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Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition)

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A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Energy Systems".

Deadline for manuscript submissions: closed (10 March 2026) | Viewed by 3454

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Special Issue Editors

Dr. Yang Li

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Guest Editor

School of Civil and Resources Engineering, University of Science and Technology Beijing, Beijing 100083, China
Interests: mine rock mechanics; rock mass stability; mine monitoring and early warning
Special Issues, Collections and Topics in MDPI journals

Dr. Guanglei Zhou

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Guest Editor

College of Energy and Mining Engineering, Shandong University of Science and Technology, Qingdao 266590, China
Interests: rock mechanics; numerical simulation; time-dependent deformation; fracturing; thermo-hydro-mechanical coupling; rock burst
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Dr. Feiyue Liu

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Guest Editor

School of Mining Engineering, Anhui University of Science and Technology, Huainan 232002, China
Interests: open-pit mine; rock stability; rock mass quality; deep learning
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Special Issue Information

Dear Colleagues,

The safe mining of mineral resources is crucial for economic development. In recent years, the production situation in mines has been stable, but the occurrence of accidents cannot be ignored. As such, it is necessary to strengthen mine safety technology. In both protecting resources and preventing accidents, intelligent, green, and safe technologies are applied in resource extraction to ensure the sustainable development of mining enterprises.

This Special Issue, Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition), aims to cover recent advances in the development and application of mining process safety. Topics include, but are not limited to, methods and/or applications in the following areas:

Intelligent and green mining technology for underground and open-pit mines;
Stability analysis, safety monitoring and early warning technology for mine rock mass;
Process control and prevention simulation of mine disasters;
AI-driven mine data analysis and process prediction model.

We look forward to your contributions and participation in this Special Issue.

Sincerely,

Dr. Yang Li
Dr. Guanglei Zhou
Dr. Feiyue Liu
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

mining technology
mine safety technology
rock mass stability
ground pressure disaster
mine monitoring and early warning

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Published Papers (7 papers)

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Research

34 pages, 5641 KB

Open AccessArticle

Flexural Failure Characteristics and Fracture Evolution Law of Layered Composite Rock Mass

by Ping Yi, Zhaohui Qiu, Yue Song, Binyang Duan, Lei Wang and Yanwei Duan

Processes 2026, 14(6), 888; https://doi.org/10.3390/pr14060888 - 10 Mar 2026

Viewed by 125

Abstract

To address the engineering challenges of frequent flexural deformation and instability of composite roadway roofs and the difficulty in accurately controlling the support strength range during deep coal mining, this study takes the soft–hard interbedded composite roof of the working face in the West No. 1 Mining Area of Shuangyang Coal Mine in Shuangyashan as the engineering background. Typical fine sandstone (hard rock) and tuff (soft rock) from the on-site roof were selected to prepare layered composite specimens, and indoor four-point bending tests were conducted. Combined with theoretical calculations, strain monitoring, and acoustic emission (AE) real-time localization technology, the regulatory mechanisms of three key factors—lithological combination, loading rate, and span—on the flexural mechanical properties, deformation and failure modes, and fracture evolution laws of layered composite rock masses were systematically investigated. The research results show the following: (1) The flexural performance of layered composite rock masses is dominated by the interlayer interface effect. Their flexural strength is 46.7% and 41.1% lower than that of single hard rock and soft rock specimens, respectively, and the competitive mechanism between interface slip and delamination fracture is the core inducement of strength deterioration. (2) The strength and deformation characteristics of layered composite rock masses exhibit a significant loading rate effect. When the loading rate increases from 0.002 mm/s to 0.02 mm/s, the flexural strength decreases by 51.8% and the mid-span deformation deflection reduces by 50.1%. High loading rates will exacerbate the deformation mismatch between soft and hard rock layers, trigger premature failure of interface bonding, and inhibit the full development of structural plastic deformation. (3) Increasing the span significantly optimizes the flexural bearing performance of layered composite rock masses. When the span increases from 170 mm to 190 mm, the flexural strength increases by 65.7% and the mid-span deformation deflection synchronously increases by 65.7%. A large span can extend the flexural deformation path, promote the coordinated deformation of rock layers, and suppress local stress concentration. (4) The flexural failure of layered composite rock masses is dominated by Mode II shear cracks, while single-lithology specimens are mainly dominated by Mode I tensile cracks. Loading rate and span significantly change the crack propagation mode and energy release law. This study establishes a calculation method for the equivalent flexural stiffness of layered composite rock masses and reveals the mesoscopic mechanism of flexural failure of heterogeneous layered rock masses. The research results can provide a theoretical basis and experimental support for the optimization of support schemes and the prevention and control of roof collapse hazards for composite roofs of deep coal mine roadways. Full article

(This article belongs to the Special Issue Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition))

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17 pages, 6511 KB

Open AccessArticle

Study of Macro–Micro Mechanical Properties and Instability Mechanisms of Rock–Soil Masses in Open-Pit Mine Slopes

by Fengke Dou, Xiu Wang, Weidong Li, Houji Li, Yu Zhang, Ruifeng Huang, Wenjun Shan and Chengyun Ma

Processes 2026, 14(5), 830; https://doi.org/10.3390/pr14050830 - 3 Mar 2026

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Abstract

Accurate determination of the physico-mechanical parameters of rock and soil masses is fundamental to the quantitative stability analysis and engineering mitigation of open-pit mine slopes. However, existing studies often rely on generalized parameters and lack systematic empirical data based on full-hole in situ core sampling to quantitatively verify the link between microscopic mineralogy and macroscopic instability. To address this gap, this study investigates the mineral composition, microstructure, and hydro-mechanical behavior of geotechnical materials, using the XG Open-pit Coal Mine in Inner Mongolia as a case study. Field drilling and sampling with a cumulative depth of 1500.7 m were conducted, combined with systematic laboratory tests. The results reveal significant lithological heterogeneity within the mining area. Specifically, hard rocks (e.g., fine sandstone) constitute the stable framework of the slope, whereas mudstones rich in hydrophilic clay minerals, along with low-strength coal seams, form potential weak sliding interfaces. Quantitative X-ray Diffraction (XRD) analysis reveals that the weak mudstone layers contain up to 32.4% hydrophilic expansive minerals (montmorillonite and illite/smectite). Scanning Electron Microscopy (SEM) and slake durability tests demonstrate that the mudstone is characterized by well-developed micropores (1–2 μm) and loose cementation. Theoretical analysis indicates that upon saturation, the strength of these weak layers is reduced by over 40%, causing the factor of safety (FoS) to drop from a stable 1.48 to a critical 0.89. Based on these findings, the slope instability mechanism driven by “Stiffness Mismatch and Hydro-Weakening” is elucidated. Consequently, targeted reinforcement and drainage measures are proposed to provide a scientific basis for safe mining operations. Full article

(This article belongs to the Special Issue Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition))

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22 pages, 5587 KB

Open AccessArticle

Study on Mechanical Response of Composite Rock Mass with Different Coal Seam Dip Angles Under Impact Load

by Tao Qin, Yue Song, Yuan Zhang, Yanwei Duan and Gang Liu

Processes 2026, 14(5), 738; https://doi.org/10.3390/pr14050738 - 24 Feb 2026

Viewed by 239

Abstract

To investigate the dynamic instability mechanism of surrounding rock in deep, rockburst-prone coal seams, a Split Hopkinson Pressure Bar (SHPB) system was utilized to carry out dynamic impact compression tests on Rock–Coal–Rock (RCR) composites featuring four different seam dip angles, namely 0°, 15°, 30°, and 45°. We systematically analyze incorporating high-speed imaging, the mechanical properties, energy evolution, and progressive failure characteristics of the composites under various strain rates. The results indicate that the dynamic compressive strength and elastic modulus of the composites exhibit a significant strain-rate hardening effect. With the increase in the dip angle of the coal seam, the compressive strength of the specimen decreases accordingly. Specifically, the range of 15–30° is identified as a critical transition zone where the failure mode shifts from matrix-dominated bearing to interfacial slip instability. At an impact pressure of 0.12 MPa, the compressive strength drops by 36.9% within this interval. Furthermore, the energy distribution is profoundly modulated by the geometric characteristics of the interface. As the dip angle increases, the degree of wave impedance mismatch at the coal–rock interface intensifies, leading to a sharp rise in the reflected energy ratio (up to 80.7%) and a pronounced attenuation of transmitted energy. Notably, the dissipation energy per unit volume increases with the dip angle, revealing that interfacial sliding and frictional work become the primary energy dissipation pathways under large-inclination conditions. High-speed camera monitoring confirms that the instability mechanism shifts from axial splitting/tension to an interfacial shear-slip mode as the dip angle increases. These findings provide a scientific reference for the stability evaluation of roadway surrounding rock and the prevention of dynamic disasters. Full article

(This article belongs to the Special Issue Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition))

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27 pages, 7743 KB

Open AccessArticle

Research on High-Temperature Resistant Bridging Composite Cement Slurry Technology for Deep Well Loss Circulation Control

by Biao Ma, Kun Zheng, Bin Feng, Qing Shi, Lei Pu, Chengjin Zhang, Zhengguo Zhao, Shengbin Zeng and Peng Xu

Processes 2026, 14(2), 364; https://doi.org/10.3390/pr14020364 - 20 Jan 2026

Viewed by 300

Abstract

Circulation is one of the most prevalent and severe complications during the drilling and completion of deep and ultra-deep wells, especially in fractured and karstic formations. In regions such as the Sichuan Basin, bottom-hole temperatures exceeding 200 °C, limited formation strength, and frequent lithological alternations significantly reduce the effectiveness of conventional granular materials under high-temperature and long open-hole conditions. Bridging-type plugging systems based on particle gradation or principles often exhibit low success rates due to fiber softening, rubber aging, and erosion-induced deterioration of the sealing structure. In this study, a high-temperature-resistant bridging composite system was developed to meet the extreme conditions in deep and ultra-deep wells. By incorporating temperature-resistant bridging particles and flexible reinforcing components, the slurry establishes a synergistic “bridging–filling–densification” sealing mechanism. Meanwhile, the combined use of retarders, fluid-loss reducers, and rheology modifiers ensures stable pumpability and adequate curing densification at 200 °C. Overall, the results provide new insights and experimental evidence for the design of high-temperature cement-based plugging materials, offering a promising approach for improving loss-control effectiveness and wellbore strengthening in complex intervals. Full article

(This article belongs to the Special Issue Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition))

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21 pages, 4682 KB

Open AccessArticle

Research on “Extraction–Injection–Locking” Collaborative Prevention and Control Technology for Coal Mine Gas Disasters

by Ting Lu, Xuefeng Zhang and Gang Liu

Processes 2026, 14(1), 115; https://doi.org/10.3390/pr14010115 - 29 Dec 2025

Viewed by 312

Abstract

In response to the issues of low synergy efficiency between gas extraction and water injection, unclear procedural connections, and high costs in coal mine gas disaster prevention, this paper proposes a collaborative prevention technology for coal mine gas disasters termed “pump–injection–lock.” First, based on the kinetics of gas desorption in gas-bearing coal under different water-bearing conditions, an optimization model for the sequence of gas extraction and high-pressure water injection was developed. This model reduced the gas desorption rate in the experimental area by 32.5% and increased the effective extraction radius of boreholes by 18.7%. Second, based on the coupling relationship between water lock formation pressure, interfacial tension, and pore structure, a criterion model for process transition was constructed, enabling quantifiable identification of the transition node between “pump–injection.” The water lock’s inhibition of gas release duration was improved by over 25% compared to conventional water injection. Finally, by integrating the multiple effects of high-pressure water injection—enhancing permeability, softening, displacement, and flow limitation—a “multi-purpose” synergistic pathway was established. This increased the pre-drainage gas concentration in the test working face by 40%, the pure gas extraction volume by 28%, and reduced gas over-limit incidents by over 50%. Experiments and industrial trials demonstrated that the application of this technology in the 15^# coal seam of Yixin Coal Mine shortened gas extraction by 36%, reduced borehole engineering by 72.8%, eliminated gas over-limit incidents during mining, and cumulatively generated economic benefits exceeding 425 million yuan in the same year, significantly improving the efficiency and cost-effectiveness of gas disaster prevention. Full article

(This article belongs to the Special Issue Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition))

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22 pages, 3586 KB

Open AccessArticle

Experimental Investigation and Numerical Simulation of Freeze–Thaw Damage Behavior in Coal Gangue Concrete Used in High-Altitude Cold Western Mines

by Guojun Gao, Jiaxin Cui, Mingtao Gao, Zhenhua Hu, Chengyang Guo, Donglin Fan, Minhui Li and Zihao Guo

Processes 2025, 13(11), 3654; https://doi.org/10.3390/pr13113654 - 11 Nov 2025

Cited by 1 | Viewed by 679

Abstract

Coal gangue concrete in high, cold mines in western China is subject to freeze–thaw damage due to prolonged low temperatures and large temperature variations, leading to surface spalling, cracking, and degradation of mechanical performance. In this study, four coal gangue concrete mixtures with replacement ratios of 0%, 20%, 40%, and 60% were prepared using gangue from the Halagou Mine in the Shendong area. Freeze–thaw cycle tests were conducted to analyze the effects of the replacement rate and number of cycles on compressive strength, elastic modulus, and peak strain. The results show that both compressive strength and elastic modulus decrease with increasing freeze–thaw cycles, while the peak strain increases. After 80 cycles, the compressive strength of the M0, M20, and M40 groups decreased by 35.0%, 41.8%, and 51.1%, respectively, and their elastic modulus dropped by 49.2%, 86.2%, and 92.0%. The M60 group was too severely damaged to be tested. Based on the experimental data, a constitutive model for coal gangue concrete under freeze–thaw conditions was developed and validated using Abaqus finite element analysis, with simulation errors below 10%. Considering both mechanical performance and resource utilization, the optimal coal gangue replacement rate is determined to be 20%. Full article

(This article belongs to the Special Issue Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition))

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17 pages, 4047 KB

Open AccessArticle

Numerical Simulation of Tunnel Boring Machine (TBM) Disc Cutter Rock Breaking Based on Discrete Element Method

by Liang Liu, Zhili Yang, Wenxin Li, Panfei Liu, Fanbao Meng, Ruming Ma, Yuexing Yu, Ruitong Zhang, Mingyue Qiu, Xingyu Tao and Shuyang Yu

Processes 2025, 13(11), 3401; https://doi.org/10.3390/pr13113401 - 23 Oct 2025

Viewed by 936

Abstract

To address the issue that the current research on TBM disc cutter rock breaking insufficiently considers actual stratified rock masses, this study constructs numerical models of stratified rock masses with different bedding dip angles and bedding spacings based on the discrete element method (DEM). The whole process of TBM disc cutter rock breaking is numerically simulated through the displacement loading mode. The research results show that the bedding dip angle has a significant impact on the crack propagation mode. When α = 45°, the bedding intersects with the contact point of the disc cutter, and cracks penetrate directly along the bedding without an obvious “crushed zone”, resulting in the minimum number of cracks. The bedding spacing regulates the rock-breaking effect in stages. When d = 45°, the “crushed zone” interacts with two beddings to form three branch cracks, reaching the peak number of cracks and achieving the optimal rock-breaking efficiency. The cracks generated by disc cutter rock breaking exhibit the characteristic of “slow initial growth and rapid later surge” with the increase in time steps, which is highly consistent with the actual mechanical process of rock breaking. This study reveals the influence mechanism of bedding properties on TBM disc cutter rock breaking, verifies the reliability of the DEM combined with PB and SJ models in the simulation of stratified rock mass breaking, and provides theoretical support and data references for the parameter optimization of TBM disc cutters and efficient tunneling under complex stratified geological conditions. Full article

(This article belongs to the Special Issue Process Safety and Monitoring of Intelligent and Green Mining Technology (2nd Edition))

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