Selection of wear-resistant materials and implementation framework for remanufacturing ground exploring tools (GETs) for coal mining applications: case-study of continuous miner cutter (CMC’s) components
Ground exploring tools (GETs), used in coal mining industries, encounter severe failure due to their continuous pressing and scratching against the coal seam embedded with hard bands and impurities. Failure of GETs lead to direct cost expenditure due to replacement of worn-out components; besides, s...
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| Published in: | Journal of remanufacturing Vol. 15; no. 2-3; pp. 207 - 271 |
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| Main Authors: | , , , , , , , |
| Format: | Journal Article |
| Language: | English |
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Dordrecht
Springer Netherlands
01.11.2025
Springer Nature B.V |
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| ISSN: | 2210-464X, 2210-4690 |
| Online Access: | Get full text |
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| Abstract | Ground exploring tools (GETs), used in coal mining industries, encounter severe failure due to their continuous pressing and scratching against the coal seam embedded with hard bands and impurities. Failure of GETs lead to direct cost expenditure due to replacement of worn-out components; besides, significant indirect cost resulting from machine downtime when they are removed, and new ones are reinstalled. Mining businesses replace worn GETs with new parts at an exorbitant cost at a great risk to their sustainability. Replacement goes against the ethos of the circular economy (CE) philosophy which aims at ensuring highest value of resource utilisation while eliminating waste by improving the design of materials, products, and systems. A critical analysis of the approaches of CE for restoring damaged GETs reveals remanufacturing is the best option to adopt to keep GETs in good working conditions. Meanwhile, there is scanty literature to guide remanufacturing practitioners on materials selection and framework for implementing remanufacturing of damaged GETs. This review addresses this challenge by identifying appropriate wear-resistant materials and the most economically feasible remanufacturing technology which restores the performance of GET’s components to at least as new upon remanufacturing. Using the components of continuous miner (CM) as a case study, the operating environments in which GETs function are described to gain insight into the modes of failure encountered. Information gathered from the operation environments of the GETs and their failure modes assisted in selecting appropriate wear-resistant materials. Techno-economic analysis of the remanufacturing of various modes of failure of the components of GETs was carried out to ascertain the economic feasibility of remanufacturing various failure modes. Future perspectives of failure analysis, material selection, and framework for implementing remanufacturing of various failure modes (based on severity of damage) in GETs are presented. This review extends the frontier of knowledge in the fields of GETs remanufacturing and potential wear-resistant materials for GETs to academic researchers and industrial practitioners. |
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| AbstractList | Ground exploring tools (GETs), used in coal mining industries, encounter severe failure due to their continuous pressing and scratching against the coal seam embedded with hard bands and impurities. Failure of GETs lead to direct cost expenditure due to replacement of worn-out components; besides, significant indirect cost resulting from machine downtime when they are removed, and new ones are reinstalled. Mining businesses replace worn GETs with new parts at an exorbitant cost at a great risk to their sustainability. Replacement goes against the ethos of the circular economy (CE) philosophy which aims at ensuring highest value of resource utilisation while eliminating waste by improving the design of materials, products, and systems. A critical analysis of the approaches of CE for restoring damaged GETs reveals remanufacturing is the best option to adopt to keep GETs in good working conditions. Meanwhile, there is scanty literature to guide remanufacturing practitioners on materials selection and framework for implementing remanufacturing of damaged GETs. This review addresses this challenge by identifying appropriate wear-resistant materials and the most economically feasible remanufacturing technology which restores the performance of GET’s components to at least as new upon remanufacturing. Using the components of continuous miner (CM) as a case study, the operating environments in which GETs function are described to gain insight into the modes of failure encountered. Information gathered from the operation environments of the GETs and their failure modes assisted in selecting appropriate wear-resistant materials. Techno-economic analysis of the remanufacturing of various modes of failure of the components of GETs was carried out to ascertain the economic feasibility of remanufacturing various failure modes. Future perspectives of failure analysis, material selection, and framework for implementing remanufacturing of various failure modes (based on severity of damage) in GETs are presented. This review extends the frontier of knowledge in the fields of GETs remanufacturing and potential wear-resistant materials for GETs to academic researchers and industrial practitioners. |
| Author | Matshediso, B. I. Prasad, R. V. S. Motimedi, T. Pityana, S. L. Botes, A. Akintunde, I. B. Lindsay, E. E. Olakanmi, Eyitayo O. |
| Author_xml | – sequence: 1 givenname: I. B. surname: Akintunde fullname: Akintunde, I. B. organization: Department of Mechanical Energy & Industrial Engineering, Botswana International University of Science & Technology, UNESCO Chair On Sustainable Manufacturing & Innovation Technologies (UCoSMIT) Team, Botswana International University of Science & Technology, Advanced Manufacturing & Engineering Education (AMEE) Research Group, Botswana International University of Science & Technology, Materials & Metallurgical Engineering Department, Federal University of Technology Minna – sequence: 2 givenname: E. E. surname: Lindsay fullname: Lindsay, E. E. organization: Department of Mechanical Energy & Industrial Engineering, Botswana International University of Science & Technology, UNESCO Chair On Sustainable Manufacturing & Innovation Technologies (UCoSMIT) Team, Botswana International University of Science & Technology, Advanced Manufacturing & Engineering Education (AMEE) Research Group, Botswana International University of Science & Technology – sequence: 3 givenname: Eyitayo O. surname: Olakanmi fullname: Olakanmi, Eyitayo O. email: olakanmie@biust.ac.bw organization: Department of Mechanical Energy & Industrial Engineering, Botswana International University of Science & Technology, UNESCO Chair On Sustainable Manufacturing & Innovation Technologies (UCoSMIT) Team, Botswana International University of Science & Technology, Advanced Manufacturing & Engineering Education (AMEE) Research Group, Botswana International University of Science & Technology – sequence: 4 givenname: R. V. S. surname: Prasad fullname: Prasad, R. V. S. organization: UNESCO Chair On Sustainable Manufacturing & Innovation Technologies (UCoSMIT) Team, Botswana International University of Science & Technology, Advanced Manufacturing & Engineering Education (AMEE) Research Group, Botswana International University of Science & Technology, Department of Chemical, Materials & Metallurgical Engineering, Botswana International University of Science & Technology – sequence: 5 givenname: B. I. surname: Matshediso fullname: Matshediso, B. I. organization: UNESCO Chair On Sustainable Manufacturing & Innovation Technologies (UCoSMIT) Team, Botswana International University of Science & Technology, Department of Mining & Geological Engineering, Botswana International University of Science & Technology, Centre for Mining & Mineral Beneficiation, Botswana International University of Science & Technology – sequence: 6 givenname: T. surname: Motimedi fullname: Motimedi, T. organization: Morupule Coal Mines – sequence: 7 givenname: A. surname: Botes fullname: Botes, A. organization: Department of Mechanical Engineering, Nelson Mandela University – sequence: 8 givenname: S. L. surname: Pityana fullname: Pityana, S. L. organization: Laser-Enabled Manufacturing Research Group, Council for Scientific & Industrial Research |
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| Keywords | Process development Mechanical properties Ground exploring tools (GETs) Microstructure Remanufacturing Wear-resistant material |
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| SubjectTerms | Business and Management Carbon Circular economy Coal Coal industry Coal mining Cost control Damage Downtime Economic analysis Economics Energy consumption Engineering Environmental Management Failure analysis Failure modes Feasibility Impurities Materials selection Miners Mining industry Product life cycle Recycling Remanufacturing Review Scratching Sustainable Development Waste Management/Waste Technology Wear resistance Working conditions |
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| Title | Selection of wear-resistant materials and implementation framework for remanufacturing ground exploring tools (GETs) for coal mining applications: case-study of continuous miner cutter (CMC’s) components |
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