A Leap Into The Future Of Longwall Mining

Underground coal mining using the longwall method faces a variety of challenges today, impacting both operational efficiency and worker safety. One of the major factors is the decreasing quality and availability of coal reserves. Coal seams are becoming harder to access, located deeper underground, making extraction more complex and costly. At the same time, safety regulations and environmental requirements continue to increase, adding further complexity to operations. In this context, optimising production processes while ensuring the safety of workers has become critical.

Another significant challenge is the reduction of risk to workers. Underground mining remains one of the most hazardous working environments worldwide, with dangers such as dust, gas, unstable rock formations, and equipment failures potentially leading to serious accidents. Minimising workers’ direct exposure to these hazards is essential, and automation has become a key component in achieving this goal.

The longwall method, which plays a central role in coal extraction, requires precise control and monitoring of machinery, especially roof supports and conveyor systems. This is where automation offers significant advantages: by deploying advanced control systems that can be monitored and managed remotely in real-time, production processes can be optimised while safety risks are minimised. Automated systems allow machines to be controlled faster and more accurately, enabling quick fault detection and immediate corrective actions, all while reducing the risk to personnel.

Overall, automation has the potential to not only make longwall mining safer and more efficient, but also to ensure the long-term competitiveness and sustainability of the coal mining industry.

In this context, the HBT PMC-R 2.0 roof support controller represents a significant step forward. This next-generation system offers advanced features designed to enhance automation and improve the overall efficiency and safety of longwall operations.

Designing the future

The new HBT PMC-R 2.0 roof support controller builds upon the reliable and proven system architecture of its predecessors, the PM4 and PMC-R, while introducing a complete overhaul of its electronic and network architecture. This upgrade positions the system for future advancements in remote and autonomous mining operations.

As HBT’s third-generation roof support controller, the PMC-R 2.0 is the ideal choice for longwall operations aiming to modernise their systems, enhance functionality, and extend the lifecycle of their equipment. The new controller brings several significant advantages:

• Reduced total cost of ownership: On-site minor repairs are now possible, minimising downtime and maintenance costs.
• Lower latency communications via high-speed ethernet backbone: Faster data refresh rates improve the safety and efficiency of remote mining operations.
• Advanced analytical tools: Real-time monitoring of equipment performance and health allows for more informed, timely decision-making.

Designed for the future, the PMC-R 2.0 not only meets the needs of today’s longwall mining operations, but also prepares them for the future of automation and remote control. The base system supply of the PMC-R 2.0 makes upgrading easy and cost-effective. It provides users with all the necessary equipment to update their roof supports to the latest generation.

To minimise costs, the upgrade includes only the components that need to be updated in order to implement the new controls, making it an efficient solution for longwall operations looking to enhance their systems without unnecessary investment.

Introduction to the PMC-R 2.0 upgrade

Tahmoor Coal Pty Ltd, a member of the SIMEC Group, operates a coking coal mine in New South Wales, Australia. The mine, which has a longwall system consisting of 159 HBT roof supports, has undergone a significant technological upgrade with the implementation of the HBT PMC-R 2.0 roof support control system. This transition marks the introduction of a new generation of longwall mining technology that offers advanced automation capabilities and increased operational efficiency.

 

 

This is a preview of an article that was originally published in Issue 1 of World Coal 2025.

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