Three-dimensional orebody modelling and intellectualized longwall mining for stratiform bauxite deposits

Acoupled biharmonic spline and linear interpolation algorithm was proposed to create a three-dimensional smooth deposit model with minimal curvature containing grade and position data. To obtain the optimal technical parameters, such as cuttingheight and drum diameter, a virtual longwall mining procedure was modelled by simulating the actual fully mechanized longwall mining process. Based on the above work, a bauxite deposit in a longwall mining panel was modelled by scattered grade data from ores sampled on the entry wall. The deposit was then demarcated by industrial indexes and sliced according to the virtual longwallmining procedure. The results show that the proposed interpolation algorithm can depict the stratiform structure of bauxite depositsand that the uncovered bauxite deposit has high proportions of high-grade and rich ore. The ranges of optimal cutting height and drum diameters are 1.72-2.84 m and 1.42-1.72 m, respectively. Finally, an intellectualized longwall mining procedure was designed to guide the mining process with the lowest dilution and loss rates.

Evaluation of coal pillar loads during longwall extraction using the numerical method and its application

It is very difficult to reasonably evaluate the loads acting on coal pillars in longwall panels during the planning of a new pillar system. The application of empirical equations is a common practice in calculating coal pillar loads while designing a new pillar. This paper proposes numerical models for evaluating coal pillar loads. The key of building a successful numerical model for calculating coal pillar loads lies in the fact that the model should represent the redistribution of stress all over the longwall panels and the surrounding areas, and it is especially important to include the characteristics of the stress rebuilding process in the gob areas, which are crucial for the building process of coal pillar loads. Based on the geo-mechanical background of the Baoshan Coal Mine, this paper details the procedures of applying numerical models to the evaluation of coal pillar loads and their local practices. The study results show it is feasible and reasonable to use numerical models to evaluate coal pillar loads.

Longwall automation:trends,challenges and opportunities

This paper explores the ongoing development and implementation of longwall automation technology to achieve greater levels of underground coal mining performance. The primary driver behind the research and development effort is to increase the safety, productivity and efficiency of longwall mining operations to enhance the underlying mining business. A brief review of major longwall automation challenges is given followed by a review of the insights and benefits associated with the LASC longwall shearer automation solution. Areas of technical challenge in sensing, decision support, autonomy and human interaction are then highlighted, with specific attention given to remote operating centres, proximity detection and systems-level architectures in order to motivate further automation system development.The vision for a fully integrated coal mining ecosystem is discussed with the goal of delivering a highperformance, zero-exposure and environmentally coherent mining operations.

Coal bursts in the deep longwall mines of the United States

Coal bursts involve the sudden, violent ejection of coal or rock into the mine workings. They are a particular hazard because they typically occur without warning. During the past 2 years three US coal miners were killed in two coal bursts, following a 6-year period during which there were zero burst fatalities. This paper puts the US experience in the context of worldwide research into coal bursts. It focuses on two major longwall mining coalfields which have struggled with bursts for decades. The Utah experience displays many of the ＂classic＂ burst characteristics, including deep cover, strong roof and floor rock, and a direct association between bursts and mining activity. In Colorado, the longwalls of the North Fork Valley （NFV） also work at great depth, but their roof and floor strengths are moderate, and most bursts have occurred during entry development or in headgates, bleeders, or other outby locations. The NFV bursts also are more likely to be associated with geologic structures and large magnitude seismic events. The paper provides a detailed case history to illustrate the experience in each of these coalfields. The paper closes with a brief discussion of how US longwalls have managed the burst risk.

Heavy rockbursts due to longwall mining near protective pillars:A case study

Rockburst represents a very dangerous phenomenon in deep underground mining in unfavourable conditions such as great depth, high horizontal stress, proximity of important tectonic structures, and unmined pillars. The case study describes a recorded heavy rockburst in the Czech part of the Upper Silesian Coal Basin, which occurred during longwall mining near the protective pillar. The artificial dividing of geological blocks and creation of mining protective pillars(shaft pillars, crosscut pillars etc.) is a dangerous task in light of rockbursts occurring mainly due to overstressing of remaining pillars. A simple model of this situation is presented. Natural and mining conditions are analysed and presented in detail as well as registered seismicity during longwall mining in the area. Recorded rockbursts in the area of interest are described and their causes discussed. Many rockbursts near protective pillars were recorded in this mining region. Methodical instructions for rockburst prevention in proximity of protective pillars as well as for gates driving were devised based on the evaluation of rockburst causes. The paper presents these principles for prevention.

Innovative backfilling longwall panel layout for better subsidence control effect-separating adjacent subcritical panels with pillars

In recent years,field trials of non-pillar longwall mining using complete backfill have been implemented successively in the Chinese coal mining industry.The objective of this paper is to get a scientific understanding of surface subsidence control effect using such techniques.It begins with a brief overview on complete backfill methods primarily used in China,followed by an analysis of collected subsidence factors under mining with complete backfill.It is concluded that non-pillar longwall panel layout cannot protect surface structures against damages at a relatively large mining height,even though complete backfill is conducted.In such cases,separated longwall panel layout should be applied,i.e.,panel width should be subcritical and stable coal pillars should be left between the adjacent panels.The proposed method takes the principles of subcritical extraction and partial extraction;in conjunction with gob backfilling,surface subsidence can be effectively mitigated,thus protecting surface buildings against mining-induced damage.A general design principle and method of separated panel layout have also been proposed.

Longwall surface subsidence control by technology of isolated overburden grout injection

Surface subsidence is a typical ground movement due to longwall mining, which causes a series of environmental problems and hazards. In China, intensive coal extractions are commonly operated under dense-populated coalfields, which exacerbates the negative subsequences resulted from surface settlement. Therefore, effective approaches to control the ground subsidence are in urgent need for the Chinese coal mining industry. This paper presents a newly developed subsidence control technology: isolated overburden grout injection, including the theory, technique and applications. Relevant procedures such as injection system design, grouting material selection, borehole layout, grout take estimation and injection process design are proposed. The applicability of this technology has been demonstrated through physical modelling, field measurements, and case studies. Since 2009, the technology has been successfully applied to 14 longwall areas in 9 Chinese coal mines. The ultimate surface subsidence factors vary from 0.10 to 0.15. This method has a great potential to be popularized and performed where longwall mining are implemented under villages and ground infrastructures.

Systematic principles of surrounding rock control in longwall mining within thick coal seams

Effective surrounding rock control is a prerequisite for realizing safe mining in underground coal mines.In the past three decades, longwall top-coal caving mining(LTCC) and single pass large height longwall mining(SPLL) found expanded usage in extracting thick coal seams in China. The two mining methods lead to large void space left behind the working face, which increases the difficulty in ground control.Longwall face failure is a common problem in both LTCC and SPLL mining. Such failure is conventionally attributed to low strength and high fracture intensity of the coal seam. However, the stiffness of main components included in the surrounding rock system also greatly influences longwall face stability.Correspondingly, surrounding rock system is developed for LTCC and SPLL faces in this paper. The conditions for simultaneous balance of roof structure and longwall face are put forward by taking the stiffness of coal seam, roof strata and hydraulic support into account. The safety factor of the longwall face is defined as the ratio between the ultimate bearing capacity and actual load imposed on the coal wall.The influences provided by coal strength, coal stiffness, roof stiffness, and hydraulic support stiffness,as well as the movement of roof structure are analyzed. Finally, the key elements dominating longwall face stability are identified for improving surrounding rock control effectiveness in LTCC and SPLL faces.

Automation in U.S. longwall coal mining: A state-of-the-art review

This paper reviews the development of U.S. longwall mining from an unknown to became the world standard in the past five decades with emphasis on automation. Large scale longwall face equipment were imported from Germany and United Kingdom to increase production in the 1970 s and great effort was made to improve them to suit U.S. conditions, rather than domestic market. Automation began with the development of electrohydraulic shields in 1984 and continue to present. Introduction of first generation semi-automated longwall system occurred in 1995 and step-to-step improvement continues to present following the development of sensor technology and internet of things(IOT). Since then, emphasis on new development has been concentrated on the improvement of equipment reliability, miner's health and safety as well as production, including dust control techniques, proximity sensor, anti-collision and remote control. Automation is classified into two categories: automation of individual face equipment and automation of longwall system. The automation development of longwall system is divided into three stages: shearer-initiated-shield-advance(SISA), semi-automated longwall system, and remote control shearer.

Fracturing,caving propagation and influence of mining on groundwater above longwall panels–a review of predictive models

Historically there have been a number of different hypotheses and empirical models developed in an attempt to describe the nature of fracturing above longwall panels in underground coal mining.The motivation for suchmodels varies,ranging fromunderstanding the impact ofmining on surface subsidence,to back-analysis of caving behaviour in the immediate roof behind the longwall face.One of the most critical motivating factors that is taking on increased importance in many coalfields,is the need for better understanding,and hence prediction of the impact of mining on overlying strata,particularly strata units acting as aquifers for different groundwater horizons.This paper reviews some of the major prediction models in the context of observed behaviour of strata displacement and fracturing above longwall panels in the southern coalfields of New South Wales,south of Sydney.The paper discusses the parameter often referred to as"height of fracturing"in terms of the critical parameters that influence it,and the relevance and appropriateness of this terminology in the context of overlying sub-surface subsidence and groundwater impact.The paper proposes an alternative terminology for this parameter that better reflects what it is and how it is used.The paper also addresses the potential role of major bedding shear planes mobilised by mining and their potential influence on overlying subsidence and groundwater interference.

Simulation of recovery of upper remnant coal pillar while mining the ultra-close lower panel using longwall top coal caving

With the depletion of easily minable coal seams,less favorable reserves under adverse conditions have to be mined out to meet the market demand.Due to some historical reasons,large amount of remnant coal was left unrecovered.One such case history occurred with the remnant rectangular stripe coal pillars using partial extraction method at Guandi Mine,Shanxi Province,China.The challenge that the coal mine was facing was that there is an ultra-close coal seam right under it with an only 0.8–1.5 m sandstone dirt band in between.The simulation study was carried out to investigate the simultaneous recovery of upper remnant coal pillars while mining the ultra-close lower panel using longwall top coal caving(LTCC).The remnant coal pillar was induced to cave in as top coal in LTCC system.Physical modelling shows that the coal pillars are the abutments of the stress arch structure formed within the overburden strata.The stability of overhanging roof strata highly depends on the stability of the remnant coal pillars.And the gob development(roof strata cave-in)is intermittent with the cave-in of these coal pillars and the sandstone dirt band.FLAC3D numerical modelling shows that the multi-seam interaction has a significant influence on mining-induced stress environment for mining of lower panels.The pattern of the stress evolution on the coal pillars with the advance of the lower working face was found.It is demonstrated that the stress relief of a remnant coal pillar enhances the caveability of the pillars and sandstone dirt band below.

Numerical simulation to determine the gas explosion risk in longwall goaf areas:A case study of Xutuan Colliery

Underground gassy longwall mining goafs may suffer potential gas explosions during the mining process because of the irregularity of gas emissions in the goaf and poor ventilation of the working face,which are risks difficult to control.In this work,the 3235 working face of the Xutuan Colliery in Suzhou City,China,was researched as a case study.The effects of air quantity and gas emission on the three-dimensional distribution of oxygen and methane concentration in the longwall goaf were studied.Based on the revised Coward’s triangle and linear coupling region formula,the coupled methane-oxygen explosive hazard zones(CEHZs)were drawn.Furthermore,a simple practical index was proposed to quantitatively determine the gas explosion risk in the longwall goaf.The results showed that the CEHZs mainly focus on the intake side where the risk of gas explosion is greatest.The CEHZ is reduced with increasing air quantity.Moreover,the higher the gas emission,the larger the CEHZ,which moves towards the intake side at low goaf heights and shifts to the deeper parts of the goaf at high heights.In addition,the risk of gas explosion is reduced as air quantities increase,but when gas emissions increase to a higher level(greater than 50 m3/min),the volume of the CEHZ does not decrease with the increase of air quantity,and the risk of gas explosion no longer shows a linear downward trend.This study is of significance as it seeks to reduce gas explosion accidents and improve mine production safety.

Passive seismic velocity tomography on longwall mining panel based on simultaneous iterative reconstructive technique (SIRT)

Mining operation, especially underground coal mining, always has the remarkable risks of ground control. Passive seismic velocity tomography based on simultaneous iterative reconstructive technique （SIRT） inversion is used to deduce the stress redistribution around the longwall mining panel. The mining-induced microseismic events were recorded by mounting an array of receivers on the surface, above the active panel. After processing and filtering the seismic data, the three-dimensional tomography images of the p-wave velocity variations by SIRT passive seismic velocity tomography were provided. To display the velocity changes on coal seam level and subsequently to infer the stress redistribution, these three-dimensional tomograms into the coal seam level were sliced. In addition, the boundary element method （BEM） was used to simulate the stress redistribution. The results show that the inferred stresses from the passive seismic tomograms are conformed to numerical models and theoretical concept of the stress redistribution around the longwall panel. In velocity tomograms, the main zones of the stress redistribution arotmd the panel, including front and side abutment pressures, and gob stress are obvious and also the movement of stress zones along the face advancement is evident. Moreover, the effect of the advance rate of the face on the stress redistribution is demonstrated in tomography images. The research result proves that the SIRT passive seismic velocity tomography has an ultimate potential for monitoring the changes of stress redistribution around the longwall mining panel continuously and subsequently to improve safety of mining operations.

Prediction of face advance rate and determination of the operation efficiency in retreat longwall mining panel using rock engineering system

A new approach for prediction of face advance rete (FAR) prior to mining operation and determination of the operation efficiency after mining operation in retreat longwall mining panel is presented based upon the concepts of rock engineering system (RES). For this purpose, six longwall panels considered in Parvadeh-I coal mine. Seven major effective parameters on FAR was selected including coal mine roof rating, gas propagation, safety factor of longwall face, ratio of joint spacing to cutting depth at longwall face, longwall face inclination, panel width, floor rock mass rating. To performance evaluation of the presented model, the relationship between the average vulnerability indexes of advance operation with FAR was determined in considered panels with coefficient of determination (R2) equal to 0.884 that indicate relatively acceptable correlation and compatibility. Investigations of the research indicated that it is possible to determine the actual operation efficiency under fair conditions by a RES-based model. The inevitable reduction of FAR for each longwall panel was determined by presented model that the difference amount between the maximum possible practical face advance rate (FARmpp) and recorded actual face advance rate (FARa) indicate the operation efficiency. Applied approach in this paper can be used to prediction of FAR in retreat longwall mining panel for same conditions that can have many benefits, including better and more accurate planning for the sales market and mine operation. Also, presented method in this paper can be applied as a useful tool to determination of actual operation efficiency for other sections and extraction methods in coal mines.

Ground response to high horizontal stresses during longwall retreat and its implications for longwall headgate support

Roof falls in longwall headgate can occur when weak roof and high horizontal stress are present. To prevent roof falls in the headgate under high horizontal stress, it is important to understand the ground response to high horizontal stress in the longwall headgate and the requirements for supplemental roof support. In this study, a longwall headgate under high horizontal stress was instrumented to monitor stress change in the pillars, deformations in the roof, and load in the cable bolts. The conditions in the headgate were monitored for about six months as the longwall face passed by the instrumented site.The roof behavior in the headgate near the face was carefully observed during longwall retreat.Numerical modeling was performed to correlate the modeling results with underground observation and instrumentation data and to quantify the effect of high horizontal stress on roof stability in the longwall headgate. This paper discusses roof support requirements in the longwall headgate under high horizontal stress in regard to the pattern of supplemental cable bolts and the critical locations where additional supplemental support is necessary.

An improved influence function method for predicting subsidence caused by longwall mining operations in inclined coal seams

Prediction of surface subsidence caused by longwall mining operation in inclined coal seams is often very challenging. The existing empirical prediction methods are inflexible for varying geological and mining conditions. An improved influence function method has been developed to take the advantage of its fundamentally sound nature and flexibility. In developing this method, the original Knothe function has been transformed to produce a continuous and asymmetrical subsidence influence function. The empirical equations for final subsidence parameters derived from col- lected longwall subsidence data have been incorporated into the mathematical models to improve the prediction accuracy. A number of demonstration cases for longwall mining operations in coal seams with varying inclination angles, depths and panel widths have been used to verify the applicability of the new subsidence prediction model.

Characteristics of evolution of mining-induced stress field in the longwall panel:insights from physical modeling

The evolution of mining-induced stress field in longwall panel is closely related to the fracture field and the breaking characteristics of strata.Few laboratory experiments have been conducted to investigate the stress field.This study investigated its evolution by constructing a large-scale physical model according to the in situ conditions of the longwall panel.Theoretical analysis was used to reveal the mechanism of stress distribution in the overburden.The modelling results showed that:(1)The major principal stress field is arch-shaped,and the strata overlying both the solid zones and gob constitute a series of coordinated load-bearing structures.The stress increasing zone is like a macro stress arch.High stress is especially concentrated on both shoulders of the arch-shaped structure.The stress concentration of the solid zone in front of the gob is higher than the rear solid zone.(2)The characteristics of the vertical stress field in different regions are significantly different.Stress decreases in the zone above the gob and increases in solid zones on both sides of it.The mechanical analysis show that for a given stratum,the trajectories of principal stress are arch-shaped or inverselyarched,referred to as the‘‘principal stress arch’’,irrespective of its initial breaking or periodic breaking,and determines the fracture morphology.That is,the trajectories of tensile principal stress are inversely arched before the first breaking of the strata,and cause the breaking lines to resemble an inverted funnel.In case of periodic breaking,the breaking line forms an obtuse angle with the advancing direction of the panel.Good agreement was obtained between the results of physical modeling and the theoretical analysis.

An influence function method based subsidence prediction program for longwall mining operations in inclined coal seams

The distribution of the final surface subsidence basin induced by longwall operations in inclined coal seam could be significantly different from that in flat coal seam and demands special prediction methods. Though many empirical prediction methods have been developed, these methods are inflexible for varying geological and mining conditions. An influence function method has been developed to take the advantage of its fundamentally sound nature and flexibility. In developing this method, significant modifications have been made to the original Knothe function to produce an asymmetrical influence function. The empirical equations for final subsidence parameters derived from US subsidence data and Chinese empirical values have been incorpo- rated into the mathematical models to improve the prediction accuracy. A corresponding computer program is developed. A number of subsidence cases for longwall mining operations in coal seams with varying inclination angles have been used to demonstrate the applicability of the developed subsidence prediction model.

A review of cavability evaluation in longwall top coal caving

Longwall Top Coal Caving has been considered as one of the most effective technologies for the extraction of underground thick coal seams. A large number of studies on the applicability of Longwall Top Coal Caving into new mine sites have linked the success of its application to the geo mechanical understanding of the cavability of the top coal. The paper aims to improve the knowledge of the top coal cavability evaluation. A range of parameters that affect the top coal cavability were first identified. Afterward, a number of cavability assessment methods and classifications were reviewed. The result is important in that it assists researchers in developing an advanced and reliable tool for the top coal cavability evaluation.

Monitoring strata behavior due to multi-slicing top coal caving longwall mining in steeply dipping extra thick coal seam

For studying the strata behavior due to multi-slicing top coal caving longwall mining along-the-strike direction in steeply dipping extra thick coal seams,the shield support pressures of the upper and lower slices of panel 37220 in Dongxia Coal Mine were monitored using the KJ513 dynamic monitoring system.The set up rooms adopted the "horizontal line-arc segment-inclined line" form and used different types of shield supports.The results show that the strata pressure of upper slice panel 37220-1 changed slightly along the strike direction,while along the dip direction it exhibited strong to weak pressure from bottom to top.The first weighting interval of lower slice panel 37220-2 was about 60.8 m,and the average periodic weighting interval were about 22.6 m.The strata behavior of panel 37220-2 exhibited a spatiotemporal characteristic in that periodic weighting occurred first in the middle-upper part,followed by the middle and upper parts,arc segment,and finally the lower part.During the periodic weighting,the weighting interval and intensity also exhibited strong space characteristics.The average dynamic load coefficient was 1.48 and the maximum lateral load of the side shield was 20-25 MPa.