high convergence rates predicted in the
gate roads and the large quantities of
dirt produced from the face, were the
extremely high in‑seam methane
content and the affect that this would
have on coal production.
Preliminary gas drainage had
already been considered necessary
during the roadway drivage phase in
order to minimise disruption to the
winning process. The stress that this
caused to the seam negatively affected
the stability of the coal face and posed
an additional risk for the face team.
Nevertheless – and with the operating
conditions as described – coal
production had to be maintained under
the present threat of gas outbursts.
For this reason, an intelligent face
automation systemwas developed for
working the Zollverein 1/2 seam that
would enable the on-face operator to
remain at a safe distance from the
machine when cutting coal.
The intelligent face automation
system combines all of the incoming
data from the winning machine, face
conveyor and shield supports to
generate a model of the coal winning
process that is both retrospective and
anticipatory. This allows analysis
routines to be carried out in order to
optimise the overall system. The
visualisation options available to the
system can be used to access and, if
need be, modify the user interfaces for
the control room operator and the
controlling instruments that are
provided for all mine management
levels.
On the basis of extensive
development work and wide-ranging
tests carried out in preparation for its
introduction in the Zollverein 1/2
seam, the intelligent face automation
system can readily be transferred for
use on other production faces. A critical
feature of the system is that it can
automatically run collision-free cutting
profiles.
The control-panel display gives the
operator perfect control of the entire
coal winning process and all
downstream plant and equipment. He
can therefore respond rapidly and in a
targeted way to any critical situations
that may develop. The technology is
also able to pinpoint operational
weaknesses, with the result that critical
operating conditions can be effectively
prevented on a sustained basis.
The intelligent face automation
system can easily be incorporated into
an existing mine control room. In the
case of greenfield projects, the
self-sustaining control room technology
could also be used to set up a total
system capable of covering all of the
different areas involved in the operation
of the coal mine. And whatever the
application, the operator will always
benefit from the following:
n
Efficient production processes.
n
Cost optimisation.
n
High levels of technical reliability
and workplace safety.
n
Transparent processes.
This technology, which is now being
used by the German coal industry,
provides an automation solution for the
efficient operation of coal faces around
the world.
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