Dependable high-pressure pumping is vital to modern longwall coal mining operations, but mines are increasingly looking beyond this requirement to apply integrated and automated solutions that respond dynamically to changing production conditions while providing real-time performance data.
According to Sabrina Zhang, General Manager of Armstrong Industrial in China, modern mines are increasingly evaluating fluid systems as strategic production assets rather than simply auxiliary infrastructure.
“As underground mining becomes more automated, every supporting system must become smarter as well,” said Sabrina Zhang. “Hydraulic power, water supply, controls and monitoring can no longer operate independently, so mines are looking for integrated systems that communicate with each other and optimise the entire mining process.”
System level optimisation
This shift reflects broader changes taking place across the mining industry as operators seek to increase production, improve workforce safety and reduce life-cycle costs while meeting growing sustainability expectations. She also highlighted how optimisation at system level – rather than focusing only on individual equipment – is the key to improving responsiveness and saving energy.
The value of this approach was demonstrated recently at the Dongtai Group’s Yongning underground coal mine in China’s Shanxi Province, where Armstrong Industrial supplied a fully integrated emulsion and water pumping solution to support the mine’s fully mechanised longwall operation. The installation combined three variable-speed emulsion pumps, water pumping equipment, intelligent controls, water treatment and filtration into a single coordinated solution. This was designed to provide hydraulic power for roof supports while simultaneously supplying water for coal dust suppression.
Underground intelligence
An important element of the solution provided by Armstrong Industrial was the incorporation of Active Performance Management (APM), enabling continuous data flow between the mechanical equipment and the control platform. The APM analyses operating conditions and adjusts performance in real time to maintain optimal efficiency.
“Production conditions underground are constantly changing,” said Sabrina Zhang. “Intelligent controls allow the customer to achieve the required hydraulic performance using fewer installed pump systems, reducing both capital expenditure and ongoing operating costs.”
Variable frequency drives (VFDs) are key to the intelligent control system active at Yongning mine, allowing motor speeds to be continuously adjusted to match changing load conditions. She pointed out that this contributes to more stable hydraulic pressure, better energy efficiency and smoother longwall production. VFDs also help to reduce mechanical stress, which in turn extends equipment life.
Data as a maintenance tool
Digitalisation is transforming maintenance strategies too, explained Sabrina Zhang. Historically, underground pumping equipment was maintained according to fixed schedules, or after failures occurred. Today, continuous monitoring allows operators to identify performance changes long before they develop into equipment failures. Pressure trends, operating hours, energy consumption and system response can all be analysed to identify early warning signs.
“The real value of monitoring is to turn data into quality decisions,” she said. “Performance reporting helps operators identify opportunities for improvement, while predictive maintenance allows interventions before equipment failures affect production.”
At the Yongning mine, Armstrong Industrial collaborated with a local control supplier to provide ongoing operating data and performance reporting following commissioning. As of the second quarter of 2026, the system had recorded no reported downtime since entering service in October 2025.
“This illustrates how intelligent monitoring can support high equipment availability alongside operational reliability,” she noted. “For mines operating around the clock, avoiding even a single unplanned stoppage can translate into significant productivity gains.”
Local presence, faster lead times
The Yongning project has illustrated how supplier capability is essential to meeting customers’ increasingly demanding lead times. Faced with a demanding delivery schedule, Armstrong Industrial drew on inventory held at its Shanghai manufacturing facility and pre-ordered key materials before receiving the final project order. This allowed the complete integrated solution to be supplied and commissioned within just two months.
“Local manufacturing capability, inventory availability and responsive engineering support are critical in building relationships of trust,” she said. “This is especially important when mining projects are working to compressed development schedules.”
Supporting continuous improvement
Digitalisation of mining operations is having further impacts on the relationships between mines and original equipment manufacturers (OEMs), she pointed out. Instead of delivering equipment and concluding a project, OEMs are increasingly expected to support continuous performance optimisation throughout the life of an installation.
“This requires close collaboration and ongoing technical support from our side – as well as transparent performance reporting,” said Sabrina Zhang. “The Yongning installation demonstrates how these longer-term partnerships are evolving.”
Benchmark installation
Following its supplier evaluation process, Dongtai Group awarded Armstrong Industrial full marks for both product quality and service. The customer assessed factors including equipment quality, acceptance performance, responsiveness and after-sales support. As a sign of its satisfaction, the company subsequently selected the longwall installation as the benchmark for future operations across the mine.
“Mining companies are no longer buying individual products; they are investing in operational outcomes,” she said. “Success is measured directly by productivity and reliability – and also by the impact that energy efficiency can have on operating costs and sustainability goals.”
The experience at Yongning suggests that when on-mine solutions are designed as connected, data-driven platforms rather than isolated components, they can deliver measurable improvements in operational resilience, concluded Sabrina Zhang.
