Examining the optimum panel pillar dimension in longwall mining considering stress distribution

Longwall mining method is widely used for underground coal production in the world. Additional stresses occur surrounding the longwall during underground mining. Stresses occurring surrounding the longwall are investigated by many researchers for years. How these stresses affect longwall production, gob, main gate, tailgate and main haulage road has been always an important issue. In this study, the effect of the safety pillar left at the end of the panel on the main haulage road is investigated. For this purpose, 6 models with different pillar distances are created and the stresses occurring in the main haulage road, tailgate and main gate at different pillar distances are examined. It has been demonstrated with numerical models that the optimum pillar distance according to these stress conditions does not damage the main haulage road, tailgate and main gate. In addition, the pillar distance of 10 m gives maximum coal recovery efficiency, and it has been shown by numerical models that the stresses occurring in the main haulage road, main gate and tailgate are not damaging to these galleries.

Methane migration and explosive fringe localisation in retreating longwall panel under varied ventilation scenarios: a numerical simulation approach

Methane-based inflammable underground coal mine environment has led to catastrophic losses in the past. Migration of methane from the working seam and desorption region above and below the seam causes explosion hazard. In this study, the computational fluid dynamics (CFD)-based simulations of a longwall panel in a methane-rich inclined coal seam of the Moonidih mine in India established that the ventilation parameters greatly influence the methane flow in the longwall tailgate and porous medium of the goaf. The field survey and CFD analysis revealed that methane accumulation on the "rise side" wall of the tailgate is attributable to the geo-mining parameters. Further, the turbulent energy cascade was observed to impact the distinct dispersion pattern along the tailgate. The numerical code was used to investigate the changes in ventilation parameters made to dilute the methane concentration in the longwall tailgate. Methane concentration in the tailgate outlet decreased from 2.4 to 1.5% as the inlet air velocity increased from 2 to 4 m/s. The oxygen ingress into the goaf increased from 0.5 to 4.5 lps as the velocity was increased, causing the explosive zone in the goaf to expand from 5 to 100 m. Amongst all velocity variations, the lowest level of gas hazard was observed at an inlet air velocity of 2.5 m/s. This study, thus, demonstrated the ventilation-based numerical method to assess the coexistence of gas hazard in the goaf and longwall workings. Moreover, it provided impetus to the necessity of novel strategies to monitor and mitigate the methane hazard in U-type longwall mine ventilation.

The current perspective of the PA 1957 gas well pillar study and its implications for longwall gas well pillars

Many states rely upon the Pennsylvania 1957 Gas Well Pillar Study to evaluate the coal barrier surrounding gas wells. The study included 77 gas well failure cases that occurred in the Pittsburgh and Freeport coal seams over a 25-year span. At the time, coal was mined using the room-and-pillar mining method with full or partial pillar recovery, and square or rectangle pillars surrounding the gas wells were left to protect the wells. The study provided guidelines for pillar sizes under different overburden depths up to 213 m (700 ft). The 1957 study has also been used to determine gas well pillar sizes in longwall mines since longwall mining began in the 1970 s. The original study was developed for room-and-pillar mining and could be applied to gas wells in longwall chain pillars under shallow cover. However, under deep cover, severe deformations in gas wells have occurred in longwall chain pillars. Presently, with a better understanding of coal pillar mechanics, new insight into subsidence movements induced by retreat mining, and advances in numerical modeling, it has become both critically important and feasible to evaluate the adequacy of the 1957 study for longwall gas well pillars. In this paper, the data from the 1957 study is analyzed from a new perspective by considering various factors, including overburden depth, failure location, failure time, pillar safety factor (SF), and floor pressure. The pillar SF and floor pressure are calculated by considering abutment pressure induced by full pillar recovery. A statistical analysis is performed to find correlations between various factors and helps identify the most significant factors for the stability of gas wells influenced by retreat mining. Through analyzing the data from the 1957 study, the guidelines for gas well pillars in the 1957 study are evaluated for their adequacy for room-and-pillar mining and their applicability to longwall mining. Numerical modeling is used to model the stability of gas wells by quantifying the mining-induced stresses in gas well casings. Results of this study indicate that the guidelines in the 1957 study may be appropriate for pillars protecting conventional gas wells in both room-and-pillar mining and longwall mining under overburden depths up to 213 m (700 ft), but may not be sufficient for protective pillars under deep cover. The current evaluation of the 1957 study provides not only insights about potential gas well failures caused by retreat mining but also implications for what critical considerations should be taken into account to protect gas wells in longwall mining.

Moderate Cover Bleeder Entry and Standing Support Performance in a Longwall Mine: a Case Study

Bleeder entries are critically important to longwall mining for the moving of supplies, personnel, and the dilution of mine air contaminants. By design, these entries must stay open for many years for ventilation. Standing supports in moderate cover bleeder entries were observed, numerically modeled, and instrumented by researchers at the National Institute for Occupational Safety and Health (NIOSH). The measurements of the installed borehole pressure cells (BPCs), standing support load cells and convergence meters, and roof extensometers are presented in this paper in addition to the numerical modeling results and visual observations made by the NIOSH researchers in the bleeder entries. The results include the effects of multiple panels being extracted in close proximity to the instrumented site as well as over one and a half years of aging. As expected, standing supports closer to the longwall gob showed the greatest load and convergence. The roof sag appeared generally independent of the proximity to the longwall gob. The BPC readings were driven by both the proximity to the gob and the depth into the pillar. The results of this study demonstrated that the entry roof can respond independently of the pillar and standing support loading. In addition, the rear abutment stress experienced by this bleeder entry design was minimal. The closer the mine development, pillar, or supports are to the gob, the greater the applied load due to rear abutment stress.

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

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

Numerical simulation of roof cavings in several Kuzbass mines using finite-difference continuum damage mechanics approach

An essential stage of mine design is an estimation of the steps of the first and periodic roof caving in longwall mines. Generally, this is carried out using the field experience and can be much enhanced by numerical simulation. In this work, the finite-difference method was applied coupled with the continuum damage mechanics (CDM) approach to simulate the stress-strain evolution of the rock mass with the underground opening during coal extraction. The steps and stages of roof caving were estimated relying on the numerical simulation data, and they were compared with the field data from several operating mines in the south of the Kuznetsk Basin, Russia. The dependence of the first roof caving step in simulation linearly correlates with field data. The results correspond to the actual roofs of longwall panels of the flat-dipping coal seams and the average rate of face advancement is approximately 5 m/day.

Influence of longwall mining on the stability of gas wells in chain pillars

Longwall mining has a significant influence on gas wells located within longwall chain pillars. Subsurface subsidence and abutment pressure induced by longwall mining can cause excessive stresses and deformations in gas well casings. If the gas well casings are compromised or ruptured, natural gas could migrate into the mine workings, potentially causing a fire or explosion. By the current safety regulations, the gas wells in the chain pillars have to be either plugged or protected by adequate coal pillars. The current regulations for gas well pillar design are based on the 1957 Pennsylvania gas well pillar study. The study provided guidelines for gas well pillars by considering their support area and overburden depth as well as the location of the gas wells within the pillars. As the guidelines were developed for room-and pillar mining under shallow cover, they are no longer applicable to modern longwall coal mining, particularly, under deep cover. Gas well casing of failures have occurred even though the chain pillars for the gas wells met the requirements by the 1957 study. This study, conducted by the National Institute for Occupational Safety and Health (NIOSH), presents seven cases of conventional gas wells penetrating through longwall chain pillars in the Pittsburgh Coal Seam. The study results indicate that overburden depth and pillar size are not the only determining factors for gas well stability. The other important factors include subsurface ground movement, overburden geology, weak floor, as well as the type of the construction of gas wells. Numerical modeling was used to model abutment pressure, subsurface deformations, and the response of gas well casings. The study demonstrated that numerical models are able to predict with reasonable accuracy the subsurface deformations in the overburden above, within, and below the chain pillars, and the potential location and modes of gas well failures, thereby providing a more quantifiable approach to assess the stability of the gas wells in longwall chain pillars.

A Field Study of Longwall Mine Ventilation Using Tracer Gas in a Trona Mine

A ventilation research study was conducted by the National Institute for Occupational Safety and Health and a cooperating trona mine in the Green River basin of Wyoming, USA. The mine operation uses the longwall mining method in trona bed 17, a commonly mined unit in the region. The longwall face length is 228 m (750 ft), and caving on the face occurred up to the back of the longwall shields. The mine is ventilated using a main blowing fan and a bleeder shaft. For this study, sulfur hexafluoride (SF6) tracer gas was released in two separate monitoring experiments. For the first experiment, tracer gas was released on the face, this test focused on airflow along the longwall face of the active panel. Face test showed the airflow patterns to be more complex than just head-to-tail flow in the main ventilation air stream on the active panel. For the second experiment, tracer gas was released 2 crosscuts inby the face on the headgate side, this test focused on gas transport in the mined-out portion of the same active panel. Gob test showed a pathway of movement through the front of the active panel gob that moved outby from the tailgate corner. The primary pathway of tracer gas movement in the active panel gob was towards the headgate and tailgate bleeders and out of a bleeder shaft. The rate of movement towards the back of the gob was measured to be 0.19 m/s (37 fpm).

Investigating the Impact of Caving on Longwall Mine Ventilation Using Scaled Physical Modeling

In longwall mining, ventilation is considered one of the more effective means for controlling gases and dust. In order to study longwall ventilation in a controlled environment, researchers built a unique physical model called the Longwall Instrumented Aerodynamic Model (LIAM) in a laboratory at the National Institute for Occupational Safety and Health (NIOSH) Pittsburgh Mining Research Division (PMRD) campus. LIAM is a 1:30 scale physical model geometrically designed to simulate a single longwall panel with a three-entry headgate and tailgate configuration, along with three back bleeder entries. It consists of a two-part heterogeneous gob that simulates a less compacted unconsolidated zone and more compacted consolidated zone. It has a footprint of 8.94 m (29 ft.) by 4.88 m (16 ft.), with a simulated face length of 220 m (720 ft.) in full scale. LIAM is built with critical details of the face, gob, and mining machinery. It is instrumented with pressure gauges, flow anemometers, temperature probes, a fan, and a data acquisition system. Scaling relationships are derived on the basis of Reynolds and Richardson numbers to preserve the physical and dynamic similitude. This paper discusses the findings from a study conducted in the LIAM to investigate the gob-face interaction, airflow patterns within the gob, and airflow dynamics on the face for varying roof caving characteristics. Results are discussed to show the impact of caving behind the shields on longwall ventilation.

Face Ventilation on a Bleederless Longwall Panel

A ventilation study using tracer gas was conducted at a western US coal mine. The objective of the study was to evaluate the movement of longwall face air exchanges between the face and worked-out area and to document the presence or absence of face airflow pathways between these locations. The mine operator uses a bleederless longwall ventilation system with a back return and a blowing mine ventilation system. The study was conducted on an active panel and included both underground and surface monitoring sites. The study used sulfur hexafluoride (SF₆) released as a slug on the longwall face and in the front of the gob inby the face. The velocity of the tracer gas movement in the gob was 0.019 m/s (3.7 fpm). The rate of movement for the overall tracer gas slug averaged about 0.0091 m/s (1.8 fpm). A separate tracer gas test initiated with the release of SF₆ into the legs of the first shield showed the existence of more than one pathway of face air in the general direction from the headgate towards the tailgate corner. Maintaining adequate ventilation air on longwall faces is important for worker safety and for the dilution of methane emitted from the face and caved gob. A more detailed characterization of longwall system air and gas movement allows a mine to better assess its ventilation design for controlling gas on the face and in the gob.

Ground response to high horizontal stresses during longwall retreat and its implications for longwall headgate support

Roof falls in longwall headgate can occur when weak roof and high horizontal stress are present. To prevent roof falls in the headgate under high horizontal stress, it is important to understand the ground response to high horizontal stress in the longwall headgate and the requirements for supplemental roof support. In this study, a longwall headgate under high horizontal stress was instrumented to monitor stress change in the pillars, deformations in the roof, and load in the cable bolts. The conditions in the headgate were monitored for about six months as the longwall face passed by the instrumented site. The roof behavior in the headgate near the face was carefully observed during longwall retreat. Numerical modeling was performed to correlate the modeling results with underground observation and instrumentation data and to quantify the effect of high horizontal stress on roof stability in the long-wall headgate. This paper discusses roof support requirements in the longwall headgate under high horizontal stress in regard to the pattern of supplemental cable bolts and the critical locations where additional supplemental support is necessary.

Analysis of monitored ground support and rock mass response in a longwall tailgate entry

A comprehensive monitoring program was conducted to measure the rock mass displacements, support response, and stress changes at a longwall tailgate entry in West Virginia. Monitoring was initiated a few days after development of the gateroad entries and continued during passage of the longwall panels on both sides of the entry. Monitoring included overcore stress measurements of the initial stress within the rock mass, changes in cable bolt loading, standing support pressure, roof deformation, rib deformation, stress changes in the coal pillar, and changes in the full three-dimensional stress tensor within the rock mass at six locations around the monitoring site. During the passage of the first longwall, stress measurements in the rock and coal detected minor changes in loading while minor changes were detected in roof deformation. As a result of the relatively favorable stress and geological conditions, the support systems did not experience severe loading or rock deformation until the second panel approached within 10-15 m of the instrumented locations. After reaching the peak loading at about 50-75 mm of roof sag, the cable bolts started to unload, and load was transferred to the standing supports. The standing support system was able to maintain an adequate opening inby the shields to provide ventilation to the first crosscut inby the face, as designed. The results were used to calibrate modeled cable bolt response to field data, and to validate numerical modeling procedures that have been developed to evaluate entry support systems. It is concluded that the support system was more than adequate to control the roof of the tailgate up to the longwall face location. The monitoring results have provided valuable data for the development and validation of support design strategies for longwall tailgate entries.

Analysis of global and local stress changes in a longwall gateroad

A numerical-model-based approach was recently developed for estimating the changes in both the horizontal and vertical loading conditions induced by an approaching longwall face. In this approach, a systematic procedure is used to estimate the model's inputs. Shearing along the bedding planes is modeled with ubiquitous joint elements and interface elements. Coal is modeled with a newly developed coal mass model. The response of the gob is calibrated with back analysis of subsidence data and the results of previously published laboratory tests on rock fragments. The model results were verified with the subsidence and stress data recently collected from a longwall mine in the eastern United States.

Deep cover bleeder entry performance and support loading: A case study

Several questions have emerged in relation to deep cover bleeder entry performance and support loading: how well do current modeling procedures calculate the rear abutment extent and loading? Does an improved understanding of the rear abutment extent warrant a change in standing support in bleeder entries? To help answer these questions and to determine the current utilization of standing support in bleeder entries, four bleeder entries at varying distances from the startup room were instrumented, observed, and numerically modeled. This paper details observations made by NIOSH researchers in the bleeder entries of a deep cover longwall panel-specifically data collected from instrumented pumpable cribs, observations of the conditions of the entries, and numerical modeling of the bleeder entries during longwall extraction. The primary focus was on the extent and magnitude of the abutment loading experienced by the standing support. As expected, the instrumentation of the standing supports showed very little loading relative to the capacity of the standing supports-less than 23 Mg load and 2.54 cm convergence. The Flac3D program was used to evaluate these four bleeder entries using previously defined modeling and input parameter estimation procedures. The results indicated only a minor increase in load during the extraction of the longwall panel. The model showed a much greater increase in stress due to the development of the gateroad and bleeder entries, with about 80% of the increase associated with development and 20% with longwall extraction. The Flac3D model showed very good correlation between expected gateroad loading during panel extraction and that expected based on previous studies. The results of this study showed that the rear abutment stress experienced by this bleeder entry design was minimal. The farther away from the startup room, the lower the applied load and smaller the convergence in the entry if all else is held constant. Finally, the numerical modeling method used in this study was capable of replicating the expected and measured results near seam.

Analysis of gob gas venthole production performances for strata gas control in longwall mining

Longwall mining of coal seams affects a large area of overburden by deforming it and creating stress-relief fractures, as well as bedding plane separations, as the mining face progresses. Stress-relief fractures and bedding plane separations are recognized as major pathways for gas migration from gas-bearing strata into sealed and active areas of the mines. In order for strata gas not to enter and inundate the ventilation system of a mine, gob gas ventholes (GGVs) can be used as a methane control measure. The aim of this paper is to analyze production performances of GGVs drilled over a longwall panel. These boreholes were drilled to control methane emissions from the Pratt group of coals due to stress-relief fracturing and bedding plane separations into a longwall mine operating in the Mary Lee/Blue Creek coal seam of the Upper Pottsville Formation in the Black Warrior Basin, Alabama. During the course of the study, Pratt coal's reservoir properties were integrated with production data of the GGVs. These data were analyzed by using material balance techniques to estimate radius of influence of GGVs, gas-in-place and coal pressures, as well as their variations during mining. The results show that the GGVs drilled to extract gas from the stress-relief zone of the Pratt coal interval is highly effective in removing gas from the Upper Pottsville Formation. The radii of influence of the GGVs were in the order of 330-380 m, exceeding the widths of the panels, due to bedding plane separations and stress relieved by fracturing. Material balance analyses indicated that the initial pressure of the Pratt coals, which was around 648 KPa when longwall mining started, decreased to approximately 150 KPa as the result of strata fracturing and production of released gas. Approximately 70% of the initial gas-in-place within the area of influence of the GGVs was captured during a period of one year.

Sequential Gaussian co-simulation of rate decline parameters of longwall gob gas ventholes

Gob gas ventholes (GGVs) are used to control methane inflows into a longwall mining operation by capturing the gas within the overlying fractured strata before it enters the work environment. Using geostatistical co-simulation techniques, this paper maps the parameters of their rate decline behaviors across the study area, a longwall mine in the Northern Appalachian basin. Geostatistical gas-in-place (GIP) simulations were performed, using data from 64 exploration boreholes, and GIP data were mapped within the fractured zone of the study area. In addition, methane flowrates monitored from 10 GGVs were analyzed using decline curve analyses (DCA) techniques to determine parameters of decline rates. Surface elevation showed the most influence on methane production from GGVs and thus was used to investigate its relation with DCA parameters using correlation techniques on normal-scored data. Geostatistical analysis was pursued using sequential Gaussian co-simulation with surface elevation as the secondary variable and with DCA parameters as the primary variables. The primary DCA variables were effective percentage decline rate, rate at production start, rate at the beginning of forecast period, and production end duration. Co-simulation results were presented to visualize decline parameters at an area-wide scale. Wells located at lower elevations, i.e., at the bottom of valleys, tend to perform better in terms of their rate declines compared to those at higher elevations. These results were used to calculate drainage radii of GGVs using GIP realizations. The calculated drainage radii are close to ones predicted by pressure transient tests.

Geostatistical modeling of the gas emission zone and its in-place gas content for Pittsburgh-seam mines using sequential Gaussian simulation

Determination of the size of the gas emission zone, the locations of gas sources within, and especially the amount of gas retained in those zones is one of the most important steps for designing a successful methane control strategy and an efficient ventilation system in longwall coal mining. The formation of the gas emission zone and the potential amount of gas-in-place (GIP) that might be available for migration into a mine are factors of local geology and rock properties that usually show spatial variability in continuity and may also show geometric anisotropy. Geostatistical methods are used here for modeling and prediction of gas amounts and for assessing their associated uncertainty in gas emission zones of longwall mines for methane control. This study used core data obtained from 276 vertical exploration boreholes drilled from the surface to the bottom of the Pittsburgh coal seam in a mining district in the Northern Appalachian basin. After identifying important coal and non-coal layers for the gas emission zone, univariate statistical and semivariogram analyses were conducted for data from different formations to define the distribution and continuity of various attributes. Sequential simulations performed stochastic assessment of these attributes, such as gas content, strata thickness, and strata displacement. These analyses were followed by calculations of gas-in-place and their uncertainties in the Pittsburgh seam caved zone and fractured zone of longwall mines in this mining district. Grid blanking was used to isolate the volume over the actual panels from the entire modeled district and to calculate gas amounts that were directly related to the emissions in longwall mines. Results indicated that gas-in-place in the Pittsburgh seam, in the caved zone and in the fractured zone, as well as displacements in major rock units, showed spatial correlations that could be modeled and estimated using geostatistical methods. This study showed that GIP volumes may change up to 3 MMscf per acre and, in a multi-panel district, may total 9 Bcf of methane within the gas emission zone. Therefore, ventilation and gas capture systems should be designed accordingly. In addition, rock displacements within the gas emission zone are spatially distributed. From an engineering and practical point of view, spatial distributions of GIP and distributions of rock displacements should be correlated with in-mine emissions and gob gas venthole productions.