Research and experience using various types of mine backfill - hydraulic, rock, paste, and blended - has indicated several benefits to the mining industry. Backfill is a general term that refers to any waste material that is placed into underground mine workings. Paste backfill in particular has shown environmental and economic benefits. Paste fill is generally produced from total mine tailings, meaning that it can include waste rock, sands, and clay-sized particles. It also contains no free water, meaning that water will not flow freely through it after placement causing post filling shrinkage. These characteristics make it the most environmentally "friendly" backfill option currently available. In addition, paste backfill is non-segregating and stackable, containing about 80% solids by weight, and having the consistency of medium-slump concrete, containing a cementitious content. These characteristics make paste backfill the best option for post-mining ground control in room and pillar coal mines. There are two main bodies of research regarding paste backfill. The first studies its composition, application, and performance in past and present mining environments; the second studies its theoretical application for both mine support and waste disposal. While this research has provided much for the burgeoning technology of paste backfill, little has been done to investigate its economic application to the industry in room and pillar coal mines. At present, surface disposal of waste is generally cheaper than underground disposal. The goal of this thesis is to initiate discourse investigating the hypothesis that paste backfill may be used in such a way as to allow for increased coal extraction, which may then not only cover the additional costs of underground waste disposal, but potentially increase overall mine profitability. Inherent to this discourse will be a consideration of the following issues: * The potential for increased extraction. * The preservation of long-term pillar stability. * Improved floor stability. * Diminished environmental impact at surface. * The cost benefits associated with all of the above. Data from three Illinois Basin room and pillar coal mines were collected and used for this thesis. Theoretical computer modeling using LaModel and Phase2, empirical analysis of mine stability, physical testing using simulated paste backfill models, and comparative cost analyses considering current and hypothetical mining scenarios were conducted to identify these potential benefits and their consequences, both theoretical and practical.

Underground coal mine ground control persists as a unique challenge in rock mass engineering. Fall of roof and rib continue to present a hazard to underground personnel. Stability of underground openings is a prerequisite for successful underground coal mine workings. An adaptation of a civil engineering design standard for analyzing the stability of underground excavations for mining geometries is given here. The ground response curve--developed over seventy years ago for assessing tunnel stability--has significant implications for the design of underground excavations, but has seen little use in complex mining applications. The interaction between the small scale (pillar stress-strain) and the large scale (ground response curve) is studied. Further analysis between these two length scales is conducted to estimate the stress on pillars in a room-and-pillar coal mine. These studies are performed in FLAC3D by implementing a two-scale, two-step approach. This two-scale approach allows for the interaction between the small, pillar scale and the large, panel scale to be studied in a computationally efficient manner. / Ph. D.

Designing a safe and economical mining activity is the main goal of every mine design engineer. With the rise of computer modeling in mine design there is a need for a standardized method to use geologic characterization of rocks in engineering design. In this research, first a review of empirical methods will be conducted and after that a step-by-step method is presented to adequately use FLAC3D, for development pillars, in room and pillar mine in development stage. ARMPS database is used to evaluate the FLAC3D model results. ARMPS database consists of 645 case study in room and pillar mines. 170 of them are mines in development phase. In this research all 170 cases will be analyzed in FLAC3D v4.0 and the results will be compared to actual success and failure from the database. Also, the stability factor found from FLAC3D will be compared to ARMPS. Finally, it is tried to calibrate FLAC3D stability factor so it can be used in room and pillar design.

O método de lavra câmaras e pilares é muito utilizado em minas de carvão subterrâneo, principalmente nos estados de Santa Catarina e Paraná, onde todas as minas subterrâneas utilizam este método. Vale ressaltar, porém, que o método apresenta recuperações de lavra abaixo de 50%, dependendo do tamanho dos pilares, e a produtividade é altamente dependente de uma boa concatenação das operações unitárias. Entre os aspectos relacionados à eficiência produtiva, a distância de transporte é um item preponderante no desempenho do sistema. Devido à profundidade da lavra, há um aumento do tamanho dos pilares de sustentação da mina, e assim, surgem problemas relacionados ao incremento no tempo de ciclo de transporte dos equipamentos. O aumento da distância de transporte entre uma frente de lavra com material desmontado e o alimentador/britador primário, reduz o resultado da produção de um conjunto de equipamentos. Em mineração a céu aberto, este tipo de problema é resolvido com o aumento da frota de transporte, todavia, na mineração de carvão subterrânea, não é possível aumentar de forma irrestrita a quantia de máquinas em subsolo, pois impactaria diretamente na necessidade de incremento da vazão de ar, assim como, limitação de espaço para o tráfego de equipamentos. A aproximação da distância do ponto de descarga para um local adjacente às frentes de serviço é uma alternativa para solucionar a necessidade de incremento da frota de produção. No entanto, o ponto de mudança deve ser avaliado de forma consistente para determinar o momento mais adequado para que essa reaproximação proporcione um resultado ótimo. Este estudo buscou compreender esta etapa necessária ao processo produtivo, utilizando técnicas de regressão para analisar o impacto da distância de transporte na capacidade produtiva. O problema foi modelado e foram propostas alternativas que forneçam um sequenciamento de lavra capaz de amenizar os problemas decorrentes do aumento da distância de transporte das frentes de lavra aos respectivos pontos de descarga. Os resultados demonstraram que a distância de transporte tem influência direta na produção, mas não somente a distância máxima, mas também, uma distância mínima que deve ser respeitada para obter maior produtividade quando se tem a associação de equipamentos de produção. É possível concluir com este estudo que a distância de transporte tem impacto relevante e deve ser considerada, não tão somente no sequenciamento, mas também no dimensionamento da frota e consequente capacidade produtiva. / The room and pillar mining method is widely used in underground coal mines. Santa Catarina and Paraná where all underground mines use this method. Indeed, the method has mining recoveries below 50% and the productivity is highly dependent on a good concatenation of unit operations. Among the aspects related to production efficiency, the transport distance is an important item on system performance. Due to the depth of the mine, there is an increment in the size of the underground supporting pillars, and consequently, problems related to the increase in equipment cycle times. The increase of the transportation distance between mining faces and the primary crusher reduces the result of a set of production equipment. In open pit mining, this problem is solved by increasing the haulage fleet, however, in the underground coal mining, the number of machines cannot be increased indefinitely because it would impact directly on the need of increased air flow. Therefore, the approximation of the distance from the discharge point to an adjacent location from the mining faces is an alternative to address the need of increased production fleet. However, the relocation point must be evaluated consistently to determine the most appropriate time to get the most from this approach. The goal of the study was to understand this imperative step for the production process, using regression techniques to analyze the impact of transport distance in productive capacity. Based on the experimental design used in this study, alternative proposals provide a mining sequence able to mitigate the problems from increasing transportation distance from mining faces to their discharge points. The results show that the transport distance has directly influence on the production, and it is not limited to the maximum distance. Likewise, a minimum distance must be respected for higher productivity when you have the combination of production equipment. So, it is possible to conclude that the transport distance has a significant impact and must be considered not only during the sequencing, but also when determining the fleet size and consequent production capacity.

Roof falls and accumulation of dangerous gasses are the most common hazards in any underground coal mine. Different mechanisms can jeopardize the stability of the roof in underground excavations and successful roof control can only be obtained if the failure mechanism is identified and understood properly. The presence of discontinuities, the inherent variability of the rock mass and discontinuity properties, and the uncertainties associated with directions and magnitudes of the in-situ stress makes the rock engineering problems challenging. The numerical modeling can assist the ground control engineers in designing and evaluating the stability of the underground excavations. If extensive geological and geotechnical data are available, then detailed predictions of deformation, stress and stability can be accomplished by performing numerical modeling. If not, still the numerical modeling can be used to perform parametric studies to gain insight into the possible ranges of responses of a system due to likely ranges of various parameters. The parametric studies can help to identify the key parameters and their impact on stability of underground excavations. The priorities of the material testing and site investigation can be set based on the selected key parameters from parametric studies. An underground coal mine in western Pennsylvania is selected as a case study mine to investigate the underlying causes of roof falls at this mine. The immediate roof at the case study mine consists of laminated silty shale, shale, or sandstone that changes from area to area, and the floor is shale or soft fireclay. This study was mainly focused in the stability analysis of the roofs with the laminated silty shale rock type, where the majority of roof falls had taken place in the roof with this type of roof material. Extensive laboratory tests were performed on the core samples obtained from the case study mine to estimate the intact rock and discontinuity properties of the materials that occur in large extent at the selected interest area of the case study mine. In this research, the three-dimensional distinct element method was used to investigate the stability of the roof in an underground room-and-pillar coal mine. The implemented technique was able to accurately capture the failure of the major discontinuities and rock masses which consist of intact rock and minor discontinuities. In order to accurately replicate the post failure behavior of the rock layers in the immediate roof area, the strain-softening material constitutive law was applied to this region. Extensive numerical parametric studies were conducted to investigate the effect of different parameters such as the variation of immediate roof rock mass strength properties, variation of discontinuity mechanical properties, orientations and magnitudes of the horizontal in-situ stresses, and the size of pillars and excavations on stability of the excavations. The distribution of post failure cohesion along with other measures such as accumulated plastic shear strain, distribution of Z-displacements at the roofline, failure state (joint slip and tensile failure) and displacement (normal and shear displacements) of discontinuities were used to accurately assess the roof stability in this case study. The research conducted in this dissertation showed that the bedding planes play an important role on the behavior of roof in underground excavations. Therefore, an appropriate numerical modeling technique which incorporates the effect of discontinuities should be employed to simulate the realistic behavior of the discontinuous rock masses such as the layered materials in roof strata of the underground coal mines. The three-dimensional distinct element method used in this research showed the clear superiority of this technique over the continuum based methods.

In this study, Computational Fluid Dynamics Modeling (CFD) was applied to model a room-and-pillar mining working area to investigate the airflow patterns for dust control. Room-and-pillar mining is a conventional underground mining technique used for the extraction of coal by cutting excavations called "rooms" using a continuous mining machine and leaving the remaining coal as "pillars" for supporting the coal seam. The FLUENT software was used to analyze the airflow in the mine whose structure was designed and meshed in GAMBIT. The analysis was carried out in four different stages. First, airflow patterns were studied in the roadway without any equipment. Next, a line curtain, which extends along the height of the coal seam, was simulated in the roadway to direct the flow of air towards the active mining face. In the third stage, a continuous miner was inserted between the mining face and the end of the line curtain. Three and six meters deep box and slab cuts were simulated and the airflow patterns were investigated. In the final stage, a wet scrubber was simulated as an integral part of the continuous miner and the effect of the scrubber on the airflow in the box and slab cuts were studied. Dead zones (areas with limited airflow) and recirculation areas were observed using velocity distribution contours. A parametric study was conducted to evaluate the effects of distance of the curtain from the pillar rib (Dcr), scrubber pressure (Psc) and height of the coal seam (Ho). The data were plotted as functions of selected dimensionless variables. It was seen that wet scrubber increased the air in the LOXC (Last open cross cut) by 7.6% and was also proved that extension of line curtain along with the cut. The results of these studies are being used to develop guidelines for dust control in the face area.

O método de lavra câmaras e pilares é muito utilizado em minas de carvão subterrâneo, principalmente nos estados de Santa Catarina e Paraná, onde todas as minas subterrâneas utilizam este método. Vale ressaltar, porém, que o método apresenta recuperações de lavra abaixo de 50%, dependendo do tamanho dos pilares, e a produtividade é altamente dependente de uma boa concatenação das operações unitárias. Entre os aspectos relacionados à eficiência produtiva, a distância de transporte é um item preponderante no desempenho do sistema. Devido à profundidade da lavra, há um aumento do tamanho dos pilares de sustentação da mina, e assim, surgem problemas relacionados ao incremento no tempo de ciclo de transporte dos equipamentos. O aumento da distância de transporte entre uma frente de lavra com material desmontado e o alimentador/britador primário, reduz o resultado da produção de um conjunto de equipamentos. Em mineração a céu aberto, este tipo de problema é resolvido com o aumento da frota de transporte, todavia, na mineração de carvão subterrânea, não é possível aumentar de forma irrestrita a quantia de máquinas em subsolo, pois impactaria diretamente na necessidade de incremento da vazão de ar, assim como, limitação de espaço para o tráfego de equipamentos. A aproximação da distância do ponto de descarga para um local adjacente às frentes de serviço é uma alternativa para solucionar a necessidade de incremento da frota de produção. No entanto, o ponto de mudança deve ser avaliado de forma consistente para determinar o momento mais adequado para que essa reaproximação proporcione um resultado ótimo. Este estudo buscou compreender esta etapa necessária ao processo produtivo, utilizando técnicas de regressão para analisar o impacto da distância de transporte na capacidade produtiva. O problema foi modelado e foram propostas alternativas que forneçam um sequenciamento de lavra capaz de amenizar os problemas decorrentes do aumento da distância de transporte das frentes de lavra aos respectivos pontos de descarga. Os resultados demonstraram que a distância de transporte tem influência direta na produção, mas não somente a distância máxima, mas também, uma distância mínima que deve ser respeitada para obter maior produtividade quando se tem a associação de equipamentos de produção. É possível concluir com este estudo que a distância de transporte tem impacto relevante e deve ser considerada, não tão somente no sequenciamento, mas também no dimensionamento da frota e consequente capacidade produtiva. / The room and pillar mining method is widely used in underground coal mines. Santa Catarina and Paraná where all underground mines use this method. Indeed, the method has mining recoveries below 50% and the productivity is highly dependent on a good concatenation of unit operations. Among the aspects related to production efficiency, the transport distance is an important item on system performance. Due to the depth of the mine, there is an increment in the size of the underground supporting pillars, and consequently, problems related to the increase in equipment cycle times. The increase of the transportation distance between mining faces and the primary crusher reduces the result of a set of production equipment. In open pit mining, this problem is solved by increasing the haulage fleet, however, in the underground coal mining, the number of machines cannot be increased indefinitely because it would impact directly on the need of increased air flow. Therefore, the approximation of the distance from the discharge point to an adjacent location from the mining faces is an alternative to address the need of increased production fleet. However, the relocation point must be evaluated consistently to determine the most appropriate time to get the most from this approach. The goal of the study was to understand this imperative step for the production process, using regression techniques to analyze the impact of transport distance in productive capacity. Based on the experimental design used in this study, alternative proposals provide a mining sequence able to mitigate the problems from increasing transportation distance from mining faces to their discharge points. The results show that the transport distance has directly influence on the production, and it is not limited to the maximum distance. Likewise, a minimum distance must be respected for higher productivity when you have the combination of production equipment. So, it is possible to conclude that the transport distance has a significant impact and must be considered not only during the sequencing, but also when determining the fleet size and consequent production capacity.

This thesis studies airflow patterns in the face area of a typical room-and-pillar mining area, using Computational Fluid Dynamics (CFD) modeling. This research is designed to develop a scientific understanding of airflow distribution in room-and-pillar mining areas that is fundamental to developing engineering controls. The overall goal of the study is to develop improved engineering controls to minimize dust exposure of mine workers in the face area. Dust exposure can be a health hazard in underground coal mining industry based on historical data of coal workers' pneumoconiosis among underground mine workers. Current regulatory dust exposure standards of 1.5 mg/m3, averaged over an 8-hour period, have been recently revised with approval of new MSHA standards in April of 2014. Mining companies are currently seeking new technologies in order to comply with the new dust standards. Since mining geometries are complex and do not lend themselves to closed-form analytical solutions, CFD numerical modeling approach was used to develop an understanding of airflow distribution in the face areas. Since previous studies had focused on some cuts in mining heights of less than 2.4 m (8-ft), this study was performed for high mining areas of 4.2 m (14-ft). Such mining heights are very common in longwall mine development areas, particularly in the State of Illinois. The primary goal was to identify major differences in airflow between the two mining heights and how they affect development of engineering controls for minimizing dust exposure. Simulations were done using ANSYS software such as DesignModeler for modeling and meshing and FLUENT for calculations. Recirculation (RC) and low air velocity (LAV) zones were located for straight deep cut, straight deepest cut, cross-cut right, cross-cut right mine through, left turn cross-cut, and left turn cross-cut mine through for low mining height (LMH) and high mining height (HMH) with varying air quantity at the end of the line curtain (ELC). Air at the ELC was adjusted to achieve a ratio of 0.85, 1.00 and 1.15 over the wet scrubber fan (WSF) discharge capacity. Results show that the air velocity in HMH case is much lower than for the LMH. In addition, the location of RC and LAV zones differ based on mining height and air quantity at the ELC. Furthermore, lower air quantity at the ELC causes the air exhausted by the WSF to recirculate back to the face area in order to satisfy the WSF requirement. Recommendations to deal with these differences are formulated.

This thesis has developed wetting characteristics of coal dust from Herrin coal seam in Illinois for improved respirable coal and quartz dust (< 10µm) control. Wetting characteristics were assessed by a wettability technique called Fixed Time Wettability (FTW) method which simulates the actual underground wetting environment. Immediate roof and immediate floor materials bulk samples were found to be 100% wettable by water alone, whereas coal seam samples were 55-90% wettable. Two variables: contact time between water droplets and dust particles and, the temperature of the water were found to affect the degree of wettability. FTW was carried out at as a function of water temperature (7.2oC to 40.5oC) and contact time (10 to 25 seconds) which increased wettability 2-18% and 8-32%, respectively. In addition, the wetted and un-wetted samples collected from wettability experiments were subjected to Scanning Electron Microscopy (SEM) and particle size distribution analyses. It was found that particles are irregular in shape in both wetted and un-wetted fractions and some agglomeration of fine particles was observed in a few un-wetted fraction samples. The concept of increased contact time was incorporated in engineering controls by increasing the wet scrubber filter screen inclination (which is a function of the screen surface area). The filter screen inclination was minimizing the pressure drop across it using Computational Fluid Dynamics (CFD) analysis. It was found that 60 degree (with respect to the vertical) would provide minimal pressure drop and should be considered for implementation. Additional research should be conducted on assessing selective wetting of different particle sizes of coal and quartz in airborne dust, developing data on wettability as a function of particle size and implementing the developed concepts such as contact time and temperature in the field for improved dust control.

O método de lavra câmaras e pilares é muito utilizado em minas de carvão subterrâneo, principalmente nos estados de Santa Catarina e Paraná, onde todas as minas subterrâneas utilizam este método. Vale ressaltar, porém, que o método apresenta recuperações de lavra abaixo de 50%, dependendo do tamanho dos pilares, e a produtividade é altamente dependente de uma boa concatenação das operações unitárias. Entre os aspectos relacionados à eficiência produtiva, a distância de transporte é um item preponderante no desempenho do sistema. Devido à profundidade da lavra, há um aumento do tamanho dos pilares de sustentação da mina, e assim, surgem problemas relacionados ao incremento no tempo de ciclo de transporte dos equipamentos. O aumento da distância de transporte entre uma frente de lavra com material desmontado e o alimentador/britador primário, reduz o resultado da produção de um conjunto de equipamentos. Em mineração a céu aberto, este tipo de problema é resolvido com o aumento da frota de transporte, todavia, na mineração de carvão subterrânea, não é possível aumentar de forma irrestrita a quantia de máquinas em subsolo, pois impactaria diretamente na necessidade de incremento da vazão de ar, assim como, limitação de espaço para o tráfego de equipamentos. A aproximação da distância do ponto de descarga para um local adjacente às frentes de serviço é uma alternativa para solucionar a necessidade de incremento da frota de produção. No entanto, o ponto de mudança deve ser avaliado de forma consistente para determinar o momento mais adequado para que essa reaproximação proporcione um resultado ótimo. Este estudo buscou compreender esta etapa necessária ao processo produtivo, utilizando técnicas de regressão para analisar o impacto da distância de transporte na capacidade produtiva. O problema foi modelado e foram propostas alternativas que forneçam um sequenciamento de lavra capaz de amenizar os problemas decorrentes do aumento da distância de transporte das frentes de lavra aos respectivos pontos de descarga. Os resultados demonstraram que a distância de transporte tem influência direta na produção, mas não somente a distância máxima, mas também, uma distância mínima que deve ser respeitada para obter maior produtividade quando se tem a associação de equipamentos de produção. É possível concluir com este estudo que a distância de transporte tem impacto relevante e deve ser considerada, não tão somente no sequenciamento, mas também no dimensionamento da frota e consequente capacidade produtiva. / The room and pillar mining method is widely used in underground coal mines. Santa Catarina and Paraná where all underground mines use this method. Indeed, the method has mining recoveries below 50% and the productivity is highly dependent on a good concatenation of unit operations. Among the aspects related to production efficiency, the transport distance is an important item on system performance. Due to the depth of the mine, there is an increment in the size of the underground supporting pillars, and consequently, problems related to the increase in equipment cycle times. The increase of the transportation distance between mining faces and the primary crusher reduces the result of a set of production equipment. In open pit mining, this problem is solved by increasing the haulage fleet, however, in the underground coal mining, the number of machines cannot be increased indefinitely because it would impact directly on the need of increased air flow. Therefore, the approximation of the distance from the discharge point to an adjacent location from the mining faces is an alternative to address the need of increased production fleet. However, the relocation point must be evaluated consistently to determine the most appropriate time to get the most from this approach. The goal of the study was to understand this imperative step for the production process, using regression techniques to analyze the impact of transport distance in productive capacity. Based on the experimental design used in this study, alternative proposals provide a mining sequence able to mitigate the problems from increasing transportation distance from mining faces to their discharge points. The results show that the transport distance has directly influence on the production, and it is not limited to the maximum distance. Likewise, a minimum distance must be respected for higher productivity when you have the combination of production equipment. So, it is possible to conclude that the transport distance has a significant impact and must be considered not only during the sequencing, but also when determining the fleet size and consequent production capacity.