The automated Bucyrus plow longwall ordered by Polish mine operator Lubelski W?giel Bogdanka SA for its Bogdanka mine in Puchaczów – 29 km from Lublin in eastern Poland – was commissioned in March this year. Within months of delivery, the new longwall had far exceeded the production target specified in the invitation to tender – and even set a new European record for plow faces as well as a new World production record for plow longwalls in mines using arches to support their entries.

Bucyrus was awarded the order for a complete automated longwall plow system with a required daily output of 10,000 tonnes. The longwall system was delivered at the end of 2009 with installed power 2 x 210/630 kW for the plow and 2 x 800 kW for the AFC. An impressive output of 13,000 tonnes was achieved already during commissioning in March.

On August 25, 2010 the Bucyrus longwall achieved a daily output record of 16,894 clean metric tonnes. During only 10.5 hours of operation, the plow made over 300 passes along the 250-meter panel, traveling a total distance of 76 kilometers or in other words a distance of 120 m/min in average.

The plow face advanced a total of 21.6 meters with a cutting height of only 1.5 meters – an achievement impossible for any shearer in such seam heights. This is the result of huge advances in plow automation and technology especially over the past 10 years. Advances in drive, control and transmission systems – with more powerful motors, stronger plow chain, faster plow, larger transverse push force, exact control of the plowing depth, and plow bit improvements – allow Bucyrus plows to be used for high volume production in any coal hardness. This is supported by greater installed power than any other manufacturer – up to 1600 kW as used for the Gleithobel® plow system GH 1600 as installed in Bogdanka mine.

The GH 1600 plow is designed for high productivity in very hard coal and the system of choice for seams up to 2.3 meters. Each of the 173 roof supports – with a support range 950 to 2000 mm – is equipped with its own PMC®-R roof support control. Other units of the Bucyrus Programmable Mining Control family are used for overall face automation and visualization as well as drive control.

The longwall is further equipped with a PF4/1032 face conveyor, a PF4/1132 entry conveyor, a SK 1111 crusher and an S147600 belt tail-piece. Power supply and pump station were also be supplied by Bucyrus.

The Bucyrus plow longwall installed in Bogdanka is working in automatic mode, allowing a significant reduction of stuff required at the face during operation to control the plow or advance the shields. In other words unlike shearers, an automated Bucyrus plow face doesn’t need operators on the face.

Incremental plowing is used, which means that the plow cuts an exactly defined depth, regardless of coal hardness, seam structure and faults. This cutting depth is electronically preset using accurate stroke sensors and an advanced algorithm Horizon control allows exact control of the plow angle, ensuring that the plow does not dig or climb unless required by the seam geology. This excellent control allows operating the plow system exactly along the seam-floor boundary and to follow even undulated seams.

Polish steam coal production declined by 11% in the first six months of 2010. Lubelski W?giel Bogdanka S.A. is the only company to buck this trend. Bogdanka is one of Poland’s major mine operators, producing 5.56 million tonnes of clean coal in 2008 and planning to increase its output to 11 million tonnes of clean coal in 2014. Bogdanka is considering the purchase of another longwall system in 2011 for its new Stefanów panel.

It is estimated that some 30 to 35% – or 1 billion tonnes – of Polish coal reserves lies in thin seams. The Polish mining industry abandoned plow technology in the 1990s because its low productivity back then (caused by low horsepower and the lack of any automation), but the success of Bucyrus’ latest plow systems is causing a renaissance. At Bogdanka alone, Bucyrus plow technology will increase recoverable reserves by some 100 million tonnes.