Longwalls are getting faster, longer, and deeper. Both longer and deeper longwalls face large increases in ground pressure. Engineers counter this with larger cylinder diameters and higher hydraulic pressures. Production demands that cutting machines (shearers or ploughs) get faster, shield cycle times get shorter, and more shields must move simultaneously. Longwalls get more capital intensive, faster, and, over time, fewer are needed for a given coal production target. Pump stations, therefore, have to deliver higher pressure, higher flow, and be more reliable.
For the most productive longwalls, the rate at which shields can be moved, and the conveyor advanced, are on the critical path to high production. Both of these are strongly dependent on the pump station’s performance. Our high-pressure systems for mining provide the required pressure and flow of longwall fluid reliably, and with high availability. These system designs have evolved based on our decades of experience worldwide, especially in the USA, Australia, China, and Russia. We led the way with fewer, but bigger pumps, and frequency-controlled variable speed motors.
Our plunger pumps can operate at between 10% and 100% speed, allowing for much smoother operation than conventional unloader valved systems. Smoother operation, with fewer pressure shocks, leads to less wear and hence a longer lifetime for hoses and fittings.
Our 3 x 500 kW pump systems have been running since 2012, powering 7-meter-high longwalls without any pump failures. Furthermore, our 800 kW pumps are now capable of delivering up to 3,500 bar where required.
A classic mining system has 3 high-pressure pumps for longwall fluid. Our frequency-controlled pumps, with their 90% bandwidth, allow us to control an entire pump station with only 1 frequency-controlled master pump. This design dramatically reduces the station’s complexity, improves reliability, and reduces the required investment.
Our longwall pump stations are in use in everything from central stations powering multiple longwalls, to state-of-the-art systems for individual 7-meter-high longwalls producing 100,000 tonnes per day.
We focus entirely on the heavy mining sector where operational continuity, safety, and high-volume flow are essential:
Is your mining organization looking for reliable, high-flow hydraulic pump stations? Contact the specialists at LMT directly for expert technical advice.
