A PROJECT REPORT ON

“EXTRACTION OF COAL BY LONGWALL

METHOD OF MINING AND SALVAGING”
Submitted by
SAMINENI VIJAY RAGHAVA (ST-6774380)
Under the guidance of

Mr. B. KARUNA KUMAR Sir

In partial fulfillment for the requirement of passing Section B Examination in
MINING ENGINEERING Branch

The Institution of Engineers (India)

AN ISO 9001:2008 CERTIFIED ORGANISATION

(ESTABLISHED 1920, INCORPORATED BY ROYAL CHARTER 1935)

8 GOKHALE ROAD, KOLKATA [Link]

1
 The Institution of Engineers, (India)
8, Gokhale Road Kolkata - 700 020

CERTIFICATE

This is to certify that this report on

“EXTRACTION OF COAL BY LONGWALL METHOD OF MINING AND

SALVAGING”

Submitted by

SAMINENI VIJAY RAGHAVA (ST-6774380)

Is an authentic work carried out by him under my supervision and guidance. To the
best of my knowledge, the matter embodied in project report has not been
submitted to any other university / institute for the award of any degree or diploma.
This report is being submitted by me as an academic curriculum activity to pursue
AMIE degree from the Institution of Engineers, India.

SAMINENI VIJAY RAGHAVA

ST-6774380
Mr. B. KARUNA KUMAR Sir
(Project guide)

2
 CONTENTS

[Link] PAGE
NAME OF THE TOPIC NO.

1. TITLE OF THE PROJECT 4

2. ACKNOWLEDGEMENT 5

3. PREFACE 6

4. LONGWALL METHOD OF MINING 7-10

5. LONGWALL EQUIPMENT 11-13

6. LONGWALL CUTTING OPERATION 14

7. GAS MONITORING 15-22

8. SALVAGING 23-38

9. CONCLUSION 39

3
 TITLE OF THE PROJECT

“EXTRACTION OF COAL BY
LONGWALL METHOD OF MINING AND
SALVAGING”

4
 ACKNOWLEDGEMENT

A lot of hard work, perseverance, inspiration and motivation goes into

the making on this project was a challenge to me.
It is often difficult to understand a wide spectrum of knowledge without
proper guidance and advice.
Firstly I like to express my sincere thanks and deepest regard to my
project guide “Mr. B. KARUNA KUMAR Sir “ who have been the
constant source of motivation and for his inspiring guidance throughout
this project. I thank him for giving me the opportunity to work under
him and helping me.
I wish to acknowledge my sincere thanks to my officers of ADRIYALA
mining system mining engineers for allowing me to collect required data
related to my project.
Lastly, I am thankful to those people who helped me directly and
indirectly in the collection of information in bringing the project work to
a success.
SAMINENI VIJAY RAGHAVA,
ST-6774380

5
 PREFACE

For solving toughest challenges in mining and rapid extraction

of coal in underground, the CAT mining system introduced an
advanced longwall mining technology. This advanced longwall
mining technology is installed in Adriyala Longwall Project for
the rapid extraction of coal by longwall mining retreating
method with high safety measures and standards.
The whole project work based on the extraction of coal by
longwall mining retreating method in underground, continuous
Gas monitoring and salvaging process. In Adriyala longwall
project the extraction of coal in panel no.1 and panel no.2 was
successfully completed by retreating method of extraction
whereas, the gate roads are already developed by doscos.
Currently salvaging of this equipment from panel-2 to panel-3 of
1seam is being done.

6
 LONGWALL METHOD OF MINING

- Longwall mining method includes drivage of two long roadways in

coal and joining them at the end by a perpendicular drivage
forming a face.
- And extraction carries where a longwall of coal is mined in single
slice
- The longwall panel is typically 2-3 kms long and 250mts wide
- Then came rapid up-gradation of technology with state of art
equipment and face lengths upto 400m, panel lengths upto 6-7kms,
Shearer installed capacity upto 3000 KW and AFC capacity upto
5000TPH.
7
Longwall advancing method:
- In longwall advancing, extraction of coal commences from the
vicinity of shafts and advances towards the boundary of the mine.
- Approach to the face is by parallel roads formed at specified
distance apart, which is equal to the length of the face.
- The roof over extracted area (goaf) is packed by sand (or pack wall
of stone) or allowed to cave in.
- The method has the advantage that coal extraction can be started
soon after reaching the coal seam by shafts or inclines. But
maintenance of approach roadways is costly and difficult.

8
Longwall retreating method:
- In longwall retreating, pairs of headings are driven in solid coal at
an interval equal to the predetermined length of the face up to the
mine or panel boundary.
- Here they are connected by a long roadway one side of which is
used as a long face. As coal is extracted on this face,
- It retreats towards the shafts. Hence it is called long wall retreating
method. Roof in the goaf is allowed to cave in.
- Longwall retreating method is preferred because
• Reserves are “proven” in development
• Easier ventilation
• Predetermined knowledge of geological disturbances
• Maintenance of approach roadways is easy
• Risk of spontaneous heating is less
• Recovering of equipment is easier

APPLICABILITY
- Fairly good reserves
- Fairly flat seams with uniform thickness
- Free from discontinuities, such as large faults or other geologic
features that could interfere with continuous coal extraction
- No gas or less gassy seams
- Overlying strata shall be cavable
- No overlying large aquifers / water bed

9
ADVANTAGES
- Bulk production from UG mines
- Safest UG mining method
- High Recovery
- Reduction of drudgery on workmen, supervisors and officers
- Suitability for thin seams, Proven technology for thick seams
- Better supervision for concentrated workings
- Perhaps the only solution for extraction of deep-seated coal
deposits
- Effective Ventilation, as limited Galleries.
- For deep seated coal deposit Air Chilling/ Conditioning is more
effective, Example: Chilling Plant at Adriyala Longwall Project.

LIMITATIONS
- Initial Capital Investment is very high
- Not very flexible and is "unforgiving" while encountering
Geological disturbances like significant Faults, Folds,
discontinuities, Dykes, Sills (L/W failed at Churcha mine for this)
etc.
- Because of the unforgiving nature of longwall, Experienced,
Skilled & Trained persons are essential for successful operations.
- The ability of the mine to develop new longwall blocks so that
longwall production continuity is not adversely impacted. Often
Development doesn’t match with Extraction.
- Condition of equipment – Spares for overhaul or replacement
during the life of a longwall block can be problematic, and is best
done during relocation.

10
 LONGWALL EQUIPMENT

Powered Roof Supports

• Support capacity - 1152 T
(2 legged DTDA version)
• Operating Range - 1.8 to 3.6 m
• Closed and open height
(Shield Range) - 1.4 to 3.9 m
• Support width - 1.75 m
• Tip to face distance - 0.51m to 0.53m
• Approx. Weight - 35 Tonnes
• Setting load - 90% of Yield load.
• Relay bar Stroke length - 0.85 m

Armoured face conveyor

• Capacity - 3X855 KW,
3.3 KV, 3-Phase, 50 Cycles,

• Width - 1141 mm
• Twin inboard chain - 48X144/160 mm
• capacity - 3100 TPH

11
2 legged powered roof supports Armoured face conveyor

Double ended ranging drum shearer

12
Shearer
• Type / Model - EL 3000
• Cutting height - 1.8 - 3.6 m
• Shearer height - 1.68 m
• Operating voltage - 3.3 KV

• Web depth - 0.85 m

• Drum diameter - 1.3 m

• Drum Web - 850mm
• Clearance between Shearer and AFC - 749mm
• Machine control - Radio control

Beam stage loader

• Make - BUCYRUS DBT MAKE
• TYPE - PF 6/1341
• Length - 19.5m with suitable overlap system
• Capacity - 400KW, 3.3 KV,
3-Phase, 50Cycles/ sec.
• Width - 1341mm wide,
• Twin in board chain 41X146mm,
• speed -1.06 m/sec
• capacity - 3100 TPH

Lump breaker
• Capacity - 400KW, 3.3KV, 3-Phase, 50 Cycles/sec,
-3100 TPH

13
 LONGWALL CUTTING OPERATION

• In Adriyala Longwall Project, the cutting operations of the Shearer

were done by uni-directional method. The Shearer cuts the face
from Tail gate to main gate and cleans the face from main gate to
tail gate.
• First the Shearer takes the sump at chock no.135 as shown in the
fig. above and cuts the coal upto tail gate and again comes to chock
no.135 by cleaning the coal. Now Shearer cuts the face from chock
no.135 to the main gate with a maximum sump of 0.8mtrs with a
height of 3mtrs. Now the Shearer cleans the face from main gate to
tail gate. Again, it takes the sump at chock no.135 and continues
the cutting process.
14
 GAS MONITORING
➢ For early detection of spontaneous gases like carbon monoxide and
other constituents of the mine atmosphere and to eliminate the risks
of fire continuous gas monitoring is required.
➢ As there are different methods of continuous gas monitoring
techniques tube bundle gas monitoring is the predominant method
used in adriyala longwall project.

Tube Bundle Gas Monitoring System

• Tube bundle gas monitoring systems were developed by the
National Coal Board in the United Kingdom (UK) in the late
sixties as a means of early detection of spontaneous combustion
(Chamberlain et al 1971).
• In brief, tube bundle systems are comprised of hollow tubes run
from the surface to the desired monitoring location, through which
gas samples are drawn to the surface by way of vacuum pumps as
shown in Fig.5.
• By switching from one tube to another on the surface, the sample
from each point in turn can be analyzed. All analysis, pumping and
switching hardware is located on the surface removing the need for
equipment to be approved for use underground.
• Electrical supply to the system can also be separate from mine
power allowing operation during loss of power underground.

15
Application of Tube Bundle System
➢ The system was originally developed to continuously monitor the
carbon monoxide content of the air passing critical points
underground in order to detect spontaneous combustion in its very
early stages before, the traditional indicators of smell and haze were
detectable.
➢ The rate of evolution of carbon monoxide had been established as the
earliest indicator of incipient spontaneous combustion.
➢ But it was quickly identified that extending the analysis to include
oxygen, methane and carbon dioxide was worth the additional
expense and provided a much better understanding of the variations in
the atmosphere of an underground coal mine.
➢ Determination of the explosibility in sealed and active gobs is a
primary function of tube bundle systems, equally as important as the
early detection of spontaneous combustion and fires.

16
Tube Bundle System at Adriyala Longwall Project:
A SICK tube bundle gas monitoring system has been purchased from
Safety in Mines Testing and Research Station (Simtars) Australia.
Simtars is a professionally independent, functional entity of the
Queensland Department of Natural Resources Mines and Energy with
extensive experience in the public and private sectors.
20-point tube bundle gas monitoring system was introduced in Adriyala
Longwall Project. The basic principle is based upon running food grade
polyethylene tubes from the surface to the required underground
monitoring point and drawing gas samples using surface installed
purging pumps for analysis on a dedicated four gas analyser. These
tubes can be up to 6 km length for ½” tube and 9.5 km for 5/8” tube.
System is of Supervisory, Control and Data Acquisition (SCADA)
software and hardware and developed specifically for continuous
automated mine gas monitoring, interpretation and decision support
system.
The system consisting of Sick Maihak 715 gas analyser configured
specifically for the monitoring of carbon dioxide (CO2), methane (CH4),
carbon monoxide (CO) and oxygen (O2) in coal mines.
➢ The analyser uses a MULTOR non-dispersive infra-red (NDIR)
bench for measuring
• CO2 in the range 0-50% and
• CH4 in the range of 0-100%,
➢ A Unor NDIR for measuring CO in the range of 0-1000 ppm, and
➢ An OXOR P paramagnetic bench for measuring oxygen in the range
of 0-25%.
➢ This analyser typically has an accuracy range of ±1% full scale for
each component measured.
17
The gas conditioning equipment consists of various flow control
components, sample gas cooler, gas selection station, filtration and water
removal equipment and presents to the analysers gas samples completely
free of water or any particulate matter. To ensure maximum safety, each
sample tube is equipped with approved flame traps at both the
underground and surface ends of the tube. A flow meter shall be
provided and visible on the analyser and the analyser generates low flow
alarms.

• Analyzer room is installed on surface near the Punch entry-5 (PE5D).

three Bundles of 7 core tubes (ID-0.35”, OD-0.5”) are laid parallel
from Analyzer room to underground along PE-5D up to 61LN/PE5D,
PE5R/74LN and PE5R/85L marshalling stations respectively.
• Individual Tubes (ID-0.35”, OD-0.5”) are laid up to monitoring
locations from respective each bundle tubes connected to marshalling
stations.
• Marshalling station and the components of Tube bundle system are
shown in fig

Water trap

Marshalling Station Flame Arrester Seal water Panel End of Line Filter

Marshalling station and the components of Tube bundle system

18
 Schematic diagram of Tube Bundle hardware in an alyzer room.

Tube Bundle supported on Side J Hooks

Tube Bundle supported on Side Cable brackets

Fig. Tube bundle installation in Main

heading

Tube Bundle supported on Roof Cable brackets

Tube Bundles supported on Side J Hooks, Side & Roof Cable bracket

19
 • Bundles are supported on supported on gallery side L shaped
hooks as well as roof cable brackets. The bundles are attached to
the fully tensioned by cable ties at an interval to prevent sagging.
• Individual tubes of the bundle as well as the individual tubes are
joined with stainless steel or brass connectors and are further taped
to ensure no leakage.
• The tubes are installed such that, there is the minimum amount of
undulation to avoid the settling of water. All tubes are run so that
the water runs down dip to the marshalling panels where there are
water traps. If single tubes are run down dip, water traps or seal
panels are installed at the low point where water accumulates.
Tubes are provided with End of line of filters with flame traps to prevent
entering of dust and flame. Flame traps are also provided at the tube end
in the analyzed room as shown

End of line both ends of the tube filter and flame trap

The monitoring points are selected based on the statutory and other mine
requirements for gas monitoring in underground coal mines. The
requirements are for methane, carbon monoxide, carbon dioxide and
oxygen to be continuously monitored at the following locations:

20
 • the return airway of each ventilation split
• the return airway from each gob area
• the return of airway at the upcast shaft
• the return side of each conveyor belt
• the return side of the Free Steered diesel Vehicle’s roadways, and
• Isolation stopping’s of Sealed off area as well as isolation
stoppings of panel under extraction.
The gas monitoring system automatically detects or calculates with the
help of Segas professional software coupled with SAFEGAS tube
bundle control software, the values and trends of

• Gas concentrations
• The ratio of carbon monoxide and oxygen deficiency (Graham’s
Ratio)
• The ratio of carbon monoxide and carbon dioxide gas explosibility
and must:
• Automatically activate an alarm if a gas alarm level is exceeded
• Record the values and trends
• Display the record at the surface of the mine where it can be easily
accessed by coal mine workers and in a way that the record can be
easily read by the workers
• Keep the information on which the values and trends were based at
the mine in a way that enables the information to be easily
accessed and inspected
• Provide for an alternative electricity supply to ensure the system
continues to function if the normal electricity supply fails.

21
Segas Professional is also the data interpretation tool used for the
Simtars supplied gas chromatographs. Segas Professional is closely
integrated with Safegas and allows operators to readily convert complex
gas data into easily understood graphs and visual interpretive tools in an
effortless fashion as shown

Segas Professional
25

8.3

20 7.4

6.4

15 5.5

Concentration (ppm)
Concentration (%)

4.6

10 3.7

2.8

5 1.8

0.9

0 0.0
2/11/2019 2/12/2019 2/13/2019 2/14/2019 2/15/2019 2/16/2019 2/17/2019 2/18/2019 2/19/2019
Date
LW Return 50m,CH4 LW Return 50m,CO (Y2) LW Return 50m,O2 LW Return 50m,CO2

Time graph of Respective Monitoring Location or Sampling Point

Analyser calibrated at the time of installation and also at intervals of

every month
Safegas allows four individual alarm thresholds (two levels for high and
two levels for low) to be set for each parameter per monitoring location.
Any value which equals or exceeds the threshold, in either direction, will
trigger Safegas to raise an alarm.

22
 SAVAGING

• Salvaging is the process of shifting of longwall machinery in

sequence from one panel which is completed to the new panel.
• This process includes dismantling of machinery from old panel,
transporting to the new face and erection of the machinery in new
face.
• Before starting of salvaging Meshing procedure has to be followed
for safe recovery of longwall machinery

MESHING
Purpose of meshing:
Mesh is designed to assist in the control of
1. Roof support and face support, and
2. Goaf flushing during the salvage of Longwall power roof supports
(PRS) and equipment.

Sequence of meshing Operation:

1. Mesh transportation
2. Mesh lifting and spreading
3. Mesh procedure
4. Accessories

23
Mesh Transportation:
1. Clean up around TG drive
2. Clean off top of shearer.
3. Ensure orientation of mesh is correct on the surface and again when
positioning it in the TG.
4. MG end of the roll (BLUE) to face in bye

5. Using pre-installed slings, take slings around the capstan and attach to
the shearer in TG.
6. Tram shearer 30m (aprox.) and stop the shearer.
7. 30m mesh roll is kept towards goaf side.

24
8. Again shearer is trammed to TG
9. Fold the mesh over the shearer and tie it.

10. Once tow sock sling is secured

11. Tram shearer towards the MG

12. Ensure effective communication all along the face for transporting
mesh.

25
13. Locate the people wherever required for tramming of shearer.
14. Immediately stop shearer if mesh jams at any place for prevention of
damage
15. Shearer is trammed upto MG
16. Double roll of mesh is straightened upto MG
17. Lift the mesh roll with the help of lifting devices.

Mesh Spreading and Lifting:

1. Cut tie holding mini roll to main roll from TG end of the roll to TG
end of the shearer.
2. Cut the white ties only.

3. Close the flipper and run the sling/rope through the hooks on the
canopy and flipper pivot from the winch.
4. Pull the sling/rope down to the mini roll and hook the sling to starter
rope of the roll as shown in the figure

26
5. Tighten the winch, starting from mid face and moving towards
both gate roads. Then, by opening the flipper, so that the mini roll
lifts upto the flipper joint
6. Drill and grout 1.8m roof bolts - for anchoring the mesh to the
roof, every alternate chock

27
7 . After completion of bolting advances the chocks from MG to TG so
that mini rolls goes on to the canopy of chock freely.

8. Once bolting is completed and supports are advanced cut the

sling/rope.
9. Tie both ends as show in the figure.

10. Close the flippers and coil the mesh.

28
MESHING PROCEDURE
1. The roof of salvage gallery/dip (total 250m width) is supported with
mesh (length of 16m, for roof-14m, for side-2m) for a longwall length
of 14m behind face stop line area.
2. At a distance of 14m behind face stop line, mesh is anchored to the
roof at one end by installing one row (145no.s) of roof bolts.
3. After anchoring, remaining mesh shall be coiled and tied to the
canopies of PRS. 4. After mesh anchoring,
4. Longwall extraction is continued for a length of 6.8m,
5. after every advance of longwall, mesh is uncoiled and
6. power roof supports are advanced,
7. This 6.8m width is not supported by roof bolts and

29
8. Mesh is allowed to pass freely over the canopies.
9. Face cutting and bolting operations are made zone wise i.e.,
Zone-1: C-145 to C-100
Zone-2: C-99 to C-50
Zone-3: C-49 to MG.
At first, one zone is cut with shearer and shearer is parked at the start
point of next zone.
10. Mesh is uncoiled and held tight against the roof with the help of
flippers.
11. Then panline bolter is introduced onto AFC and bolting operations
carried throughout the zone.
12. Pan line is then removed from AFC and mesh is coiled.
13. Similar procedure is followed for other two zones.

30
Panline bolter

31
14. In the next 4.8m of longwall extraction (up to canopy stop line),
the roof is supported by mesh anchored with 7 rows of roof bolts at
0.8m interval in between rows.
15. After every 0.8m of retreat, mesh is uncoiled and made to contact
firmly to the roof by grouting roof bolts and PRS are advanced, and
mesh is allowed to pass over the canopies.
16. In every such advance, mesh is uncoiled, coiled and tied to
canopies of PRS firmly.
17. In a row, about 145 no.s of vertical roof bolts (full column resin
grouted roof bolts 2.4m long of 20/22mm diameter) are installed.
18. The next/last 2.4m (up to longwall face stop line) the roof is
supported by mesh anchored with 3rows of roof bolts at 0.8m interval
in between rows.
19. After every 0.8m of retreat, mesh is uncoiled and contact firmly to
the roof by grouting with roof bolts and without advancing the PRS.

32
 15. One row of cable bolts (6.1m Length) is installed in the roof at
1.2m from face stop line with an interval of 0.8775m (i.e. 2 cable bolts
per one shield support in the face).
16. The last row of roof bolts is installed up to 0.2m from the face.
17. The coal face at the longwall Stop Line area is supported by two
rows of side bolts (2.4m long full column cement grouted) anchored
with mesh (up to 2.0m from roof ).

33
Preparatory works for meshing:
➢ Winches and pulleys fixing for every alternate chock
➢ Transport and fixing of capstan in TG
➢ Before starting of mesh spreading

• Shearer has to be parked in TG

• AFC should not be advanced from MG to TG
• Face should be thoroughly cleaned
❖ Soon after completion of meshing dismantling of machinery and
salvaging process begins in a sequence order.

Dismantling order of equipment:

➢ MG DRIVE
➢ CHAINS OF ARMOURED FACE CONVEYOR & BSL
➢ BSL ADAPTOR PAN, CRUSHER INTAKE, CRUSHER & FLC
➢ SHEARER RANGING RAM AND CUTTER DRUM
➢ MG SPECIAL PANS REMOVING AND NORMAL PANS
LAYING
➢ SHEAEARER AND THEIR PARTS
➢ AFC LINE PANS &BSL
➢ MONORAIL
➢ ENERGY TRAIN
➢ POWERED ROOF SUPPORTS

34
❖ In this equipment except powered roof supports all are transported to
surface or salvaging station, then powered roof supports are
transported to the new face.
❖ After erection of powered roof supports in the new face then follows
by TG drive, AFC pan sets shearer, TG drive, BSL unit, Boot end
unit, monorails, and energy train unit.

AFC LOADS:
➢ Dismantling of MG drive and transportation
➢ Removing of AFC chain
➢ Removing of MG special pans
➢ Removing of normal pans
➢ Removing of TG special pans
➢ Dismantling and transportation of TG drive

SHEARER LOADS:
➢ After removing MG drive and MG special pans, normal pans are
laid in addition to existing pans for marching of shearer towards
MG.
➢ Cutter drums and ranging arms of the shearer are dismantled
➢ MG cutter drum and ranging arm are transported at first
➢ Shearer main frame is divided into parts and transported
➢ Then after TG ranging arm and Cutter drums are transported

35
BEAM STAGE LOADER:
1. BSL ram plate 2. Mini pans
3. Crusher intake 4. Crusher
5. Face load centre 6. Crusher outlet
7. Saddle pan (convex) 8. Skid
9. Long pan 10. Saddle pan (concave)
11. Boot end return unit 12. Boot end middle unit
13. Adaptar pan 14. BSL drive
15. BSL chain 16. Discharge chute
17. Belt transfer unit 18. Belt lifter

POWERED ROOF SUPPORTS (CHOCKS):

1. After completion of dismantling AFC, AFC chain, Shearer, C-145,
C-144 AND C-143 chocks, and then Face move will start with the
help of 2 butters chocks.
2. Old Face salvage will be done from TG to MG with help of 2
butters chocks, line chocks salvage one by one.
3. C-142 and C-141 chocks are treated as butters chocks. Then PRS
withdrawal is done from c-140 to MG line by line.
4. FBL with trailer is transported to near the line chock & the line
chock will be loaded with the help of chock trailer.
5. This method continues up to completion of line chocks.
6. After salvage of Line chock immediately cog support is erected for
prevention of Goaf flushing into the Face.

36
37
• Thus the chocks are withdrawn from the face.
• Risk assessment shall be done afresh before starting the salvage
operations keeping the safe operating procedures in view.

38
 CONCLUSION
• The underground performance has dwindling trend at 50 MT over the
years in the country. The share of underground production in the
country has a decreasing trend from 16% to 9% during last ten years.
• In order to achieve 1 BT by Coal India, 0.1 BT by SCCL and 0.4 BT,
it is required to increase underground production by introducing High
Capacity Longwalls in every subsidiary of Coal India Limited and in
private sector coal blocks, where ever Geology permits by utilizing
the experience of Adriyala Longwall Project.
• SCCL ventured high-capacity longwall with heavy investment
considering clean reserve and to adopt UG technologies of future.
Currently producing about 5 to 6 thousand ton/day and shortly
reaches the rated production of 10,000tpd.

39