Mining system

Abstract

A mining system to convey mined materials (eg., coal) from a mining machine (10) to a remote location has a crushing unit (20) receiving the mined material from the mining machine (10) via a surge bin (21). The material is crushed and sized and mixed with water to form a slurry in a pumping unit (30). Slurry pipes (41-43) interconnect pumps (31-33) on the de-watering unit (50) to convey the slurry to the de-watering unit (50) from which it can be conveyed by fixed conveyors (60) to the remote location. The slurry pipes (41-43), and return water pipe(s) (51), have intermediate portions (41a-43a) suspended from a monorail (106) and/or mounted on a sled (206), and flexible end portions (41-43a, 41c-43c) to allow advance off the mining machine (20) along gateroads (101) and/or crossroads (103) in the mine.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] THIS INVENTION relates to a mining system.

[0003] In particular, the invention relates to a method of, and apparatus for, conveying mined material(s) from a mining machine to a remote location, eg., for processing.

[0004] More particularly, the invention relates, but is not limited to, a method of and apparatus for the continuous transfer of coal from the mining face during development of roadways underground, including longwall gateroads.

[0005] Throughout the specification, including the claims, the term “pipe(s)” shall include pipe(s), pipeline(s), conduit(s), hose(s) and the like.

[0006] 2. Prior Art

[0007] Conventionally, gateroads and cross-roads (or cut-thru's) are cut in a coal seam to enable a longwall mining machine to mine the coal in the seam.

[0008] A small mining machine cuts a tunnel (or gateroad) through the seam and the coal is transferred to a remote location, eg., a main tunnel or road via shuttle cars, eg., operating in pairs.

[0009] There is danger to the miners in the gateroads as they are liable to be run down by the shuttle cars in the gateroads. The shuttle cars quickly cut up the floors of the gate roads and the damaged floors incur high maintenance loads on the shuttle cars.

[0010] As an alternative to the shuttle cars, modular conveyors (eg., as disclosed in AU-A-10873/92 (MECO AUSTRALIA PTY LTD)) have been proposed to transfer the coal.

[0011] While the conveyors are safer to the workers, and result in less damage to the gateroad floors, production must be halted each time a conveyor module must be added to allow for the advance of the mining machine.

SUMMARY OF THE INVENTION

[0012] It is an object of the present invention to provide a method for the transfer of mined material, eg., coal, from a mining machine to a remote location which can allow for advance of the mining machine.

[0013] It is a preferred object to provide a method which can allow such an advance with minimal reduction in the transfer rate.

[0014] It is a further preferred object to provide a method where the advance of the machine can be over a considerable distance.

[0015] It is a still further preferred object to provide a method which can use, or incorporate, existing equipment.

[0016] Other preferred objects will become apparent from the following description.

[0017] In one aspect, the present invention resides in a method for transferring mined material(s) (eg., coal) from a mining face to a remote location, including the steps of:

[0018] a) crushing and/or sizing the mined material;

[0019] b) mixing the crushed/sized material with water to form a slurry;

[0020] c) pumping the slurry to the remote location through one or more flexible slurry pipes; and

[0021] d) de-watering the slurry to recover the mined material.

[0022] Preferably, the method further includes the step:

[0023] e) returning the water for mixing with further mined material for step (b).

[0024] In a second aspect, the present invention resides in apparatus to effect the method.

[0025] The mined material (eg., coal and rock) is preferably crushed and/or sized in a crushing unit which has a surge hopper or bin to receive the mined material from a mining machine.

[0026] Preferably, the surge hopper or bin is dimensioned to receive 30 seconds to several (eg., 5) minutes' output from the mining machine.

[0027] Preferably, the sized material is mixed and pumped by a pumping unit having at least one, but preferably two or more, pumps, the pumps being connected to (preferably) respective slurry pipes operable to convey the slurry to a de-watering unit at a remote location.

[0028] The crushing unit and the pump unit may be separate machines, or be mounted on a single (preferably articulated) frame.

[0029] Preferably, the de-watering unit has one, or more, return water pipes connected to the pumping unit.

[0030] Preferably, each slurry pipe and each return water pipe has at least one flexible portion connected to the pump and/or the de-watering unit to allow for advance of the pumping unit (with the advance of the mining machine) relative to the de-watering unit.

[0031] Preferably, the flexible portions include one or more coils, is and/or concertina-like sections, supportable from the roof, walls and/or floor of the mine, eg., by a monorail or sled(s).

[0032] The pipes may further include one or more rigid portions, which may be suspended from the roof and/or walls of the mine.

[0033] Additional flexible portions may be interposed in the pipes to accommodate further advance of the pumping unit (and mining machine) along the gateroads and/or around corners into crossroads (or cut-thru's).

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] To enable the invention to be fully understood, a preferred embodiment will now be described with reference to the accompanying drawings in which:

[0035] FIG. 1 is a schematic plan view of a portion of a longwall coal mine incorporating the present invention;

[0036] FIG. 2 is detail B on FIG. 1 on an enlarged scale;

[0037] FIG. 3 is a sectional side view taken on line A on FIG. 1 on an enlarged scale; and

[0038] FIG. 4 is a plan view corresponding to FIG. 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] The coal mine 100 has gateroads 101 to enable the coal 102 to be mined, eg., by longwall mining methods.

[0040] The machinery of the present invention must be designed to be capable of negotiating the junctions between the gateroads 101 and cross roads 103.

[0041] As shown on an enlarged scale in FIGS. 3 and 4, coal 102 is mined from the mining face 104 by a mining machine 10 to enable the gateroad 101 (or cross road 103) to be developed.

[0042] The coal 102 is transferred to the rear of the mining machine 10, eg., via an armoured chain 11 along the centre of the mining machine 10.

[0043] The coal 102 is discharged into a surge bin 21 at the front of a crushing unit 20. The capacity of the surge bin 21 is selected so that the flow of the coal from the crushing unit 20 can be interrupted for, 30 seconds to a few (eg., 5) minutes, without interruption to the operation of the mining machine 10.

[0044] The coal 102 is crushed and sized in the crushing unit 20 and is transferred to a pumping unit 30, where it is mixed with the water to form a slurry. (The water is returned to the pumping unit 30 via a return pipeline from a de-watering unit, to be hereinafter described.)

[0045] On the pumping unit 30, three slurry pumps 31-33 are respectively connected to slurry pipes 41-43 of the pipe system 40, to be described in more detail.

[0046] The crushing unit 20 and pumping unit 30 may be provided as separate machines, or on a single articulated chassis or frame—see FIG. 2.

[0047] Each slurry pipe 41-43 is connected, at its downstream end, to a de-watering unit 50, where the coal 102 is de-watered (i.e., separated from the slurry) and directed to a conveyor 60 which carries the coal out of the mine, eg., via a series of other conveyors. At least one return water pipe 51 returns the water from the de-watering unit 50 to the pumping unit 30.

[0048] The pipe system 40 has the three slurry pipes 41-43 where intermediate portions 41b-43b comprise, eg., 150 mm diameter pipes suspended from the roof 105 of the gateroad 101. (The pipes may be suspended from the walls and/or supported from the floor, eg., by sleds 206.) At the downstream end, the slurry pipes 41-43 have flexible end portions 41c-43c connected to the de-watering unit 50. Each slurry pipe 41-43 has a flexible end portion 41a-43a connected to a respective pump 31-33, where the flexible portions 41a-43a are coiled and suspended from a monorail 106 on the roof 105 (or supported by sleds 206 on the floor) of the gateroad 101. It will be readily apparent to the skilled addressee that as the mining machine 10, crushing unit 20 and pumping unit 30 advance, the flexible end portions 41a-43a are de-coiled and supported at spaced intervals by the monorail 106.

[0049] The return water pipe(s) 51 can also have intermediate portions (or rigid/coiled pipes) supported on the monorail(s) 106/sled(s) 206 with flexible end portions connected to the pumps 31-33 and de-watering unit 50 in the manner of the slurry pipes 41-43.

[0050] When the flexible portions 41a-43a are nearly fully decoiled, a further monorail 106 is fixed to the roof 105 between the existing monorail 106 and the machine/units 10/20/30, the new monorail 106 supporting additional lengths of flexible pipe. Alternatively, the additional lengths are supported by further sleds 206.

[0051] One of the pumps, eg., 31, may be stopped, and slurry pipe 41 disconnected therefrom to allow one of the new flexible pipes to be interconnected to the pump 31 and flexible end portion 41a of slurry pipe 41.

[0052] Pump 31 can be restarted, and the procedure repeated successively with pumps 32 and 33. This means that only one-third of the transfer capacity between the mining machine 10 and the conveyor 60 is lost at any time. This is in contrast with existing transfer methods where production is halted when additional conveyor modules are supplied to allow for the advance of the mining machine 20.

[0053] Even if a pump 31-33 fails, production, albeit at a reduced rate, can be maintained.

[0054] It will be readily apparent to the skilled addressee that the number/capacity of the pumps 31-33/slurry pipes 41-43 return water pipe(s) 51, can be varied to suit the particular mine requirements.

[0055] In certain applications, it may be preferable that the full length of the pipelines 41-43 is of flexible material.

[0056] Advantages of the invention include:

[0057] the process described can be totally continuous, providing no interruptions to the miner cutting coal at the face;

[0058] the process allows maximum access to the face—the machinery can operate close to one wall of the roadway, thus allowing supplies and other equipment to access the road and the miner at the face;

[0059] maximum access allows other mining processes to take place simultaneously whereas they would normally have to wait until the shuttle cars are stopped;

[0060] safety (eg., for roof bolting, ventilation, installation/modifications) is greatly enhanced, as there are no shuttle cars wheeling along roads, thus:

[0061] less exposure to gas initiation via cable damage;

[0062] less chance of driver injury from shuttle cars wheeling on rough roads;

[0063] much less road damage, and full access to maintain roads, so less chance of damage to vehicles and passengers and pedestrian traffic;

[0064] no sudden cable movement to cause injury.

[0065] multiple pumps provide continuous operation—pumps can be maintained or interchanged during production;

[0066] very reliable crushing unit, with possibility for backup motor and rotor.

[0067] ability to carry supplies and spares on the machinery, for easy access;

[0068] low maintenance costs, due to simplicity of operation and construction;

[0069] simplicity of construction and use of existing components provides for simple maintenance;

[0070] flexibility to adapt system to a variety of requirements, which creates many options for mining operators—this creates a positive effect for mine planning and logistics;

[0071] capacity can be increased by additional or larger pump units;

[0072] distance for material transfer can vary from hundreds of metres, to thousands of metres, depending upon requirements;

[0073] articulated frame between the crushing unit 20 and pumping unit 30 provides mobility;

[0074] ability to pump slurry from the face means pumps can be used to clean muck from the roads at the face and create a cleaner and safer work environment;

[0075] the present invention can be used in conjunction with existing mining equipment;

[0076] the present invention can be used in main headings development as well as gateroad development;

[0077] the present invention can be used for bolting equipment and for cut and flit arrangements;

[0078] continuous conveyor panel extension operations;

[0079] first aid and smoke room can be close by; and

[0080] other additional equipment can be added to the framework, eg., bolting equipment, carrying of supplies, ventilation apparatus, floor cleaning/pumping apparatus, etc., and operator F.O.D.S.

[0081] Various changes and modifications may be made to the embodiments described and illustrated without departing from the present invention.

Claims

1. A method for transferring mined material(s) from a mining face to a remote location, including the steps of: a) crushing and/or sizing the mined material; b) mixing the crushed/sized material with water to form a slurry; c) pumping the slurry to the remote location through a plurality of flexible slurry pipes; and d) de-watering the slurry to recover the mined material; and e) returning the water for mixing with further mined material for step (b); wherein: in step (b), the crushed/sized material is mixed and pumped by a pumping unit having at least one pump, the pump(s) being connected to at least one slurry pipe operable to convey the slurry to a de-watering unit at the remote location; to effect step (e), a de-watering unit has one, or more, return water pipe(s) connected to the pumping unit where the crushed/sized material is mixed with the water to form the slurry of step (b); and each slurry pipe and/or return water pipe has at least one flexible portion connected to the pumping unit and/or the de-watering unit to allow for advance of the pumping unit (with the advance of the mining machine) relative to the de-watering unit.

2. A method as claimed in claim 1 wherein: the mined material is crushed and/or sized in a crushing unit having a surge hopper or bin to receive the mined material from a mining machine.

3. A method a claimed in claim 2 wherein: the surge hopper or bin is dimensioned to receive 30 seconds to 5 minutes' output from the mining machine.

4. A method as claimed in any one of claims 1 to 3 wherein: the flexible portions include one or more coils, and/or concertina-like sections, supportable from a roof and/or walls of the mine by monorail(s).

5. A method as claimed in claim 4 wherein: the slurry pipe(s) and/or return water pipe(s) further include one or more rigid portions, which are suspended from the roof and/or walls of the mine.

6. A method as claimed in claim 5 wherein: additional flexible portions are interposed in the slurry pipe(s) and/or return water pipe(s) to accommodate further advance of the pumping unit (and mining machine) along gateroads and/or around corners into crossroads or cut-thru's in the mine.

7. A method for transferring mined material(s) from a mining face to a remote location, including the steps of: a) crushing and/or sizing the mined material; b) mixing the crushed/sized material with water to form a slurry; c) pumping the slurry to the remote location through one or more flexible slurry pipes; d) de-watering the slurry to recover the mined material; and e) returning the water through one or more return water pipes for mixing with further mined material for step (b); wherein: the flexible portions including one or more coils, and/or concertina-like sections, supportable from a roof and/or walls of the mine by monorail(s).

8. A method as claimed in claim 7 wherein: the slurry pipe(s) and/or return water pipe(s) further include one or more rigid portions, which are suspended from the roof and/or walls of the mine.

9. A method as claimed in claim 8 wherein: additional flexible portions are interposed in the slurry pipe(s) and/or return water pipe(s) to accommodate further advance of the pumping unit (and mining machine) along gateroads and/or around corners into crossroads or cut-thru's in the mine.

10. A method as claimed in any one of claims 7 to 9 wherein: in step (b), the crushed/sized material is mixed and pumped by a pumping unit having at least one pump, the pump(s) being connected to at least one slurry pipe operable to convey the slurry to a de-watering unit at the remote location.

11. A method as claimed in any one of claims 7 to 10 wherein: to effect step (e), a de-watering unit has one, or more, return water pipe(s) connected to a pumping unit where the crushed/sized material is mixed with the water to form the slurry of step (b).

12. Apparatus for transferring mined materials from a mining face to a remote location, including: a crushing unit to receive the mined material from a mining machine at the mining face, and operable to crush and/or size the mined material; a pumping unit to mix the crushed/sized material with water to form a slurry and having at least one pump; a de-watering unit at the remote location to de-water the slurry to recover the mined material; at least one slurry pipe interconnecting the pump(s) on the pumping unit to the de-watering unit and operable to convey the slurry therebetween; and at least one return water pipe interconnecting the de-watering unit to the pumping unit and operable to return water to the pumping unit for mixing with further mined material; each slurry pipe and/or return water pipe has at least one flexible portion connected to the pumping unit and/or to the de-watering unit to enable advance of the crushing unit and pumping unit, with the advance of the mining machine, relative to the de-watering unit, the flexible portion(s) includine one or more coils, and/or concertina-like sections, supportable from a roof and/or walls of the mine by monorail(s).

13. Apparatus as claimed in claim 12, wherein: each slurry pipe and/or return water pipe includes one or more rigid portions suspended from the roof and/or walls of the mine.

14. Apparatus as claimed in claim 13 wherein: additional flexible portions are interposed in the slurry pipe(s) and/or return water pipe(s) to accommodate advance of the crushing unit, and the pumping unit, with the mining machine, along gateroads and/or around corners into cross-roads or cut-thru's in the mine.

15. Apparatus as claimed in any one of claims 12 to 14, wherein: the crushing unit has a surge bin or hopper, dimensioned to receive 30 seconds to 5 minutes' output of the mined material from the mining machine.

16. Apparatus as claimed in claim 15 wherein: the mining machine, crushing unit and pumping unit are interconnected to advance simultaneously.

17. Apparatus as claimed in any one of claims 12 to 16 wherein: a respective slurry pipe interconnects each pump to the de-watering unit.

18. Apparatus for transferring mined materials from a mining face to a remote location, including: a crushing unit to receive the mined material from a mining machine at the mining face, and operable to crush and/or size the mined material; a pumping unit to mix the crushed/sized material with water to form a slurry and having at least one pump; a de-watering unit at the remote location to de-water the slurry to recover the mined material; a plurality of slurry pipes interconnecting the pump(s) on the pumping unit to the de-watering unit and operable to convey the slurry therebetween, at least one return water pipe interconnecting the de-watering unit to the pumping unit and operable to return water to the pumping unit for mixing with further mined material; and each slurry pipe and/or return water pipe has at least one flexible portion connected to the pumping unit and/or to the de-watering unit to enable advance of the crushing unit and pumping unit, with the advance of the mining machine, relative to the de-watering unit.

19. Apparatus as claimed in claim 18 wherein: the flexible portion(s) include one or more coils, and/or concertina-like sections, supportable from a roof and/or walls of the mine by monorail(s).

20. Apparatus as claimed in claim 18 or claim 19 wherein: each slurry pipe and/or return water pipe includes one or more rigid portions suspended from the roof and/or walls of the mine.

21. Apparatus as claimed in claim 20 wherein: additional flexible portions are interposed in the slurry pipe(s) and/or return water pipe(s) to accommodate advance of the crushing unit, and the pumping unit, with the mining machine, along gateroads and/or around corners into cross-roads or cut-thru's in the mine.

22. Apparatus as claimed in any one of claims 18 to 21, wherein: the crushing unit has a surge bin or hopper, dimensioned to receive 30 seconds to 50 minutes' output of the mined material from the mining machine.

23. Apparatus as claimed in claim 22 wherein: the mining machine, crushing unit and pumping unit are interconnected to advance simultaneously.

24. Apparatus as claimed in any one of claims 18 to 23 wherein: a respective slurry pipe interconnects each pump to the de-watering unit.

25. Apparatus as claimed in any one of claims 12 to 24 wherein: the crushing unit and the pumping unit are mounted on a single articulated chassis or frame.