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International Journal of Mining Science and Technology xxx (2015) xxxxxx

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International Journal of Mining Science and Technology


journal homepage: www.elsevier.com/locate/ijmst

Underground mining of thick coal seams


Kumar Rakesh a,, Singh Arun Kumar a, Mishra Arvind Kumar b, Singh Rajendra a
a
Central Institute of Mining and Fuel Research (CIMFR, under CSIR), Dhanbad 826015, India
b
Indian School of Mines (ISM), Dhanbad 826004, India

a r t i c l e i n f o a b s t r a c t

Article history: This paper reviews underground mining methods for total thickness of a thick coal seam in single lift
Received 8 October 2014 (TTTCSSL). Review shows the required engineering for extraction of thick seams needs to be fitted with
Received in revised form 4 January 2015 thickness of the seam, behavior of rock-mass and surrounding stress conditions for efficient mining.
Accepted 23 April 2015
Variants of TTTCSSL are able to extract a maximum 1012 m thickness only. An improvement in bending
Available online xxxx
moment of the overlying coal band in longwall top coal caving (LTCC) provides better under-winning
opportunity for the roof coal band. An acceptable limit of 25 MPa compressive strength of coal for the
Keywords:
success of LTCC may be increased under favorable geo-technical conditions. Bord and pillar in India
Thick coal seam
Single lift depillaring of total thickness
adopted induced caving of roof coal band for single lift depillaring of total thickness (SLDTT) of a compe-
(SLDTT) tent thick coal seam developed along floor. Case studies are given to arrest the adverse effects of extrac-
Extraction height tion height on pillars.
Pillar instability 2015 Published by Elsevier B.V. on behalf of China University of Mining & Technology.
Caving of coal

1. Introduction process has played vital role in success of the opencast mining.
Presence of thick coal seams at shallow cover is a welcome condi-
Thickness of a coal seam is an important geological parameter tion for opencast mining, where introduction of machines did not
during selection of a suitable underground mining method for its confront much geo-technical problems. But underground mining
efficient extraction. A coal seam of around 34 m thickness is, gen- of a thick coal seam inherits a number of geo-technical challenges
erally, observed to provide normal working height for efficient [2] which makes it difficult for mining and mechanization. Multi-
extraction and is suitable for most of the conventional mining slice working of a thick coal seam is a normal choice to reduce
methods. Considerable increase in thickness of a coal seam makes operational constraints and optimize recovery and safety during
it challenging for efficient underground mining and is called thick. underground mining. Multi-slice working encounters different
Although there is no any standard universal value of thickness to problems [3] and the order of slices to win a complete thickness
call a coal seam thick, different countries have different limits [1] is decided according to the local geo-mining conditions of the site.
for categorizing thick coal seams (Table 1). The adopted limit to Slices in ascending order (from bottom to top) require stowing/fill-
call a coal seam thick in India is 4.8 m, which is on higher side of ing of the void created due to mining, which decreases productivity
the range. Even after adoption of this higher limit, over 60% of and becomes expensive. Slices in descending order (from top to
the total coal reserve in the country belongs to thick seams. It is bottom) experience strata control problems because the working
difficult to find any regular pattern of the coal seam thickness in the lower slices are to be carried out directly below the broken
due to diverse depositional conditions of different coalfields. Some overlying strata due to top slice working. Literature survey [411]
of the thick seams are nearly 30 m thick, while one exceptionally shows that the conventional multi-section mining approach for
thick coal seam in Singrauli coalfield is 162 m thick. Exploration underground extraction of a thick coal seam is, now, being
of coal in Indian coalfields is done up to 1200 m depth only and replaced by extraction of TTTCSSL.
an estimation of thickness-wise coal reserve during the exploration One-slice longwall mining [12] of a thick coal seam, with the
is given in Table 2. help of special equipment, provides an opportunity for single lift
Thick coal seams at shallow cover are, generally, being working of 67 m thick coal seams. Some special variants of long-
extracted by opencast mining due to favorable techno-economic wall and room and pillar mining, involving natural or induced cav-
reasons. Large scale mechanization and automation of the mining ing of roof coal band for the extraction of TTTCSSL, are able to
extract a maximum thickness of 1012 m only. Here, generally, a
Corresponding author. Tel.: +91 943 1292718. normal height working is adopted along the floor of thick coal
E-mail address: kumarrakesh18@yahoo.com (R. Kumar). seams and rest of the seam (as overlying coal band) flows/caves

http://dx.doi.org/10.1016/j.ijmst.2015.09.003
2095-2686/ 2015 Published by Elsevier B.V. on behalf of China University of Mining & Technology.

Please cite this article in press as: Kumar R et al. Underground mining of thick coal seams. Int J Min Sci Technol (2015), http://dx.doi.org/10.1016/j.
ijmst.2015.09.003
2 R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx

Table 1 2.1.1. Longwall route


Minimum thickness of coal seam to be called thick in different countries (after Singh Generally, a longwall mining face is mechanized, 100% sup-
et al. [1]).
ported and applied to win normal height of coal along floor of a
Sl. Country Minimum thickness to be a thick Total workable thick seam. Here, the left out roof coal band along the roof is
No. seam (m) reserve (Mt) won with the help of the applied mechanized support system. A
1 Australia 4.0 18,128 chute in the rear part of the chock shield support is used for under
2 China 3.5 98,883 winning of the roof coal band during sublevel caving. An armoured
3 Canada 4.0 8708
4 France 4.0 427
rear conveyor (ARC) is placed below the chock shield support to
5 Hungary 3.5 225 withdraw the caving roof coal band behind the shield (Fig. 1). This
6 India 4.8 35,345 arrangement of under-winning worked well for, relatively, softer
7 Japan 2.3 1000 coal but some improvement in the system is felt [18] during
8 Turkey 3.5 6056
under-winning of a competent roof coal band. Chinese have
9 USA 3.0 113,230
10 Poland 3.3 20,800 achieved, relatively, better results [5] for sublevel caving method
11 Yugoslavia 3.5 8465 after improving bending moment of the overlying coal parting
span between the face and goaf line. Suitable modification in the
chock-shield for the increased bending moment (Fig. 2) provided,
(natural or induced) down on floor under gravity for withdrawal. relatively, better fracturing and flow of the overlying coal band
The role of strength of coal, caveability of roof strata and stability under gravity and the method is renamed as longwall top coal cav-
of natural supports are observed to be important factors [13] for ing (LTCC). The method is essentially an extension of the original
the selection of an underground mining method for extraction of soutirage concept [19], but with significant equipment and opera-
TTTCSSL. This paper reviews literature related to underground tional changes related to the use of the ARC behind the chock
mining of TTTCSSL and presents two case studies to visualize the shield for handling the caved coal.
suitability of SLDTT for developed thick coal seams under changing Factors influencing the roof coal caveability during LTCC opera-
site conditions. Underground extraction of a steeply inclined thick tions have been studied widely [9,10]. Based on such a study,
coal seam also attracts application of special mining methods but Table 3 presents an index developed to assess the coal recovery
this review is limited to nearly flat coal seams only. during LTCC and known as Chinese caving index (CCI) [20]. Impor-
tant factors for safe and effective implementation of LTCC are: (a)
coal seam caveability/fragmentation, (b) effect of massive strata
2. Problems of single lift working
units in immediate/near seam roof and (c) effect of high horizontal
stress ratios. Three main geotechnical components affecting coal
Both, longwall and room and pillar methods of underground
caveability are: uni-axial compressive strength (UCS), geological
coal mining have been adapted for extraction of TTTCSSL. The nat-
(cleat, slip, bedding, etc.) and other discontinuities and vertical
ure of adaption in these two mining methods varied, largely,
stress on the coal seam (Fig. 3). It is observed that a range of
according to the site conditions and involved technology. But the
1525 MPa of compressive strength is well suited for LTCC. With
final extraction of coal by the adopted method witnessed consider-
an increase in UCS, the coal cohesion or internal friction angle
ably increased height of void, which adversely affected the mining
increases and stress needed to fracture roof coal band also
activity. The increase in height of void caused (i) large amount of
increases [21]. Caving of roof coal bed becomes difficult above
overlying strata movement [14]; (ii) dilution in pillar strength
25 MPa of UCS, subject to the other parameters of discontinuities
and (iii) requirement of high roof support [15,16]. Again, when nat-
and stress [6]. Underground extraction of deep seated coal seams
ural or induced caving of roof coal band is involved for the extrac-
[22] experiences high value of induced stresses, which dilute com-
tion of TTTCSSL, winning and withdrawal of the roof coal band is
petency [23] of the roof coal bed of a thick seam for better under-
also an important issue.
winning. There are some other parameters like geometry and
dimensions of longwall panel, applied support density and produc-
2.1. Winning of roof coal band
tion scheduling, which also affect natural caving of the coal under
gravity.
When primary working (development) of normal height in a
It is observed that the under-winning interval of the roof coal
thick coal seam is done along floor and SLDTT is planned, an effi-
band [11] is one of the most significant affecting factors for
cient winning of roof coal band is an important issue. It is observed
that uniform fracturing of the roof coal mass is significant [17] to
improve the efficiency of under-winning of the roof coal band. Both
routes of conventional mining methods i.e. longwall and bord and
pillar are used to win the roof coal band during final extraction. Easily caveable
roof strata
Due to different geological and techno-economical reasons, long-

t
wall route to win the roof coal band is popular in China while Flow of coal due to gravity
the Indian coal mining industry is, mainly, practicing B&P route
Soft and thick coal seam

for winning the roof coal band.

Table 2
t
Coal seam thickness and their percentage of share in India.

Coal seam thickness (m) Percentage share (%)


0.51.5 15
1.53.5 15
Roof coal
3.55.0 12 Armored face conveyor Armored rear conveyor
5.010.0 20
10.020.0 19
Fig. 1. Extraction of full thickness of a thick coal seam in a single lift by the sub-
Above 20.0 19
level caving method (section) (after Singh et al. [2]).

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R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx 3

T max Lclr  tan h 1

Flow of coal due to gravity where Lclr is the maximum distance of the coal clearance behind the
shields and h is the caving angle.
So the recovery of the roof coal in any given thickness (T) is
given below:
Improved fracturing Recovery T max =T  100% 2
of roof coal band
t
when T > Tmax.

2.1.2. B&P route


LTCC Competency of thick coal seam, shallow depth of cover and
other techno-economic considerations, many times, favor its
development along floor on B&P method. Here final extraction
i.e. depillaring operation remains broken and, generally, does not
involve 100% supported extraction face due to operational limita-
tions. Therefore, a controlled under-winning of the hard roof coal
band becomes difficult during final extraction. A French mining
Flow of coal due to gravity
method, called Blasting Gallery (BG), utilized long hole drilling
and blasting approach to extract the full height (1012 m) of a
thick and developed coal seam in one lift. This method involved
drilling holes right through the entire thickness of the seam
Fractured coal
(Fig. 4a) in a systematic fan cut fashion to bring the roof coal band
in bigger lump t down on floor by blasting. Side-discharged-loaders/load-haul-dum
pers (SDL/LHD) are used for withdrawal of the blasted coal from
the production face. In comparison to the conventional multi-
slicing of a thick coal seam, BG method introduced considerable
Sublevel improvement in production, productivity and safety but some
caving
problems [2] were observed during the field trial of this method.
Lack of a provision to support the high roof (created after blast-
ing of the roof coal band) became a vital issue from efficiency point
Caved roof coal
Armored face conveyor Armored rear conveyor of view for depillaring of a thick coal seam under thinly laminated
immediate roof strata. In fact, machines were frequently deployed
Fig. 2. Changed under-winning system during LTCC from the conventional sub- below the unsupported roof to withdraw the blasted coal. In this
level caving (section) for a better fracturing of roof coal band.
situation, reinforcement of the immediate roof strata [16] proved
to be an important step to improve the safe span of overhanging
recovery ratio during the LTCC. Different field experiences find that beam/cantilever for withdrawal of the blasted roof coal lying on
the size of the fractured roof coal needs to be uniform, as possible, floor inside the goaf edge. Application of cable bolting (Fig. 4b) dur-
in order to facilitate a good gravitational flow. The gravitation flow ing depillaring of a thick and developed coal seam provided
of a heterogeneous mixture of fine and coarse materials is, gener- encouraging results [10] and is being practiced by the coal mining
ally, complicated. While a uniform size mixture flows at an angle of industry of India to extract total thickness (78 m) of a thick and
40, a heterogeneous mixture of fines and blocks will tend to flow developed (along floor) coal seam. More details on B&P based thick
at an angle more than 85 from the horizontal plane. However, the seam mining in single lift is provided in latter part of this paper.
flow of granulated material in bins and hoppers cannot be consid-
ered exactly the same as caving of the roof coal band. 2.2. Overlying strata movement
As mentioned above, top coal recovery (TCR) in LTCC depends
on the geo-mechanical and operational factors. As per [10], a Ground movement during an underground mining of coal is
matching value of main caving distance (MCD) with support design directly proportional to height of extraction. A simple model of dif-
becomes vital to optimize the recovery percentage during LTCC. ferent ground movement zones during an underground extraction
Here, MCD is the face distance in which the whole thickness of of a coal seam is given in Fig. 5. The range of caved zone increases
the top coal starts to cave. An estimation of shear and tensile frac- with an increase in height of extraction (Fig. 6), which will influ-
turing of the roof coal band and the caving angle may help in ence the behavior of the goaf. Changed goaf bahaviour with an
understanding MCD. Under an influence of the front abutment increase in the range of the caved zone will affect the performances
peak, caving angle of the roof coal and thickness [5] affect, both, of natural and applied supports [18]. In fact, during development of
TCR and MCD. Maximum thickness of the roof coal (Tmax) that a coal seam (primary working), the mining induced stress does not
can potentially be recovered from behind the shields is given as get much influenced by height of working. However, the increased
[10]: height of mining during final extraction influences the mining
induced stress development, mainly, due to increased height of
strata movement. Generally, the value of mining induced stress
over a pillar against a caving goaf depends on the location of the
Table 3
self supporting strata in the roof [22]. The location of self support-
Chinese cavability index (CCI) assessment (after Zhongming [20]).
ing strata in the roof is estimated through an idea of bulking factor.
LTCC classification 1 2 3 4 5 It is difficult to estimate the value of bulking factor but, for strong
Mining conditions Very good Good Medium Bad Very bad and massive strata of Indian coalfields, it is estimated to be around
CCI >0.9 0.80.9 0.70.8 0.60.7 <0.6 1.1 only. Therefore support estimation for a normal height (3 m) of
Coal recovery (%) >80 6580 5065 3050 <30
working considers only 30 m of the overlying strata but an

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ijmst.2015.09.003
4 R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx

Front
Primitive abutment
vertical Stress Primitive
stress Low stress abrupt Rear vertical
drop abutment stress

Immediate
roof

Pre fractured
Caving coal
height

Goaf
Virgin
coal Caving
Cutting rimitive
height

Floor
Main caving distance (MCD)

Fig. 3. Conceptual model of LTCC system showing natural fracturing due to mining induced stress.

where h is working height, e is extraction in percent, x HL =NEW, L


Main roof is width and H is depth of cover of the panel. NEW is width of
extraction in the panel at the time of appearance of the first
symptom of surface subsidence.
Long blast holes
Further, on the basis of different field investigations,
Immediate roof strata
CSIR-CIMFR [24] established a line of demarcation between contin-
Caved goaf uous and discontinuous subsidence cases (Fig. 7). This line of
Roof coal bed
Unsupported roof strata demarcation is found valid for, both, single and multiple seam min-
Space limitation
ing cases and the relationship is expressed as:
Poor
fragmentation H=he 0:3 4

(a) Both Eqs. (3) and (4) show that working of a thick (increase in h)
at shallow cover (decrease in H) may cause large/discontinuous
Cable bolts surface subsidence, which may result pothole formation in pres-
Main roof
ence of weak and laminated overlying strata [25]. Such ground
movement, generally, requires immediate attention not only to
deal with the occurred ground undulations but to blanket the
Immediate roof strata Blast holes wider cracks also [14], which may provide breathing path for spon-
taneous heating of the coal left out inside the goaf.
Caved
goaf
2.3. Pillar strength dilution
Roof coal bed

In case of a longwall face, up to some extent, performance of the


applied support is influenced by the increase in extraction height
(b) [18,26] due to working of TTTCSSL. But here the solidity of natural
support remains, more or less, intact due to its large size. However,
Fig. 4. (a) Sectional view of SLDTT of a thick coal seam by blasting gallery (BG)
method and (b) section showing ring hole drilling from level and split (after Singh during full thickness depillaring (B&P working) of a thick coal
et al. [16]). seam, developed along floor with normal height of working, the
effectiveness of natural support gets diluted. It may be mentioned
increased height of working (10 m) height of working considers
around 100 m of the overlying strata. Surface subsidence
deformation
Continuous

Ground movement due to underground extraction of total


zone

thickness of a thick coal seam at shallow cover becomes an area


of concern. Surface subsidence is proportional to the extraction
Fractured

height. Therefore, the increased height of extraction may induce


zone

discontinuous subsidence resulting extensive damage and fracture


to the surface and sub-surface features. The amount of maximum Tensile fractures
Caved
zone

surface subsidence (Sub) for single seam mining cases in Indian coal
fields [24] is given as:
Sub 0:33he1 1:1 tan h1:4x  1:8 3 Fig. 5. Three different zones of the disturbed overlying strata due to an
underground excavation (after Kelly et al. [6]).

Please cite this article in press as: Kumar R et al. Underground mining of thick coal seams. Int J Min Sci Technol (2015), http://dx.doi.org/10.1016/j.
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R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx 5

support. Here, a mechanized longwall face, generally, do not face


much challenge because of the specially designed chock shield
support. A special arrangement in the chock shield provides good
protection to the ARC during under-winning of the roof coal band.
However, withdrawal of the blasted/fallen roof coal band during
depillaring (B&P working) requires deployment of machines below
Increased height
Normal height high roof, which remains, generally, unsupported. The increase in
of extraction
of extraction the height of extraction through blasting of roof coal band may
not be suitable for the length of the available conventional roof
support systems. CSIR-CIMFR developed a methodology called
Cable bolt based depillaring of a thick coal seam [16], where
application of a grouted steel rope under tension for supporting a
high roof as well as an overlying coal band provided improved safe
Fig. 6. A physical model study showing effect of extraction height on overlying span of overhanging strata near the goaf edge for withdrawal of the
strata movement. blasted/fallen roof coal band of a thick coal seam (Fig. 4b).
An idea of underpinning is successfully applied for simultane-
ous underground extraction of contiguous sections (3.5 m top
Single seam, continuous and 6.0 m bottom) of 12.5 m thick coal seam [30]. Nearly 3.0 m
Multi-seam, continuous
Single seam, discontinuous
thick and highly laminated parting between the two sections was
400
Multi-seam, discontinuous found to be incompetent for safe and clean underground working
of both the sections. Both, top and bottom sections were developed
Depth of cover H (m)

300
on superimposed pillars along floors using roof bolts. Based on lab-
oratory testing and investigations on simulated models, an idea of
200 H/he=0.3
underpinning was conceived for simultaneous depillaring of both
the sections. Taking advantage of existence of openings in top sec-
100
tion, the laminated parting and roof coal band of bottom section
were reinforced simultaneously by a full column grouted cable bolt
0 100 200 300 400 500 600 700 of suitable length from the floor of the top section (Fig. 8). This pro-
Extraction height extraction (%) he (m) cess of reinforcement called underpinning, which consolidated
parting stability and provided additional thickness to the critical
Fig. 7. Line of demarcation between continuous and discontinuous subsidence parting as the roof coal band of the thick bottom section is stitched
(after Sheorey et al. [24]).
together with the parting. Maintaining superimposition of work-
that the height of working is increased through winning of roof ings in the two sections, pillars of both the sections were extracted
coal band during depillaring but their width remains the same. simultaneously by splitting and slicing. Field and laboratory inves-
Coal pillar strength (S) estimation for Indian coal fields is done tigation found that splits and slices of the bottom section did not
by Sheorey [27] by the following relationship: experience any roof instability (Fig. 9) problem due to the presence
of reinforced overlying roof coal band and parting by underpin-
S 0:27  rc  h
0:36
H=250 1W e =h  1 MPa 5 ning. The roof coal band of the thick bottom section was blasted
down during the retreat and withdrawn under support high roof
where rc = uniaxial compressive strength of coal in MPa, h = work- by the underpinning.
ing height in m, H = depth of cover in m, We = effective pillar
width = 4A/Pc, A = area of pillar = L1  L2, Pc = perimeter of the pillar
(corner to corner) = 2  (L1 + L2), L1 = length of the pillar (corner to 3. International scenario
corner) and L2 = width of the pillar (corner to corner).
Most of the formulations for pillar strength, including the above Application of a conventional mining method, suitable for nor-
one, find that the increase in working height reduces strength of mal height of extraction, even for a slightly thicker coal seam (>4 m
the coal pillar. A drop in pillar strength during full thickness depil- and <6 m) may cause loss of coal left inside goaf. This coal becomes
laring of a thick coal seam becomes a matter of concern, specially, a source of spontaneous heating. Here, one-slice longwall mining is
during working below competent overlying strata. Here, it is adopted by different countries (Table 4) to extract [7,31] a coal
required to have a strong natural support along the goaf edge to seam up to 6 m thickness in single lift. At the moment, the one-
break the competent roof strata for caving. A coal pillar of squat slice equipment are not available to extract more 7 m thick coal
nature during development (primary working) becomes slender seam [12] and, therefore, involvement of natural or induced caving
and may encounter catastrophic failure during the full height of roof coal band for the extraction of TTTCSSL (>7 m) becomes a
depillaring. Such failure of the natural support always remains a need. However, as per literature survey, a coal seam up to maxi-
threat for safety, production and productivity. Generally, a good mum 12 m thickness only can be extracted with an involvement
resistance of the natural support is applied to control the caving of natural or induced caving of the roof coal band for, both, long-
of competent roof strata but creation of such resistance for a full wall and B&P mining.
height depillaring of a thick coal seam is practically not feasible. Sublevel caving method (soutirage) [19] is used for extraction of
Probably, an elegant approach to tackle this problem of mining of thick coal seams in France, Russia and other countries since 1950s. In
TTTCSSL is dilution of competency of the roof strata through an the beginning of 1980s, China began to explore sublevel caving tech-
effective hard/competent roof management technique [28,29]. nology and, after many years of research and testing, they developed
fully mechanized sublevel caving equipment, especially power sup-
2.4. High roof support port [32]. Presently this technology is modified as LTCC and is under
operation in many coal mines of China for underground mining of
Winning of the roof coal band for full height extraction of thick thick coal seams [33]. Last 20 years have been full of research and
coal seam creates an immediate roof, which is relatively higher to development and large scale field applications of LTCC technology

Please cite this article in press as: Kumar R et al. Underground mining of thick coal seams. Int J Min Sci Technol (2015), http://dx.doi.org/10.1016/j.
ijmst.2015.09.003
6 R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx

Roof

1.0 m
Top section

2.5 m
Goaf
4.5 m 17.5 m

3.0 m
Laminated & weak parting
Underpinning

1m
3.2 m

Bottom section
2.8 m

4.5 m 17.5 m

Floor

Fig. 8. Schematic diagram showing simultaneous depillaring of top and bottom sections with underpinning and roof bolt support (after Mandal et al. [30]).

0
-0.05 -0.006
-0.10 -0.008
-0.15
-0.010
-0.20
-0.25 -0.012
-0.30 -0.014
-0.35 None -0.016
-0.40 Shear-n shear- p
-0.45 Shear-n shear- p tension -p -0.018 None
Shear-n tension-n shear- p tension-p Shear-n shear-p
-0.50 Shear-p -0.020 Shear-n shear-p tension-p
-0.55 Shear-p tension-p -0.022 Shear-p
-0.60 Tension-n shear- p tension-p Shear-p tension-p
-0.024
-0.65
1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 (10 4 ) 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 (10 4 )
(a) Without underpinning (b) With underpinning

Fig. 9. Results of numerical study (quarter symmetry models) sowing conditions of different blocks along with convergence at junction and middle of roadways during
development (after Mandal et al. [30]).

method to extract TTTCSSL utilizing normal height working along


Table 4 the floor and under-winning of the overlying roof coal band. Under
Thick seam single pass longwall operations in different countries (after Hebblewhite existing conditions of the coal mass, a requirement of induced frac-
[7]) (m).
turing of the roof coal band is felt for underground extraction of
Mine Face height Maximum LW support TTTCSSL. The application of LTCC to Australian conditions has been
(maximum) height successful but has also highlighted several additional operational
Lazy mine, Czech 5.5 6.0 and geotechnical factors that need to be managed [35].
Republic Underground extraction of thick coal seams in United States of
Sihe mine, China 5.5 5.5 America is not much visible in literature. However, application of
Shendong mine, China 5.0 5.5
Daming mine (AACI), 5.0 5.5
hydraulic mining for thick coal seams in New Zealand has shown
China good results [7,36] but for a scanty band width of the geo-
Zhouchuang mine, 6.0 mining conditions. This approach offered considerable financial
China benefits, but has limited potential for large scale production.
Shangwan mine, China 5.0 5.5
Therefore, hydraulic mining is considered suitable method for only
Mada mine, South Africa 5.5 6.0
few selected site conditions, where floor is not likely to be dam-
aged by water and gradient of the coal seam is greater than 15.
There is another possibility of hydraulic mining for thick coal
in China with success. The Chinese coal industry has reported an seams with gradient less than 15 that, taking advantage of the
average production of 15,00020,000 t of coal per day from a LTCC thickness, this method may operate at apparent dips in excess of
face. Up to large extent, the success of a LTCC operation depends the actual seam dip.
on appropriate geo-technical environment and successful geo-
technical management within that environment [8].
Australia has significant reserves of thick coal seams, which led 4. National scenario
them to conduct extensive research for an alternate mining
method [34] beyond the conventional B&P or standard longwall Facts and figures about coal reserve and its exploitation trend in
systems. Here, different rock mechanics considerations found that India [37] reveals that the underground mining technology is
the option of extending the height of a conventional single pass important for production of coal in coming days. Generally, upper
longwall has limited possibilities. Presence of competent coal mea- coal seams of Indian coalfields are developed on B&P method of
sure formations introduced problems for application of a mining mining, resulting locking of more than 3000 Mt of prime coal in

Please cite this article in press as: Kumar R et al. Underground mining of thick coal seams. Int J Min Sci Technol (2015), http://dx.doi.org/10.1016/j.
ijmst.2015.09.003
R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx 7

pillars under varying geo-mining conditions [38]. In fact, presence As mentioned in Section 2.1, Indian coalfields did not experi-
of coal seams with, relatively, high UCS (uni-axial compressive ence any longwall route for underground extraction of TTTCSSL
strength) value (Table 5) under competent roof strata provided except one [18]. Underground extraction of TTTCSSL in Indian coal-
encouraging mining condition for the development on B&P fields is done, mainly, by B&P method. When development of a
method. Any attempt to increase coal production from under- thick coal seam on B&P method is done along floor horizon, the left
ground mines in the country encounters challenge of depillaring out roof coal bed is, generally, won during depillaring. However, if
of these coal seams, standing on pillars. Indian coalfields, generally, a thick coal seam is developed on B&P method along the roof hori-
inherit difficult conditions for a depillaring operation, which is zon, there is a requirement of another development of the seam
going to be even more complex in near future, mainly, due to along floor horizon for SLDTT. On the basis of different laboratory
exhaustion of coal reserve from easy site conditions. Here, it is and field investigations, it is found that the required development
not very straightforward to apply any foreign technology for the along floor of a thick coal seam (already developed along roof)
depillaring, mainly, due to uniqueness of the Indian coal measure should be staggered one [1].
formations. Most of the imported underground mining technolo- Even after more than 100 years of research and development in
gies could not fulfill the techno-economic expectations of the the field of underground coal mining, depillaring under competent
industry [39] as they encountered a coal/rock mass of different roof strata experiences the problem of massive collapses, pillar
character. It is realized that a good knowledge and understanding squeezing, pillar bumps, etc. [42]. A depillaring operation exposes
of the geo-mining conditions of the site becomes an important men and machineries at risk due to these strata control problems.
input for a new technology. It may be mentioned that most of these Suitable sequence and manner of pillar extraction to counter the
developed pillars are lying under strong and massive sandstone implications of overlying strata dynamics [43,44] becomes an
roof of Lower Gondwana age. This roof is known for delayed and important consideration for a successful depillaring. Required
violent failure [40,41] after creation of large void during competency/stiffness to break the competent roof strata is, gener-
depillaring. ally, produced by the coal pillars and, therefore, the design of pil-
Efficient underground extraction of a thick coal seam is an lars becomes an important input for depillaring. In fact, a
important issue in India, mainly, due to its substantial presence successful depillaring operation needs design of pillars of variable
in almost every coalfield of the country. Different practiced shapes and sizes [45,46] at different positions of the operation
approaches for underground extraction of thick coal seams in India under the influence of overlying strata dynamics. Here, the design
are summarized in Fig. 10. of final stook/rib against gallery junctions is an important issue for
Multi-slice working of a thick coal seam is a normal choice [4] varying conditions of the depillaring operation. Further, the
to reduce operational constraints and optimize recovery and increased height of extraction during depillaring of total thickness
safety. Orientation of a slice is controlled by seam gradient and of a thick coal seam dilutes competency/stiffness competency of
massiveness of the coal seam while thickness of the slice is, mainly, the pillars, which may lead to strata control problems [47].
dependent upon the quality and dimension of the available roof
support system. Order of different slices to win a complete thick-
ness is decided according to the local geo-mining conditions of 4.1. Longwall mining
the site. Slices in ascending order (from bottom to top) require
stowing/filling of the void created due to mining, which decreases Selection of a suitable mining method for extraction of a thick
productivity and becomes expensive. Slices in descending order coal seam with optimal recovery and safety is an extremely deli-
(from top to bottom) experience strata control problems because cate process. An access to international market provides some
the working in the lower slices is to be carried out directly below options to select a suitable mining method for underground win-
the broken overlying strata due to top slice working. Difficulty in ning of thick coal seams in the country. Out of the two types of
caving of the massive overlying roof strata also creates problems mining methods for a thick coal seam: (i) multi-slice working
during slicing of a thick coal seam in descending order. Even under and (ii) extraction of TTTCSSL, the latter one is preferable due dif-
weak and laminated roof strata, slices in descending order require ferent techno-economic reasons [4]. However, the scope of single
a technology/system (generally artificial roofing) to differentiate lift working of a thick coal seam by a mechanized longwall sublevel
the caved rock piles from the excavated coal. Working of TTTCSSL caving method (soutirage) is restricted by massiveness and higher
has always an edge over the multi-slice working due to favorable strength of Indian coal mass. Further, large capital investment,
economics and improved production and productivity. presence of massive roof strata (difficult for caving) and shallow
depth cover are other major problems with this approach.
Table 5 Only one attempt was made to introduce mechanised longwall
Strength parameters of some of the Indian coal seams (after Singh et al. [16]). sublevel caving face [18] for thick seam mining in India without
Name of colliery Name of seam UCS (MPa)
any encouraging result. A number of other longwall projects
including longwall (powered support) face of Charcha colliery
Patharkhera Bagdona 44.2
Seetalpur Hatnal 43.3
and longwall (powered support) face of Kottadih colliery have
Dhemomain Borachak 32.5 failed due to single technical reason: the presence of massive over-
Moonidih XVI top 22.0 lying roof strata. The coal measure formations of India and Aus-
East katras X 27.0 tralia are similar as both belong to Lower Gondwana age.
Gopalichak X 27.7
Australian coal mining industry has achieved great success in
Chinakuri Disergarh 36.3
Kottadih Samla 31.2 mechanised longwall mining while, in India, the approach is
East bhuggatdih VII/VIII 18.0 adversely affected by strata control problems in the beginning
Jhanjra R-VIII 35.8 itself. A review of the support capacity applied to the longwall
GDK-8 III (top) 56.0 faces of the two countries shows that the average support density
GDK-8 III (bottom) 59.0
Belampalli Ross 48.0
of an Australian longwall face is almost double to that of an Indian
Belampalli Salarjung 46.0 longwall face. The existing complexities in designing support
Mandmari III 47.0 capacity for Indian longwall increases further for mechanised long-
Mandmari IV 30.9 wall sublevel caving [18] of a thick coal seam due to increase in
GDK11 I 50.0
extraction height.

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ijmst.2015.09.003
8 R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx

Underground mining methods for thick coal seams

Longwall Bord & Pillar


Methods

Total thickness Multi-section


Total thickness Multi-section
in single lift in single lift

Up to 15 m 8 to 10 m 8 to 12.5 m
7 to 12 m 5 to7 m
Up to 7.5 m Up to 9-11 m Stowing in Simultaneous Simultaneous
depillaring depillaring with
ascending order Blasting with stowing underpinning
Sublevel Artificial roofing gallery
caving based sublevel Continuous mining
caving Cable
bolting with floor coaling

Fig. 10. Different underground mining methods used to extract thick coal seams in India.

78L coal band is adopted [48,16] during SLDTT. Most of the thick coal
seams of the country are developed along the floor with 2.5 m
average gallery height and 4.2 m average gallery width. The
Bottom section
increase in extraction height for better recovery from a thick coal
Top section
(Centre line)
seam severely affects the design and rating of roof support, move-
79L
ment of overlying roof strata, stability of pillars and, in fact, dilutes
most of the safety norms of underground mining [14,18,27]. A high
value of mining induced stresses in and around a depillaring face
e

under a massive roof condition [49] creates threat of collapse of


lin

Pillar split
af

80L
the depillaring face and instability of barrier pillars during SLDTT.
Go

30
31D 32D 33D 34D
D 5.1. Collapse of a depillaring face
81L
BG method of mining for SLDTT was first introduced by Coal
India Limited (CIL), in technical collaboration with Cdf, France
D
ire

[48]. This semi-mechanised method of thick seam depillaring is


ct
io
n

82L
of

extensively utilized by another coal company of the country: Sin-


fa
ce

gareni Collieries Company Limited (SCCL). BG involves conven-


ad
va
nc

tional machinery and the total capital investment is also not very
e

high with an average daily output of around 800 t per day. For a
83L thick coal seam, developed on bord and pillar along floor, this
method involves drilling holes from existing galleries right through
the entire thickness of the seam in a systematic fan cut fashion to
84L bring the roof coal down by blasting. Before blasting of the roof
coal, the developed pillars are split along the face line to increase
the number of loading points and to reduce the length of the ring
holes to be drilled to win the roof and side coal. All the ring holes
Fig. 11. Offset plan of panel No. II/2 of No. 3 seam showing top and bottom section are drilled in the same plane at 30 inclination toward the goaf
developments and face position of BG extraction at the time panel closure due to from the vertical. Ring hole blasting makes large amount of coal
face collapse.
available at the face. Machines (LHDs/SDLs) are used for loading
4.2. B&P mining and transportation of coal from the production face. Remote con-
trolled coal evacuation machines are used to lift the fallen coal
Due to lack of financial investment in the coal industry and piles lying inside the goaf.
inherited geotechnical characteristics of thick coal seams of India,
these seams are being extracted mainly by B&P mining. Many thick 5.1.1. Site conditions
coal seams of India are developed in single or multiple sections to To extract complete thickness of about 10.5 m thick No. 3 seam
meet the increasing demand of coal. For a developed thick coal in one lift, GDK-8 Incline in RG-II area, SCCL adopted the BG
seam along floor, induced caving of roof coal band during retreat method. It is nearly flat coal seam with gradient 1 in 10. This seam
is used for SLDTT. This caused an increase in goaf height during was extensively developed on pillars along roof, prior to the plan-
depillaring, which created pillar instability problems as detailed ning of the BG method. The development was made along the roof
in following section. horizon, mainly, due to presence of the competent overlying sand-
stone roof strata. Average width and height of the gallery were 4.2
5. Single lift depillaring of total thickness and 2.5 m respectively during this development. Average size of
the pillars so formed was 39.5 m  39.5 m (center to center). A coal
As discussed above, the scope of under-winning of roof coal band of 8 m thickness remained intact along the floor during the
band through natural gravitational flow during working of a thick top section development. The planning of application of BG
seam along the floor is limited due to the massiveness and hard- method in the panel BG-II/2 led to another superimposed bottom
ness of Indian thick coal seams. Here, induced caving of the roof section development along floor. Thus, average thickness of coal

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R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx 9

phase of the depillaring. With the progress of depillaring, the panel


experienced considerable overhang of roof strata inside the goaf,
throwing large amount of mining induced stress over the pillars
[50] facing goaf line. There was no instrumentation to measure
the stress change but the observed heavy side spalling of the pillars
indicated the presence of high value of mining induced stress. Fur-
ther advancement of the face created localized fall of coal parting at
some junctions. This depillaring panel experienced major face col-
lapse after a 12,380 m2 area of goaf exposure (Fig. 11), which led
to closure of the panel. It was difficult to map the exact configura-
tion of the failure but a complete failure of junctions parting is
noticed in the middle of the depillaring face span. Limited access
to the collapsed area also indicated partial failure of spitted pillars
around the collapsed junctions.

5.1.3. Staggered bottom section development


It is observed that a stook of around 10 m width experienced a
width to height ratio (w/h) less than one after collapse of parting
between the two sections of the 10.5 m thick coal seam. A stook,
standing in front of large overhanging roof strata inside the goaf,
with such a low value of w/h is likely to face catastrophic failure.
Based on simple ideas and results of laboratory investigations on
simulated models, conventional superimposed development of
the thick seam was replaced by staggered one (Fig. 14) for the
depillaring and under-winning of roof coal by the BG method.
The performance of staggered development based depillaring by
the BG method was found satisfactory [41]. This approach is being
Fig. 12. Observed physico-mechanical properties of the formation of GDK-8 Incline
adopted as regular method by Indian coal mining industry for
colliery (BH No. -632).
SLDTT by BG method, where a thick seam is present with develop-
parting between the two developments was 5.5 m only. Dimen- ment along the roof horizon.
sions of pillars and galleries of bottom section were kept exactly
same as those of the top section. Selected panel BG-II/2 (Fig. 11) 5.2. Failure of barrier pillars
consisted of 12 pillars for the extraction at an average depth cover
of 298 m. Nearly 10.2 m thick No. 3 seam (gradient 1 in 10) at GDK 10
Only overlying No. 1 seam was depillared and the caved goaf, at Incline mine of Ramagundam Area, SCCL is extensively developed
nearly 90 m height from the panel, was observed to be free from
water while other coal seams were virgin in the area. Laboratory
compressive strength of the No. 3 seam is observed to be
L L
35.3 m

25.7 m

57.5 MPa. The overlying strata section including lithology, com- 15.5m
pressive strength, rock quality designation (RQD), etc. up to 50 m
height from the seam is shown in Fig. 12. Around 85% cover strata 5.4 m
L L
over the proposed panel consisted of sandstone indicating that the D D D D D D
roof would cave with difficulty. 35.3 m

L L
5.1.2. Problem encountered
Although the 10.5 m thick No. 3 seam consisted of two superim-
posed developed sections, only bottom section is used during depil-
laring and under-winning of roof coal through ring hole blasting. A Top Bottom
sectional view of ring hole drilling through a split in No. 3 seam of
GDK8 incline is shown in Fig. 13. The coal parting of 5.5 m thickness Fig. 14. Staggered bottom section development for the BG method for No. 3 seam of
between the two developments was found competent during initial GDK-8 Incline (after Singh et al. [1]).

17.2 m
Top 2.5 m Top 2.5 m

4.2 m 4.2 m
10.5 m

No.3 seam
of GDK8
4.2 m 4.2 m

Bottom 2.5 m Split 2.5 m

Developed gallery Ring hole drilling from the split

Fig. 13. Dimensional details and sectional view of drilling of ring holes to win roof and side coal by the BG method in panel No. II/2.

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10 R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx

RQD Recovery UCS ( )


(%) (%) (MPa)
Depth
163.40 m 1 Seam 0 50 100 0 50 100 0 40 80

Fg.- Fine grained, Cg.- Coarse grained, Mg.- Medium grained


sst.- Sandstone and Carb.- Carbonaceous

Clay Fg. sst. with irregular mica laminae

Fg. sst
Shale
Carb. Shale
183.40 m 3.11 m
2 Seam C oal

Cg. sst.

2 0 1 .2 0 m 1.54 m Mg. sst.


3B Seam
Fg. to Mg. sst.

Shaly sandstone
100.47 m

Carb. shale with thin coal bands

Mg. sst. with garnetiferous

229 m 0.87 m Coal with thin sst. bands at middle


3A Seam
Fg. sst. with quartz felspar pebbles at places
Mg. sst. with occasional quartz & felspar
pebbles at places
Very cg. sst. with quartz, felspar pebbles,
carb. streaks at middle
Mg. sst. with quartz, felspar pebbles at places
253.58 m pyritic
3 Seam 10.29 m

263.87 m

Fig. 15. Strata section of partings between Nos. 1 and 3 seams of GDK-10 Incline Mine, SCCL (BH No. 637).

56L

57L
Proposed BG

Panel no. 1C

58L
No.1B
Panel

No.1A
Panel

59L
60L
61L

62L

63L
No.2E
Panel

No. 2A
No.2F

No.2C
No.2D

No.2B

Panel
Panel

Panel
Panel

64L
Panel

65L
12D 14D 16D 20D 24D 26D 31D 37D 40D

B.H.No. 441

Fig. 16. Plan showing different worked out and working panels of No. 3 seam of GDK-10 Incline.

on pillars of nearly 3.0 m height and 37.5 m width along floor. Symptom of heating and carbon mono-oxide gas was noticed dur-
More than 90% coal of the seam is locked in pillars and overlying ing working in the panel 2B, just after the first major fall. Incidence
coal band at 200350 m depth of cover. Overlying No. 1 seam of heating after the first major fall did not remain restricted to
was depillared and the caved goaf, at nearly 90 m height, was panel 2B only but SLDTT in other panels 2C and 2D met similar
observed to be free from water. Rests of the overlying and under- phenomena. This repeated encounter of heating and premature
lying coal seams were virgin in the area. BG method is adopted closure of these panels attracted attention toward the safety of
at this mine for SLDTT of No. 3 seam. Strata over the seam were the barrier pillars. It is only barrier pillars between two BG panels,
observed to be strong and massive (Fig. 15). Presence of difficult which experienced full height goaf from both sides. In comparison
roof over nearly 10.2 m high void of the method created a difficult to the value of w/h of original pillars at development stage, there is
condition for SLDTT. Previous experiences of working in No. 1 seam a remarkable change in w/h of the barrier pillars located between
indicated that the main roof fall occurs nearly after 60008000 m2 the two depillared panels (Fig. 17).
of roof exposure. It is observed that the w/h of the barrier pillars at the time of
After completion of SLDTT of the No. 3 seam in the panel 2A of development was 12.5, which reduced to 3.6 after formation of a
GDK 10 Incline (Fig. 16) by BG method, the SLDTT in neighboring full height goaf toward both sides of the pillar. This change in
panel 2B experienced premature sealing due to indication of fire. the nature of the barrier pillars (from squat to slender) due to

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R. Kumar et al. / International Journal of Mining Science and Technology xxx (2015) xxxxxx 11

Stress due to
overburden ( H )
Development

4.2m

10.2 m
Barrier pillar

3.0 m

37.5 m 4.2 m
H + mining induced stress
Depillaring

Poor w /h in view
full height

of full height working

10.2 m
Goaf of

Barrier pillar
17.2
Face direction 3.0 m

37.5 m 4.2 m

Fig. 17. A sectional view of barrier pillar against development and goaf of full height (nearly 10.2 m) of No. 3 seam.

Table 6 nes, maximum 1012 m thick coal seam can be extracted in single
Safety factor of barrier pillar at GDK-10 Incline colliery, SCCL. lift. Here, a normal height working is practiced along floor of the
Parameter Panel length = 113.5 m Panel length = 150 m thick coal seam and rest of the overlying coal band is won under
gravity (called under-winning). Longwall route for underground
Length (m) 44 44 44 44 44 44
Width (m) 37.5 37.5 37.5 37.5 37.5 37.5 mining of TTTCSSL has a number of advantages and is being exten-
Effective width (m) 40.5 40.5 40.5 40.5 40.5 40.5 sively used in China. Weak coal mass and high vertical stress on
Gallery width (m) 4.2 4.2 4.2 4.2 4.2 4.2 coal seam are the two important geological parameters for the suc-
Depth (m) 322 322 322 322 322 322 cess of this approach, otherwise induced caving of the roof coal
Working height (m) 10.2 3.0 6.5 10.2 3.0 6.5
band is adopted for the under-winning. Existing geological condi-
rc (MPa) 43 43 43 43 43 43
Safety factor 0.44 1.36 0.66 0.40 1.24 0.60 tions and poor financial investment of Indian coal mining industry
have led large scale development of thick coal seams on bord and
pillar. These pillars are formed in competent coal mass under com-
SLDTT created favorable condition for catastrophic failure of the petent overlying strata. SLDTT of a developed thick coal seam
pillars. It is apprehended that catastrophic failure of the barrier pil- adopts induced roof caving but the increased height of extraction
lar during first major fall is interconnecting the working panel with adds the problem of pillar instability. In addition to a site condi-
the adjacent sealed goaf of the exhausted panel. Later, this appre- tions based approaches to improve strength of the pillar against
hension of interconnection between the two panels was confirmed the increased height of goaf, an effective management of the com-
through nitrogen flushing in the exhausted panel and gas sampling petent overlying roof may prove to be significant to arrest the pillar
in the panel under progress. instability problems.
Safety factor of barrier pillars of panel 2B is estimated during
first major fall and the results are mentioned in Table 6. During this Acknowledgments
estimation, mining induced stress is anticipated for a non-
effective-width [51] of the panel. From this simple calculation, it Thanks are due to the management of the GDK-8 Incline and
is observed that the safety factor of barrier pillars for normal height GDK-10 Incline mines for their valuable co-operation during the
(3 m) depillaring remains close to 1.5 but the same for full height reported field observations. A part of the study reported in this
of depillaring of the seam by BG goes down to 0.44 only. During paper is based on a project funded by the Singareni Collieries Com-
the BG operation, hard roof management system through drilling pany Limited (SCCL). Authors acknowledge the support of Depart-
and blasting is practiced to bring down the roof strata inside the ment of Mining Engineering, ISM for making use of different
goaf. However, due to limitations of the available drilling system, facilities. The authors also thank the director, Central Institute of
only 46 m of the roof strata could be dislodged inside the goaf. Mining and Fuel Research, Dhanbad, for permitting to publish the
Even after considering the favorable effect of the induced caving paper. The views expressed in this paper are those of authors
of 46 m height roof strata on pillar strength, the safety factor and not necessarily of the organizations they represent.
remained below one (Table 6). This table gives two values of safety
factors for two widths of the panel as per site conditions. To References
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Please cite this article in press as: Kumar R et al. Underground mining of thick coal seams. Int J Min Sci Technol (2015), http://dx.doi.org/10.1016/j.
ijmst.2015.09.003

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