3.

BROAD AREA OF RESEARCH

Broad research area has been decided as “Effects of Non-Working Longwall panels on the working
panel & strata control.”

3.1 Introduction: The global demand for energy continues to grow at a rapid pace, driven by both
developed and developing countries. The coal is the most important and abundant fossil fuel in India it
accounts 55% of the country’s energy need Coal has major role to play in meeting this demand and it
must be ensured that it remains available and competitive with other energy sources. Coal occupies the
center-stage in the energy economy of both China and India; coal has a share of more than 70% of the
primary consumption of energy in the current mix of commercial energy. Underground mined coal
accounts for more than 50% of total global hard coal production and in China, 95% of hard coal
production comes from underground mining. Surface mined coal alone cannot meet the huge growth in
demand that is forecast for India. Some import of coal will be necessary, the amount dependent on how
successful the Indian underground coal industry is in stepping up to the challenge. In order to keep pace
with the growing Indian economy at the rate of 8 to 9%, the coal industry requires narrowing down the
supply-demand gap at a competitive price. Mechanized Longwall mining is a sustainable option to
achieve higher production and productivity. Longwall mining is a widely used underground mining
method for the extraction of relatively thick, sub-horizontal and uniform coal seams. After mining of
the coal seam, the panel roof strata above the mined-out area or goaf will be destressed. With continued
face advance, the immediate roof will collapse and cave into the goaf area, and the disturbed roof strata
gradually extend upwards. Longwall mining is the most productive and safe coal extraction method
from deep seated deposits. Design of the powered supports, which are critical is based on the
surrounding rock, coal strata and production capacity. Understanding the interaction between powered
supports is the key for successful operation. The technological developments, in the last two decades
resulted in higher coal outputs in longwall mining and has become the preferred choice for bulk output
from underground coal mines. The significance of powered roof supports increases day-by-day since
the capacity and design of roof support must be in accordance with the rate of face advance and
production capacity. in longwalls. Roof support systems, longwall shields, have persistently grown and
capacity for the past 25 years. The Cost of Supports alone is nearly 70% of total longwall package cost
which is also dependent on length of longwall face.

Fig.
4
1: Longwall mining method
3.1 Objectives of research work:

To understand the strata behavior in longwall mining at greater depths, literature survey and field
investigations were conducted with the following objective:

1. To critically evaluate the strata behavior during longwall mining at greater depths.

2. Analysis of gate road way convergence and load cell date of longwall panel 1 & panel 2.

3. Analysis of the field results of longwall panel.

4. To check the effects of longwall panel-1 depillaring, panel-2 development by the goafed
panel on the working panels.

5. To prepare a numerical model on longwall by using ANSYS software

3.3 Statement of problem:

Strata control in longwall mining has been a grey area of research since its introduction in
underground coal mining industry worldwide. A reliable prediction of the caving behavior of strata
and its interaction with the roof support helps in selection of sustainable mining parameters and
rational capacity of supports. It is pre-requisite for developing a reliable support selection tool
essential for successful planning of longwall working in a given geo-mining condition. A number of
approaches have been developed to address this important subject of applied rock mechanics.

The main reasons for the underperformance of the longwalls in India, among others, have been
strata control problems due to inadequate geological and geotechnical assessment, poor
understanding of strata behavior and selection of under rated supports. Complex strata mechanics
issues like excessive stress concentrations, strata dilation or convergence of roof strata in longwall
workings are potential hazard of strata failure. Therefore, proper understanding of geo-mechanics of
strata and continuous strata monitoring in longwall workings is prerequisite for its effective control
and ensuring safe workings.

3.4 Scope of the work:

The scope of the work is to study how the longwall working panel is affected by the non-working panels
or completely mined out panels and also to study about the strata control problems related to it. To conduct.
This also include in the research on various analysis of the field data and also to conduct the experiments by
taking the different parameters such as roof convergence in the gate roadways, stability of roof etc. are taken
into consideration. A numerical modelling technique are also included in this research study. A thorough
understanding of the in-situ stress environment is essential for effective ground control during all
underground mining. In particular, understanding the stress field around a longwall panel and its gate roads
is one of the key components that enables mining engineers to predict potential failures. The condition of
strata and the stress environment around any working place is always
5
dynamic in nature. No two working place are having identical strata condition. It is therefore essential
to assess the roof condition of the working places at regular intervals by scientific methods. Strata
problems include roof sagging, floor heaving, presence of shale or clay bands, heavy water seepage,
faults, cleavage planes, cracks, joints etc. State of art of monitoring system through instrumented rock
bolts, tell-tales, multiple point bore hole extensometers, convergence indicators, local cells etc. are
available for continuous monitoring the strata movement. Strata control instruments are helpful in
analyzing the deterioration in the roof and indicates roof moment.

4.Research Progress

• Study area for research work has been decided.

• Review of literature was done and it is still in progress.
• Objectives of research have been partially decided.
• Development of methodology of research project is in progress

4.1 LITRATURE REVIEW

S.K. Das (1999) [1] studied about the behavior of longwall panels in various coal mines in India,
concentrating on the geology, physico-mechanical rock properties and the behavior of the coal measure
roof rocks during mining. His research has highlighted the splitting and caving characteristics of the
strata rocks and enabled the development of a roof-rock classification system. The behavior of the
different layers and composite layers in the immediate roof rock mass is also enumerated. Relations
between the rock strength properties and values for the bulking factor of the failed rock are included.
The concepts of a `weighting zone' and `caving zone' are proposed. The paper also clarifies the
occurrence of different types of failure, such as periodic falls. All these supports are helpful during
calculation of the powered support capacity. A detailed study of the mechanical behavior of the strata
around the longwall coal mining panels was made. After identifying the type of coal measure rock
formations, their splitting capabilities, formation of parting planes in the strata, caving characteristics,
strata mechanics, etc. are identified and correlated with the physico-mechanical properties.

J.A Nemcik et al (2000) [2] studied about the Floor failure analysis at a longwall mining face based on
the multiple sliding block model. Prepared an analytical model of a floor failure at a longwall coal
mining face based on the multiple sliding block model. Underground observations of the rock floor and
the computational modelling of the longwall face indicate that two types of fracture dominate floor
failure. The fractures that initially develop ahead of the longwall face are subject to a “secondary”
movement when exposed ahead of the longwall supports. In response to the stress relief as the coal is
mined from above, strata move towards the opening and bending of the floor occurs. If fractures in the
floor exist, the floor blocks will displace in response to the floor movement and interact at the fractured
surfaces. This analysis attempts to explain how the stress distribution develops within the broken floor
during an active movement of floor strata leading to high stress concentrations at the floor level. The
analytical formulation in this paper is supplemented by numerical modelling, and results are presented
to verify that the analytical solutions are in accordance with the numerical predictions.
6
V.Palcik (2003) [3] studied about fractured zones caused by mining in the overburden through the
change in natural gas emission from these zones during longwall coal excavation. Zones of
interconnected fractures and separate horizontal fractures were studied with vertical wells drilled from
the ground surface down to active underground workings. The maximum heights of the zone of
interconnected fractures and separate horizontal fractures may reach 19–41 and 53–92 times the
thickness of the coal seam respectively. It was found that the ratio between the maximum height of the
zone of interconnected fractures and the thickness of the extracted coal seam increases with the
increasing number of rock layer interfaces and decreases with the increasing stiffness of immediate roof

Debasis deb and a A.K Verma (2004) [4] briefly discussed about the various aspects of ground
control problem in longwall faces. The need for continuous monitoring and analysis of shield pressure
data for forecasting of upcoming events are also explained in detail. Moreover, understanding and
evaluation of interaction between the powered support and the floor are carried out case by case by
using numerical modelling techniques and should be verified using data collected in the field.

A.K Verma and Debasis Deb (2007) [5] studied about the Statistical and neural regression approach for
prediction of longwall chock-shield support pressure. 324 finite element models were developed considering
different geo mining conditions of Indian coal measure strata and types of powered support installed at
various panels. The major idea was to analyze the responses of 4-legged chock-shield support, the popular
powered support in India with surrounding rock and coal strata. Based on the results obtained from the
elastic-plastic finite element analyses, statistical regression and feed forward neural network
(NN) models were developed to establish the relationship between input parameters and front leg
pressure. Validation of model was carried out with the field monitored data and found that the
combination of finite element analysis results and neural regression models can be used to forecast face
stability conditions at a longwall face.

G.S.P. Singh and U.K. Singh (2009) [6] studied about the numerical modeling approach for
assessment of progressive caving of strata and performance of hydraulic powered support in longwall
workings. A numerical modeling approach is proposed for predicting the progressive caving behavior
of strata and performance of powered roof support in a given geo-mining and strata condition. The
study suggests that face convergence slope of 75 mm/m of face advance may be considered as the
maximum permissible value for selection of optimal capacity support for safe working in a given strata
condition. this study also reveals that mass caving of strata is responsible for dynamic loading leading
to collapse of supports if they are not designed to discharge the fluid at the desired rate.

Mahdishabanimashcool (2012) [7] studied about the numerical approach to simulate the longwall
mining in detail, aiming to investigate the stability of gates and the loading process to rock bolts. The
results of the simulations are used to analyze the loading process of the rock bolts in the gates. The
numerical model is calibrated with the measurement data. The simulations reveal that the stability of the
gates and the loading to the rock bolts are closely related to the width of the chain pillars. With slender
pillars, shear displacements along weak interlayers and bedding planes results in heavy loading to the
rock bolts. Therefore, the locations of weakness zones should be taken into account for rock bolt
design. The proposed numerical approach can be used to find an optimal combination of dimension of
the chain pillars and the rock reinforcement in the gates.

7
Gangwei et al (2015) [8] studied about the interpretation on the abnormal roof shock in longwall coal
mining under gullies using physical modeling, numerical modeling, and mechanical analysis. The
modeling results show that the roof movement causes the shock load onto the stope in longwall coal
mining under surface gully. The triggering mechanism of shock load depends on the direction of the
face retreat with respect to the bottom of the surface gully. The slope tends to slide along the interface
plane with a long periodical weighting intervals when mining towards the bottom of the gully
(downslope direction), while the overburden strata may be split into blocks and tend to topple towards
the free face of gully when mining away from the bottom of the gully (upslope direction). The
mechanical models showed that, during the period of mining in downslope direction, planar sliding and
key fragmental blocks cause a sudden roof shearing off which could result in shock load and, during the
period of mining in upslope direction, the overburden blocks may become unstable due to shearing off
which could result in large shock pressure onto the stope.

A.K Verma et al (2016) [9] studied about the Bayesian neural network (BNN) model for estimation of
leg pressure and associated uncertainty. The 396 data sets from seven longwall panels are collected
which includes depth of working, height of extraction, main roof thickness, face retreat distance,
overhung length behind powered support and leg pressure of hydraulic powered support. The leg
pressure developed in a hydraulic powered support is a manifestation of the various geo-mining
parameters and therefore functional relationship exists between them. The results from BNN are
compared with the Levenberg–Marquardt neural network and linear regression and found that BNN
applied for prediction of leg pressure perform better than the other two approaches. The developed
model can be used to predict the leg pressure and hence powered support capacity for longwall projects.

Sreenivasa Rao et al (2016) [10] proposed a methodology to incorporate the process of web-cutting into
the modelling environment with the application of user-defined setting pressure. As a result,
displacements, strains and stresses those developed in the shield and surrounding rock strata after web-
cutting can be obtained for any pre-defined setting load. All together 216 three dimensional numerical
models are analyzed by varying different roof parameters and setting pressures. They also develop a
statistical procedure to combine all input parameters into an index termed as “Longwall Index” for
determination of axial strain and load that may develop on hydraulic legs of the powered support.

Wang et al (2016) [11] studied about the comparative approaches, including empirical formula
calculation, physical simulation, numerical simulation and PROTEM transient electromagnetic analysis
are employed to identify the development of the fracture zones in longwall caused by water-flowing so
as to ensure mining safety and protection of groundwater in shallow coal seams beneath gully
topography. An empirical formula was used to calculate the height of the water-flowing fracture zone,
and an experimental study utilizing a model based on a similar material was adopted to analyses the
movement and fracture development of the overlying strata. The PROTEM transient electromagnetic
apparatus was employed to detect the water-flowing structure conductivity of the overlying strata
induced by mining beneath gully topography in the field. Accordingly, the control technologies in the
field were implemented and discussed regarding preventing gully water from rushing into underground
mining spaces through water-flowing fracture zones. Results indicate that safe and efficient mining of
shallow seams beneath gully topography can be achieved by prevention of gully accidents and
protecting the surface water resources of the ecological environment.

8
Heritage et al (2017) [12] studied about the method of simulating the mining induced fracture network and
associated increase in hydraulic conductivity. It is necessary to improve mine design, hazard management
planning and gas drainage efficiency. Computer modelling illustrates the formation of mining induced
fractures below a longwall block and their connectivity for gas make into an active goaf. A number of
elements have been identified as key factors in the connectivity of lower seam gas to the active seam. 1.
Cyclic mining induced fracture formation below longwall panels 2. Stress redistribution
3. Pore pressure reduction 4. Vertical hydraulic conductivity Preliminary field gas flow measurements
measured at the case study mine are within the range of connectivity expectations based on rock failure
modelling of longwall extraction. This report presents the first validation results for vertical
conductivity estimates for the modelling approach is presented.

Xuan et al (2017) [13] studied about the Surface subsidence and ground movement due to longwall
mining. This paper presents a newly developed subsidence control technology: isolated overburden
grout injection, including the theory, technique and applications. Relevant procedures such as injection
system design, grouting material selection, borehole layout, grout take estimation and injection process
design are proposed. The applicability of this technology has been demonstrated through physical
modelling, field measurements, and case studies. Since 2009, the technology has been successfully
applied to 14 longwall areas in 9 coal mines. The ultimate surface subsidence factors vary from 0.10 to
0.15. This method has a great potential to be popularized and performed where longwall mining is
implemented under villages and ground infrastructures.

Qingsheng Bai et al (2017) [14] studied about the comprehensive field observations and numerical
simulations were used to investigate the chain pillar and adjoining gate road failure during a longwall top
coal caving (LTCC) face retreat. The results show that hard roof strata did not cave behind the longwall face
but overhung to form a cantilever beam above the chain pillar. Numerical simulations found that hard roof
treatment could fill the space near the goaf edge and deliver support pressure to the roof as well as alleviate
the stress concentration in the pillar and the solid side of the next longwall panel. Simulations suggested that
a pillar size of 50 m or larger was feasible without consideration of hard roof treatment. A 40-m chain pillar
with hard roof treatment could also satisfy the demand on the pillar and supply gate road safety during the
service period. Field practices verified the numerical results and suggested that hard roof treatment by
hydraulic fracturing is a feasible method for overcoming ground control problems.

Kang et al (2018) [15] studied about the massive roof collapse in mined-out area during retreat mining.
And also prepared a large-scale physical model based on a real case to simulate massive roof collapse
during longwall coal retreating mining. A numerical model was created based on the model
configuration of the physical model. The physical result and the numerical result were in good
agreement with each other in terms of many features including roof failure mechanism, abutment
pressure distribution and collapsed roof pattern. The physical and numerical result suggested that
massive roof collapse is a typical snap-through failure where bedded roof crack through cross joint at
midspan. Substantial increase in horizontal stress at the center of the potential failure zone is a reliable
geotechnical precursor of massive roof collapse. It is suggested that horizontal stress increasing up to
five times pre-mining can be considered as a threshold of the precursor of massive roof collapse

9
I.B Tulu et al (2018) [16] studied about the 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.

Qingsheng Bai and Shihao (2019) [17] studied about the longwall mining-induced fractures., which
are essential for the successful operation of longwall top coal caving mining. From a global perspective,
longwall mining-induced fractures in the overburden has been studied, which improves the
understanding of the mining pressure and ground control. They gave a general summary of the current
achievements in characterizing mining-induced fractures in near-face regions. The characteristics of
mining-induced fractures in the coal wall, chain pillar, immediate roofs and top coal, and floors are
reviewed and summarized. Remarks are made on the current progress of, fundamental problems with,
and developments in methodologies for characterizing mining-induced fractures using methods such as
field observations, small-scale laboratory tests, physical modeling, and numerical modeling. Based on a
comprehensive analysis, the advantages and disadvantages of each method are discussed, and the ideal
conditions for applying each of these methods are also recommended.

Srikanth et al (2019) [18] studied about the monitoring and analysis of roof convergence in gate roads
by convergence recorder as well as double telescopic tell-tale devices. Based on the analysis results,
design is modified to improve the stability of gate roads. Cumulative roof convergence (CRC) data
during development of gate roads are found to vary as tangent hyperbolic function with passage of time
and are analyzed using artificial neural network to estimate the key parameters of the function.
Convergence increase rate along with the maximum CRC is then used to prepare a Trigger Action
Response Plan for immediate notification of the ground control problems. Data analysis also suggests
that during retreat of longwall panel, CRC increases exponentially if the longwall face approaches
within 10 to 25 m from a measuring station installed along main and tail gate roads. In this paper,
methodologies are described for the analysis of CRC data for better understanding of roof behavior and
for taking timely decision for any unusual event.

4.2 Numerical Modelling

Numerical modelling is a powerful tool to solve the problem related to rock mechanics in various
area like civil and mining engineering. Understanding of caving behavior of rock is the primary need to
control the strata and estimating the capacity of shield support in longwall. Various norms and method has
been developed to predict the behavior of strata but they have very limited application due to base on some
empirical equations and two dimensional beam theories. It is very difficult to predict the behavior of each
section of roof with these equations. So, there is a need of something which can predict the behavior of
each section of roof carefully. In these consideration, numerical modelling has a wide application.
Development in area of numerical modelling, it become easy to predict the geological behavior. Now,
we can simulate the field conditions in this numerical modelling software’s and can analyze it in very
easy way and success fully.
10
4.2.1 ANSYS

ANSYS is an explicit three-dimensional finite element analysis software, which can simulate the
geological conditions related to civil and mining field. It provides the facility of simulating the underground
extraction with support like roof bolting, hydraulic props, cable bolting, simple props, beams, support
system, loading conditions etc.

Typically, Ansys users break down larger structures into small components that are each modelled and tested
individually. It creates grids with different nodes and divide the problem into small parts. It analyze each small
component separately. Many parameters like vertical and horizontal stress, vertical and horizontal displacement,
vectors of these parameters can be plot. It is also capable to calculate factor of safety.

Problem Solving With ANSYS

The problem is solved by using ANSYS in the following sequence of steps

Finite element solution can be divided into 3 main stages:

1. Pre-processing stage

2. Solution

3. Postprocessing

Steps for Numerical Analysis in Geo-mechanics

Step 1: Define the Objectives for the

Model Analysis

Step 2: Create a Conceptual Picture

of the Physical System

Step 3: Construct and Run Simple

Idealized Models

Step 4: Assemble Problem-Specific

Data

Step 5: Prepare a Series of Detailed

Model Runs

Step 6: Perform the Model

Calculations

Step 7: Present Results for Interpretation

11
Preparation of model

Basic long wall model has been prepared in ANSYS 18.1 software with 3 working panels by the

fallowing dimensions:

1.lengths of the panel –2014m

2.width of the panel -250m

3.gallery dimension – 5.4m*3.6m

4.barrier pillar width 63m and length is about 70.2 m

5.out roof is about 60 degrees from the horizontal

12
13
14
4.3 Study area:

The study area has been selected related to my work. A field visit is done in the Adriyala longwall

project SCCL located in Godavarikhani.

Details of Adriyala longwall project:

Adriyala Longwall Project is located in Ramagundam Coal Belt of Godavari Valley Coalfields in
Karimnagar District of Telangana State. Nearest Railway Station is Ramagundam which is about 25km
from the project. This project is equipped with new generation Longwall technology and it is the first of
its kind to be introduced in Indian coal mines.
Entries made to this mine through highwall of the existing opencast mine (RG OC-II) which are used
for transport and downcast. These are driven in coal seam (I seam) by Road heading machines. There
are 4 number of entries, length of drivage of 1810m up to dip side gate of first longwall panel i.e., 68L.
The gradient of the entries is 1 in 4 with a cross section of 5.5m x3.6m

Salient features of mine:

Workable seams : I, II, III and IV

Seam thickness : I -5.7m II -3.3m III -9.4m IV -3.7m

Gassiness of seams : Degree-I

Gradient : 1 in 5 to 1 in 7

Geological Reserves : 110 Mt

Extractable Reserves : 78.597 Mt (Approx.)

Depth range : 300 - 720m

Length of Longwall panels : 1800 - 2400m

Width of Longwall panels : 250m

Distance from surface : 4500 - 6500m

15
REFERENCES:

1. Das SK. Observations and classication of roof strata behaviour over longwall coal mining
panels in India, 1999.
2. J. A. Nemcik, B. Indraratna, and W. Gale, “Floor failure analysis at a longwall mining face based
on the multiple sliding block model,” Geotechnical and Geological Engineering, vol. 18, no. 3,
pp. 175–192, 2000.
3. V. Palchik, “Formation of fractured zones in overburden due to longwall mining,”
Environmental Geology, vol. 44, no. 1, pp. 28–38, 2003.
4. Verma AK, Deb D (2007) Statistical and neural regression approach for prediction of longwall
chock-shield support pressure. In: 11th ISRM Congress, 9–13 July, Lisbon, Portugal
5. Mahdi S, Li C (2012) Numerical modeling of longwall mining and stability analysis of gates in
a coal mine. J Rock Mech Min Sci 51:24–34
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numerical analysis of the scope of fractured zones around gate roads under longwall
influence,” Rock Mechanics and Rock Engineering, vol. 47, no. 5, pp. 1939–1950, 2014
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8. F. Wang, S. Tu, C. Zhang, Y. Zhang, and Q. Bai, “Evolution mechanism of water-flowing
zones and control technology for longwall mining in shallow coal seams beneath gully
topography,” Environmental Earth Sciences, vol. 75, no. 19, p. 1309, 2016.
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capacity using field monitored data of a longwall panel and uncertainty—based neural network.
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grout injection,” International Journal of Mining Science and Technology, vol. 27, no. 5, pp.
813–818, 2017.
11. Y. Heritage, W. Gale, and A. Rippon, “Connectivity of mining induced fractures below
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University of Wollongong, pp. 41–50, Australia, 2017
12. Q. Bai, S. Tu, F. Wang, and C. Zhang, “Field and numerical investigations of gate road system
failure induced by hard roofs in a longwall top coal caving face,” International Journal of Coal
Geology, vol. 173, pp. 176–199, 2017.
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Min Sci Techno 28:127–135
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failure induced by hard roofs in a longwall top coal caving face,” International Journal of Coal
Geology, vol. 173, pp. 176–199, 2017.
15. Srikanth, Deb D, Hemanth Kumar,” Neural Network Assisted Analysis for Longwall Gate
Road Stability Using Measured Roof Convergence Data”(2019)

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