Coal mining

     Contents

     1 Methods of extraction

     1.1 Modern surface mining

     1.2 Underground mining

Methods of extraction

     The most economical method of coal extraction from coal seams depends on the depth and quality of the seams, and also the geology and environmental factors of the area being mined. Coal mining processes are generally differentiated by whether they operate on the surface or underground. Many coals extracted from both surface and underground mines require washing in a coal preparation plant.

Modern surface mining

     When coal seams are near the surface, it may be economical to extract the coal using open cut (also referred to as open cast or open pit) mining methods. Typically, for coal, strip mining is used. Strip mining exposes the coal by the advancement of an open pit or strip. The earth above the coal seam(s) is known as overburden. A strip of overburden next to the previously mined strip is usually drilled. The drill holes are filled with explosives and blasted. The overburden is then removed using large earthmoving equipment such as draglines, shovel and trucks, excavator and trucks and conveyors. This overburden is put into the previously mined (and now empty) strip. When all the overburden is removed, the underlying coal seam will be exposed as a strip known as a 'block'. This 'block' of coal may be drilled and blasted (if hard) or otherwise loaded on to trucks or conveyors for transport to the coal preparation (or wash) plant. Once this strip is empty of coal, the process is repeated with a new strip being created next to it.

     Open cast coal mining recovers a greater proportion of the coal deposit than underground methods. Opencast coal mines can cover many square kilometers.

     Most open cast mines in the United States extract bituminous coal. In South Wales open casting for steam coal and anthracite is practiced. In Australia and South Africa open cast mining is used for both thermal and metallurgical coals. Surface mining accounts for around 80% of production in Australia, while in the USA it is used for about 67% of production. Globally, about 40% of coal production involves surface mining.

     Mountaintop removal is a form of surface mining that takes place at the topmost portion of a mountain, and is a technique that is commonly applied in Appalachia in the United States. Utilized for the past 30 years, mountaintop mining involves removing the highest part of the mountain for the maximum recovery of coal. The process is highly controversial for the drastic changes in topography, the practice of hollow fills with mining debris, and for covering streams and disrupting ecosystems.

Underground mining

     Most coal seams are too deep underground for opencast mining and mining these seams involves underground mining. Underground mining currently accounts for about 60% of world coal production. In deep mining, the room and pillar or bord and pillar method progresses along the seam, while pillars and timber are left standing to support the coal mine roof. Once room and pillar mines have been developed to a stopping point (limited by geology, ventilation, or economics), a supplementary version of room and pillar mining referred to as second mining or retreat mining is commonly started. This is when miners remove the coal in the pillars, thereby recovering as much coal from the coal seam as possible. A work area that is involved in pillar extraction is called a pillar section. Modern pillar sections use remote controlled equipment, including large hydraulic mobile roof supports, which can prevent cave ins until the miners and other equipment have left a work area. The mobile roof supports are similar to a large dining room table, but with hydraulic jacks for legs. After the large pillars of coal have been mined away, the mobile roof support legs shorten, and the mobile roof supports travel out to a safe area. The mine roof typically collapses once the mobile roof supports leave an area.

     There are four major underground mining methods:

     • Longwall mining – accounts for about 50% of underground production. The longwall shearer has a face of 1,000 feet (300 m) or more. It is a sophisticated machine with a rotating drum that moves mechanically back-and-forth across a wide coal seam. The loosened coal falls onto a pan line that takes the coal to the conveyor belt for removal from the work area. Longwall systems have their own hydraulic roof supports for overlying rock that advance with the machine as mining progresses. As the longwall mining equipment moves forward, overlying rock that is no longer supported by the coal that has been removed is allowed to fall behind the operation in a controlled manner. The supports make possible high levels of production and safety. Sensors detect how much coal remains in the seam while robotic controls enhance efficiency. Longwall systems allow a 60-to-100% coal recovery rate where the surrounding geology allows their use.

     • Continuous mining– Utilize a machine with a large rotating steel drum equipped with tungsten carbide teeth that scrape coal from the seam. Operating in a “room and pillar” system – where the mine is divided into a series of 20-to-30 foot “rooms” or work areas cut into the coalbed – it can mine as much as five tons of coal a minute – more than a non-mechanised miner of the 1920s would produce in an entire day. Continuous miners account for about 45% of underground coal production, and also utilize conveyors to transport the removed coal from the seam. Remote controlled continuous miners are used to work in a variety of difficult seams and conditions and robotic versions controlled by computers are becoming increasingly common.

     • Blast mining – An older practice that uses explosives such as dynamite to break up the coal seam, after which the coal is gathered and loaded onto shuttle cars or conveyors for removal to a central loading area. This process consists of a series of operations that begins with “cutting” the coalbed so it will break easily when blasted with explosives. This type of mining accounts for less than 5% of total underground production in the U.S. today.