Search Results (26)

Maintaining the stability of the mine roadway is of paramount importance, as it is critical in ensuring the daily operational continuity, personnel safety, long-term economic viability, and sustainability of the entire mining operation. Significant instability can trigger serious disruptions—such as production stoppages, equipment damage, and severe safety incidents—which ultimately compromise the project’s financial returns and future prospects. Therefore, the proactive assessment and rigorous control of roadway stability constitute a foundational element of successful and sustainable resource extraction. In China, thick and extra-thick coal seams constitute over 44% of the total recoverable coal reserves. Consequently, their safe and efficient extraction is considered vital in guaranteeing energy security and enhancing the efficiency of resource utilization. The surrounding rock of gob-side roadways in typical coal seams is often fractured due to high ground stress, intensive mining disturbances, and overhanging goaf roofs. Consequently, asymmetric failure patterns such as bolt failure, steel belt tearing, anchor cable fracture, and shoulder corner convergence are common in these entries, which pose a serious threat to mine safety and sustainable mining operations. This deformation and failure process is associated with several parameters, including the coal seam thickness, mining technology, and surrounding rock properties, and can lead to engineering hazards such as roof subsidence, rib spalling, and floor heave. This study proposes countermeasures against asymmetric deformation affecting gob-side entries under intensive mining pressure during the fully mechanized caving of extra-thick coal seams. This research selects the 8110 working face of a representative coal mine as the case study. Through integrated field investigation and engineering analysis, the principal factors governing entry stability are identified, and effective control strategies are subsequently proposed. An elastic foundation beam model is developed, and the corresponding deflection differential equation is formulated. The deflection and stress distributions of the immediate roof beam are thereby determined. A systematic analysis of the asymmetric deformation mechanism and its principal influencing factors is conducted using the control variable method. A support approach employing a mechanical constant-resistance single prop (MCRSP) has been developed and validated through practical application. The findings demonstrate that the frequently observed asymmetric deformation in gob-side entries is primarily induced by the combined effect of the working face’s front abutment pressure and the lateral pressure originating from the neighboring goaf area. It is found that parameters including the immediate roof thickness, roadway span, and its peak stress have a significant influence on entry convergence. Under both primary and secondary mining conditions, the maximum subsidence shows an inverse relationship with the immediate roof thickness, while exhibiting a positive correlation with both the roadway span and the peak stress. Based on the theoretical analysis, an advanced support scheme, which centers on the application of an MCRSP, is designed. Field monitoring data confirm that the peak roof subsidence and two-side closure are successfully limited to 663 mm and 428 mm, respectively. This support method leads to a notable reduction in roof separation and surrounding rock deformation, thereby establishing a theoretical and technical foundation for the green and safe mining of deep extra-thick coal seams. Full article

Large-mining-height technology has been increasingly applied in thick seam mining to enhance productivity and resource recovery. However, it also intensifies strata pressure and complicates surrounding rock control, leading to greater overburden movement, stronger roof weighting, and severe coal wall spalling. Taking the 12306 working face of the Wangjialing Mine as a case, this study employs physical similarity experiments and UDEC numerical simulations to investigate the coupled mechanism of overburden migration and coal wall instability. Results show that abutment stress induces non-uniform deformation, while strata pressure changes directly govern spalling depth. Moreover, coal wall instability is strongly affected by multiple factors: greater burial depth intensifies crack propagation, larger mining height expands failure depth, larger mining step size extends the stress-affected zone, larger dip angle shifts failure upward, and lower support resistance weakens control capacity. These findings clarify the disaster mechanism of deep large-mining-height faces and provide theoretical and engineering guidance for optimizing support design and enhancing coal wall stability. Full article

Significant risk of water and sand inrushes is commonly encountered during coal seam mining when thin bedrock is directly overlain by thick, water-bearing, unconsolidated layers. Achieving effective strata control and establishing reliable water-isolating mechanisms under these conditions represent critical scientific and technological challenges for safe mining operations. Furthermore, this is a vital research direction for advancing the extraction limit (or recovery height) in coal seams. Initially, drawing on key stratum theory, ground pressure behavior patterns, and mining operation characteristics, the weathered zone was identified as the critical grouting horizon. During the initial mining stage, the first two periodic weighting intervals (approximately 60 m) were identified as the key area. Subsequently, a strategy of high-pressure grouting was proposed to modify the weathered stratum. Numerical simulation methods were employed to optimize the grouting parameters, with the core specifications determined as follows: grouting pressure ≥30 MPa, water–cement ratio of 0.7:1, and grouting hole spacing ≤30 m. Ultimately, a grouting system was designed that used directional drilling from the surface to access the weathered zone, followed by branched horizontal boreholes for staged high-pressure grouting. The borehole trajectory was predominantly L-shaped. Field implementation demonstrated that the grouting intervention increased the first weighting span by an average of 17.3%. Critically, no water inflow was observed throughout the initial caving period, and significant roof falls or rib spalling were effectively mitigated. This confirmed a substantial improvement in key stratum stability, ensuring the safe and efficient advancement of the mining face. This study provides essential technical support and a practical model for safely and efficiently extracting coal seams under thin bedrock under similar complex hydrogeological conditions. Full article

This study addresses gas drainage challenges in the Pingdingshan NO.10 mine JI_15-16 coal seam through coupled COMSOL-FLAC^3D numerical simulations. The research evaluates the effectiveness of a cross-measure borehole drainage system. It analyzes the failure mechanisms of the surrounding rock in both the machine roadway and floor roadway of the 24130 working face under the influence of boreholes. The results demonstrate that extended drainage duration progressively reduces both gas content and pressure within the borehole-affected zone of the coal seam while enhancing the effective permeability of the JI_15-16 coal stratum. The operational system extracted 1,527,357 m³ of methane, achieving a pre-drainage efficiency of 59.18% through cross-measure boreholes. The measured gas content aligns with simulated predictions, though field-recorded gas pressure registered slightly higher than modeled values. This validated drainage design complies with the Pingmei Group’s regulations for coal and gas outburst prevention. Critically, cross-measure boreholes alter stress distribution around both coal and floor roadways, promoting plastic zone expansion. Consequently, during the development of the 24130 working face’s machine roadway, intensified ground pressure monitoring is essential near borehole locations in the roof, floor, and rib strata. Supplementary support reinforcement should be implemented when required to prevent rib spalling and roof collapse incidents. Full article

Mining operations in fold structure zones are often subject to dynamic disasters due to the influence of tectonic topography. To explore the interaction between the tectonic stress field and the mining-induced stress field throughout the entire mining process of adjacent working faces in fold structure zones, this study adopts a comprehensive research methodology that integrates field investigations, theoretical analysis, numerical simulations, and industrial experiments. The stress distribution characteristics before and after mining in fold structure zones are systematically analyzed to elucidate the evolution laws of stress and displacement in coal seams, reveal the mechanisms of surrounding rock instability, identify high-risk locations for roof collapse, and propose targeted surrounding rock control strategies for practical application. The key findings of this research are as follows: (1) In fold structure zones, the horizontal stress is significantly influenced by tectonic factors, whereas the vertical stress is predominantly affected by mining activities. (2) The evolution of the mining-induced stress field in fold structure zones is jointly governed by the initial tectonic stress and the mining-induced stress. The advancing position of the working face determines the specific locations of stress concentration, while the tectonic stress regulates the intensity of stress concentration across different regions. (3) The mechanism of surrounding rock failure and instability in fold structure zones is irreversible, with the stress field being a superposition of tectonic and mining-induced stresses. The extent of failure depends on the combined stress concentration at specific locations, which is directly correlated with the distribution of the initial tectonic stress field. (4) Based on the failure patterns of surrounding rock in fold structure zones, a coordinated control strategy incorporating supplementary roof support was developed, along with detailed parameter specifications. The practical implementation of this strategy ensured the stability of surrounding rock during mining through fold structure zones, effectively preventing incidents of roof collapse or rib spalling. Full article

The great success of fully mechanized mining with a large mining height of 8 m and above in Mongolia and Shaanxi proves the feasibility of this technology. Although fully mechanized mining with a large mining height significantly increases the production capacity of mining areas, there are higher requirements for mining safety. Due to the special conditions of the 8 m coal seam in Huoxi Coalfield, the adoption of fully mechanized mining with a large mining height faces a serious problem of spalling. The key to whether complete equipment for fully mechanized mining with a large mining height can be adopted lies in the possibility to reduce such risks. In this paper, the mechanism of spalling on the 8 m fully mechanized mining face in Huoxi Coalfield is analyzed through theoretical analysis, numerical calculations and comparison of on-site data, and a “one point four zone” comprehensive evaluation method for coal seam at the front end of the working face is established based on the failure characteristics of the coal seam; according to the numerical simulation test results, it is believed that the presence of a dirt band in the middle and upper parts of the coal seam has a positive effect on the control of spalling; the overburden structure of Huoxi Coalfield exhibits the changes in “cantilever-instability-hinge”, and there is a risk of caving before the mining face, which exacerbates spalling; the advance blasting roof cutting of the working face has a significant effect on controlling the spalling of production coal faces. This research provides a theoretical basis and engineering reference for the treatment of spalling in fully mechanized mining with a large mining height in Huoxi Coalfield. Full article

In the mining of shallow coal seams, the increase in mining height will lead to a sharp increase in the probability and degree of coal wall spalling. Rib spalling will affect the normal production of coal mines and may also threaten the safety of miners. Under the state of coal wall ganging in large mining height working faces, determining the working face’s support resistance is a key engineering problem that involves many factors, such as bracket design, the mechanical behavior of the roof rock layer, coal wall stability, and so on. In this paper, (1) the relationship between coal wall pressure and working face support resistance is analyzed by constructing a mechanical model of roof control in the large height mining field, (2) and four roof structure models are established based on the single and double key layer structures of step rock beams in shallow buried coal beds. (3) The calculation methods of working face support resistance after coal wall sheet ganging under the four structural models are deduced. Determining the working face’s support resistance is the key to solving the problem of coal wall ganging in large height working faces, which has a significant impact on the design of bracing, the mechanical behavior of the roof rock layer, and coal wall stability. Full article

This article discusses the challenges and remedial measures (roof blasting) adopted to deal with extremely difficult cavable roofs while working with Continuous Miner Technology (CMT) in Bord and Pillar mining method. The main objective of the roof blasting in the goaf is to induce caving to minimize the abutment load in and around the working face to prevent incidences of coal bumps, goaf swelling, pillar spalling, and air blasts. It was found that roof blasting is subjected to the nature of local roof falls, results of strata monitoring studies, and the hanging span of roof strata near the line of extraction. Efforts have been made to design different geotechnical elements and structures involved during the mechanized depillaring panel of the Tawa-I mine, using empirical methods to minimize the issues of roof overhang in the goaf. Numerical simulation studies were also performed to validate the design predicted by empirical methods. The Cavability Index indicated that the roof at Tawa-I mine is difficult to cave. To address this, roof blasting design strategies have been discussed to promote caving and minimize roof overhang, ensuring safe and efficient strata control while operating CMT in the challenging and complex geo-mining conditions of the mine. Full article

This paper presents an innovative numerical approach to simulating the progressive caving of rock mass in the overburden and floor during longwall mining. A modified caving algorithm is incorporated into FLAC3D 9.0, augmented with the IMASS constitutive model, to accurately replicate the fracturing response of various strata. This study aimed to analyze the longwall caving performance, overburden fracturing response, and shield support characteristics to optimize the mining process and enhance safety. The numerical analysis revealed a progressive stress release at the longwall face, attributed to damage in the form of spalling, which was accompanied by a high level of displacement. The fracture process zone above the shield canopy was not significant, indicating the effective performance of the shield in controlling the roof. However, the floor heave highlights the need for the implementation of effective risk and safety measures. Goaf is predicted to form with a longwall advance rate of 25.0–30.0 m, resulting from progressive macroscopic fracturing caused by the development of cracks initiated by bedding plane and rock mass failures. Above the caved zone, an active fracture zone is observed to evolve due to the continuous longwall mining and caving process. Full article

The hydraulic support face guard system is essential for supporting the exposed coal wall at the working face. However, the hydraulic support face guard system approaching the coal wall may cause impact disturbances, reducing the load-bearing capacity of coal walls. Particularly, the hydraulic support face guard system is characterized by a large turning radius when mining thick coal seams. A strong disturbance and impact on the coal wall may occur if the approaching speed is too fast, leading to issues such as rib spalling. In this paper, a feedforward fuzzy PID displacement velocity compound controller (FFD displacement speed compound controller) is designed. The PID controller, fuzzy PID controller, feedforward PID controller, and FFD displacement speed compound controller are compared in terms of the tracking characteristics of the support system and the impact response of the coal wall, validating the controller’s rationality. The results indicate that the designed FFD displacement speed compound controller has significant advantages. This controller maintains a tracking error range of less than 1% for target displacement with random disturbances in the system, with a response adjustment time that is 34% faster than the PID controller. Furthermore, the tracking error range for target velocity is reduced by 8.4% compared to the feedforward PID controller, reaching 13.8%. Additionally, the impact disturbance of the support system on the coal wall is suppressed by the FFD displacement speed compound controller, reducing the instantaneous contact impact between the support plate and the coal wall by 350 kN. In summary, the FFD compound controller demonstrates excellence in tracking responsiveness and disturbance rejection, enhancing the efficacy of hydraulic supports, and achieving precise control over the impact on the coal wall. Full article

Solving the challenges facing the mining industry is crucial for shaping the global attitude towards clean energy technologies associated with critical minerals extracted from depth. One of these challenges is the well-known explosion-like fractures (rockbursts) or spalling failures associated with the initiation of internal cracks. To prevent such catastrophic failure, shotcrete, as a cement grout, is widely used in tunnel support applications. In areas where the tunnels are constructed within the limestone strata using tunnel boring machines (TBM), drilling, and/or blasting, millions of cubic meters of crushed limestone (CL) in powder form are extracted and landfilled as waste. Given the fact that natural sand consumption as a raw material in the construction industry exceeds previous records, recycling of such excavation material is now becoming increasingly needed. From this perspective, this study aims to utilize crushed limestone as a potentially sustainable alternative to natural sand in shotcrete applications in deep tunnels. Accordingly, several strength characterization and crack initiation determinations through various stress–strain-based models were carried out on cylindrical samples containing different proportions of crushed limestone. By increasing the crushed limestone content in the shotcrete mix, the crack initiation stress (as a measure of the in situ spalling strength) increased as well. The results suggest that the crushed limestone has good potential to replace the natural sand in the shotcrete mixture used in tunnel support applications. Full article

According to field observation and theoretical analysis, the failure of the 1523103 reserved roadway is mainly affected by the lateral support pressure, rock mass strength, and support mode. With the mining of the 152309 working face, the lateral pressure of coal pillars on both sides of the reserved roadway increases, and since the lithology of the two sides and the floor of the roadway is weak, the reserved roadway experiences spalling and floor heave. Through numerical simulation, the distribution law of surrounding rock stress and the displacement of surrounding rock are obtained after the roof cutting and pressure relief of the reserved roadway with hard roof. According to the cause of surrounding rock failure of a reserved roadway, the combined control technology of roof cutting and pressure relief, grouting anchor cable support, and bolt support is put forward. After cutting the roof and releasing the pressure on the working face, the lateral support pressure of the two sides of the roadway is significantly reduced, the deformation of the two sides of the roadway is small, the maximum shrinkage rate of the section is reduced from 70% to 11%, and the deformation of the surrounding rock of the 1523103 reserved roadway is effectively controlled. The successful control of the surrounding rock in the 1523103 tunnel reduces the number of coal pillars to be installed, improves the coal extraction rate, and is conducive to the sustainable utilization of limited natural resources and the sustainable development of the coal industry. Full article

The coal walls in a caving face with a tall mining height are prone to rib spalling, which leads to the phased cessation of the mining of the working face, causes heavy losses, and endangers the safety of underground workers. In order to prevent serious rib spalling accidents of coal walls in fully mechanized caving faces with a large mining height and to improve the prediction of and ability to control rib spalling, a load-bearing mechanical model of the roof–coal wall–support system was established based on the moment-balance relationship. The expressions for the deformation and stress distribution in a coal wall were calculated. Then, the influences of key factors on the horizontal displacement of the coal wall were investigated. A numerical simulation model of the working face was established, and an orthogonal test design was introduced. On this basis, the influences of four factors: cutting height, breaking position of the main roof, support strength, and sidewall protecting force of the support on the horizontal displacement and volume of a plastic zone of coal wall, were analyzed. Moreover, their order of importance was ranked on the basis of sensitivity. Based on the engineering conditions and production practices in the Cuncaota II Coal Mine, key parameters for controlling and measures for preventing the rib spalling of the coal wall are proposed to guide practical actions. Full article

Solutions for the maintenance of safety in an isolated working face has not been well achieved; this is attributed to its unique overburden structure and the strong mining-induced stress during the advancement. This paper is devoted to filling this research gap and is based on the case study of LW 10304 in the Xinglongzhuang Coal Mine, in China. The overburden structure and stress distribution characteristics of this isolated working face were theoretically investigated, followed by the development of a comprehensive identification method. The research results showed the following: (1) The overburden strata of LW 10304 is in the form of a short “T” shape and the stress increment is featured with the overall “saddle” shape before the extraction of the isolated working face. During this period, the lower key strata and main key strata affect the stress level at the two ends and the central part of the working face, respectively; (2) Both the frequency and energy of micro-earthquakes in the working face account for more than 95%, which is positively correlated with roof damage and rib spalling, associated with some overlaps between the damaged zones; (3) The fracture movement of inferior key strata near the coal seam plays a dominant role in affecting microseism activity and mining-induced stress. The microseism energy attributed to roof breakage accounts for 43.34% of the overall energy; (4) A comprehensive indexing system, covering microseism frequency, microseism energy, and support resistance, was established to identify the mining-induced stress intensity of the isolated working face. The early warning efficiency of the “strong” degree of mining-induced stress is 0.94, which is believed to provide an option for other isolated working faces with similar geological and mining conditions. Full article

Coal wall rib-spalling is regarded as a key technical problem influencing safe and efficient mining of fully mechanized working face with great mining height (FGH) while the coal wall stability is influenced by the strength of the coal body, of which the internal joint fissures have a crucial impact on the strength of the coal body. This research attempted to explore how the coal wall stability of FGH is influenced by the occurrence of joint fissures. This paper uses physical and numerical simulations to systematically analyze the instability characteristics and displacement law of FGH. Research results show that the form and scope of the instability of coal wall rib-spalling depend on the state of the coal seam joint fissures development area, and the development state of coal seam joint fissures is related to the combination of the coal seam joints; under the condition of hard coal, the coal wall stability is better at the inclination angle of 90°, and less stable at 45° and 135°; under the condition of medium-hard coal and joint surface inclination angle of 45° and 135°, the smaller the spacing of joint surface, the larger the area of the working face rib-spalling, and the less stable the coal wall. Full article