SUEK-Kuzbass, Leninsk-Kuznetsky, Russia:

Stebnev A. V., Chief Mechanic
Mukhortikov S. G., Vice-Chief Mechanic, Candidate of Engineering Sciences

Saint-Petersburg Mining University, Saint-Petersburg, Russia:
Zadkov D. A., Associate Professor, Candidate of Engineering Sciences, dzadkov@yandex.ru
Gabov V. V., Professor, Doctor of Engineering Sciences

The geological conditions and mining technology used in mines of SUEK-Kuzbass company are described. Mining machines and equipment included in the powered longwall mining systems are examined. The main criteria of any longwall system efficiency are output per face, productivity, life time and failure-free operation of mining machines. This study is focused on the downtime in longwalls and on the most significant factors connected with the mining equipment failures and complicated ground conditions including unstable roof, frequent roof rock falls, rockburst-hazard, high gas content, etc. It is found that 15% of downtime is taken by the mine safety measures to be implemented, and 56% of idling is due to the other production and technical reasons. Such events that intersection of faults, high methane release, unstable and very unstable roof with doming and rock falls, high water inflows and kicks, increased strata pressure, false floor and intensive roof rock fracturing entail long-term stoppage of work of the powered longwall systems, many non-productive operations and appreciable production loss. The productivity of the powered longwall systems in mines of SUEK-Kuzbass is analyzed with a view to estimating their operational stability in rational modes in fully mechanized longwalls. To this effect, the curves of output per face for 12 months and for a few years have been analyzed. An emphasis should be laid on the high nonuniformity in the values of output per face, i.e. there is considerable deviation of actual performance of the powered longwall systems from their specifications. The plotted density functions for output per face per mines within SUEK-Kuzbass are closely spaced, which points at the similar history of the processes. Despite the modern high-tech equipment, longwall mining has an erratic performance and capabilities of the powered longwall systems are used inefficiently. In order to refine the factors that condition the nonuniformity of output per face, it is planned to study the actual feed velocities of shearers and the real-time operation of a powered longwall system.

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