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By Patrick Ph. D. Kennedy, Osvaldo A. Ph. D. Bascur

With the revolutionary progress in information and computer technologies, applying the latest information technologies in metallurgical complexes has become a serious challenge to both a major opportunity and a serious challenge to both management and technical teams. The emerging component and object technologies are changing the way everyone can beneficially use their computer and networks to add to their corporate bottom lines. Most mining and metallurgical plants use predictive maintenance policies based on statistical analysis and special techniques, like vibration analysis and oil and lube analysis for critical equipment. Process control strategies are installed in several metallurgical sites. All process equipment and control strategies require maintenance from local personnel at the mine. Integrated use of existing and emerging technologies is making it possible to implement an overall process effectiveness control index. This index is based on key indices such as losses due to plant availability, performance efficiency and rate of quality. The availability of real time and process history to identify the most critical part of the processing system from mechanical integrity is highlighted. An emerging plant integration paradigm is described to simplify the implementation of business enterprise resources management and distributed plant management systems.

Jan 1, 1998

By Roger G. Haga, Richard P. Campbell

Introduction Project scheduling . . . . • What is it? • Why is it done? • Who does it? • How is it done? • When is it done? These are some of the questions that will be addressed in this paper. It is intended that by exploring these questions, an understanding of project scheduling, its purpose and benefits can be achieved. The purpose of this article is not to describe in detail "how to schedule", but rather to give an overview of the scheduling function on a project. A successful scheduling effort is dependent upon the people responsible for developing, implementing, and monitoring the schedule, and the tools and procedures that are used. These three elements are integral components of project scheduling. What is it? A schedule is the integration of network relationships, resource constraints and the calendar. The schedule identifies when the activities "will" be done, while the network states when they "must" be done. Networking techniques are the most widely accepted scheduling tool for complex projects. The benefit of the network is the simplicity in illustrating, presenting and analyzing the dependency relationships of a project. The logic network is the foundation of the schedule. When calendar dates are applied to the logic network, it becomes a schedule which provides the basis for evaluation of project status, forecasting the occurrence of events and controlling the project. The sequence of activities that requires the longest time to complete determines the overall duration of the schedule. This longest sequence of activities is called the "critical path". The "critical path method" (CPM) is used to describe this particular schedule network methodology. The two common conventions of CPM networks are the "arrow diagram met hod" (ADM) and the "precedence diagram method" (PIM). There are arguments in favor of each of these two methods, and usually the one that is used is a matter of personal preference, project directive or corporate procedure.

Jan 1, 1986

By J. R. Walls

The United States potash industry had its beginning in the early Colonial days. Potash was initially manufactured by leaching of hardwood ashes in large iron pots. Production of potash was recorded as early as 1631 in New Hampshire, and in Maine a few years later. According to the census of 1850, the production of potash was America's most thriving chemical industry and, at that time, 569 plants were reported producing potash from wood ashes. Interest in potash was so great prior to the 1800's that the very first United States patent, signed by George Washing- ton, was granted for the production of potash on July 31, 1790. A new era for the production of potash began when potash was discovered by the analysis from a brine well in 1839 near Stassfurt, Germany while exploring for salt. The predominant use of potash at that time was in the chemical industry rather than agriculture. The discovery, by Justice von Liebig in about 1858, that potash salt contributed greatly to the essential plant food in soil opened up an enormous potential market for a suitable potash material.

Jan 1, 1985

By T. D. Dreger

In the spring of 2009, Suncor Energy Inc. technical personnel saw an opportunity to improve planning and mining of overburden material in order to address aggressive construction goals and increased mining complexity. By tying together current and historical equipment performance, geological model information, and material observation in the field new operating elevations for the shovels were developed. At the same time, methodology of recording and reporting overburden movement through the Modular Mining DISPATCH system was changed. The result of this first stage of improvements was an increase in construction-grade material available at the face. The personnel involved realized that other opportunities were available to build on the initial successes and establish processes that would stand up to attrition and experience levels. A cross-functional technical team was assembled to identify ways of further improving workflows around overburden mining. Some of the opportunities realized include greater alignment between planning, reporting and operations as well as development of reporting tools that help steward Mine Operations to the plan. All of which have resulted in Suncor meeting or beating its forecast overburden targets. The cross-functional technical team continues to seek out new and better ways of doing business so Suncor can continue to deliver on its commitment of outstanding performance and results.

Jan 1, 2012

By W. M. Ma, Daniel W. H. Su, K. Centofanti, Yi Luo, W. L. Zhong, Syd S. Peng

1.1 INTRODUCTION When underground mining involves total extraction, it induces overburden strata movements. If not properly planned it causes surface subsidence and affects surface environmental conditions. Total extraction usually refers to longwall mining and room and pillar mining with pillar extraction. Surface subsidence has long been a subject of intensive research for scientists all over the world and considerable achievements have been obtained. However due to its difficulties and complicated nature, research into overburden movement has been thus far incomplete as compared to that into surface subsidence. Since surface subsidence is a manifestation of the results of overburden movement, the processes and mechanisms of overburden movement must be fully understood in order to establish the mathematical prediction models of surface subsidence. In this chapter the processes of overburden movement and its zones of movement in the overburden will be discussed. 1.2 PROCESSES OF OVERBURDEN MOVEMENT When total extraction is used, it produces a large void in the coal seam and disturbs the equilibrium conditions of the surrounding rock strata. The roof strata bend downward while the floor heaves. When the excavated area (or gob) expands to a sufficient size, the roof strata will cave. As a result, the overlying strata continue to bend and break until the piles of the fallen rock fragments are sufficiently high to support the overhanging strata. At this tie the overhanging strata no longer cave, but bend and rest on the underlying strata. Strata bending and subsidence develop upward until reaching the surface and forming a subsidence basin. The whole overburden strata and the surface subsidence basin will further go through a period of compaction and gradually become stabilized. Current knowledge regarding the process of overburden movement has been derived from several sources. One is the direct observation of the mined sections and their surfaces, another from field monitoring of strata movements in the overburden, and others from computer modeling and scale modeling in the laboratory. For example, Figs. 1.1 and 1.2 show the results of a borehole monitoring experiment (Borehole B-2) using the full profile borehole inclinometer and full profile borehole extensometer for lateral displacements and vertical subsidence, respectively (Conroy and Gyarmaty, 1983). The panel, 400 ft wide by 5000 ft long and 630 ft deep, was extracted from the Pittsburgh No. 8 seam which had an average thickness of 54 in. The face advanced from east to west. Curve A in Fig. 1.1 shows the inclination of the borehole when it was 45 ft ahead of the face at Position A (i.e., on the solid coal side). The total deviation of the borehole was 1/7000. The first shear movement occurred at 130 ft above the coal seam and appeared to have occurred along the bedding plane with large contrast of rock strata on both sides, i.e., sandstone vs. shale. When the face had passed the borehole 79 ft at Position B, the borehole deformed to assume a bow shape with a maximum deviation of 2.8 in. from the center line. Numerous shearing planes occurred and extended further upward. When the face had passed the borehole by 75 ft at position C, strata subsidence was measured. Fig. 1.2 shows that a strata separation as large as 4 ft occurred at 40 to 100 ft above the coal seam. Above this level, the strata subsided more uniformly with bedding separations within 1 to 2 in. Another example is the longwall mining with complete caving in the Soviet Union's Karaganda Coalfield (Kolebaeva, 1968). The coal seam was 6 ft thick and 154 ft deep. The immediate roof was the fine-grained sandstone interbedded with coarse-grained sandstone. Above this, there was sandy shale and shale. In order to monitor the process of overburden movement, 15 stations were established in a borehole (Fig. 1.3). The elevations of those stations were measured when the face was at various distances from the borehole. Fig. 1.3 shows the movement history of each station. For convenience of comparison, the movement history of each station was plotted on a common reference point as shown in Fig. 1.4. Clearly, the movements of strata from Station # 1 to #6 were nearly simultaneous, i.e., they behaved as a single unit. The strata from Station #7 to # 15 had differential separations, the maximum of which was 40 in. As the face passed by and moved away, strata separations in general reduced gradually. But strata separation between Stations #12 and #13 remained the same until the end of the monitoring period. The total bed separation between Station #7 and # 15 reached 11 in., approximately 18% of seam thickness, when the face was 132 ft beyond. Based on the above observations, the author developed a conceptual model of overburden movement due to underground longwall mining (Fig. 1.5). The above-mentioned two case studies illustrated that subsidence in the overburden strata propagates upward and subsidence velocity decreases from the bottom to the top. When the subsidence velocity at the surface reaches the maximum value, the subsidence velocity at the bottom portion of the overburden strata has decreased considerably and the strata have begun to compact. Bed separation occurs within a certain distance above the coal seam and reduces from the bottom to the top. When the face has moved away, bed separation reduces gradually, so that eventually some beds completely close and others partially close. Bed separation reaches the highest level when the subsidence velocity at the surface is at its maximum value. For instance in Fig. 1.4 surface subsidence velocity was maximum when the face was 38 to 44 ft past the point. At this time the total bed separation was maximum. Overall the strata directly above the opening are subjected to tension in the vertical direction. But above a certain level, all strata move nearly simultaneously. There is also significant shear movement along some bedding planes. 1.3 ZONES OF MOVEMENT INTHEOVERBURDEN After the extraction of a longwall panel or room and pillar section of sufficient width the strata in the overburden are subjected to various degrees of movement from the bottom to the top. According to the movement characteristics, the damaged overburden can be divided into four zones (Fig. 1.6). Caved Zone. After the extraction of coal, the immediate roof caves irregularly and fills up the void. The strata in this zone not only lose their continuity completely, they also lose their stratified

Jan 1, 1992

By J. G. Pippenger

The Coteau Properties Company's Freedom Mine is a surface lignite mining operation utilizing large draglines, trucks and shovels, tractor-scrapers, and bulldozers to uncover a single coal seam. In 1989, a work order system was instituted to record data by equipment type, cost, productivity, and distance, and to provide historical information for planning the most efficient and economic use of each equipment type in the mining operation. This report explains how the work order system was initiated, what data is tracked, and how the data is utilized for equipment and project scheduling.

Jan 1, 1994

By R. Sandrik

Northwestern Resources Co. (NWR) was established in 1972 as a wholly-owned subsidiary of Western Energy Company of Butte, Montana, to acquire, explore, develop, and produce energy resources outside the state of Montana. Western Energy is a coal mining company with successful operations in Montana and Wyoming. In 1974, NWR acquired its first lignite lease in Texas. NWR eventually acquired a large leasehold in central Texas, which was identified as having a high potential for future production. In 1979. NWR contracted to supply lignite to Utility Fuels, Inc. (UFI), a fuel affiliate of Houston Lighting and Power Company (HL&P). This project, together with leases held by UFI, became the Jewett Mine. Lignite from the Jewett Mine is used as fuel at the adjacent HL&P Limestone Electric Generating Station, at an annual rate of approximately 7.3 Gkg (eight (8) million tons) per year.

Jan 1, 1991

By J. Chai, Q. Yuan, B. Qiu

"Overburden strata deformation monitoring is one of the key problems in ground control. Using geophysical method through surface drilling to detect strata deformation is commonly used in the industry. In this paper, a geophysical method based on the distributed optical fiber sensing (DOFS) system were conducted in the laboratory, where a DOFS-based strata deformation monitoring experiment was performed with three physical models. The results show that the DOFS method precisely detects the rock mass deformation and strata structure forming with the Brillouin frequency shifts (BFS) representation. The BFS curves are divided into three phases, which reflects the horizontal three zones developed in the overburden. The BFS distribution presents a multiple stages form, the 1st stage corresponds to the caving zone and the 2nd stage corresponds to the fracture zone. Based on the multiple stages form, the evolution of the water flowing through fractured zone have been determined and the controlling effect of key strata over the water flowing fracture has been pointed out. In the end, the comparison validation proves the accuracy and reliability of this method, and it could be a new approach for the ground control research. INTRODUCTION Overburden rock strata above the work face space will propagate from slight deformation, part destruction to violent movement because of the underground coal mining. It is fundamental and an intrinsic requirement of ground control to monitor the mining-induced rock mass deformation.[1] Overburden strata have their significant mechanical behaviors and movement under damage deformation and fracture. Overburden strata deformation affect the mining ground pressure control directly, and performance in the relationship of supporting equipment and the surrounding rock, the mining-induced fracture distribution and the loss of underground water resource, the ground surface structure stability and the ecological environment.[2] From the perspective of the concept of safe and efficient scientific coal mining: the overburden strata deformation is an important part of mining method selection and reasonable supporting solutions decision which can solve the issues like the roof supporting force calculation, overburden fracture distribution and gas drainage, ground subsidence, separation of coal and rock control and top-coal recovery rate and so on. From the perspective of green and ecological mining: the overburden strata deformation is the key basis of studying the mining-induced ground subsidence and mining area ecological damage, and such engineering problem like environmental protection in mining area, ecological restoration in mining subsided land and the water conservation in fragile ecology area of mining could be solved based on it.[3-6] Therefore, the mining-induced overburden strata deformation is the key of ground control and needs to be controlled artificially."

Jan 1, 2017

By Haitao Wang, Shen Wang, Dongyin Li, Yongjia Xu, Jinzhao Liu, Xiangjun Chen

The safe and efficient driving of the roadway along the gob is becoming an increasing challenge due to the influence of the integrity and bearing capacity of the side coal and rock mass in the gob under the roof cutting mining mode. The mechanism of protection of the gob-side roadway is shown by modeling the influence of roof cutting and the application of a destress technique on the lateral coal and rock mass zones. The distribution characteristics of stress, displacement, and fracture in the overburden are analyzed by numerical simulation method under the three working conditions. The results indicate (1) construction of row holes and blasting can form artificial structure’s fracture plane above the roadway, which can effectively cut the connection of overburden. The artificial structure’s fracture plane decreases the peak value of the lateral coal body’s support pressure. The peak point and the critical location of the stress reduction area are both transferred to the deep part at the same time, providing adequate space for the gob-side roadway. (2) The stress arch foot in the lateral rock mass rises to the rock layer at the bottom of the roof cutting plane after top cutting, as does the high-pressure area of deviator stress. The fracture plane prevents lateral coal and rock mass instability and limits the negative effects of roof deformation above the gob-side roadway. (3) The triangle slip fracture zone moves to over the roof cutting drilling zone due to the fracture plane, showing a high position compared to its original zone.

Jul 11, 2023

By John M. Hird

Texasgu1f's Lee Creek Mine in Eastern North Carolina is usin8 a combination Dredge-Dragline method for mining deep phosphate ore at a rate of 8.5 million tons per year. The matrix is thick, uniform in grade, and is processed into agricultural products. As in many other good mineral deposits, there are tough obstacles to overcome in recovering the ore. The deposit is in an area with a land surface of about ten feet above sea level, is close to tidewater, is overlain with 90 to 130 feet of unconsolidated overburden, and is underlain by an artesian aquifer with over 140 feet of natural hydrostatic head at the bottom of the bed, The upper 40 feet of overburden will not support stripping equipment and is unstable when cast as spoil. Barriers are emplaced to prevent flooding from hurricane tides. The ground water problems have been successfully controlled by pumping 60 million gallons per day from the aquifer. Only recently have the severe ground problems been overcome by this unusual Dredge-Dragline combination of mining equipment.

Jan 1, 1978

By Robert W. Cope

"Mining began, in the Colstrip area in the 1920's by the Northern Pacific Railroad. The coal was used for steam locomotives until 1957, when the advent of diesel power made them obsolete. In 1959, Montana Power Company purchased the Northern Pacific properties including the mining equipment, coal leases and the town of Colstrip. Western Energy Company, a wholly owned subsidiary of Montana Power Company was formed in 1966 to manage the mining operations in Colstrip. The Rosebud Mine officially re-opened in 1968 to supply coal for Montana Power Company's J. E. Corette Plant In Billings. Since 1970, Long Construction has operated the mine equipment for Western Energy Company". The Rosebud Mine is located in Southeast Montana and supplies coal to two 350 megawatt power plants located in Colstrip and one 180 megawatt plant located in Billings. Approximately 30 percent of Western's annual production is consumed by these plants. The remaining production is shipped to the mid-west and burned by utility companies and municipalities.

Jan 1, 1981

By Jack G. Pippenger

The Coteau Properties Co.'s Freedom Mine is a surface lignite mine that uses large draglines, trucks and shovels, tractor-scrapers and bulldozers to uncover a single coal seam. In 1989, a work order system was instituted to record data by equipment type, cost, productivity and distance. The system was also used to provide historical information to plan the most efficient and economic use of each equipment type in the mining operation. The Coteau Properties Co. is a wholly owned subsidiary of The North American Coal Corp. The company was formed in 1972 to supply lignite from its Beulah-Hazen coal reserve to a coal gasification project and an electrical generating facility located near Beulah, ND. The reserve consists of a single coal seam between 3 and 7 m (10 to 23 ft) thick. The overburden above the coal is predominately glacial tills and clays and ranges from 6 m (20 ft) to more than 60 m (200 ft) thick.

Jan 1, 1994

By Tim Brick, Peter Jewell, Stephen Thompson, Simon Morgan

The $980m (€750m) Dublin Port Tunnel, Europe’s biggest urban highway tunnel project, was opened in December 2006. The culmination of this immense scheme is set to transform the environment, mobility and road safety of Ireland’s capital city. This paper summarizes the key aspects of a project linking both sequential and parallel construction of individual tunnels and describes various approaches to bored, mined and pre-support cut-and-cover tunneling in a wide variety of ground types and depth of cover. Examples of innovative approaches to deal with structural and geotechnical problems while maintaining full operation of both road and rail traffic and the integrity of properties in a dense urban corridor are described.

Jan 1, 2007

By Jerry Wang, Greg Bold, Mahmood Khwaja, Rebecca Caldon, William Simcoe

Phase III and Phase IV of the Beaver Creek Clean River Project, Albany, NY, includes microtunnel construction of 2,320 feet of 48-inch/36-inch internal diameter (ID) conveyance pipe and a 525 foot long 9.5-ft horseshoe shape roadheader excavated tunnel. Notable challenges were encountered during the construction including mixed face tunnel conditions, undocumented existing fill ground conditions that resulted in settlement during shaft construction, and unstable tunnel face conditions. This paper discusses several of the key challenges encountered during construction and selected solutions to construction sequencing and methodology to successfully complete Phase III and Phase IV of the Beaver Creek Clean River Project.

Dec 1, 2022

By Zhenqi Cai, Mike Lichte, Kimberly Kennedy

The Ohio River Tunnel is the first of three combined sewer overflow tunnels to be constructed under Allegheny County Sanitary Authority's Clean Water Plan. The project consists of a total of approximately 5.5 miles of 18-ft and 14-ft finished diameter, segmentally lined deep rock tunnels and smaller diameter dewater and flow connector tunnels, as well as 8 deep flow drop and access shafts varying from 25-ft to 70-ft in finished diameter and 130-ft to 170-ft in depth. This paper describes the project components and the primary engineering challenges faced during design, including tunnel alignments and shaft site optimization with tight right-of-way constraints and multiple railroad and highway crossings. Assessment of tunneling methodology as well as tunnel and shaft designs and constructability included overcoming 5-bar hydrostatic pressure, abrasive bedrock, and the selection of the appropriate support of excavation systems in high-permeability alluvial soils adjacent to the Ohio River.

Jun 23, 2024

By G. Balletto, C. Furcas

"The mineral raw materials industry is a key-component of the Gross Domestic Product of industrialised economies, closely related to both the building and the industrial sectors. Despite this, at local level mining and quarrying are associated with both irreversible environmental damage and several visual alterations affecting the natural landscape. In this sense, SIA (Social Impact Assessment) has become a strategic tool that can not only improve the prediction but also the assessment of the social impact by involving the local communities in a participatory process. Taking into account the SIA experience, together with the examination of some relevant international case studies, it is possible to draw up a list of good practices for mining project management, from exploration through to closure and beyond, with quarry restoration. Such good practices will complement the existing studies, focusing on environmental issues, with the social issues arisen considered in SIA application."

Jan 1, 2011

By Hiroyuki Tamaru, Futoshi Kusumoto, Kosuke Tanimura, Atsuyuki Kimura

"SUMMARY The Hachinoshiri tunnel is a 2,469 m long two-lane road tunnel on the Chubu-Odan Expressway. Since more than 70% of the total tunnel length consists of low strength rock masses the competence factor of which is less than 1.0, it is expected that a self standing span cannot be achievable because of no ground arch to be established. The tunnel was thus designed with tunnel support patterns forming multi-arc early ring closure that can develop the load-carrying capacity estimated from the exerted earth pressure, Po, which can result from the competence factor, cf. The tunnel support pattern was selected based on the competence factor at tunnel face, then the subsequent tunnel support patterns were determined with reference to the monitoring data. The tunnel construction adopted full-face excavation accompanied by early ring closure using a 330 kW road header. The proposed construction methods at this tunnel site have turned out ensuring tunnelling in massive squeezing rock, so that they can be verified as reasonable tunnelling technologies, clarifying the relationship between the characteristics of the mechanical behaviour of the tunnel and its design parameters. INTRODUCTION The presence of highly weathered mudstone having the competence factor less than 1.0 where the tunnel became unstable with the early ring closure having the distance to early ring closure, Lf, of 6 meters, resulting in difficulty in maintaining the inner section of the tunnel, prompted a substantial amount of high strength double support and replacing of the tunnel support (Sato et al., 2015). Based on the mechanical characteristics learned from the construction, the mechanical stability of multi-arc tunnels was investigated using 3D FDM analyses with respect to the ratio of the radius for early ring closure, r3/r1, and the distance to early ring closure, Lf, so that tunnel support patterns for early ring closure can be established in terms of the competence factor, of, which was employed for a 725 m long section. Consequently the tunnel support patterns for early ring closure which can be determined from the competence factor became applicable to tunnel construction. The relationship between the characteristics of the mechanical behaviour of the tunnel and its mechanical parameters was also clarified. The early ring closure method adopted ensured tunnelling in massive squeezing rock, verifying its effectiveness in stabilizing the tunnel."

Jan 1, 2016

By James Humphrey

There is a natural resistance to change in any form. When it comes to implementing a game-changing technology like autonomous haulage on an operating mine site, the resistance can at times appear insurmountable. Whether based on real information or misguided preconceptions, it?s essential that we don?t underestimate the effort it will take to overcome this resistance, while clearly recognizing when it?s worth the effort. These realizations did not happen overnight for sites where autonomous haulage has been implemented. Nor did they happen overnight for manufacturers of autonomous mining equipment. Caterpillar, for example, began building toward autonomy more than 30 years ago and had a truck operating in the mid-1990s. Lessons learned during those early years led to the realization that there was much more to be learned ? not just about the machines themselves, but about the systems and knowledge that must be in place for a successful implementation. Working closely with customers, initiating real-life demonstrations on mine sites, having discussions with regulatory agencies and other stakeholders ? these and many other activities were necessary before autonomy could be fully and successfully launched. After decades of effort, Caterpillar?s first official commercial autonomous mine site went to work in 2011 in Farmington, NM.

By Bernd Hagenah, Eric C. Wang

New tunnels of significant alignment lengths such as mountain tunnels, base tunnels, as well as beneath urban centers pose unique environmental challenges. This paper highlights key environmental considerations for planning, design, construction, and operations by sharing lessons-learned from the authors' extensive project experience on these types of tunnels. Discussion of unique constraints include limited right-of- way, ventilation and emergency egress during the construction phase and revenue service, safety and security, and protection of existing structures. Practical approaches and applied innovative state-of-the-art solutions addressing distinct sustainability challenges and unique requirements are shared from US and international project examples.

Jun 23, 2024

When most people think of coal mining, they envision men in soot-covered clothes and hard hats digging at deposits in deep underground caverns. These mental images commonly include coal cars rumbling on rails as they emerge from the earth, filled to the brim with rocky ore. The world of modern, longwall coal mining is a far different place. Yes, it?s underground, the miners still wear hard hats and the environment is filled with soot. However, today?s mining operations are carefully monitored and the entire process is highly automated. Five kilometers (3 miles) underground, a sophisticated, high-powered mining machine moves steadily through a 2-m (6-ft) high tunnel at an average speed of 3.2 km/h (2 mph), carving out coal, then conveying it to a crusher and carrying it to the surface. Instead of digging out the ore, a longwall mining system slices it from the exposed tunnel face, using giant rotating shears. The shorn coal tumbles onto a conveyer below the shears and is conveyed to the stageloader, where it is crushed and dumped onto the main conveyer belt that eventually hauls it out of the mine. Integral to the longwall shear and conveyor is a moving metal roof that protects it from the thousand plus feet of ground above. The ceiling panels automatically advance above the shears, powered by hydraulic roof supports that stand on the other side of the tunnel, moving in a slow, sideways lock-step with the shears. This complex and massive machine makes longwall mining the most ef?cient and productive method for excavating coal. In fact, it produces 2.7 kt to 22.6 kt (3,000 to 25,000 st) of ore per shift, versus 544 to 907 st (600 to 1,000 st) for the conventional room-and-pillar mining. Using that method, miners develop one section of a mine at a time after carving out load-bearing columns of coal to support the roof above their heads. Longwall mining also is considered safer than the room-and-pillar method, largely because the process is mostly automated, requiring fewer workers. Still, longwall mining has its drawbacks: The equipment is expensive and the mining conditions are harsh. An entire longwall system can cost between $50 million and $100 million, while the electrical controls used to operate it can cost an additional $1 million to $2 million. These investments grind away all day, every day, in hot tunnels filled with coal dust.