S = 0,063 m2
Volume current: I = 0.127 m3/s
Mass flow: Im= 106.3 kg/s (~ 390 t/h) alone

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2.4 Coal crusher htz

In the process of development of preparatory sites we developed together with experts from
HTZ the HTZ coal crusher. Crushed coal on the entire transport line is the basis for the
successful execution of automation of the transport line system from roadway development.
In the case that coal is not broken, they occur on the presses of causing large quantities of coal
to fall and the loss of coal from the entire transport system. The crusher is mounted on the
DVT 470 double-chain conveyor.
The crusher is based on the principle of direct drive with built-in asynchronous water-cooled
electric motor in the crushing roller. The transfer of rotation to the crushing roller takes place
through a planetary gearbox with a protective shaft. We took into account the basic operating
requirements in the coal roadways and with the design solutions significantly reduced the
height and weight of the crusher.

Figure 3: Coal crusher HTZ

3. EQUIPMENT CONFIGURATIONS AND VARIOUS PREPARATORY SITE

CONFIGURATIONS

In the preparation site, we can have different equipment configuration, which depends on
several different factors. Depending on the available equipment, we can assemble the entire
equipment system for advancement, manipulation of material and transport of excavation
from the preparation site, which in the given case best suits us.

3.1 Basic equipment in preparation workshops

GPK-PV advance loading machine

Double chain conveyor (DVT 470)
HTZ coal crusher
Shunting train
800 mm rubber belt conveyor (AST 800)

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Shunting train 800 mm rubber belt

Double chain conveyor
conveyor

Figure 4: Diagram of equipment on the preparatory site

3.2 Basic equipment in preparatory sites with an arc feeding machine

Due to the higher level of humanization in the preparatory sites, we have developed and
manifactured a new PL 08 PV steel arch feeding machine in the technological process. By
doing this, we significantly facilitated the installation of steel arch support, while at the same
time, with the PL 08 PV, we facilitated the delivery of the necessary material to the forehead
of the preparatory site and the installation of steel arch support. A schematic representation of
the described is shown in Figure 5 and is as follows:
GPK-PV advance loading machine
Double chain conveyor (DVT 470)
HTZ coal crusher
Shunting train
800 mm rubber belt conveyor (AST 800)
PL 08 PV arch feeding machine

PL 08 PV
arch feeding
machine Double chain conveyor Shunting train 800 mm rubber belt
conveyor

Figure 5: diagram of equipment at the preparatory site

3.3 Automatization of the transport system from roadway development

In the process of the production of coal mine roadways, we transport coal with the transport
system to the main transport routes and from there to the surface.
In several cases, the shipping routes are long and broken down into individual transport
blocks. When switching from one transport conveyor to another, it is necessary to provide the
most continuous flow of coal. In order to ensure reliable operation, workers have to be

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stationed on individual presses, which are responsible for switching on the components of the
transport equipment. In cases where the breakdown of the roadway is large, we need a large
number of people who would otherwise use them elsewhere in the work process to cover
these prescriptive sites.
With the introduction of technical-operational solutions in the coal mine Velenje, we replace
the individual switchgear and thus increase the economic optimization of the working process
of the production of coal mine roadways.
We use the Becker Mining automatization system as a basis for managing and controlling the
coal transportation process. The industrial computer Mincos communicates with peripheral
input output units via two AST communication lines. Physically, AST is a communication
line composed of communication, security and NF circuits. With AST line 0 we cover the
control part of the conveyor. At the beginning there is a PP4100 adapter, to which switches
for selecting the mode and turning on the tape are connected. At the plant there is a compact
station KT 1002 manufactured by Becker Mining. For the compact station, the multi-adapter
PE4110 is located, through which we monitor the Tuschen & Zimmerman brakes, belt
tensioning position, speed control, drive gear reducer temperature, overflow protection, pre-
tape lock.
To ensure safety, emergency stop switches and speaker unit are installed every 50 meters
along the rubber belt conveyor. Off switches are connected to the steel rope, which is
mounted on the hook side of the conveyor with a rubber band, which serves an emergency
(safety) switch-off. In the middle of the conveyor and finally there are two pairs of switches
for controlling the displacement of the rubber conveyor. On the last adapter there is also a
switch-off switch and a connecting member, which gives the condition for the transporter to
operate.
In operation of systems without the presence of servers, the tension control of the belt is also
an essential safety element. In the event of slipping the belt off the conveyor belt drums, the
belt speed is less than the nominal one. Due to friction between the belt and the drive drum,
the heating occurs and consequently there can be a fire. The tread speed controller detects a
reduction in the speed of the belt due to slip on the drive drum and sends a signal to the
steering system which switches off the conveyor belt drive. Presets without the presence of
servers are additionally protected with CO detector that are installed at the drive parts of
conveyors with rubber band. The role of CO detector is to detect smoke (increased
concentration of carbon monoxide) that would occur if slipping of the rubber band on the
conveyor drum or any other rotating part of the conveyor would occur and, consequently, the
conveyor operation was stopped.
On the presses of individual transport elements, oscillation probes are installed that turn off
the operation of the conveyor system in the event of a blanket of one of the presses.

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Figure 6: A swing probe mounted on a rubber belt conveyor AST 800

On conveyors with rubber belt we have installed, as an additional safety measure, also
switches for rubber shift control. The task of these switches is to shut down the operation of
the conveyor with a rubber band in the event of excessive deflection of the rubber belt from
the center-ideal position to the left or right.

Figure 7: Tilt control switch on the rubber belt conveyor AST 800

In order to prevent additional dustiness in the coal mine roadways in the Velenje Coalmine,
we use showers on all transport cross sections routes. The showers are switched on by
completing the necessary logical condition for the transporter operating and by extracting the
additional logical condition that the transporter is loaded with coal or excavated.

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Figure 8: Automatic shower on AST 800 rubber belt conveyor

4. CONCLUSION

In Velenje Coal Mine, we pay great attention to continuous improvement and development of
new equipment and processes, especially in areas that have a direct impact on safety and
health at work and the humanization of work processes. An important development direction
is also the tendency for a higher performance of the working process of the production of coal
mine roadways, which directly affects the economic aspect of coal mining.
In the presented topic discussed and in the process of work, the introduced equipment and
procedures are the result of our own development and the ideas of highly skilled personnel
within the company in cooperation with foreign and domestic business partners.
Development products made in our company and fully functionality implemented in the coal
mine Velenje, we offer potential buyers on the world market.
In Velenje Coal Mine, we pay great attention to development in all areas, while at the same
time we strive to constantly improve work processes and equipment that influence the
increase in the level of humanization and the highest possible level of safety and health at
work.

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