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By Keenan. Albert M

The challenge of mining coal seams having a pitch of 30 degrees is one not frequently found in the United States, due primarily to the scarcity of such deposits. However, in the Thompson Creek District in Pitkin, Colorado, such a challenge exists to produce high quality medium volatile coking coal, and development of a longwall system is underway. The deposits under consideration are those of the Anschutz Corporation Inc. of Denver, Colorado, which are not in a virgin state. The properties were originally mined by the Colorado Fuel and Iron Corporation from 1894-1907, and by the Thompson Creek Coal and Coke Corp. from 1953-1966. Approximately five and one half million tons of coal have been mined by the above companies, attesting to its quality. The cessation of operations in both instances was occasioned by economics. Both companies employed a room and pillar system of mining, but being denied the use of high capacity mining and loading machinery because of the excessive pitch of the coal seam. This resulted in an unfavorable productivity expressed as output per man-shift, and thus the high cost of production occasioned by hand loading and semi-mechanization dictated cessation of operations. The specific location of these deposits are in Pitkin County,

Jan 1, 1971

By Ernest A. Curth

An estimated 49 billion tons or 29 percent, of the coal reserve base to a depth of 1,000 feet in the eastern United States fall in the 28- to 42-inch range. Often left out as a consequence of selective mining, it is a paramarginal source that will become increasingly important. At present, all active thin seam longwalls are located in the Eastern Coal Province, and a number of operations have been suspended due to the erosion of the market for metallurgical coal. Extensive premining studies, appropriate mine planning, reliable equipment that is designed with ergonomics in mind, adequate roof support, intensive training, and strong face discipline are the ingredients that provided a measure of consistency in production for the last 10 to 16 years, particularly in the Pennsylvania bituminous coalfield where single drum shearers dominate. Plows, which were found to be very productive in suitable strata in Europe, are used in the Pocahontas field. Low seam four- and six-legged shields have been introduced recently. The future holds automation at progressive levels. The first step is batch control with the benefits of quickly applied roof support and reduction of workmen exposure to environmental hazards.

Jan 1, 1981

By David Wilson, T. V. Rao

INTRODUCTION The Alchem trona mine, owned and operated by Allied Chemical Corp., is located approximately 32 km (20 miles) west of the town of Green River, and 8 km (5 miles) north of Interstate 80 in southwest Wyoming. Trona, a naturally occuring sodium sesquicarbonate (NaCO3 • NaHCO3 • 2H2O), is used for the production of sodium carbonate (Na2CO3), commonly known as soda ash. Present annual US consumption of soda ash is approximately 9.07 Mt (10 million st), out of which approximately 7.3 Mt (8 million st) is produced from the Wyoming trona mines. About 44% of soda ash is consumed by the glass industry; 3 % by exports; and the remaining portion by paper, chemical, soap, textile, and nonferrous industries. Allied Chemical operates an underground mine at an average depth of about 488 m (1600 ft). There are three other trona mines in the area operated by FMC Corp., Stauffer Chemical Corp., and Texasgulf Inc. (see Fig. 1). Allied Chemical became interested in southwest Wyoming trona deposits in the early 1940s. Explora¬tion work was begun in 1959 with the acquisition of federal leases. Exploitation of the reserves began in 1968. Two shafts, one 6.1 m (20 ft) and another 3.7 m (12 ft), were completed prior to 1968. The 6.1-m (20-ft) diam service shaft is divided in half by a cur¬tain wall, with one half used for men and material and the other for ventilation as a return air shaft. During the period from 1968 to 1974, the 3.7-m (12-ft) shaft was used as production shaft with two 7.3-t (8-st) skips. Due to the increased demand for soda ash, plant and mine expansions were completed during 1974. Under this expansion, the material handling system capacity was increased by constructing a new 2721-t (3000-st) capacity ore bin, sinking a 6.1-m (20-ft) diam produc¬tion shaft, and installing a friction hoist with two 22.7-t (25-st) skips. The Alchem mine manpower is 484 employees and about 2.3 Mt (2.5 million st) of trona was produced during 1976. Three different mining systems are used at the Alchem mine: conventional, continuous, and longwall. Allied Chemical introduced its first longwall unit in 1973, which was also the first longwall system introduced in the Wyoming trona district. At present, four conventional, seven continuous, and two longwall units are in operation. This equipment is operated in ten production areas. GEOLOGY The bedded trona and trona-halite in the Green River basin of southwestern Wyoming is a major re¬source for the nation. There are 25 beds that exceed 0.9 m (3 ft) in thickness and underlie areas of about 2590 km2 (1000 sq miles). There are other minor beds that range in thickness from 0.3 to 1.2 m (1 to 4 ft). Allied Chemical's Alchem mine is located in bed 17. The trona bed numbering system starts at the lowest elevation and increases upwards. The trona beds are in the Wilkens Peak member of the Green River formation. The Green River formation was deposited in a lake that began in early Eocene as a large body of fresh water, shrank in size and became saline, and then became fresh water again. The sedi¬ment during the saline phase of the lake, which includes the trona beds, is called the Wilkens Peak member. The underlying freshwater lake deposit is called the Tipton member and includes a 25.9-m (85-ft) sand unit which is a high pressure, low permeability aquifer. The over¬lying sediment is called the Laney shale. The Green River formation is underlaid by the Wasatch formation and overlaid by the Bridger formation (see Fig. 2). The structure of the beds in the area of the Allied Chemical mine is mostly postdepositional asymmetrical folds of small amplitude. These folds range in size of 3 to 6.1 m (10 to 20 ft) to as much as 45.7 m (150 ft). The trend of the folds is northwesterly with the north¬east flank of the anticlines having a steep dip and the southwest having gentle dips. Trona bed 17 varies in thickness from 2.4 to 3.4 m (8 to 11 ft) over the 93.2 km2 (36 sq miles) holdings of Allied Chemical and is flat lying except for the rela¬tively minor folding and a negligible regional dip of about 0.017 rad (1°). Trona occurs naturally in several physical forms in the Green River basin, being both massive and crystal¬line. The trona ore in the Alchem mine is a fine-grained massive ore with a compressive strength of approxi-

Jan 1, 1982

By Philip Lindstrom

Retreat mining, using yielding steel friction props, over a seven-year period has been successful at a uranium mine operated by Hecla Mining Company in southeast Utah. The support system allow good roof control, maximum profit, complete extraction, and good ventilation. Unusual subsidence observations were made in that some of the surface was raised rather than lowered, Longwall mining, commonly practiced in European coal mines, has a potential of broader application because of mechanization possibilities and better roof control and ventilation at greater depths.

Jan 1, 1964

By D. Y. Geng

Longwall mining is a relatively new mining method in the United States. Early trials in the eastern and central coal fields were not successful, mainly because, among others, the face supports did not have sufficient capacity. It was not until in the late 1960's, when the high- capacity self-advancing powered supports became available, that longwall mining was successfully reintroduced. Since then the number of mines employing the longwall method has been steadily increasing. It has reached approximately 7.5% in 1981. Currently longwall mining is used mainly in the Appalachian coal field. The seam depth ranges from 150 to 2500 ft. but mostly between 300 and 1400 ft. The seam thickness ranges from 32 to 144 inches with the majority between 40 and 100 inches. Nearly all longwall mining are in flat or nearly flat seams extracting in single slice, although one inclined and one thick seam longwall mining have been either operated or initiated in Colorado.

Jan 1, 1983

By W. M. Ma, W. L. Zhong, Syd S. Peng

In a longwall section that consisted of 7 longwall panels, there were two high pressure gas transmission pipelines across the panels burying from 3 to 10 ft. below the surface. One pipeline was 20 in. in diameter while the other was 24 in. in diameter. In order to investigate the stress conditions sustained by the pipelines during underground longwall mining, strain gages were mounted on the pipelines above panel #3, #4, and #5. Survey monuments were also installed along but near the pipelines. This paper presents a subsidence prediction method and the preliminary results of the pipelines' stress conditions as affected by underground longwall mining.

Jan 1, 1986

By M. D. Ross

Complex combinations of technical, economical, safety and environmental factors are causing mining engineers everywhere to review their operations. Naturally, some of the traditional methods still have a large role to play because they are, in certain circumstances still adequate and are well understood. But, as circumstances change, a new approach is required. The combination of technical and economical reasons for introducing Long- wall mining in some seams in the United States is associated with strata control. Other reasons include simplifications and improvement of ventilation, reduced coal dust, more output from each unit and crew, increased percentage of recovery from each area of the coal deposit, and reduction of rock dusting. The innovations which transformed Longwall mining from a cyclic to a continuous mining system were the armored conveyor and power loading machines, but the crucial breakthrough for application to high production was the development of the powered roof support, which at once gave the system the advantages of mastery of strata control, increased rate of advance, significant reduction of manpower, and increased safety.

Jan 1, 1974

By Brad C. Lewis

The coal mining industry has experienced a general trend toward longwall operations. An increasing percentage of underground coal is being mined by longwalls. And productivity in longwalls is likewise increasing. Operators of longwalls, however, have not yet reached a state of mining euphoria. Competitiveness within the industry and from alternate fuel sources is forcing continued pursuit of higher productivities and lower costs. [Figures 1, 2 and 3] present trends in the industry. Longwall mines, as defined here, are those reportedly having longwall installations in each of the respective years. Production from both the continuous miner and longwall units is included in the longwall mines. Nonlongwall mines are all other underground mines. Productivity calculations are based on total employee-hours associated with the operation. Annual percent increases in productivity appear to have peaked in the 1985-1987 time frame. This was due, in part, to implementation of technological advancements and improvements in management-labor relations. The results shown in [Fig. 3] aroused the author's curiosity. The first question was "Have technological advancements to increase productivity peaked?" It does not appear so.

Jan 1, 1990

By William Harrison, Robert H. Trent

GENERAL DESCRIPTION History The most striking feature of mining in the United States has been the infrequent use of longwall systems. This system, which accounts for the majority of coal production in Europe, Japan, and other countries, is only recently growing out of its infancy in the mining of normal coal seams and is still untried in the mining of thick coal seams in the US. Its use in the mining of metal and nonmetal ore bodies has been virtually ig¬nored, except for isolated instances in trona, copper, and uranium. Longwall mining is believed to have originated in Shropshire, England, towards the end of the 17th cen¬tury (Laird, 1973). Although the method used would be considered primitive by today's standards, many of the basic concepts have remained unchanged. Longwall mining of coal in the US was first introduced before the turn of the century, but it never gained acceptance as it did in Europe. Historically, longwalling was a cyclic method where a single cut of coal was removed from the face on the producing shift each day, and the work of building stone packs in the gob and manually moving roof support was completed on the off shifts. Due to the amount of dead work, productivity was extremely low. In Europe, however, longwall methods were required despite the high costs involved, because only by this method could coal under heavy depth be mined with any reasonable degree of recovery. Reserves of coal lying under shallow cover, and therefore minable by room¬and-pillar methods, were long ago inadequate to supply most of Europe's coal requirements. In the US coal min¬ing has historically proceeded laterally with the new mines in virgin areas to replace old mines; in Great Britain, Germany, Japan, and many other countries, mining must proceed downward to greater depths. The depth of cover for most coal operations in the US is shallow, i.e., 61 to 305 m (200 to 1000 ft). This, combined with large reserves, has made room-and-pillar methods almost universally applicable. However, longwall systems were tried around the turn of the century. Whenever used, it was frequently noted that the opera¬tion was under the direction of men with foreign ex¬perience and was tried under ideal conditions. Some of the mines that were using longwall or had tried longwall prior to 1910 were the Radiant mine, CO; Vinton Coal Co., PA; Cambria Steel Co., Johnstown, PA; Grundy County and Spring Valley, IL; and unnamed mines in Washington, West Virginia, Kentucky, Iowa, and Kansas. As late as 1961, there was one circular longwall in operation at Centerville, IA. The first modern-day op¬eration to take advantage of European technology and longwall methods was Kaiser Steel Corp. at its Sunnyside mine near Price, UT. Due to deep cover and extremely poor roof conditions, combined with a need for in¬creased production, Kaiser management decided a new method was required and turned to longwall in 1961. The first longwall consisted of an Anderson Mavor shearer loader, British Jeffrey-Diamond conveying equip¬ment, and Dowty roof supports with a capacity made up of two and three 27-t (30-st) capacity props. After nor¬mal start-up problems, this unit averaged over 454 t (500 st) per shift (White and Palacios, 1976). During and after World War II, technology in hy¬draulics and controls had advanced to the point that self-advancing supports and hydraulic props were being developed. In 1960 only I % of West German produc¬tion was from mechanized longwall faces. This in¬creased to 37% in 1970 and 63% in 1973 (Kohlgruber, 1974). In 1976 there were 246 coal mines operating in the United Kingdom. Although this is only 50% of those operating ten years ago, the production has increased 42%, mainly through improvements in longwall equipment and methods (Hunter, 1976). In France and other European countries, the devel¬opment of longwall mechanization has been similar in seams up to 2.44 m (8 ft) thick. In seams that exceed 9.14 m (30 ft), a variety of longwall caving has been developed for coal seams with dips of 0 to 1.6 rad (0 to 90°). Those with the greatest success will be discussed later. As noted, the development of longwall mining to its present state of the art has mainly taken place since World War II with substantial gains in the last ten years. Mechanized longwall has been the result of several re¬lated major innovations (Jackson, 1975) 1) Development of the flexible armored face con¬veyor which can be installed along the face and moved forward without disassembly. 2) Development of face machines such as single and double drum shearer and coal plows which operate in conjunction with the armored conveyors. 3) Development of self-advancing hydraulic roof supports which now include chocks, chock shields, and shields. 4) Reliance of caving of the immediate roof based on proper planning and development. 5) Use of pneumatic slowing to enable extraction below overbuilt areas. The most recent developments in the mining of coal by longwall in the US include the introduction of shield supports at Kaiser's York Canyon mine in New Mexico, single-entry longwall development at Kaiser's Sunnyside mine, and Mid-Continent's advancing longwall system in Colorado. Metal and nonmetal longwall systems in the US have included the mining of copper at White Pine, MI; uranium in Utah and New Mexico, and trona in Wyoming.

Jan 1, 1982

This paper presents the results of a unique study conducted by the National Institute for Occupational Safety and Health (NIOSH) from 2016 to 2019 to evaluate the effects of longwall-induced subsurface deformations on shale gas well casing integrity and underground miner safety and health. At both deep and shallow cover instrumentation sites, surface subsidence measurements, subsurface in-place inclinometer measurements, and underground pillar pressure measurements were conducted as longwall panels were mined. Comparisons of the deep and shallow cover test site results with those from a similar study under medium cover reveal an interesting longwall-induced response scenario. Under shallow and medium covers, measured horizontal displacements within the abutment pillar are one order of magnitude higher than those measured under deep cover. Conversely, measured vertical compressions under deep cover are one order of magnitude higher than those under shallow and medium covers. However, FLAC3D simulations of the casings indicate that, in all three cases, the P-110 production casings remain intact under longwall-induced deformations and compressions, which has serious implications for future mine design in areas where shale gas wells have been drilled ahead of mining.

Jan 7, 2020

By R. G. Jurd

This paper considers the introduction of large-scale longwall mining into South African coal mining, instead of the conventional mechanized bord-and-plllar mining that is widely practised at present. The two methods are compared, and longwall mining is found to have the advantage in several respects in some seams. The most cogent reasons for the introduction of the longwall method In some seams are associated with safety strata control and increased labour costs.

Jan 1, 1978

By Jinsheng Chen

Longwall mining-induced abutment loads on the surrounding coal pillars can be grouped into two categories in terms of the relative position of the coal pillars and the longwall face. They are the front and side abutment loads. Even though a lot of research and efforts have been made to study the nature and behavior of these longwall mining-induced abutment loads, their influence zones and magnitude are still not well defined and fully understood due to the complexity of geological conditions and the longwall muting-induced overburden strata movement. The uncertainty about the mining-induced abutment loads often forces consultants and mining engineers to employ a conservative approach in designing coal pillars and entry roof control plans. The problems with this approach are that: (a) it increases CM development¬longwall retreat footage ratio, (b) it decreases coal recovery, and (c) it increases !Ill' operating costs. However, a more liberal approach may create safety issues and result in loss of production. Therefore, the importance of accurately defining the influence zones and magnitude of the front and side abutment loads induced by longwall mining can never be over emphasized. The authors in this paper attempt to define the influence zones and discuss the magnitude of the longwall mining-induced abutment loads by analyzing the field data measured at RAG American Coal Company's longwall mines. In addition, the relationship between entry stability and the balance among roof/floor conditions, pillar design, and roof control plan is also briefly discussed.

Jan 1, 2002

In recent years, improvements made to the longwall system have accelerated at a faster pace than those made to the gate entry development system. As a consequence, unless planned years ahead of time, extending the panel length is nearly impossible without some innovative approach. At Cyprus Amax Coal's Emerald mine the G panel length was extended by 3,500 ft- by developing three entries across it to facilitate development of its headgate and tailgate entries simultaneously when the adjoining F panel was in operation. After evaluating alternative supporting methods and associated risks, determination was made to backfill these entries and crosscuts using a low strength flyash cement mixture prior to mining thru. Instrumentation was also used to monitor the stress change or front abutment stress in both the coal and the backfilled material ahead of the face. Longwall mining thru these three entries took about four eight-hour shifts and proved to be very successful. The designed flyash cement mixture provided adequate roof stability and caused no difficulty in the shearer's cutting while eliminating an in-panel longwall face move and minimizing the risk of roof or floor failure in the in-panel openings, or in the worst scenario loss of the face during the longwall cutting thru. This approach provided the intended result of extending G panel and recovered about one million tons of coal. This paper summarizes the engineering design of the cutting-thru project and flyash cement mixture, front abutment stress changes within the longwall coal block, backfilled material, and coal pillars ahead of the longwall face, and our underground observations

Jan 1, 1997

By R. H. Thorpe

Longwall working in Britain developed to overcome problems arising from depth of seams causing roof and ventilation difficulties. This system became very widespread particularly in the thicker seams, where faces of up to one mile in length were not uncommon. In the thinner sections, in order to remain competitive, the longwall undercutting machine was developed. Following the development of the coal cutter, every other aspect of the face operation was examined and mechanized as it became a bottleneck to output and efficiency. The face system itself was modified and workings concentrated with the same objectives.

Jan 1, 1977

By B. C. Lewis

The mining industry has experienced a general trend toward an increasing number of longwall operations, an increasing percentage of underground coal being mined by longwalls, and increasing productivity from the longwalls. Longwall operators have not yet reached a state of mining euphoria. Competitiveness both within the industry and from alternate fuel sources is forcing continued pursuit of higher productivities and lower costs. The following graphics present trends in the industry. Longwall mines, as defined for this presentation, are those reportedly having longwall installations in each of the respective years. Production from both the continuous miner and longwall units is included in the longwall mines. Non-Longwall mines are all other underground mines. Productivity calculations are based on total employee-hours associated with the operation.

Jan 1, 1990

By Vincent A. Scovazzo

During the winter months of late 1985 and early 1986, residents along Dry Fork near Grundy, Virginia (United States) experienced seismic events that they attributed to longwall mining at Island Creek Corporation’s (Island Creek) Virginia Pocahontas Mine No. 3 (VP-3 mine). Island Creek contacted STS D’Appolonia Ltd. (STSDL) on March 7, 1986, to investigate these events. An STSDL representative, Vincent Scovazzo, interviewed residents of Dry Fork on March 10, 1986. It was noted that only people within a residential structure felt the events they described as house shaking, vibrating walls, and ceramics falling from shelves. STSDL representative installed a blast monitor at a residence. Within 2 days, various events were recorded. Some could be attributed to truck and heavy equipment movement. Eight events had no obvious cause but appeared on resident’s written logs as earthquakes caused by mining. STSDL contacted Utah Geophysical, Inc. who had developed a technique to determine the mode of rock failure using the seismic record. Utah Geophysical was engaged to install and monitor a microseismic network, locate the epicenter of the events, and work with STSDL in determining modes of failure. The network was comprised of six geophones located at five stations. Data was recorded for 24 days from May 20 through June 13, 1986. The data was filtered to eliminate events determined to have an origin other than the longwall panels’ overburden and under-burden. The larger events from this filtered data set were selected and analyzed to determine their hypocenter locations, time of occurrence, magnitudes, and failure mode. Processed data was interpreted, tabulated, and plotted by STSDL to provide information relative to the sources of the seismic vibrations and their possible relationship to the mining operation.

Jul 1, 2023

By Michael A. Berdine

In early 1997, Twentymile Coal Company took a dramatic departure from traditional longwall recovery methods. Previously, Twentymile's standard longwall meshing procedure included the use of chain link fencing material. Beginning with the 9-Right to 8-Right longwall recovery operation, Twentymile incorporated a polyester geogrid mesh system supplied by DYWIDAG-Systems International. This paper discusses the subsequent utilization of the polyester geogrid mesh system at Twentymile.

Jan 1, 2001

By K. Y. Haramy

Deep coal mines with strong roof and floor strata frequently encounter face and rib bursts. The burst problem becomes more severe with increased depth. While the exact causes of bursts are often difficult to determine, localized high stress zones are common to their occurrence. This Bureau of Mines report describes a study at a mine using longwall systems that experienced both face and floor bursts. The study correlates shield loading, entry closure, and forward abutment pressure increases to observed burst occurrences. The results indicate that strong roof strata that overhang behind the longwall supports create additional abutment stress. When caving lags behind the face and the abutment zone does not advance ahead of the face during mining, stresses on the face may increase to a critical level, resulting in a burst. The critical level occurs when the stress in the abutment zone exceeds the ability of the coal and/or adjacent strata to store strain energy. Caving characteristics may be improved by inducing fractures in the roof or by providing sufficient support resistance to shear the roof. Data analysis of a major burst indicated a dramatic increase in floor heave, with a maximum occurring 80 to 100 ft inby the face, and a lag in the cave line behind the face supports. Analysis of the effects of caving characteristics and floor heave on burst occurrences is presented.

Jan 1, 1987

Effective ground control in the gate entries, particularly in the tailgate travelways, is essential for safe longwall mining. Longwall pillars maintain gate entry stability and carry abutment loads. To answer the need for effective longwall pillar design, an empirical method called Analysis of Longwall Pillar Stability (ALPS) was proposed several years ago. Some recent research at the Bureau of Mines has focused on the refinement and verification of the ALPS method. ALPS was originally developed from field studies in which multiple stressmeters were installed in longwall pillars and monitored during mining. Several new field studies have now been incorporated into the ALPS data base. The field measurements have' been used to verify formulas for predicting abutment strength and pillar loads, and to develop an expression for the distribution of the abutment load.

Jan 1, 1989

By B. Qiu, Y. Luo

The design of the predriven recovery room is not an easy task, because the stress distribution in the barrier pillar, standing supports, fender pillar and the immediate roof is changing as the longwall face approaches the predriven recovery room. An analytical approach is proposed to determine the stress distribution in the barrier pillars, fender pillars, standing supports and immediate roof of the recovery room based on the fracture mechanics approach. Based on the developed mathematical model, a stand-alone computer program has been developed to facilitate the required computations. The parameters such as overburden depth, recovery room width, mining height, shield and standing support capacities are incorporated into this program to access the feasibilities of predriven recovery room designs. Compared to the finite element method previously employed, this analytical approach offers the same, if not better, accuracy without requiring expensive computer hardware and software or specialized expertise.

Jan 1, 2012