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Abstract

Work was done as a part of the project " New generation haulage system of highly productive longwall systems" aiming to develop and implement a new longwall shearer system called KOMTRACK. The widely used EICOTRACK feed system developed forty years ago is not adapted to modern longwall shearers' power. Within the project, an innovative, flexible feed system with a modular structure was created with the possibility of continuous adjustment to the carbon wall's unevenness. Newly-developed three cast steels variants have been initially selected to fabricate this system's elements. The material's final selection was realized based on the tensile tests, Charpy impact tests, Brinell hardness surveys, and wear resistance measurements. Results analysis allowed to select cast steel marked as "2", which fulfilled all requirements and was used in further casting trials.
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Bibliography

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[6] Pirowski, Z., Uhl, W., Jaśkowiec, K., Krzak, I., Wójcicki, M., Gil, A., Kotulski, W., Kurdziel, P., Pieczora, E., Zachura, A. (2015). Innovative FLEXTRACK feed system - quality assessment of the manufactured prototype castings, in: A. Klich, A. Kozieł: Innovative techniques and technologies for mining. Safety - Efficiency - Reliability - KOM-TECH 2015, KOMAG Institute of Mining Technology, 250. ISBN 978-83-60708-90-3.
[7] Kalita, M. (2019). Designing process of a toothed segment of the KOMTRACK haulage system. New Trends in Production Engineering. 2(1), 121-129. https://doi.org/10.2478/ntpe-2019-0013.
[8] Nieśpiałowski, K., Kalita, M., Rawicki, N, (2019). System for tensioning the toothed path of the longwall shearer's feed system, Scientific and Technical Conference: KOMTECH Innovative Mining Technologies – IMTech. [9] Pirowski, Z. (2015). Thermal Analysis in the Technological “Step” Test of H282 Nickel Alloy. Archives of Foundry Engineering. 15(1), 87-92. DOI: 10.1515/afe-2015-0016.
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[13] Grudzień-Rakoczy, M., Rakoczy, Ł., Cygan, R., Kromka, F., Pirowski, Z. & Milkovic, O. (2020). Fabrication and characterization of the newly developed superalloys based on Inconel 740. Materials. 13, 2362. https://dx.doi.org/10.3390%2Fma13102362.
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[19] Pirowski, Z., Olszyński, J., Turzyński, J. & Gościański, M. (2006). Elements of agricultural ma-chinery working in soil made of modern casting materials. Motrol. 8, 169-180. (in Polish).
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[22] Srinivasu, R., Sambasiva Rao A., Madhusudhan Reddy G., K. Srinivasa Rao, K. (2015). Friction stir surfacing of cast A356 aluminiumesilicon alloy with boron carbide and molybdenum disulphide powders. Defence Technology. 11(2), 140-146.
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Authors and Affiliations

D. Wilk-Kołodziejczyk
1 2
ORCID: ORCID
Z. Pirowski
2
ORCID: ORCID
M. Grudzień-Rakoczy
2
ORCID: ORCID
A. Bitka
2
ORCID: ORCID
K. Chrzan
2
ORCID: ORCID

  1. AGH University of Science and Technology, Al. A. Mickiewicza 30, 30-059 Krakow, Poland
  2. Łukasiewicz Research Network – Krakow Institute of Technology, 73 Zakopiańska Str., 30-418 Kraków, Poland
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Abstract

The mining in seams with a high methane content by means of a longwall system, under conditions of high extraction concentration, results in exceeding methane concentrations allowed by the regulations at workings of the longwall environment, with the effect of mining machines’ standstill periods. The paper is a part of a study supporting the development of a system for shearing cutting speed control at the longwall, which should substantially reduce the production standstills due to exceeded limits and switching off the supply of electric equipment. Such a control system may be appropriate for longwalls ventilated using “Y” and “short Y” methods. Efficient Computer simulations of the 3D airflow and methane propagation may assist the design and initial evaluation of the control system performance. First chapters present studies that are necessary for a proper formulation of the properties of the longwall model. Synthetic analysis of production during the period of longwall operation allowed one to choose the input assumptions to carry out ventilation-methane computations in a CFD numerical model of longwall Z-11. This study is followed by a description of the model that is used for a case study, considering three variants of the shearer position. Finally, initial simulation results and directions of further studies are discussed.
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Bibliography

[1] S. Prusek, E. Krause, J. Skiba, Designing coal panels in the conditions of associated methane and spontaneous fire hazards 30 ( 4), 525-531 (2020). DOI: https://doi.org/10.1016/j.ijmst.2020.05.015
[2] W. Dziurzyński, A. Krach, T. Pałka, Shearer control algorithm and identification of control parameters. Arch. Min. Sci. 63 (3), 537-552 (2018).
[3] W. Dziurzyński, A. Krach, J. Krawczyk, T. Pałka, Numerical Simulation of Shearer Operation in a Longwall District. Numerical Simulation of Shearer Operation in a Longwall District. Energies 13, 5559 (2020). DOI: https://doi.org/10.3390/en13215559
[4] E. Krause, A. Przystolik, B. Jura, Warunki bezpieczeństwa wentylacyjno-metanowego w ścianach o wysokiej koncentracji wydobycia. XXI Międzynarodowa Konferencja Naukowo-techniczna Górnicze Zagrożenia Naturalne. 6-8.11.2019 r., Jawor k. Bielska Białej.
[5] A. Walentek, T. Janoszek, S. Prusek, A. Wrana, Influence of longwall gateroad convergence on the process of mine ventilation network-model tests. International Journal of Mining Science and Technology 29, (4), 585-590 (2019).
[6] A. Juganda, J. Brune, G. Bogin, J. Grubb, S. Lolon, CFD modeling of longwall tailgate ventilation conditions. In: Proceedings of the 16th North American mine ventilation. Golden, CO; 2017.
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[8] E. Krause, J. Skiba, B. Jura, Overview of Ventilation Characteristic, Practices and regulations in Poland. XXVIII Szkoła Eksploatacji Podziemnej, Kraków, 25-27.02.2019 r. https://unece.org/fileadmin/DAM/energy/images/CMM/CMM_CE/12._Krause_Skiba_Jura.pdf
[9] E. Krause, B. Jura, J. Skiba, Mining speed control in the coal panel with high coal output concentration. Kontrola prędkości urabiania w ścianach o wysokiej koncentracji wydobycia. Spotkanie Grupy Roboczej Ekspertów ds. metanu z kopalń Europejskiej Komisji Gospodarczej ONZ. Genewa 7-8.11.2019 r.
[10] J. Qin, Q. Qingdong, H. Guo, CFD simulations for longwall gas drainage design optimization. International Journal of Mining Science and Technology 27 (5), 777-782 (2017). DOI: https://doi.org/10.1016/j.ijmst.2017.07.012
[11] E. Krause, Ocena i zwalczanie zagrożenia metanowego w kopalniach węgla kamiennego. Prace Naukowe GIG nr 878. Katowice 2009.
[12] K .M. Tanguturi, R.S. Balusu, Computational fluid dynamics simulations for investigation of parameters affecting goaf gas distribution. Journal of Mining and Environment 9, 3, 547-557 (2018). DOI: https://doi.org/10.22044/jme.2018.5960.1410
[13] G . Xu, K.D. Luxbacher, S. Ragab, J. Xu, X. Ding, Computational fluid dynamics applied to mining engineering: a review. International Journal of Mining, Reclamation and Environment 31 (4), 251-275 (2017).
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[17] SolidWorks Flow Simulation 2012 Technical Reference. https://d2t1xqejof9utc.cloudfront.net/files/18565/SW_CFD_technical_reference.pdf?1361897013
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Authors and Affiliations

Tomasz Janoszek
1
ORCID: ORCID
Jerzy Krawczyk
2
ORCID: ORCID

  1. Central Mining Institute (GIG), 1 Gwarków Sq., 40-166 Katowice, Poland
  2. Strata Mechanics Research Institute, Polish Academy of Science, 27 Reymonta Str., 30-059 Kraków, Poland
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Abstract

Deposits in the form of seams are most often exploited by means of mechanised longwall systems. Hard coal seams of various thicknesses are mined by plowing and shearer complexes. Both solutions are commonly used in Polish and global mining. Mechanised longwall systems consist of many machines, the most important of which are the mining machine, powered support, armoured face conveyor and beam stage loader. The article is concerned with the failure frequency of longwalls equipped with plow and shearer longwall systems in one of the Polish hard coal mines. The analysis covers a period of 13 months of the mine’s operation, during which 2,589 failures were recorded. It was carried out for all longwalls exploited in that period, i.e. five plow and five shearer ones, operating in six different sections. In the analysed period, these longwalls worked for an average of 150 days, and a total of 1,484 days. The analysis takes into account the basic division of failures used in the mining branch, i.e. mining, electrical and mechanical failures. The plow and shearer complexes were analysed separately, taking into account the failure category for all devices. A comprehensive analysis of the failure rates has revealed that the failure rate of longwalls equipped with plow complexes is noticeably higher than that of shearer ones. Moreover, it has been demonstrated that mining failures are prevalent in the analysis of both the number of failures and the average duration of failures.
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Authors and Affiliations

Łukasz Bołoz
1
ORCID: ORCID
Zbigniew Rak
2
ORCID: ORCID
Jerzy Stasica
2
ORCID: ORCID

  1. AGH University of Krakow, Faculty of Mechanical Engineering and Robotics, Department of Machinery Engineering and Transport, Al. Mickiewicza 30, 30-059 Krakow, Poland
  2. AGH University of Krakow, Faculty of Civil Engineering and Resource Management, Department of Mining Engineering and Occupational Safety, Al. Mickiewicza 30, 30-059 Krakow, Poland

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