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.

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.

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.

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.

New development of longwall mining equipment based on automation and intelligent technology for thin seam coal

The paper introduced complete sets of automatic equipment and technology used in thin seam coal face, and proposed the comprehensive mechanization and automation of safe and high efficiency mining models based on the thin seam drum shearer. The key technology of short length and high power thin seam drum shearer, and new type roof support with big extension ratio and plate canopy were introduced. The new research achievement on automatic control system of complete sets of equipment for the thin seam coal, which composed of electronic-hydraulic system, compact thin seam roof supports, high effective shearer with intelligent control system, and characterized by automatical follow-up and remote control technology, was described in this paper..

Fractured zone height of longwall mining and its effects on the overburden aquifers

As mining depth becomes deeper and deeper,the possibility of undermining overburden aquifers is increasing.It is very important for coal miners to undertake studies on the height of fractured zone during longwall mining and the effects of longwall mining on the underground water while mining under surface water bodies and underground aquifers.In order to study this problem,piezometers for monitoring underground water levels were installed above the longwall panels in an American coalmine.Large amounts of pre-mining,during mining and post-mining monitoring data were collected.Based on the data,the heights of fractured zones were obtained and the effects of longwall mining on the underground water were studied.The results demonstrate that when the piezometer monitoring wells had an interburden thickness of less than 72.7 m,the groundwater level decreased immediately to immeasurable levels and the wells went dry after undermining the face of longwall.The height of the fractured zone is 72.7-85.3 m in the geological and mining conditions.The results also show that the calculated values of fractured zones by the empirical formulae used in China are smaller than the actual results.Therefore,it is not always safe to use them for analyses while mining under water bodies.

Impact of longwall mining on groundwater above the longwall panel in shallow coal seams

Since longwall mining causes subsidence through the overlying strata to the ground surface, the surface water and groundwater above the longwall panels may be affected and drained into the lower levels.Therefore, loss or interruption of streams and overburden aquifers is a common concern in coal industry.This paper analyzed the potential effects of longwall mining on subsurface water system in shallow coal seam. In order to monitor different water level fluctuations throughout the mining period, three water wells were drilled down to the proposed deformation zone above the longwall panel. A GGU-SS-FLOW3 D model was used to predict water table contours for the periods of pre- and post-mining conditions. The field data from the three water wells were utilized to calibrate the model. The field test and numerical model can help to better understand the dewatering of shallow aquifers and surface waters related to ground subsidence from longwall mining in shallow coal seam.

Optimization of gob ventilation boreholes design in longwall mining

Gob ventilation boreholes(GVBs)are widely used for degasification in U.S.longwall coal mines.Depending on geological conditions,30–50%of methane can be recovered from longwall gob using GVBs.A NIOSH funded research at the Colorado School of Mines confirmed that GVBs can efficiently reduce methane at the face.However,GVBs can also draw some fresh air from the face and create explosive gas zones(EGZs).Explosive gas mixtures may be formed in gob areas due to the increased ingress of oxygen from GVBs.It is critical to identify the locations for GVBs for maximizing extraction of methane and minimizing hazards of explosion.This study analyzes the effect of operating parameters and design of GVB on methane extraction,EGZs formation,and face and tailgate methane concentrations.Methane extraction,formation of EGZs,and concentration of methane in working areas are significantly impacted by various factors.These factors include the distance of work face and tailgate from GVBs,diameter of GVBs,vacuum pressure of wellhead,GVB distance from the roof of the coal seam,and number of operating GVBs in a panel.Computational fluid dynamics(CFD)evaluations suggest optimal design and operating parameters of GVBs that can contribute to maximum benefits with minimum risks.

Study on effects of longwall mining on the underground water

It is very important for secure mining under water bodies to study the effects of Iongwall mining on the underground water. In order to study this problem, piezometers for monitoring underground water levels were established in an American coalmine. Large amounts of pre-mining and post-mining monitoring data were collected. Based on the data the effects of Iongwall mining on the underground water was studied. The results demonstrate that when the piezometer monitoring wells have an interburden thickness less than 72.7 m, the groundwater level decreases immediately to immeasurable levels and go dry after undermining. The height of the fractured zone in is 72.7-85.3 m in this geological and mining conditions. The results also show that the calculated value of fractured zone by the empirical formulae used in China is smaller than the actual results. Therefore, it is not always safe to use them in analysis of mining under water bodies.

Trial of small gateroad pillar in top coal caving longwall mining of large mining height

Coal seams in Tashan Mine of Datong Coal Group in China average 15 m thick and have been mined by the top coal caving longwall mining method of large mining height. Mining height was 3.8 m and the top coal caving height was 11.2 m. The gateroad pillar between panels was 38 m. During retreat mining,serious bumps occurred in the gateroads on both sides of the pillar affecting safety production. Therefore,pillarless mining was experimented. Using numerical modeling and comparative study of cases of similar mining condition,it was decided to employ a 6 m wide pillar,rather than the previous 38 m wide pillar.Support system for the gateroads was designed and implemented. During gateroad development,pillar failure conditions and entry deformation were monitored. Hydraulic fracturing method was employed to cut off the K3 sandstone along the entry rib so as to reduce the abutment pressure induced during retreat mining. Support reinforcement method combining grouting and advanced reinforcement methods was proposed to insure stable gateroad ahead of mining. Methane drainage and nitrogen injection were implemented to eliminate hazards associated with mine fire and spontaneous combustion. Since the development of gateroad has just completed,and retreat mining has not begun,the effectiveness of the proposed methods is unknown at this point. However,monitoring will continue until after mining.The results will be published in a separate paper.

Numerical Study on Effect of Longwall Mining on Stability of Main Roadway under Weak Ground Conditions in Indonesia

The purpose of this research is to study the effect of longwall mining on the stability of main roadway in the underground coal mine. The PT GDM （Gerbang Daya Mandiri） underground coal mine in Indonesia, where the rocks are weak, was selected as a representative study site. To accomplish the objective of the research, the finite difference code software FLAC3D was used as a tool for the numerical simulations. The longwall mining of several panel and barrier pillar widths at various depths was simulated and discussed. Based on the simulation results, it indicates that the effect of coal panel extraction on the main roadway stability depends on the width of panel and barrier pillar. The greatest effect occurs when the large panel width and the small barrier pillar width are applied, whereas the smallest effect happens when the narrow panel width and the large barrier pillar width are adopted. In this paper, therefore, to maintain the stability of the main roadway with the aim of maximizing the coal recovery, the appropriate size of panel and barrier pillar width is proposed for each mining depth for this underground coal mine.

Punch Multi-slice Longwall Mining System for Thick Coal Seam under Weak Geological Conditions

Most of coal is produced from open-cut mines in Southeast Asian countries. However, the conditions of their surface mines are worsening each year： the stripping ratio is increasing, approaching economic ratio and the regulation of environmental protection. To meet the demand for coal, underground mines have to be developed in the near future. Under these circumstances, the development of new coal mines from open-cut highwalls are being planned in Southeast Asian Countries. Moreover, some of the Southeast Asian mines have thick coal seams. However, if the conventional mining systems and designs introduced in US, Australia and European Countries are applied, several geotechnical issues can be expected due to the mines＇ weak geological conditions. From these backgrounds, this paper proposed a punch multi-slice mining system with stowing for thick coal seam under weak geological conditions and discussed its applicability and suitable design by means of numerical analysis.

Assessment of Relationship of Some Causal Factors Associated with Productivity of Longwall Mining Using Structured Equation Modeling

Enhancement of productivity optimization is steadily gaining the priority in mining companies especially in the underground coal mining industry which faces a daunting task to balance marginal profit generation with a comparatively high cost of production, volatile market price and rapid grade variation. This paper is aimed to analyze some of the causal factors both technical and site specific which are directly or indirectly impacting the productivity of the longwall coal mining system such as downtime of equipment system in longwall panel, overloading of conveyors and bin, preventive maintenance, gas management practices and injury severity rate. Structured Equation Modelling (SEM) was used to study the causal relationships between the above-mentioned factors and mine productivity. The equipment considered for analysis included shearer, armored face conveyor, crusher, bridge stage loader, chock supports, main gate drive, gate conveyor, hydraulic pumps and crusher. SEM was applied to relate the correlations existing among these causal variables in order to assess their direct or indirect impact on mining productivity. Based on the data extracted over a period of 10 months which included the extraction of 2 longwall panels, the study revealed a significant negative causal relationship between injury severity rate (p < 0.01) and equipment downtime (p = 0.001), with mine productivity. However, preventive maintenance delay time, gas management delay time and conveyor overloading delay time were found to have an insignificant direct influence on mine productivity but indirectly modify it through a significant mediator relationship with equipment downtime. This information would assist mine management to take proper preventive measures.

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.

Longwall automation: Delivering enabling technology to achieve safer and more productive underground mining

The ongoing need to deliver improved safety, productivity and environmental benefit in coal mining presents an open challenge as well as a powerful incentive to develop new and improved solutions. This paper assesses the critical role that enabling technologies have played in the delivery of remote and automated capability for longwall mining. A brief historical account is given to highlight key technical contributions which have influenced the direction and development of present-day longwall technology. The current state of longwall automation is discussed with particular attention drawn to the technologies that enable automated capability. Outcomes are presented from an independently conducted case study that assessed the impact that CSIRO＇s LASC longwall automation research has made to the longwall mining industry in Australia. Importantly, this study reveals how uptake of this innova- tive technology has significantly benefitted coal mine productivity, improved working conditions for personnel and enhanced environmental outcomes. These benefits have been widely adopted with CSIRO automation technology being used in 60 per cent of all Australian underground operations. International deployment of the technology is also emerging. The paper concludes with future challenges and opportunities to highfight the ongoing scope for longwall automation research and development.

Theoretical description of drawing body shape in an inclined seam with longwall top coal caving mining

Understanding the characteristics of drawing body shape is essential for optimization of drawing parameters in longwall top coal caving mining.In this study,both physical experiments and theoretical analysis are employed to investigate these characteristics and derive a theoretical equation for the drawing body shape along the working face in an inclined seam.By analyzing the initial positions of drawn marked particles,the characteristics of the drawing body shape for different seam dip angles are obtained.It is shown that the drawing body of the top coal exhibits a shape-difference and volume-symmetry characteristic,on taking a vertical line through the center of support opening as the axis of symmetry,the shapes of the drawing body on the two sides of this axis are clearly different,but their volumes are equal.By establishing theoretical models of the drawing body in the initial drawing stage and the normal drawing stage,a theoretical equation for the drawing body in an inclined seam is proposed,which can accurately describe the characteristics of the drawing body shape.The shape characteristics and volume symmetry of the drawing body are further analyzed by comparing the results of theoretical calculations and numerical simulations.It is shown that one side of the drawing body is divided into two parts by an inflection point,with the lower part being a variation development area.This variation development area increases gradually with increasing seam dip angle,resulting in an asymmetry of the drawing body shape.However,the volume symmetry coefficient fluctuates around 1 for all values of the seam dip angle variation,and the volumes of the drawing body on the two sides are more or less equal as the variation development volume is more or less equal to the cut volume.Both theoretical calculations and numerical simulations confirm that the drawing body of the top coal exhibits the shape-difference and volume-symmetry characteristic.

Developing selective mining capability for longwall shearers using thermal infrared-based seam tracking

Longwall mining continues to remain the most efficient method for underground coal recovery. A key aspect in achieving safe and productive longwall mining is to ensure that the shearer is always correctly positioned within the coal seam. At present, this machine positioning task is the role of longwall personnel who must simultaneously monitor the longwall coal face and the shearer's cutting drum position to infer the geological trends of the coal seam. This is a labour intensive task which has negative impacts on the consistency and quality of coal production. As a solution to this problem, this paper presents a sensing method to automatically track geological coal seam features on the longwall face, known as marker bands, using thermal infrared imaging. These non-visible marker bands are geological features that link strongly to the horizontal trends present in layered coal seams. Tracking these line-like features allows the generation of a vertical datum that can be used to maintain the shearer in a position for optimal coal extraction. Details on the theory of thermal infrared imaging are given, as well as practical aspects associated with machine-based implementation underground. The feature detection and tracking tasks are given with real measurements to demonstrate the efficacy of the approach. The outcome is important as it represents a new selective mining capability to help address a long-standing limitation in longwall mining operations.

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.

Transport model for shale gas well leakage through the surrounding fractured zones of a longwall mine

The environmental risks associated with casing deformation in unconventional(shale)gas wells positioned in abutment pillars of longwall mines is a concern to many in the mining and gas well industry.With the recent interest in shale exploration and the proximity to longwall mining in Southwestern Pennsylvania,the risk to mine workers could be catastrophic as fractures in surrounding strata create pathways for transport of leaked gases.Hence,this research by the National Institute for Occupational Safety and Health(NIOSH)presents an analytical model of the gas transport through fractures in a low permeable stratum.The derived equations are used to conduct parametric studies of specific transport conditions to understand the influence of stratum geology,fracture lengths,and the leaked gas properties on subsurface transport.The results indicated that the prediction that the subsurface gas flux decreases with an increase in fracture length is specifically for a non-gassy stratum.The sub-transport trend could be significantly impacted by the stratum gas generation rate within specific fracture lengths,which emphasized the importance of the stratum geology.These findings provide new insights for improved understanding of subsurface gas transport to ensure mine safety.

New development of sets equipment technologies for coal mine longwall face in China

Background of the development and achievement on sets equipment technologies for coal mine longwall face in China was reviewed initially. On the theoretical side, a coupling model of hydraulic support and surrounding rock, support pa- rameters optimization and threedimensional （3D） dynamic design method were presented. On the practical side, this paper out lined some of practical issues and discussed some relative methods and technologies. In thin seam coal longwall mining, how to lower equipment height is the first problem that should be solved. Roof pressure regularity, control of rooffall and collapse, and hydraulic support stability were investigated preferentially in 5-7 m coal seam longwall mining. The application of equip- ment for longwall mining with 5-7 m cutting height in China was concluded. The characteristics of full-mechanized top coal caving for extra thick seam coal were presented. The automation of top-caving hydraulic support and relevant equipment have achieved important breakthrough. At the end of this paper, further development of China＇s coal industry and longwall mining technologies and equipment were prospected in brief. This paper gives readers a comprehensive understanding of China＇s coal mine longwall face equipment technologies. It will give help to other countries on its coal mining development.