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By John Latilla

Exxaro Mining?s Matla Coal situated in Mpumalanga, South Africa operates two shortwall faces on the No 4 and No 2 seam while the No 5 seam has also been longwalled in the past. Severe strata loading events have lead to a number of serious roof falls on the wall face (facebreaks) resulting in safety threats as well as considerable production losses. In 2002 the No 4 seam shortwall suffered a facebreak restricted mainly to the tailgate side of the mining panel due to a thick, near surface dolerite sill not breaking properly. This was partly due to the premature suspension of longwalling in the overlying No 5 seam. The resultant overloading lead to severe pillar damage and subsequent bord collapse. Surface pre-split blasting was successfully used to relieve the pressure as well as to pre-condition the dolerite above the following two panels. The shortwall on the No 2 seam has experienced mid-face loading due to No 4 seam chain pillars lying over this area and creating a secondary cantilever effect. Pre-split blasting of the solid rock above the No 4 seam pillars has resulted in a significant reduction in the number of facebreaks. The panel layout of the No 2 seam was subsequently changed so that the chain pillars on both the No 4 and No 2 seam are superimposed whereas previously they were offset.

Jan 1, 2007

By Peter B. Lilly

Thank you, Syd, for the kind introduction and for inviting me to give the Keynote Address at this very prestigious gathering of some of the finest intellect and talent in the domestic and international coal industry. CONSOL Energy has been a part of this conference for its entire 24-year existence. We have presented 27 papers over that time. CONSOL employees have also been members of the planning committee for the conference, and we have been pleased to support the event both financially and with many participants. So I am honored to be here with all of you this morning, especially during such a positive period for coal. You can just feel the enthusiasm in this room for our industry, and for this conference. I can tell you, there?s also a lot of enthusiasm and excitement in CONSOL Energy?s boardroom. And our enthusiasm is mirrored on Wall Street. But there remains an ironic twist to all of this attention. Even when times are good, the coal industry seems to go largely unnoticed by the mainstream. Outside of West Virginia and other coal-producing regions, the industry still seems to lack influence and support, at least here in America. As an example, last month, an ABC News crew visited our Blacksville 2 Mine, near here, to do a feature story on increased employment in the coal industry.

Jan 1, 2006

By Kot Unrug

Mine seals are necessary in nearly every mine to isolate mined-out areas from the ventilation network. There is a large number of seals in active mines and that number continually increases as the development spreads across the reserves. The recent accident caused by the failure of seals in the Sago mine resulted in new regulations. These regulations have been set based on a principle of eliminating the risk of failure, rather than the sound engineering and understanding of the conditions that may cause seal failure during an explosion of methane in sealed areas of the mine including the probability of such occurrences. This paper discusses the following subjects related to mine seals: The potential causes of methane explosions and the dynamic effects of pressure wave propagation. Seal materials and methods of construction in view of the interaction of the seal with the host rock environment as well as requirements for gathering geotechnical data. The design of seal dimensions is based on loading conditions, therefore the probable ranges of such loading is reviewed. There is also discussion of possible methods for shielding of seals from pressure pulses following an explosion. Particular seal?s types are examined in reference to the conditions at the seals location. A novel design is presented that will be a low- cost solution for the sealing of mined out areas. Recommendations are given for further research leading to a rational engineering system for design of new seals in coal mines.

Jan 1, 2008

By Ebrahim Ghasemi

Problem statement: One of the most challenging safety problems in room-and-pillar coalmines is controlling roof falls during retreat mining. Roof falls not only cause both fatal and non-fatal injuries to miners, stoppages in mining operations, and equipment breakdowns, but also results in the inefficient recovery of coal reserves. Approach: Sufficient awareness of effective parameters related to roof falls is an important factor in roof control. In this study, the major contributing parameters on roof falls during retreat mining are introduced based upon experience and judgment acquired from extensive retreat mining case histories and a review of relevant literature. Key findings: The main roof fall parameters in retreat mining can be divided into three categories: geological, design, and operational. Key conclusions: The design and operational parameters can be controlled by the engineer and/or operator. By the appropriate selection of these parameters in the design and implementation stages of retreat mining, the roof fall risk can be decreased to an acceptable extent.

Jan 1, 2012

By Thomas Barczak

A cooperative study was conducted with Emerald Coal Resources, L.P., an affiliate of Foundation Coal Corporation, and the National Institute for Occupational Safety and Health (NIOSH) to evaluate the effectiveness of (partially) pre-driven longwall recovery rooms supported with pumpable roof supports. This paper evaluates the load transfer mechanics associated with the advancement of the longwall face into the pre-driven recovery room and the widening of the room to recover the longwall shields. The results show that the yielding of the panel fender produced uncontrollable convergence that caused yielding of the shields and stiff pumpable roof supports when the face was approximately 10 ft from the recovery room. The shields continued to yield until the face advanced into the recovery room. Convergence in the pre-driven recovery room typically reached 6-8 in once the pumpable supports yielded and shed load through a declining residual load capacity prior to being cut out by the longwall shearer. Roof deformations occurred beyond the 32-ft horizon with total deformation ranging from 2 to 4 in, indicating that standing support was necessary to help control the span as the longwall face advanced into the pre-driven recovery room. Stability improved as the pumpable supports were cut out, thereby reducing the span between the shields and the outby pillars. In the end, the shields were successfully recovered under stable ground conditions. However, a disconcerting discovery was the load shedding of the outby pillars as the recovery room was mined into. It is postulated that this may be due to the progression of the rear ?abutment? moving toward the recovery room as the panel fender and standing support in the recovery room yield and shed load. This behavior was not expected with a relatively narrow room that is fully supported with standing support. If this mechanism is indeed occurring, the width of the room and performance of the standing support becomes even more critical. Premature failure of the support can lead to excessive convergence on the shield line that cannot be controlled even with modern shields, resulting in roof instabilities that can lead to catastrophic results.

Jan 1, 2007

By Wenbing Guo

Strip pillar mining method is one of the most important techniques for mining subsidence control in China. Mining depth is one of the most important factors that affect subsidence in strip pillar mining method. Six numerical simulation models were set up in this paper to simulate surface subsidence of strip pillar mining at different mining depths. The mining depth in these models ranged from 300 to 800 m. The simulated results were compared and analyzed. The results showed that the subsidence factor of strip pillar mining is related to mining depth. While other things being equal, the subsidence factor of strip pillar mining increases logarithmically with increase in mining depth. Their quantitative relationship was established based on the simulated results.

Jan 1, 2007

By Murali M. Gadde

Welded wire mesh is the most commonly used skin control technique in the United States underground coal mines. Currently, selection of the mesh is based on trial and error rather than any rigorous design methodology. Several factors affect a wire mesh?s performance including the amount of rock material to be supported and how the load is distributed, wire gauge, aperture size, grade of steel, weld strength, bolting pattern and sheet size. Although the best way to choose the mesh is to conduct full-scale physical load tests, because of the limitations on the number of variables that can be considered in such tests and the requirement of an elaborate test set-up, it may not always be possible to use this option. An alternative would be to use numerical modeling to study the load-deformation behavior of a wire mesh. In addition to providing a very detailed stress, strain distribution in the entire mesh, the advantage of this approach is the ease with which parametric studies can be conducted. In this paper it is shown that the load-deformation curves generated by nonlinear numerical models match closely with laboratory derived ones. Then, based on parametric studies, design guidelines are developed to choose the mesh appropriate for different loading conditions. The modeling studies also bring forth the limitations of the current lab studies. For example, under some conditions it was noticed that the small sheet size considered in lab tests would produce higher mesh deformations than a full-size one used in actual practice.

Jan 1, 2006

By Rob Thomas

Pre-driven recovery roads are used to speed up the longwall recovery process by reducing bolt-up requirements and by improving ground conditions on the face during the removal of the powered supports. To lower the geotechnical risks associated with the use of pre-driven recovery roads, and so improve its overall acceptance in the industry as a viable alternative to more conventional, potentially difficult and costly longwall recoveries, this paper outlines (i) a geomechanical model for the use and design of pre-driven recovery roads, (ii) an updated version of the worldwide database on pre-driven recovery roads, (iii) a summary of the various methods of holing a longwall into a pre-driven recovery road and (iv) a series of relevant ground support and strata management guidelines.

Jan 1, 2008

By Nic Slatalla

Acoustic emission monitoring techniques are a powerful tool for analysing deformation behaviour and fracture characteristics of rock samples under uniaxial loading. Uniaxial compression tests were carried out on three different types of sandstone for a better understanding of acoustic emission response with respect to rock deformation and damage develop-ment. All sandstone samples revealed congruent characteristic acous-tic emission patterns which correlated directly with distinct stress-strain stages. However, the acoustic response and development within the individual stages proved to be entirely different due to variations in their microstructure.

Jan 1, 2008

By Luis Giraldo

The installation procedure of fully grouted rebar bolts requires that the bolt be pushed through the resin grout until it is fully inserted in the borehole. Resin grout is a highly viscous fluid that is forced to flow through the annulus between the bolt and the borehole as the bolt advances. Variables such as bolt insertion speed, bolt vs. borehole diameter and grout viscosity determine the magnitude of the pressure generated ahead of the bolt tip. Under weak rock conditions, the magnitude of the pressure of bolt insertion is often sufficient to initiate hydraulic fracturing along joints or bedding planes that allow injection of grout into the strata leading to significant loss of bolt encapsulation. The grout pressure front has also been linked to gloving, a bolt installation problem that reduces bolt effectiveness. A series of tests were conducted to characterize the pressure of bolt insertion during bolt installation under various conditions. Analysis of the data shows three distinct stages of pressure build up during bolt installation. Understanding of the mechanisms involved may allow development of strategies for controlling the pressure buildup and its negative impact during roof bolting under weak rock conditions.

Jan 1, 2006

By John A. Rusnak

"This paper discusses the variation of coal strength based on the megascopic coal lithotypes for Central Appalachian high-volatile A coal beds. The composition of coal beds is complex and variable, depending on the depositional environment associated with original plant material, inflow of clastic material, and water level fluctuations in the original swamp/mire environment. Thus, different types of coal and sediment are formed within each coal bed. These differences in coal composition were first classified by Marie Stopes, a paleobotanist, in 1919. The classic coal megascopic lithotypes are vitrain, clarain, and durain, which correspond to bright, bright banded, and dull coal, respectively. Stopes also identified that the lithotype fusain, which is mineral charcoal, has no inherent strength and can act as a plane of discontinuity. In this study, two other coal-bed lithologies are also considered—bone and carbonaceous shale. This makes for a comprehensive suite of coal-bed stratigraphic components apart from rock partings. A total of 1,000 uniaxial compressive strength (UCS) and 440 indirect tensile strength (ITS) tests were conducted on cores from southern West Virginia that were specifically logged and described using the megascopic coal lithotype nomenclature. Statistical analysis is presented showing the results for each lithotype group with mechanical properties correlated to the lithotype. Previous studies have analyzed the mechanical breakage properties associated with coal lithotypes, which correlate well with these results. However, coal rank does appear to be a contributing factor, and this study is confined to only high-volatile A bituminous rank. Application of these results would be well suited to a rock mass classification system to address coal pillar rib stability. This would allow for rib support design and implementation to consider relative coal strength by visual observation of the seam stratigraphy through ongoing observations within a mine. Changes in seam composition can be readily identified, allowing the adjustment in rib support design. Another application would be for the determination of numerical modeling inputs based on detailed seam stratigraphy. However, these results, even with the standard strength reduction criteria, may not be applicable to currently accepted empirical coal pillar design procedures."

Jan 1, 2017

By Nic Slatalla

Resin anchored rock bolts are an effective tool to control the deformation of an underground opening because they combine high support capacity with fast installation. However, there are still numerous shortcomings concerning the understanding and interaction of the system bolt-resin-rock. Field and laboratory test series have been conducted for evaluating the load capacity and bond strength of resin grouted rock bolts in different host rocks under axial load. This paper describes that the behavior and shear strength of the system bolt-resin-rock depends on the rock type and discusses a simple correlation between peak shear strength and shear stiffness in the ratio 1:1000 which may moreover be helpful for estimating rock bolt capacity after installation.

Jan 1, 2006

By Anthony Iannacchione

A Major Hazard Risk Assessment (MHRA) was developed in Australia after a series of mine disasters in the 1990?s. A MHRA is used to help prevent major hazards, i.e. fire, explosion, wind-blast, outbursts, spontaneous combustion, roof instability and chemical and hazardous substances, from injuring miners. A MHRA is a structured process that identifies the characteristics of major hazards, assesses and ranks the risk they present, and evaluates engineering and administrative controls to mitigate them. These controls typically consists of a broad spectrum of prevention, monitoring, first response, and emergency response techniques and helps to move an operation from a reactive to a proactive approach towards safety. This paper documents a MHRA performed at an underground mine where strata instabilities and fire hazards may threaten the condition of its escapeways. The objective of this MHRA is to 1) identify what hazards could affect the egress through the mine?s escapeways, 2) determine what unwanted events pose the greatest threat for the mine, and 3) recommend a plan to prevent or recover from the potential disruption of egress through the escapeway. The plan provides information on the key existing controls that should be monitored and audited, and makes recommendation of new potential controls to further reduce related risks. By documenting the use of MHRA to this specific ground control issue, this paper provides a framework for others to judge the merits of this approach and to help design and perform these activities.

Jan 1, 2007

By Christopher Mark

"Many problems in rock mechanics are limited by our imperfect knowledge of the material properties and failure mechanics of rock masses. Mining problems are somewhat unique, however, in that plenty of real world experience is generally available and can be turned into valuable experimental data. Every pillar that is developed, or stope that is mined, represents a full-scale test of a rock mechanics design. By harvesting these data, and then using the appropriate statistical techniques to interpret them, mining engineers have developed powerful design techniques that are widely used around the world. Successful empirical methods are readily accepted because they are simple, transparent, practical, and firmly tethered to reality.The author has been intimately associated with empirical design for his entire career. But where his past papers have described the application of individual techniques to specific problems, the focus of this paper is the process used to develop a successful empirical method. A six-stage process is described:1. Identification of the problem, and of the end users of the final product2. Development of a conceptual rock mechanics model, and identification of the key parameters in that model3. Identification of measures for each of the key parameters, and the development of new measures (such as rating scales) where necessary4. Data sources and data collection5. Statistical analysis6. Packaging of the final productEach of these stages has its own potential rewards and pitfalls, which will be illustrated by incidents from the author’s own experience. The ultimate goal of this paper is to provide a new and deeper appreciation for empirical techniques, as well as some guidelines and opportunities for future developers."

Jan 1, 2015

By Rob Thomas

Main gate roof control during longwall retreat is subject to a significant increase in horizontal stress and risk. The implementation and management of an appropriate roof support design is as a result, an imperative requirement for any longwall mine and must in addition to the likely consequences of a roof fall, also consider the variables of the geotechnical environment, associated support costs and practicalities. This paper will therefore summarise a number of recent advances in main gate roof control in the Australian coal industry. Points considered include; (i) the ?Longwall Acceleration? concept, (ii) macro-scale horizontal stress notching, (iii) micro-scale horizontal stress notching, (iv) bedded versus laminated roof types and (v) the type of cable reinforcement used.

Jan 1, 2006

By David Hill

The Australian underground coal mining industry is increasingly operating in an environment that challenges traditional concepts of coal pillar design, against a background of heightened expectations and demands from other stakeholders with regard to the protection of both natural surface features and burgeoning civil infrastructure. The result is greater possibility of conflict between mine operators, developers and regulatory bodies, with potential for unnecessary sterilisation of Australia?s coal resources and/or escalating surface development / infrastructure protection costs. On the positive side some significant advances have occurred in the general level of understanding of pillar behaviour and stability, both in Australia and overseas. This paper examines some current issues in coal pillar design, focussing particularly on the application and limitations of analytical models of pillar loading. Established methodologies are reviewed and alternative approaches explored, including examples of key geometrical, geological and probabilistic concepts. Practical experiences from the Southern Coalfield of New South Wales (NSW) are examined for the purpose of highlighting critical variables. Finally, some suggestions are made with regard to the direction and opportunities for future research, with particular regard to coal pillar loading, in the interests of all stakeholders.

Jan 1, 2008

By John E. Feddock

Retreat mining plays an important role in the coal production within Kentucky and the Appalachian Coal Basin. In Kentucky, the majority of retreat mining is performed in the Eastern coal field. However, since September 2004, Kentucky has suffered four mining fatalities during retreat mining operations, and the coal industry has focused attention on the safety concerns associated with retreat mining practices. The Kentucky Department of Natural Resources (KYDNR) engaged Marshall Miller & Associates, Inc. (MM&A) to conduct a study to ensure that retreat mining is utilizing the best technology currently available and that the current available employee training programs afford maximum safety to miners. MM&A studied 34 coal mines that were conducting active retreat mining operations and represent about one third of all the mines with approved retreat mining plans in Kentucky. This paper summarizes the major research work conducted (Feddock and Ma, 2006) and recommends the practical methods for improving safety during retreat mining operations.

Jan 1, 2006

By Dennis Dolinar

In this National Institute for Occupational Safety and Health (NIOSH) investigation, numerical modeling is used to evaluate the degree the pillar strength is increased with a rectangular pillar over a square pillar. Three-dimensional models are developed with pillar sizes and geometries typical of underground limestone mines in the United States. Physical properties for the models are based on geotechnical surveys of nearly 30 underground limestone mines. To examine the effects of pillar length on pillar strength with the modeling, a parametric study was conducted where the pillar width was held constant while the length and height were varied resulting in width-to-height ratios ranging from 0.5 to 1.5 and width to length ratios ranging from 1 to 6. There are two aspects to pillar strength and failure. At relatively low stresses, pillars can fail as a result of geologic structure. At greater depths and sufficient extraction ratios, the pillars can also fail as a result of the vertical stresses exceeding the pillar strength. The effects of increasing pillar length regarding both strength aspects are presented in this study. Equations were developed for the increase in pillar strength with both height and length based on the model results. The results from these equations were compared to those from previously developed empirical equations for rectangular pillars. For the more slender limestone pillars with a width-to-height ratio below one, there is little increase in pillar strength for length-to-width ratios above 2 and almost no increase with length for a width-to-height ratio of 0.5. Only with the more squat pillars is there a significant improvement in strength with length. The gain in pillar strength with length for the pillars is explained by the change in the ratio of the area of the pillar affected by the ends to the area of the pillar. For the squattest pillar, the change in strength is also affected by an increase in pillar confinement along the central length of the pillar as the pillar transitions from a square to a long rectangular pillar. With geologic structure, added pillar length can significantly improve the pillar strength, depending on the strike of that structure with respect to the long pillar axis.

Jan 1, 2007

By Jeffrey Whyatt

Mining coal in deep, gassy strata is difficult, particularly in deep mines of the west. Dynamic failure (bumps, bounces, etc.) is commonplace, particularly where strong sandstone strata are encountered in the overburden. The disaster potential posed by dynamic failure in these mines is examined and found to be significant. Recent trends in MSHA reportable bumping of deep western coal mines have been increasing. Recent clusters of bumps are explored, a number of which have ended badly. The mechanisms of these bumps and their interactions with geologic structures are explored. Significant progress in controlling these hazards depends on a full understanding of their interaction with geologic conditions. It is apparent that not all MSHA reportable bumps have the same mechanism. These reports describe bumping of pillars, rolling of ribs, outbursts of coal, heaving of floor, shaking-induced roof falls, etc. Progress depends on understanding the underlying mechanisms of these events, and then determining which are potentially active at a particular location. Designs and other protective measures can then be adapted and deployed appropriately. Explicit consideration of mechanisms also supports extrapolation beyond experience as design extends into new mine geometries, geologies, mining methods and increasing depth. Finally, the goal should not be only to design hazard out of mines, but also to provide assurance that this, in fact, has occurred. Pursuit of this goal has been taken up by a major NIOSH research project. The centerpiece of this project is development of a Dynamic Failure Control Program to monitor evolution of dynamic failure hazards with changing geologic conditions to assure that control and protective measures are appropriately deployed.

Jan 1, 2008

By Matt Leeming

Several of the underground mines in the UK require a significant number of cable bolts to be installed, remedially, to control worsening roadway conditions. Often the access is limited and the only power source is compressed air. Machines for this duty are generally designed to perform with 100 psi but regularly only half of this is available. This paper seeks to outline the difficulties this situation causes the Rock Bolting Engineer, highlight the technical requirements for a machine of this type to succeed and detail a solution offered by our engineers.

Jan 1, 2007