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By Bruce K. Hebblewhite

This paper provides an overview of the international ?state of the art? with respect to underground coal mining methods used in seams of thickness greater than 4.5 m, through a review of a selection of high performing thick seam mining operations around the world?both Single Pass Longwall (SPL) and Longwall Top Coal Caving (LTCC). The paper discusses the recent operational experiences from these selected faces, together with the ground control issues faced, and identifies some of the major, inherent geotechnical factors that can influence the mining method selection, design criteria, and ultimate performance, from both an operational and safety perspective. It is clear that both of these methods are developing quickly? not only from an operational and equipment perspective, but also from the understanding of critical geotechnical criteria. There is an increasing role for both methods in thick seam environments, although the higher SPL faces will only be successful in the near to mid-term under benign geotechnical environments. Regardless of the method, a thorough understanding of the critical geotechnical factors is a key to successful implementation of either method.

Jan 1, 2013

By Ming-Gao Qian

How to monitor and control the support and surrounding strata system on a longwall face effectively is one of the major research problems in ground control. Based on observations on movements of the support and surrounding strata of face No. 2703 of Dongpang colliery, the relationship between the downtime related to support and surrounding strata and other influential factors is analysed systematically in this paper. Monitoring indices and control measures are then determined by taking corresponding downtime as an objective function. When the monitoring method, developed from the above findings, was used on face No. 2703, the downtime due to support and surrounding strata was remarkably reduced, and the face advanced normally.

Jan 1, 1992

By Josh Johnson, Stephen Tadolini, Mark Ferster, Curt Jacobs

"Stillwater Mining Company is the only U.S. producer of platinum group metals (PGMs) and the largest producer outside of South Africa and Russia. The Company controls a considerable portion of the J-M Reef and is currently developing the ""Blitz Project,"" which will provide a main haulage level, ore pass systems, backfill plants, and flow-through ventilation to increase production and ensure sustainable extraction of this critical strategic mineral. While driving two sub-parallel footwall laterals to about 8,125 m (26,000 ft) long, one of the development drifts experienced a massive fall in a geologically disturbed area created by a dike intrusion. Combinations of a void fill material (Tekseal), polyurethane injection, fore poling coupled with steel arches, and supplemental bolting allow safe and efficient advance through this geologically disturbed zone. This paper presents the details of this project.INTRODUCTIONStillwater Mining Company is the only U.S. producer of platinum group metals (PGMs) and the largest producer outside of South Africa and Russia. The Company controls a considerable portion of the J-M Reef and is currently developing the ""Blitz Project,"" which will provide a main haulage level, ore pass systems, backfill plants, and flow-through ventilation to increase production and ensure sustainable extraction of this critical strategic mineral.Tunnel Boring Machines (TBMs), shown in Figure 1, have been used extensively at both the Stillwater Mine and the East Boulder Mine to develop access to the J-M Reef. The J-M Reef is a PGMbearing reef deposit located in the Stillwater Complex near NyeMontana. The mining property and location are shown in Figure 2.The Blitz Project is named after the Blitz mining claims and is developing the Eastern extent of the J-M Reef Project., This consists of a 5.5 m (18 ft) diameter TBM drive on the SOE (1,562 m (5,000 ft) above sea level and east of the shaft collar) and a 4.7 x 4.7 m (15 x 15 ft) drill and blast heading on the 5,600E (1,750 m (5,600 ft) above sea level and east of the shaft collar). The Benbow Decline will be completed running perpendicular to the TBM by drilling and blasting methods. The TBM drift will be used for exploration drilling, ventilation, and will serve as the main haulage level. The 56E will be used for ventilation and exploration drilling. The Benbow decline will serve as the exhaust drift."

Jan 1, 2016

By Frank Chase

Longwall mining has gained the reputation as being the safest extraction method in underground coal mines. However, one of the most difficult tasks associated with longwall mining is moving the face once a panel is completed. Based on Mine Safety and Health Administration (MSHA) fatality reports since 1996, longwall face recovery operations have claimed the lives of 5 U.S. miners and have resulted in numerous injuries. Recovery operations can be hazardous because they involve moving large pieces of equipment in very confined spaces. They are also conducted in highly stressed ground conditions due to front abutment loads generated by panel extraction. Shield removal is the most hazardous operation during face recovery because miners are constantly exposed to the unpredictable gob edge. To protect the miners, one or more walking shields, cribbing and/or other supplemental roof and standing supports are typically employed as breaker line supports as each shield is removed. At the Harris No. 1 Mine in southern WV, mobile roof supports (MRS?s) have been used in lieu of traditional walking shields on 17 face moves since 1997. MRS?s are shield-like support units mounted on crawler tracks and are commonly used during room-and-pillar retreat mining operations. For longwall recovery, the two biggest advantages that MRS?s have over traditional walking shields are that they are remotely controlled and are highly maneuverable. MRS?s have contributed to safer shield recovery and shorter move times at the Harris No. 1 Mine. This paper will address both the safety and the operational issues associated with MRS usage during shield recovery. It will also discuss new developments, including the use of the inherently safer battery powered MRS?s, which have been recently certified by the Mine Safety and Health Administration.

Jan 1, 2007

By Holger Witthaus

There is more than a century of experience in multiple seam mining in Germany. In several mines up to 20 seams had been excavated within the last decades. Due to the nature of the deposit and the history of technical development the older panels cause a complex stress distribution for the lower seams and the current longwalls in descending order of mining. The depth of the longwalls reaches up to 4000 ft. This causes a maximum vertical stress that reaches between 30 and appr. 60 MPa. To handle these conditions several support systems are applied for roadway heading. A central knowledge management system for ground control is used for design and dimensioning of support within the DSK. This paper gives an overview to the nature of German multiple seam mining and the solutions in matters of panel layout and support design. It describes the full lifecycle for roadways in the seam starting with the geological and geotechnical evaluation, the basics of roadway deformation in great depth, the development of planning tools and standards for German coal mines, the range of alternative of support systems and roadheading techniques, as well as the reinforcement measures and the processing of support at the T-junction of the face entry. This paper uses exemplary descriptions that are consolidated in a specialized reference book ?Gebirgsbeherrschung von Flözstrecken? ? ?Ground Control in Roadways? which summarizes the standards of ground control based on the development of the past 25 years in German coal mines.

Jan 1, 2007

By Zhang Liandong

Roof control in thick-seam mining has long been a difficult problem in mine design and coal mining. In the early 1980's, through ground control instrumentation and investigation the rules of roof strata movement were determined, based on which the sliding roof bar powered support was properly designed and successfully applied to roof control to thick seam mining with caving. Underground trials in Huating Coal Mine produced satisfying results. The technique is being employed in many Chinese coal mines and won the national price for technical advance.

Jan 1, 1990

By Andre Vervoort

Falls of ground, such as falls of roof and sidewall collapses, are a major cause of fatalities and injuries in South African collieries. Based on information obtained from the accident reports of the various Chief Inspectors of nines, a statistical analysis was conducted covering the period 1970 to 1988. This study shows that the volume of rock in a fatal fall of ground is often quite small. In intersections, fatal falls are on average larger than in roadways and at the face. It was also found that in 36 % of all fatal falls of ground no temporary or permanent support was installed at the site of the accident.

Jan 1, 1990

By A. Wahab Khair

Coal mining has evolved into extensive use of continuous mining machines for development and production. This has resulted in an increase in dependence on the versatile continuous miners. The present-day continuous miners are powerful in terms of rated power but are still plagued by wear of bits which hinders development and production as the bits have to be continuously changed at regular intervals. Previous attempts to analyze bit wear has been either restricted to the theoretical approach and or laboratory testing. This paper discusses about the overall aspect of bit and drum design for different conditions. Using the laboratory model set up, numerical models and field testing, a new bit and drum design was analyzed to evaluate their performance under different conditions. The results proved that a newer bit design and drum design were successful in limiting the amount of wear as well as improving the performance of the continuous miner and production.

Jan 1, 2008

By John Ellenberger

The nature of a stone deposit is rarely defined through exploration and engineering design, but more through the actual experience encountered as the mine develops; hence, issues with ground control are often at the forefront for a new mine. Ground control problems account for over 15 percent of lost-time injuries in underground stone mines. The objective of this work is to present actions taken during early development of a stone mine to mitigate the obvious effects of high horizontal stress on ground control. The mine was developed from a box cut with relatively little cover, and high horizontal stresses were not anticipated. Early recognition of possible high horizontal stress resulted in mapping of the mine using the NIOSH-developed Roof Fall Risk Index (RFRI) to provide a baseline to objectively analyze roof conditions. A program of borescoping the mine roof provided valuable roof beam thickness data and found that the roof beam was of minimal thickness, approximately 10 percent of drift width. As the mine developed, it became apparent that ground control problems related to high horizontal stress existed. A concentrated effort was made to improve ground conditions by implemeting a number of mitigation techniques. Actions taken by the mine included systematic roof support, reorientation of mining direction, a lower roof horizon, reduced span widths and reduced mining height in crosscuts to prevent running falls. These strategies resulted in signifcantly improved ground stability.

Jan 1, 2012

By David Miller

Longwall gateroad support can be supplied by a variety of methods. The system of support also needs to be flexible as conditions change. This is especially true in the complex geological conditions of the west Kentucky # 13 seam. Methods of gateroad support used in this seam will be presented along with the successes and failures of the systems as conditions changed Lodestar Energy's gateroad support progression through the seven longwall panels retreated to date will provide an insight into planning for future panels

Jan 1, 1998

By Archie Richardson

The trona mines in the Green River Basin, commonly known as the "trona patch," present an interesting set of rock mechanics issues stemming from mining in a unique underground environment. Like other minerals occurring in tabular deposits, trona is mined using high-productivity room-and-pillar and longwall methods. However, trona does not behave quite like other evaporites and behaves far differently than coal. In this paper, the following key issues in trona patch rock mechanics are discussed: material properties, in situ stress field, water and gas pressure effects, creep characteristics, pillar behavior, roof span stability, floor stability, underground tailings storage, longwall mining, two-seam mining. and solution mining. Many of the existing trona producers are entering potentially more difficult mining conditions, and much consideration is being given to "new" technologies such as longwall mining and solution mining. In analyzing 20 years of experience with trona patch rock mechanics issues the authors have identified key comparisons and contrasts with conventional tabular deposit rock mechanics that will help illuminate what has been learned as the trona patch enters the 21" century.

Jan 1, 1999

By Richard E. Bischke

Computer assisted finite element model analysis, originally developed to study stress distributions in aircraft, has been modified into a versatile mining program, that can be used to assist the engineer with predictions of mine subsidence. International Exploration, Inc. has developed an in-house finite element model program which incorporates a multitude of factors influencing mine subsidence such as mine design, physical rock properties, structure, faults, joints and topography. Finite element analysis of a mine model can mathematically determine the magnitude and direction of the principal stresses within each of the elements forming the model. By comparing the calculated in-situ stresses to the actual rock strengths, high risk regions within a mine can be identified. These potentially unstable regions of the mine can be allowed to fail within the model and the resultant stress redistribution and element movement calculated. Thus, the effects of the mine collapse at the surface can be predicted for the purpose of determining the potential damage, if any, that could occur to surface structures from deep mine failure. Stabilization materials can also be mathematically inserted into the model to design and analyze the effectiveness of subsidence prevention programs. Two examples are presented of the finite element program being used to predict mine subsidence at substantially different geologic and mining provinces in Pennsylvania.

Jan 1, 1984

By Tobias U. Papst

The German Ruhrgebiet is slowly transitioning into a post-mining state. It has been subjected to industrial-grade hard coal mining operations for more than 150 years. Due to a political decision, German hard coal mining will come to an end in 2018. By then the surface will have subsided up to 20 meters. After all mining activities in the area have ended, there will be no need to maintain the current mine water level. Accordingly, the company operating the last remaining coal mines has decided to let the water level rise to an as yet undetermined level. Alongside other issues that may be caused by rising groundwater levels, the protection of the area?s drinking water supply is of utmost importance. This notion is also represented by European and German law. The primary intent of the applicable laws is to protect the health of the citizenship. This means protecting ground water that may be used by humans from being contaminated by the mine water. This paper outlines the consequences of European and German legislature on mining aftercare using the example of one of Europe?s largest agglomerations.

Jan 1, 2014

By Holger Witthaus

Various seam conditions had been examined during longwall production at RAG German hard coal mines. Based on the field data a prediction method was developed considering separation planes as influencing factors for roof falls at the face. The characteristics, orientation, and density of separation are important factors on the occurrence of roof falls. In addition to geological influences, the performance parameters and geometry of support must be considered and optimized for the prediction and prevention of roof falls in a longwall face. Based on detailed macro- and microscopic investigations of e coal seams considering various ranks of carbonization, the origin and characteristics of separation planes are determined and a strata-specific influence on roof fall is interpreted. It was assessed that the coal face fracturing and displacement caused by the stress depend on the floor and roof strata conditions due to activation of the existing separation planes. Field studies are shown giving an idea of influences by advance rates of the longwall face, support delay and hydraulic pressure to the roof control in longwall faces in depth of more than 3000 ft. The analysis includes the application of specific software developed for longwall roof fall prediction as a result of a European research project. The software allows a laminar graphic display of roof fall probability, which is used for recognition of risk areas and risk management.

Jan 1, 2009

By Andre Zingano

The coal seam strength and the failure criteria that represent the behavior of the coal seam are very important for mine section and pillar design. Additionally, mine section and pillar design take into account roof and floor layers, which form the roof-pillar-floor system. Therefore, underground ground control design begins, most importantly, with rock mass characterization. Another issue is the distribution or behavior of the coal seam strength for the whole mine area. Sometimes, the coal seam strength is assumed to be the same for an entire area, but this is not true because the coal seam is heterogenic and anisotropic, and also the coal strength is affected by faults and spacing between fractures. The objective of this paper is to demonstrate the use of the methodology for geomechanics characterization to determine the strength for the Bonito coal seam, and discuss the coal seam strength distribution around the entire mine area. The intact coal strength was determined by laboratory tests that were completed during the last 17 years, including triaxial and uniaxial strength tests. It was noted that there is a strong correlation between all laboratory strength tests with 90% confidence interval. The explanation for this coal seam strength variation is the presence of the discontinuities and their variation in quantity and quality at each location in the mine area, because the coal seam rock classification and its behavior will be affected by the quantity and quality of fractures.

Jan 1, 2014

By Chris Mark

Successful longwall mining requires a stable tailgate entry. Gate entry performance is influenced by a number of geotechnical and design factors, including: - Pillar size and pillar loading; - Roof quality; - Floor quality; - Entry width; and, - Artificial support (primary and secondary). This paper describes a comprehensive, practical, design methodology, based on statistical analysis of a nationwide data base of longwall ground control experience. Geotechnical surveys were conducted at 44 U.S. longwall mines, and underground observations of site geology, entry conditions, and support design were recorded at each mine. The observations were combined with discussions with mine personnel to identify 69 longwall gate entry designs as satisfactory, unsatisfactory, or borderline. Only conventional longwall designs, in which the pillars are expected to carry the full abutment loads, were included in the data base. Designs which employed yield pillars only were excluded. The case histories were characterized using five descriptive parameters. Pillar design was described by the Analysis of Longwall Pillar Stability Factor (ALPS SF). A major new contribution is the Coal Mine Roof Rating (CMRR), a rock mass classification system that quantifies the structural competence of bolted mine roof. Other quantitative measures were developed for primary support, secondary support, and entry width. Multivariate statistical analyses indicated that in 84% of the case histories the tailgate performance could be correctly predicted using just ALPS and the CMRR. Most of the misclassified cases fell within a very narrow borderline region. The analyses also confirmed that primary support and gate entry width are essential elements in successful gate entry design. The relative importance of the floor and of secondary support could not be determined from the data. Based on these results, a simple equation was developed to guide the design of longwall pillars and gate entries: ALPS SF,, = 1.76 - 0.014 CMRR Where: ALPS SF, = ALPS SF suggested for design. Guidelines for entry width and primary support density, as related to the CMRR, are also provided.

Jan 1, 1993

By P. Gaskell

The paper examines the development of rock movement between a longwall extraction horizon and the surface for a fully caved mining situation. Physical modelling has been used to examine the mechanics of ground movement and the propagation of fractures around the longwall working. The paper discusses dimensional analysis, model construction and measurement technique and data processing of the results into effective graphical forms for further study.

Jan 1, 1988

By B. Tulu, D. Gearhart

A comprehensive monitoring program was conducted to measure the rock mass displacements, support response, and stress changes at a longwall tailgate entry in West Virginia. Monitoring was initiated a few days after development of the gateroad entries and continued during passage of the longwall panels on both sides of the entry. Monitoring included overcore stress measurements of the initial stress within the rock mass, changes in cable bolt loading, standing support pressure, roof deformation, rib deformation, stress changes in the coal pillar, and changes in the full three-dimensional stress tensor within the rock mass at six locations around the monitoring site. During the passage of the first longwall, stress measurements in the rock and coal detected minor changes in loading, while minor changes were detected in roof deformation. As a result of the relatively favorable stress and geological conditions, the support systems did not experience severe loading or rock deformation until the second panel approached within 30–50 ft of the instrumented locations. After reaching the peak loading at about two to three inches of roof sag, the cable bolts started to unload, and the load was transferred to the standing supports. The standing support system was able to maintain an adequate opening inby the shields to provide ventilation to the first crosscut inby the face, as designed. The results were used to calibrate modeled cable bolt response to field data and to validate numerical modeling procedures that have been developed to evaluate entry support systems. It is concluded that the support system was more than adequate to control the roof of the tailgate up to the longwall face location. The monitoring results have provided valuable data for the development and validation of support design strategies for longwall tailgate entries.

Jan 1, 2017

By D. E. Winston

Roof falls are the major cause of fatalities in the, coal mining industry and the prevention of roof failure is a major concern of mine management. Many ground failures observed underground are associated with geological discontinuities such as fractures, faults, clay veins and sandstone channels inherent in the earth's crust (Rinkenberger, 1977). To properly design a mine requires an advance knowledge of such geologic discontinuities and this is not always available from exploration boreholes. The use of remote sensing for mine planning is a relatively new development, and is at present being used primarily by the Roof Control Support Branches of the Mane Safety and Health Administration (MSHA) in Denver and Pittsburgh. However, technical advances, coupled with public access to previously unavailable photographic products, make remote sensing a useful aid in the difficult process of mine planning (Jansky and McCabe, 1979). Remote sensing techniques are being used to predict the location of geological features in advance of mining which influence roof conditions. The features appear on photographic images as linears, which are plotted on a mine map and serve as a planning tool for mine management. Also, during development of entries toward a linear, mining personnel will be on alert for signs of unstable roof conditions which might normally go undetected. Preventive action can then be taken before a fall occurs. A confusing aspect in remote sensing, analyses is terminology such as linear, lineament, fracture trace and joint. In this report the term "linear" refers to a line-like appearance on an aerial photograph or satellite imagery which signifies a naturally occurring geologic feature no the earth's surface. The objective of this paper is to describe the use of remote sensing techniques as an aid in predicting geological discontinuities which might produce hazardous roof conditions to a mine operating in the Pocahontas No. 4 Seam in southern West Virginia. Mine projections and roof control plans will he developed based on this and other available information such as data from cored drill holes.

Jan 1, 1982

By Vincent A. Scovazzo

"The most significant study on the effects of longwall mining on gas and oil well integrity was completed by a consortium of coal and shale gas industry participants. A field study was conducted in 2013 and 2014 and is referred to by its location on Well Pad NV-35. The experiment site was located at the CONSOL Enlow Fork Mine in Washington County, Pennsylvania.The experiment was completed to verify John T. Boyd Company (BOYD) calculations and studies completed under contract by for the Pennsylvania Department of Environmental Protection Gas Well Pillar Study Update. The findings of the original study were presented by BOYD at the 32nd Conference, while numerical analysis of the Well Pad NV-35 field study was presented by Dr. Su at the 35th Conference.This paper addresses the findings of the experiment and how it confirmed the conclusions of the original study.INTRODUCTIONA field study was conducted in 2013 and 2014 by a consortium of coal and shale gas industry members to test the effects of longwall-induced ground movement on the stability and integrity of wells drilled through a gateroad abutment pillar. The project was initiated to test initial John T. Boyd Company (BOYD) findings of the Gas Well Pillar Study Update (Scovazzo and Moran, 2014), completed for Pennsylvania Department of Environmental Protection, Bureau of Oil and Gas Management (PDEP). Background and initial findings on this project were presented at the 32nd Conference (Scovazzo and Moran, 2012). The field work and numerical analysis were spearheaded by CONSOL Energy, Inc. (CONSOL) with participation by Chevron, EQT, Noble Energy, Range Resources, Marcellus Shale Coalition, and the Pennsylvania Coal Alliance.Dr. Wen H. Su of CONSOL was the leader of the field experiment with input from the participants. Dr. Su also completed numerical analysis of the results and model casing deformation. Analytical results were presented by Dr. Su at the 35th Conference (Su, 2017)."

Jan 1, 2018