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By Garth Kuhnhein

The Black River and Maysville underground limestone mines operated by Carmeuse Lime and Stone, Inc. in northeastem Kentucky are two of the largest underground limestone operations in the United States. The combined output of these two options has consistently averaged over 5.5- million tons per year for the last decade. The mines operated beneath 650-ft and 1,200-ft of overburden and are affected by high horizontal stress. In 1982 changes to the mine design were made at the Maysville mine to improve ground conditions. A series of design changes were initiated in 2002 at Black River to improve ground conditions. This paper reviews the results of the changes made at Maysville, recent horizontal stress measurements conducted at the Black River mine, and the recent modifications to the Black River mine design. Roof fall statistics at both operations are used to compare the distinctly different mine layouts used at the two mines.

Jan 1, 2004

Case study data were analyzed to develop and quantify empirical stress transfer relationships between seams for both longwall and room and pillar mines. Layering in the innerburden and the distance between seams were determined to be the controlling factors. To evaluate the effect of bedding planes on stress transfer, laboratory studies were conducted using layered, low modulus gravity loaded photoelastic models. Parameters investigated were thickness, number of discrete layers, modulus and friction between layers. Results showed that there was significant distortion of the pressure bulb in highly laminated conditions which correlated with the results of empirical analysis. Relationships developed were used to modify the results obtained from numerical modelling between multi-seam longwall operations. Research conclusions were demonstrated using case studies.

Jan 1, 1995

By J. R. M. Hill

The U.S. Bureau of Mines is involved in research to improve geological sensing (or geo-sensing) techniques. This paper presents results from field trials of two research projects concerned with new technologies for geosensing. The goal of the first project was to develop a "smart" roof bolter drill so that it could probe into roof rock to evaluate rock conditions. The goal of the second project was to modify an existing mine-wide monitoring system in a continuous mining operation so that the system could interface with geotechnical instruments to provide near real-time geosensing. Integration of this mine-wide monitoring system with the smart roof drill to collect, reduce, and analyze geotechnical data and the potential applications of the resulting technology in mining, are described.

Jan 1, 1992

By Gregory M. Molinda

Difficult mining conditions in deep western U.S. Iongwalls have necessitated the use of novel tailgate support systems. Extreme ground movement in these yielding gate systems has caused operators to utilize secondary support systems which match yield and strength characteristics with expected ground reaction. Other benefits include ventilation and safety gains, as well as lower costs. Recently, the use of novel support has been tried at longwall mines in other U.S. coal basins. One of the main considerations is the capability of the support to maintain an adequate airway for gob ventilation in gassy eastern coal mines. In one large Pennsylvania mine working the Pittsburgh seam, a number of support configurations were monitored over a 2,300 ft tailgate test area. The test included 4-pt wood cribs, Link-N-Lock cribs, Propsetter yieldable posts, cable trusses, and vertical cable bolts. Ground reaction, and thus support performance, was documented by roof sag and convergence instruments, ventilation measurements, and photographs. Various combinations of standing support and cable truss and vertical cable bolts provided adequate support for ventilation and safe escape. A cribless configuration consisting of only cable trusses and vertical cable bolts was inadequate to provide inby gob ventilation to the next open crosscut. Instrument ground movement data and visual documentation are presented.

Jan 1, 1997

By Laxminarayan Holla

There exist many formulae for designing coal pillars. However, when applied to a given set of mining parameters, they lead to different pillar sizes and factors of safety. From the subsidence point of view, the pillars designed as protection pillars not only have to be stable, but also have to limit subsidence over them to a level acceptable to the structure being protected. The subsidence over a pillar of given width to height ratio depends upon the mining depth. A pillar may be stable, but the subsidence over it may be quite large and unacceptable for the structure. In many cases even though pillars may yield, they support the undermined strata and reduce surface subsidence. In addition, the yielding pillars eliminate peaks and troughs in the surface subsidence profile and reduce ground strains. In a given situation, whether a pillar yields or not depends primarily upon its width in relation to mining depth.

Jan 1, 1992

By John L. Hill

Cutter roof failure is a specific type of ground control problem which frequently results in massive roof failure. It is a cannon occurrence in coal mines of the Northern Appalachian Coal Sasin, causing delays in production and posing a safety hazard to mine personnel. The Bureau of Mines is conducting research on the causes of cutter roof failure togain a basis from which to prevent its occurrence and to support such roof when failure does occur. Research conducted in a coal mine of central Pennsylvania has revealed a correlation between the occurrence of clastic dikes and fonation of cutter roof failure. Inmine mapping of ground conditions showed an increase in roof failure in areas of high frequencies of clastic dikes. Rock pressure monitoring around clastic dires registered the greatest amount of roof loading near the inter- section of dikes with the rib. Load cells measurim horizontal pressure changes in the roof indicated that the greitest pressure changes were occurring perpendicular to entry headings when clastic dikes were present. Analysts of rock pressure nwnitiring shows that the roof behaved as two cantilever beams when severed by a clastic dike. Additional roof supports such as trusses and cribbing were found to effectfvelv suooort the roof in areas of clastic dikes and prevent cutter roof iailure. However, there lnethads were only successful when employed shortly after mining.

Jan 1, 1984

By S. S. Peng

This paper presents a convenient way for the preliminary design of the shield supports. The locus equations which are applicable for all kids of shield supports are derived. These equations facilitate the statics analysis of the shields. An indirect method in determining the coefficient of friction, the external toads and their locations are also developed.

Jan 1, 1982

By Gregory M. Molinda

The U.S. Bureau of Mines has developed a rock mass classification system for coal mine roof control. The Coal Mine Roof Rating System (CMRR) evaluates the structural competence of mine roof using simple field tests and observations obtained from underground exposures in roof falls or overcasts. The basis of the WRR is a weighing system which converts descriptive geologic roof rock data to a numerical value, facilitating its use in engineering design. A full suite of data collection and hand calculation sheets accompanies the CHRR A data base is currently being collected from all major coal basins in the United States to validate the CMW. To date, CHRR values are available from 96 roof exposures in 59 coal mines representing these basins. The system can be used to help solve many practical ground control problems, including longwall gate road design, roof support selection, and decisions regarding extended cut length.

Jan 1, 1993

By G. K. Rogers

Portals, which are the surface entrances to underground excavations, are frequently overlooked and often difficult areas In terms of ground control. Failures commonly occur In the typically high angle approach cuts and Initial subsurface portion of the portal. In order to permit rigorous design of all types of portal structures, failures are Identified and subsequently classified. Based on the failure classification and suggested analysis methodology, optimum ground and support loading can be determined.

Jan 1, 1988

By Olayemi Akinkugbe

As coal production in the United States continues to increase, the availability of unexploited or virgin fields continue to diminish. As a result, mine operators are forced to mine in unfavorable or multiple seam conditions. The safe, productive exploitation of coal in multiple-scam conditions requires specific design technology. At present, there are two general design approaches that the mining engineer can use to analyze the multiple-seam problem in question, either simple empirical relationships or complex numerical models. Often, the empirical approaches are too general for the specific problem and the numerical models require too much time and expertise for the practicing engineer. This paper introduces a new computer program, Lam2D, designed specifically to enhance multiple seam mining operation by quickly and easily calculating, stress, displacement, subsidence, horizontal strain and safety factors associated with multiple seam mining situations. The program implements a simplified, two-dimensional boundary-element method in order to model the complex multiple-seam stress and displacement interactions. Most importantly, the program is greatly simplified by incorporating automatic overburden, interburden, coal and gob property generation thereby reducing typical modeling and solution time to a few minutes.

Jan 1, 2004

By J. D. Cole

In order to reduce the number of longwall face moves and to increase the rate of gateroad construction, super longwall panels, 1000 feet wide and 12000 to 14000 feet long, are planned for Wolf Creek Collieries No. 4 mine. The development of the longwall panels at the mine has evolved from 5-entry, to 4-entry, to 3-entry systems. A three-entry system including pillar size and entry supporting method for the super longwall panels was designed for long-term stability. The design procedures included field observation and studies, laboratory properties tests, in-situ stress measurement, and computer analysis. Three pillar design methods consisting of PILLAR, ALPS, and the Wilson Method, and one entry supporting method, ROOFBOLT, were adopted in this study. The procedures, methods, and results are discussed in detail.

Jan 1, 1990

By D. A. Payne

Large excavations, such as Iongwall panels, result in extensive vertical stress redistribution in the surrounding strata. The large abutment stresses developed may produce damage to pre-existing or planned excavations in the same seam or in seams above and below the workings. Knowledge of the magnitude and location of these stresses is therefore important in the design of mine openings; pillar sizes for panel and pillar layouts, roof supports in longwall gateroads and workings over or above pre-existing or planned extraction in adjacent seams. In an attempt to reduce costs, the Cape Breton Development Corporation (CBDC), a Federal Crown Corporation responsible for operating two retreat longwall coal mines, examined the potential for either interpanel barrier pillar width reduction or entire pillar elimination by the adoption of dual life gateroads for the longwall panels. In order to assess the potential for reduced interpanel barrier widths or total elimination, an investigation of the redistribution of vertical stresses around longwall panels in the Sydney Coalfield was established. The study was conducted jointly by the Cape Breton Coal Research Laboratory (CBCRL), of CANMET (a division of Natural Resources Canada) and the Denver Research Center (DRC) of the United States Bureau of Mines. The program included monitoring of vertical stress changes around longwall panels and gateroad behaviour in two seams. USBM-style hydraulic borehole pressure cells connected to chart recorders for continuous monitoring were deployed at four sites, two at Lingan Colliery and two at Phalen Colliery. This report describes the investigations conducted at Phalen Colliery. Contoured plots of stress redistribution around two sites are presented.

Jan 1, 1995

By Liang Yin-Huai

In Fuxin Coal Mines, there are more than 20 million tons of coal buried under seasonal streams. The coal seams are mostly shallow. We have mined more then 50 mining blocks distributed in 5 coal mines. Their natural conditions are different, and the consequences are also more or less different. However, no stream-water-inrush accidents under regular mining conditions are the same. There were 3 exceptions. They were caused by unexpected roof caving which made valleys or alluvia subside as funnel-like cavities and let in inrush of stream flow. The key to our success in mining shallow under-stream coal seams, according to our analysis, is that valleys or alluvia subside gently and basically evenly with contractible tension fissures and that fissures both in valleys or alluvia and in rock seams are blocked up or sealed by cohesive deposits either from alluvia or rock. This paper treats: (1) some typical illustrations of mining shallow coal seams of different occurrences under streams of different sizes, flowing capacities and valley structures, (2) observations of the height of caved and fissured zones and subsidence of valleys or alluvia, (3) observations of underground water flow before, during, and after mining and the fluctuation with respect to stream flow, (4) observations and analyses of blocking up of fissures caused by mining, and (5) feasibility of mining shallow under-river coal seams.

Jan 1, 1990

By Keith Heasley

An eastern longwall mine was required to mine through a set of three entries located midway down the length of a panel. Of course, the mine desired to design a successful support system for the mine-through area at the least cost. To further complicate the design process, the mine-through entries were located directly under the end of a previously mined, overlying longwall panel and the entries were close enough to be subject to stress interactions from the overlying seam. In order to accurately evaluate the multiple-seam stresses and modify the mine-through support system appropriately, the boundary element program LaModel was used to model the stress and displacements in the two mines. Using the results of the model's stress analysis, the support density was systematically varied throughout the mine- through entries for optimum sup@ efficiency and economics. During the actual mining of the cross panel entries, the longwall experienced few, if any, additional delays, and overall, the support and mine through of the cross-panel en- tries at Harris #1 was very successful, saving the mine confineable time and money.

Jan 1, 2003

By Takashi Sasaoka

EGAT Mae Moh Lignite Mine in Thailand produces about 16 million tons of lignite annually from open-cut mining. The coal is used to generate 2,400 MW of electricity. In the near future, however, the coal must be extracted from underground at 400? 500 m (1,312?1,640 ft) deep from the surface. The problem is the thickness of the coal seams. There are two coal seams that are about 25 m (82 ft) thick with 20?25 m (66?82 ft) of interburden between them. Up to now, many mining systems for thick coal seams have been used and improved in the world. However, where the thickness of coal seams is beyond the limitation of the current mining technology and system, an applicable mining system has to be introduced, considering influencing factors such as caving and subsidence. In order to investigate thick seam mining systems and propose a new mining system in ultra-thick coal seams in Thailand, a joint research group was established by Japanese and Thai researchers and mining engineers in early2009. This paper describes underground mining systems for thick coal seams and proposes an innovative underground mining system for thick coal seam, ?eco-friendly underground mining system?, considering geological, geotechnical, and environmental conditions in this mine. This paper discusses its applicability to this mine by means of numerical analysis from the geotechnical point of view.

Jan 1, 2011

By Eric G. Zahl

Researchers at the Spokane Research Laboratory of the National institute for Occupational Safety and health are evaluating stress and displacement measurements in a longwall coal mine. The objective is to determine the best indicators of coal bump hazards during operations so that mine foremen and technical stall can make more informed intervention decisions to protect miners from coal bumps. Instruments were clustered in two panels, a yield pillar, and the immediate roof and floor of a two-entry longwall coal mine. Data were gathered continuously from a variety of instruments as mining proceeded toward and past the instrument cluster. Researchers and the mine's technical staff evaluated these data with respect to coal bumps and bump mechanisms. Selected graphs were then presented to mine foremen on a periodic basis to test their usefulness in identifying hazards. Of particular interest was the use of horizontal stress data from the immediate roof. To measure changes in horizontal stress, a new technique was devel¬oped for installing a grouted biaxial stressmeter in the roof. An evaluation of the development of this stress monitoring system in producing data beneficial to mine foremen is presented.

Jan 1, 2000

By Chris Adams

The application of pre-tensioned tendon roof support assisted Harworth Colliery in their revival, from impending closure to lowest cost deep-mined producer in the UK, over just six months last year. The paper describes this success story, how it came about, the reasons "why", and the method "how"

Jan 1, 2003

By William D. Gallant

This paper describes a joint cooperative project between the CANMET Cape Breton Coal Research Laboratory and the Cape Breton Development Corporation to conduct a trial of split set cable slings for remedial support in longwall gateroads. Slings were installed in two test sections of the 2 West panel, Phalen Mine which exhibited deformation and the potential for excessive deterioration when subjected to the front abutment of the wallface. Roadway support behaviour was monitored at the trial sites, including lengths of roadway with the standard support of steel sets without remedial support. Observations were made on convergence, loading of the steel supports, loading of the slings, and wallface performance. Comparisons are made of the results obtained from the areas with remedial support to that without, which demonstrates that the slings provided effective remedial support limiting further deterioration of the roof. Improved face end conditions have contributed to increases in safety and productivity of the longwall panel.

Jan 1, 1990

A procedure fm the estimation of pilla1 strength is presented where the design of underground coal pillars is emphasized. An analytical approach has been developed, proposing that the effect of end constraints on the pillar strength and the ductile behavior of coal material should be incorporated in the computation of the stability of coal pillars. Bad on this approach, it has been found that end constraint has a significant influence on the pillar strength. The study indicates that when the end constraint is zero the computed strength of the pillar is the same as the unconfiied compressive strength of the coal mass and will not increase with the increase in the width to height ratio. However. when the end constraint is greater than zero the pillar strength will increase exponentially as the width to height ratio increases.

Jan 1, 1990

By Thomas M. Barczak

The initial Support Technology Optimization Program (STOP), Version 1.0, was released at the 19th Gmund Control Conference. This original program has since been updated to Version 2.3 which was released in May, 2001. This paper describes the additional features of Version 2.3, focusing primarily on the following three aspects: (I) including uncontrolled convergence into the design requirements for standing roof supports, (21 the addition of design procedures for cable bolts as an alternative secondary roof support, and (3) the addition of new standing roof support technologies. Another new feature which should facilitate the development of design criteria for standing roof support is the capabilily to define ground reaction curves through convergence measurements alone wthout having to make support loading measurements. There are several other new features provided in Version 2.3 which are only briefly addressed in the paper. These include: (I) additional graphics capabilities to facilitate rapid assessment of support comparisons. (2) an East-West designation for support selection to more accurately provide cost and support availability data, (3) additional safety measures including a safety factor to identify support design near the peak support capacity, checks to see if the support dimensions comply with aspect ratio requirements, and measure of roof coverage for the design layout of the support system These new features of STOP provide more capabilities to design and analyze secondary roof support systems for conditions whlch could not be fully analyzed in the original version of the program.

Jan 1, 2001