Innovative Solutions for the SA Mining Industry. Charl Veldman Technical Director Joy South Africa

Transcription

1 Innovative Solutions for the SA Mining Industry Charl Veldman Technical Director Joy South Africa

2 Today s Presentation Health and safety - always a priority Technology Roadmap Integrated Entry Development Longwall Innovations Dust and Noise reduction Partnering

3 Health and Safety Always a Priority Health & Safety raising the bar continuously: Exposing less people to the working face Reducing the release of dust and noise Integrated systems solutions Continuous productivity improvement Driving health solutions into practice: The Joy WetHead system Scrubber noise ongoing challenge Conveyor noise technologies developing Driving safety solutions into practice: Enhancing machine control and automation Safety in man/machine interaction Increasing productivity & availability

4 Entry Development - 14ED25 and 4FCT 14ED25 Entry Driver Continuous mining and bolting 5,2m cutting width 1,3m advance while bolting Completed 6 month underground trial main road development Positive feed back on AFX drills Machine now cutting 24/7 in a Longwall gate road Flexible Conveyor Train Flexible Continuous Haulage Operating in an LW Entry Development section for a high productivity mine Increased daily development rates by 50% compared to SC haulage Next step a linked system the ED + FCT.

5 7LS7 Shearer The worlds largest, most powerful shearer Developed to cut to 6.5+ meters Increasing capacity to 3000 kw meter Single operator to INS automated Great Wall of China Super Longwalls Powered Roof Support 1750 tonne rated capacity Highest capacity PRS 480 mm bore legs 2.0 meter wide RS20S Control platform 5.0 meter max operating height Increasing max height to 8.0 meter Taking Longwall mining to greater heights.

6 Longwall Automation Customer Needs & Problems Longwall Automation Reduce Personnel Hazard Exposure Inefficient Production The Solution Inertial Navigation System on Shearer Automatic Face Straightening Automated Shearer Sequences Horizon Control of Shearer Results Keeps Face Straight within 100mm Only two persons on the face Highest producing Longwall faces Data Information Direction Results Combining safety and productivity.

7 Continuing the Search for Solutions.. Cameras on Shearers Camera and fiber cable survivability Camera image when cutting to the headgate Both systems experimental High Speed Wireless Communications Utilizes wireless system remote operation in the future Delivery in March 08 PSU Tailgate Area PSU Mid-Face PSU Headgate Area Health, safety and productivity through innovation.

8 Raising the Bar in SA Longwall Mining 6LS & 4LS shearers Reliable workhorses of SA Longwall mines Sustained production double digit increases 100% SA market share last 2 years 7LS6 New generation shearers 7LS6 shearer (5,5m, 750kW/cutter, 2200kW total) 7LS2 shearer (3,5m, 525kW/cutter, 1120kW total) VFD traction, full Faceboss, INS ready Joy Outbye System (JOS) SA designed JOS system Full communication with all face electronic systems Platform for face automation 7LS2 Serious about Longwall mining in SA! 6LS5 production history

9 WetHead introduction The Joy WetHead System Standard WetHead (44 ) 5 in operation Mega WetHead 4 in operation Operational experience Spray nozzle maintenance Water quality & filtration systems Water leakage water feed and seal improvements Confirmed WetHead benefits 4mg/m³ 7.00 Reduced respirable dust exposure by >35% Improved workface visibility Increased pick life by >50% Reduced potential for frictional ignitions Case Study - Wet Head Wet Head Installed <2mg/m³ Scrubber Fan switched off 1.00 compliance with 90% requirement every month Mandatory [for us] to use WetHeads.. 26-Jul 02-Aug 10-Aug 17-Aug 28-Aug 04-Sep 11-Sep 18-Sep 26-Sep 03-Oct 10-Oct 17-Oct 22-Oct 31-Oct 07-Nov 14-Nov 21-Nov 28-Nov 5-Dec 12-Dec 15-Dec 22-Dec 3-Jan 08-Jan 15-Jan 22-Jan 26-Jan 2-Feb 9-Feb 16-Feb 23-Feb 02-Mar 09-Mar 16-Mar 26-Mar

10 Scrubber noise Increase fan efficiency noise levels of 92dBA possible Reduce scrubber size improved dust capture efficiency Fan efficiency Fan design optimization Durability against coal particles Dust removal efficiency Scrubber Noise Reduction Ensuring unblocked screens Auto-back flushing systems Less manual maintenance intervention Can the Joy WetHead decrease scrubber dust load.??

11 Conveyor Noise Reduction Joy Global Task Force Reliable effective solutions to reduce noise Cost effective implementation Conveyor sprocket noise Dual sprocket conveyor chain developed 3dBA reduction confirmed To be introduced in 2008 Conveyor structures Focus on rear conveyor structures Noise treatment of chain path Coated conveyor chain Durability of coating 3 dba reduction possible Noise reduction an ongoing challenge.

12 Integrated Noise & Dust Solutions. Integrated solutions Kill dust and noise at source Improve methane dilution Reduce scrubber workload Improve scrubber efficiency Downsize the scrubber? Creating a new Industry standard Kloppersbos testing during 2008 Quantify WetHead qualities Methane dilution Face ventilation The Kloppersbos WetHead Standard Integrate solutions through innovation.

13 The Value of a Partnership.. Continuing the search for solutions that will enhance the partnership between Joy and its customers: Acknowledging the challenges faced by the mining industry Providing proven system solutions Testing in the coal face Strengthening the relationship Health and safety always a priority A joint commitment to raising the bar continuously..!

14 Thank You