Adam Kalwar, Roman Filipek, Paweł Madejski, Krzysztof Pytel, Franciszek Kurdziel

The energy balance of a CHP unit fuelled by mine gas

This paper presents the results of a study of a gas engine heat recovery system in terms of efficient use of the energy contained in the fuel, with the study performed determining the most efficient variant of gas engine operation. A comparison between the manufacturer’s data and the performance results was also made. Simulations performed on the system model allowed the optimum engine load range to be determined. The results of the analyses also indicated which variant of the engine heat recovery system is the most effective.

Key words: gas engines, mine gas, coke-oven gas, gas fuel, cogeneration

https://doi.org/10.7494/miag.20234.1.557.7

Tomasz Krakowski

The magnetic testing of steel ropes in hard-to-access places

The increasing requirements for safety, reliability and quality mean that the testing of steel ropes has become an inseparable element in their production and operation stages. The basic method used in testing has become the magnetic testing method of steel ropes (MTR). Despite the extensively developed knowledge, equipment, and methods of analysing diagnostic signals, difficult to access places and the ends of steel ropes are not fully covered by diagnostics. Visual inspection, which is one of the basic methods of non-destructive testing in this area of ropes, has many limitations. This area of magnetic defectoscopy is a place where new solutions and structures for testing steel ropes are created. The article presents an example of solutions used for diagnostics in places with difficult access. A new concept of a diagnostic system for magnetic testing of ropes in these sections is described. The results of initial laboratory verification measurements of the new solution are also presented.

Key words: steel ropes, diagnostics, magnetic testing of steel ropes

https://doi.org/10.7494/miag.20234.1.557.25

Nr 4/2023 (556)

Juliusz Krupiński¹, Herbert Wirth^1
1 Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology, Poland

Opportunities for the future development of energy infrastructure after production closure in the KGHM shaft, by the example of the creation of an underground pumped – storage hydropower plant

The article touches on the technical and technological aspects in the field of the possibility of creating energy infrastructure after the end of production in a selected shaft of “KGHM Polska Miedź S.A.” A cascade system of placing turbines in the shaft was proposed and the possibility of its creation was evaluated, respecting the dimensions of the turbines and the shaft. During the analysis, the relevant turbine capacities, flows, infrastructure dimensions, and possible solutions to overcome the limitations of developing an Underground Peak and Pumped Storage Power Plant (UPSH) in a post-mining facility were examined.

Key words: energy storage, hydroelectric power plant, reclamation, underground pumped
storage hydropower, post-mining facilities

https://doi.org/10.7494/miag.2023.4.556.7

Ryszard Snopkowski¹, Marta Sukiennik¹, Aneta Napieraj^1
1 Faculty of Civil Engineering and Resource Management, AGH University of Krakow, Poland

Decision-making in hard coal mines
with the support of selected stochastic methods

The article presents selected methods of stochastic process modeling that can support decision-makers in Polish hard coal mines. It outlines the classification of determinants that have a significant impact on the processes carried out in the mines. The article also distinguishes between programmed and non-programmed decisions made by the management in the mines. In the following sections, three selected methods are presented, enabling decision-makers to make more effective decisions that may be crucial for the processes implemented in hard coal mines.

Key words: hard coal mining, decision making, stochastic methods

https://doi.org/10.7494/miag.2023.4.556.19

Beata Świątek^1
1PORR S.A., Poland

A case study of the TS-26 tunnel – the longest non-urban road tunnel in Poland using NATM technology

The article describes in detail the legal, technical and geological conditions faced by the designers and contractors of the TS-26 tunnel, located within the S3 expressway. The tunnel, which is the longest non-urban road tunnel in Poland, was constructed using the New Austrian Tunnel Construction Method (NATM). The project represented a considerable engineering challenge due to the geological conditions and the need to ensure the highest safety standards. The article describes the design process, including detailed geological analyses, and the construction phases of the tunnel, which included excavation, construction of the primary and secondary lining, and the installation of advanced safety systems. The TS-26 tunnel is a key element of the road infrastructure that will significantly improve communication in the region and support the economic development of Lower Silesia.

Key words: tunnelling, tunnelling and tunnel construction, mining method of tunnelling

https://doi.org/10.7494/miag.2023.4.556.29

Jacek Zarzycki^1
1Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, Poland

The influence of selected parameters on the elasticity modulus of conveyor belts with a polyester-polyamide core

The article compiles information on the influence of selected factors on the elasticity modulus of conveyor belts with a textile core. It presents a laboratory method for testing the modulus of elasticity, highlighting how its value changes depending on the load range and temperature. The modulus of elasticity is a parameter essential for the proper design of conveyor belts, especially those that are long or unconventional.

Key words: conveyor belts, modulus of elasticity, influence of temperature and load

https://doi.org/10.7494/miag.2023.4.556.49

Nr 3/2023 (555)

DOMINIK BUKSA, PAWEŁ MADEJSKI, MICHAŁ KARCH

Rapid prototyping of water nozzles using CFD modeling and 3D printing results

Rapid prototyping of water nozzles using CFD modeling and 3D printing results In recent years, there has been greater interest in rapid prototyping methods employed in various industries. Prototypes are increasingly often made using 3D printing technology, which is mainly due to the relatively low costs of developing and producing such a structure and the short time needed for their physical production. The work presents the possibility of using rapid prototyping techniques, such as water propulsion nozzles. They are mainly used in the energy industry, e.g. for the production of water mist in jets or condensers.
Such nozzles enable the formation of a stream, and its range and efficiency depend on the design requirements. CFD (computational fluid dynamics) tools and 3D printing will be used to assess the nozzle’s effectiveness. A 3D printer based on FDM technology was used to produce nozzle prototypes. The CFD results were verified with experiment. Analyzes for four different nozzle shapes are presented and the discrepancies between the results of the initial experimental and numerical analyses are explained. To indicate the imperfections resulting from 3D printing, a 3D scanner was used to show the internal cross-section of the nozzle. The research conducted indicates the significant potential of 3D printing in rapid prototyping and its effectiveness in creating functional models for various engineering applications.

Key words: CFD, rapid prototyping, 3D printing, water nozzles

https://doi.org/10.7494/miag.2023.3.555.7

PAWEŁ GARA, YAROSLAV FEDOROVYCH, BOGDAN KOPEY

A study of the resistance of sucker rods to fatigue failure

The article presents the results of laboratory tests on the fatigue of samples made from fullscale sucker rods of 15H2GMF steel in various corrosive environments. For comparison, similar tests were carried out on corrosion fatigue of samples made from fullscale sucker rods of steels 20N2M, 15H2NMF and 15N3MA. The limited endurance limit of the tested rods of 15H2GMF steel in formation water is 22 lower than that of 20N2M steel and 13 lower than that of 15H2NMF steel, and in an environment simulating the action of H2S it is 34 lower than that of 20N2M steel and 32 lower than that of steel 15H2NMF. The results were obtained using a complex surface method of strengthening sucker rods, which was developed in the laboratory of the Department of Oil and Gas Machines and Equipment of the Ivano-Frankivsk National Technical University of Oil and Gas and tested at the NGVU “Dolynanaftogaz”.

Key words: fatigue damage, corrosion fatigue, pump rod, drilling

https://doi.org/10.7494/miag.2023.3.555.37

GRZEGORZ OLSZYNA, TOMASZ ROKITA, ANDRZEJ TYTKO

A new approach to the assessment of the fatigue life of typical steel ropes

The issue of the future prediction of the technical condition of ropes during their operation is a very important issue related to the safety of use and operation of the devices. Steel wire ropes, as load bearing elements, are subject to degradation through various forms of wear during operation. Variable loads cause a complex state of stress in the wires, which translates into different tensile, twisting and surface pressures between the wires. Ropes are also exposed to difficult working conditions, e.g. corrosive environment, fatigue wear, which consequently leads to a weakening of their functional properties.
Ropes, as responsible elements, require an accurate and at the same time simple way of predicting their failure-free operation in a simple and unambiguous manner. This article concerns a new approach to determining the fatigue life of steel ropes. The issue of safety related to steel ropes has been a difficult and ambiguous issue for many years to determine without knowing the fatigue life of the object. The paper discusses experimental and practical methods for determining the fatigue life of steel ropes.

Key words: steel wire ropes, fatigue durability, compacted ropes, wear

https://doi.org/10.7494/miag.2023.3.555.49

TOMASZ GÓRAL, STANISŁAW KRAWCZYK, JAN PAWLIK

Possibilities of manufacturing spatial elements using the 135 hardfacing method

3D printing with thermoplastic materials is slowly becoming commonplace as additive manufacturing has gained a large number of dedicated users over the past few years, and the prices of the requisite equipment have significantly dropped. However, in terms of materials, only plastics have enjoyed this popularity. Although metals are, in a sense, thermoplastic materials, their spatial application would require very advanced setups, which in turn generates high costs and complicates process control. This article discuss- es the possibilities of the additive manufacturing of metal elements using a three-axis
numerically controlled plotter combined with a semi-automatic welding machine using the 135 method. The authors also examined the impact of sudden changes in velocity vectors on geometric deviations.

Key words: 135 method, 3D printing, WAAM, hardfacing, additive manufacturing

https://doi.org/10.7494/miag.2023.3.555.71

Nr 2/2023 (554)

Marek Borowski¹, Klaudia Zwolińska-Glądys¹, Andrzej Szmuk¹

¹AGH University of Krakow

An analysis of the potential use of methane from hard coal mines in a trigeneration system to reduce emissions into the atmosphere

Greenhouse gases and their emissions are issues that are being increasingly discussed due to climate change. Next to carbon dioxide, methane is considered one of the most important greenhouse gases. Reducing methane emissions could result in noticeable environmental benefits in a short time. Anthropogenic emissions constitute approximately 60 of total methane emissions and thus solutions to reduce emissions of this gas are most often sought in this sector. The subject of the study is the methane capture system in the “Pniówek” mine, belonging to the Upper Silesian Coal Basin (southern Poland), and the potential for methane management using a trigeneration system. The article discusses the utilization of methane from hard coal mines to reduce its emissions into the atmosphere and as a profitable solution to use the emitted gas. The authors describe a trigeneration system in which methane from the mine is burned in gas engines and used to produce electricity, heat, and cooling energy. This allows for reducing methane emissions into the atmosphere while increasing the efficiency of coal use. The article shows the results of measurements carried out in a hard coal mine in Poland. The presented example indicates the ecological and economic benefits resulting from the use of a trigeneration system.

Słowa kluczowe: methane emission, emission reduction, economic use, trigeneration system

https://doi.org/10.7494/miag.2023.2.554.7

Konrad Trzop¹

¹Polska Grupa Górnicza S.A., Department KWK RUDA Ruch Bielszowice

Application of a measuring and recording system with MEMS technology for a powered roof support

Innovative technologies in hard coal production are indispensable for building a modern business enterprise. The pace of environmental and social changes inspires the need for continuous improvement of the coal mining process. The domain of machinery and equipment is the most important element of the entire production process. Machines and equipment require the constant monitoring of their operating parameters to ensure production continuity and safety. A solution addressing those needs is a measuring system that records the parameters of the powered roof support. The constructed measuring
system uses MEMS technologies to measure changes in the transverse and longitudinal inclination of the elements and the height of the powered roof support. The measuring system allows for determining the parameters of the powered roof support’s operation in the mining wall. The following paper presents an example of the use of MEMS technology in the measuring system sensors, as well as the stages of real-life research on adapting the powered roof support to the measuring system.

Słowa kluczowe: powered roof support, efficiency, safety, FEM, MEMS, underground mining

https://doi.org/10.7494/miag.2023.2.554.31

Paweł Galant¹, Radosław Srebniak¹

¹LW “Bogdanka” Mine

Optimalization of the transport of excavated material in hard coal mines
based on improvements in the automatic control mode

Hard coal mines are increasingly struggling with the widespread phenomenon of the decarbonization of the economies of European countries. As a result, they are forced to constantly look for opportunities to reduce unit mining costs. This is extremely difficult because producers of mining machinery and equipment are unwilling to incur high costs for the research and development of new products, as this industry is burdened with a high risk of unprofitability. This article describes one of the examples in which an attempt was made to reduce the costs of hard coal mining by modifying the method of controlling underground haulages consisting of belt conveyors in the Polish LW “Bogdanka” mine.

Słowa kluczowe: conveyor belt, control mode, automatic

https://doi.org/10.7494/miag.2023.2.554.45

Franciszek Niezgoda¹, Janusz Zając¹, Kazimierz Mitko¹, Izabela Górecka¹, Stanisław Mojżysz¹

¹ Urządzenia i Konstrukcje S.A.

Innovative Mine Floor Grinding Machine

This article describes the process of development of the Hydroma floor grinding machine. It describes the current methods of solving exploitation problems related to uplifting of the floor in mining facilities and the issues of the need to maintain proper crosssections of roadways under current mining exploitation conditions in order to ensure the continuity and safety of mining facility operations. The existing methods of floor grinding were analyzed in terms of cost, labor intensity, safety, and environmental protection. The following section outlines the process of developing a mine floor grinding machine at Urządzenia i Konstrukcje Spółka Akcyjna, namely the stage of technical and marketing analysis is discussed, during which the needs and possibilities of implementing the floor grinding machine were assessed, as well as the process of preliminary research and design, construction and tests conducted on a prototype grinding machine. The operation of the floor grinder – which is driven by an electric motor to grind the elevated rock bed, load and transport the grinded rock to the hauling trucks, all performed by remote control – is described. In conclusion, the advantages of the Hydroma grinder are discussed, as it performs the work efficiently, effectively and safely, without exposing the environment to harmful emissions.

Słowa kluczowe: longwall mining, longwall grinding machine, longwall face raising

https://doi.org/10.7494/miag.2023.2.554.53

Janusz Zyśk¹, Artur Wyrwa¹, Maciej Raczyński¹, Marcin Pluta¹, Sabina Michalska¹, Emilia Wyrwa¹, Tadeusz Olkuski¹, Wojciech Suwała¹

¹AGH University of Krakow, Faculty of Energy and Fuels, al. A. Mickiewicza 30, 30-059 Krakow, Poland

Energy and emission balance of the Małopolskie Voivodeship in 2020

The article presents the energy balance for the Małopolskie Voivodeship in 2020. It shows the production, import, input and output of transformation, own consumption of power plants, combined heat and power plants, network losses and consumption in the economic sectors (industry, waste), transport (road and rail), buildings (residential and tertiary), as well as in agriculture and forestry of the following energy carriers: hard coal, crude oil and petroleum products (including gasoline, diesel, LPG), non-renewable
waste, derived heat and electricity. An estimate of greenhouse gas emissions in 1990 and 2020 in the Małopolskie Voivodeship is also presented.

Key words: greenhouse gas emissions, energy scenarios, energy balance

https://doi.org/10.7494/miag.2023.1.553.7

Tomasz Kuś¹, Navaneethan Subramanian¹, Paweł Madejski¹, Michał Karch¹

¹ AGH University of Krakow, Faculty of Mechanical Engineering and Robotics, al. A. Mickiewicza 30, 30-059 Krakow, Poland

Assessment of the potential for CO₂ capture using post-combustion methods

The combustion of fossil fuels in the process of generating electricity causes the emission of carbon dioxide, which is considered the main anthropogenic reason for global warming. The paper’s subject is to assess the potential for CO₂ capture using post-combustion methods. Post-combustion methods such as chemical absorption, physical separation, membrane separation, and chemical looping, are described. The thermodynamic modeling of a coal-fired supercritical power plant integrated with a post-combustion carbon capture installation using the solvent method is performed. The results obtained from the model are used to investigate the impact of the power plant when carbon capture is performed.

Key words: CO₂ emissions, PCCS, amine technologies

https://doi.org/10.7494/miag.2023.1.553.19

Richard Kandzia¹, Mariusz Szot²

¹ THIELE GmbH & Co.KG, Werkstr. 3, 58640 Iserlohn, Germany
² GIG Central Mining Institute pl. Gwarków 1, 40-166 Katowice, Poland

Technological aspects of mining chain production development

This paper presents a brief historical overview of the development and types of mining chains currently in production, as well as their contribution to the global market. The directions of development for mining link chains were identified in terms of the materials and strength parameters applied. The negative influence of certain factors that decrease the performance of mining chains are also demonstrated.

Key words: chain, safety, durability

https://doi.org/10.7494/miag.2023.1.553.35

Radosław Rejman¹, Karolina Greń¹, Rafał Żelazko¹, Wojciech Liwacz¹

¹AGH University of Krakow, al. A. Mickiewicza 30, 30-059 Krakow, Poland

The Kalman autonomous planetary rover

The project presented in the article is proof of the usefulness of student organizations and its effectiveness in the popularization of advanced technologies as well as future solutions in industry. A student-developed planetary rover, using a Kalman filter and other algorithms responsible for dynamic terrain mapping and pathfinding, is capable of non-collision movement in the most challenging environments. Moreover, the rover uses a 6DOF arm developed by students to undertake manual actions, such as soil sampling or maintenance tasks with ease. The invention is provided with a drill to be capable of extracting a sample from a depth of 30 cm, which is expected to greatly enhance the research of the geological history of the surveyed region. The robot has been tested numerous times at planetary rover competitions with success, proving the potential of such platforms as one of starting points in space exploration and opportunities in industrial use, especially in hard-to-reach mining areas. The featured project represents an inspiration for future young engineers and scientists by opening perspectives for implementing similar technologies for more efficient and safer operations in industry.

Key words: rover, robot, autonomy, mechanization, mining

https://doi.org/10.7494/miag.2023.1.553.35

Tomasz Budniok¹, Bernard Krakowczyk¹, Andrzej Tor¹, Wojciech Zasadni¹, Leszek Żyrek¹

¹Becker-Warkop Sp. z o.o, ul. Przemysłowa 11, 44-266 Świerklany, Poland

Modern means of underground transport – Technical and economic effects and benefits to working environment resulting from the operation of monorail VOLTER battery-powered locomotives

Battery-powered means of transport are more and more often used in underground mining. The article describes a suspended VOLTER battery-powered locomotive, which is designed for transport of equipment, materials and people. The technical and economic effects related to the operation of this innovative solution in comparison with diesel locomotives, including energy (fuel) costs and maintenance time, are presented. The article also describes the benefits to the working environment connected with the use of battery locomotives resulting from the lack of exhaust emissions and significant reduction in noise and heat generation, which improves the climatic conditions in comparison with diesel locomotives.

Keywords: suspended transport, battery locomotive, energy costs, operating costs, working environment, climatic conditions

https://doi.org/10.7494/miag.2022.4.552.7

Grzegorz Wąs¹, Adam Kluska¹, Marek Sobolowski¹, Marcin Garbacz¹, Marcin Pałka, Marek Wojtas²

¹Polska Grupa Górnicza S.A., Oddział KWK Piast-Ziemowit Ruch Ziemowit, ul. Granitowa 16, 43-155 Bieruń, Poland

²Elsta Elektronika Sp. z o.o., ul. Janińska 32, 32-020 Wieliczka, Poland

Underground Water Monitoring and Visualisation System at Piast-Ziemowit Hard Coal Mine, Ziemowit Operation

The paper presents a monitoring system for the pipeline network at Piast-Ziemowit Hard Coal Mine, Ziemowit Operation, which was implemented in February 2023. The system covers monitoring of both fire system pipelines and pipelines of the dewatering and drinking water systems. Ziemowit Operation is self-sufficient in terms of water consumption both for technological and domestic purposes. Precise monitoring of pipelines allows to maintain installation parameters at a level sufficient for technological and mine fire safety purposes. The system also provides for the detection of emergency conditions, monitoring of water levels in storage reservoirs, while in terms of hydrogeology it is used for water balancing. Flowmeters installed at the pumps allow the actual measurement of pump performance, determine their efficiency, and thus allow diagnostics to anticipate future failures and take preventive measures. Visualisation of the performance of the system is available from a web browser and enables convenient and intuitive configuration to suit the user’s current needs related to making changes to the system. The visualisation application has extensive functionality for current viewing and analysis of historical events and diagnostics of emergency conditions.

Keywords: monitoring, mine water, dewatering, visualisation

https://doi.org/10.7494/miag.2022.4.552.21

Grzegorz Wojdyło¹

¹Euro-Tech Plus Sp. z o.o., Siekierzyce 1A, 59-407 Mściwojów, Poland

BETEK modern tool systems

During the transformation period, in order to secure sufficient energy amounts and to ensure that energy systems remain stable, it will still be necessary to produce energy based on raw materials such as coal, natural gas and oil derivatives. Hence, mining techniques are being developed to increase productivity and improve safety by eliminating the workstations that pose a risk to human health and life. This is ensured by fully automated mining systems. However, even the best-designed system is only as strong as its weakest link. In most mining machines, the cutting tool that has an impact on performance are the conical picks. Fully automated mining machine systems make sense only if the working units are designed with high-quality materials used in the production of picks holders, pick sleeves and the picks themselves. This is something that EURO-TECH PLUS Sp. z o.o. has been working on together with BETEK  for years.

Keywords: conical picks, sintered carbide, mining

https://doi.org/10.7494/miag.2022.4.552.43

JAN KUREK
TOMASZ WYDRO

THE MINING OF IGNEOUS ROCKS – MINING TECHNOLOGY EXEMPLIFIED BY THE “ZALAS” PORPHYRY MINE

The geological structure and rock resources of the region of Krakow are very diverse. This results from its location at the junction of three structural units as well as from the variety of geological processes that have taken place during their geological history. Devonian to Quaternary formations are visible on the surface, while the rocks found in boreholes are even older.

Igneous rocks in the region of Małopolska (Lesser Poland) are concentrated in a relatively small area. The following rocks have been mined in the past: red porphyry in Miękinia, melaphyre in Regulice, porphyry in Orla. Currently active mines – quarries, which are engaged in continuous exploitation, include the “Zalas” Porphyry Mine in Zalas and the „Niedźwiedzia Góra” Diabase Mine in Tenczynek.

https://doi.org/10.7494/miag.2022.3.551.7

PIOTR KULINOWSKI

DIRECTIONS FOR REDUCING THE ENERGY CONSUMPTION OF MINING BELT CONVEYORS

The article discusses the issue of energy savings in the operation of mining belt conveyors. Using the concept of energy consumption indicators, the directions for reducing the energy consumption of belt conveyors are presented by applying energy-efficient components, upgrading the drive system, or introducing organizational and technical changes in the conveying process.

https://doi.org/10.7494/miag.2022.3.551.21

ZYGMUNT ZUSKI

THE CREATION OF A NEW TRANSPORTATION ROUTE NEAR THE CRYSTAL GROTTO IN THE “WIELICZKA” SALT MINE THROUGH THE CONSTRUCTION OF A FORE-SHAFT EQUIPPED WITH A TRANSPORTATION DEVICE

This article presents the planned fore-shaft construction between the 2nd upper and 2nd lower levels equipped with a hoisting device for materials transportation. The main aim of this venture was to create a means of transporting materials used in the process of protecting and maintaining the Crystal Grotto. There is currently no vertical connection between the 2nd upper and 2nd lower level. As a result, all material transportation is performed manually over the incline paths.

https://doi.org/10.7494/miag.2022.3.551.35

BEATA BORSKA DAWID SZURGACZ JAN GIL

DEVELOPMENT OF A CHARGING SYSTEM ENSURING THE LOAD-CARRYING CAPACITY FOR POWERED ROOF SUPPORT

The powered roof support is an essential part of the protection of the mining wall. Its main task is to support the roof of the wall excavation and, as such, it must resist the coal mass that has the potential to collapse the mining pit. The force with which the powered roof support acts on the roof of the excavation is called load-carrying capacity. This paper describes the problem of the load-carrying capacity of powered roof support, in particular reviewing their charging systems. The research aims to ensure that the re quired initial load-carrying capacity is obtained and the working load-carrying capacity is maintained. This paper presents the research results of a double-block prototype equipped with an automatic charging system. We present the results of both bench and operational testing in real conditions.

https://doi.org/10.7494/miag.2022.3.551.53