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A new coal pillars design method in order to enhance safety of the retreat mining
in room and pillar mines
E. Ghasemi ⇑, K. Shahriar
Department of Mining and Metallurgical Engineering, Amirkabir University of Technology, Tehran, Iran
a r t i c l e i n f o a b s t r a c t
Article history: Most of the proposed methods for coal pillar design determine pillar dimensions using pillar load estima-
Received 12 September 2010 tion only through the tributary area theory. Designing pillar based on these methods is not appropriate in
Accepted 3 November 2011 room and pillar mines with pillar recovery because retreat mining and gob creation generate abutment
Available online 29 November 2011
loads. Neglecting abutment loads in design stage may lead to pillar failure and destructive effects during
retreat mining. Thus proper pillar design has a remarkable effect on mining safety. In this paper, a step-
Keywords: by-step method is presented to design pillars with square shape in room and pillar mines with regard to
Pillar design
existing pillars in the active mining zone (AMZ) and estimating abutment loads according to experimen-
Room and pillar
Retreat mining
tal equations. A decrease in pillar failure risk during retreat mining is the most significant benefit of this
Active mining zone method. This method has been applied to determine optimum pillar dimensions in the main panel of
Abutment loads Tabas Central Mine (TCM), located in the mid-eastern part of Iran. Obtained results show the abutment
loads account for 27% of the total loads applied on pillars in AMZ in this panel. Pillar width, based on this
method, is also obtained 11.6 m.
Ó 2011 Elsevier Ltd. All rights reserved.
1. Introduction of failed and successful case histories. In 1980, field studies con-
ducted by the US Bureau of Mines had developed the classic pillar
In underground coal mining, room and pillar is the method of design methodology. It consisted of three steps (Mark, 2006):
working preferable for flat, tabular deposits in thin seams, where
rooms or entries are driven in the solid coal to form pillars in the 1. Estimating the pillar load;
development panels (Hustrulid, 1982; Hartman, 1987). Pillars of 2. Estimating the pillar strength, and
coal are left behind to support the roof and prevent its collapse, 3. Calculating the pillar safety factor.
thereby allowing miners to extract coal between them and to tra-
vel safely. In some cases, the pillars are removed partly or fully in a The average pillar load, in regular layouts of pillars can be esti-
later operation, known as retreat mining (also known as secondary mated by tributary-area theory. Base on this theory, each individ-
mining or pillar recovery operation). Coal mine pillar design has ual pillar is assumed to carry the weight of the overburden
been the subject of sustained and intensive research in the major immediately above it. In the other words, a pillar uniformly sup-
coal producing countries of the world. Pillar design and stability ports the weight of rock overlying the pillar and one-half the width
are two of the most complicated and extensive problems in mining of rooms or entries on each side of the pillar (Peng, 1978). Pillar
related to rock mechanics and ground control subjects. Although strength can be defined as the maximum resistance of a pillar to
these problems have been investigated for a long time, to date only axial compression (Brady and Brown, 1993). Empirical evidence
a limited understanding of the subject has been gained. The subject suggests that pillar strength is related to both its volume and its
of pillar design in the US goes back nearly a century. Prior to this shape (Salamon and Munro, 1967; Brady and Brown, 1993).
the dimensions of pillar were largely determined by experience Numerous formulas have been developed that can be used to esti-
based on trial and error, intuition or established rules of thumb, mate the strength of pillars in coal mines, which Table 1 shows the
such research as there was tended to be isolated and sporadic. most applicable of them. Each of these formulas estimates the pil-
But nowadays, various pillar design formulas are developed, based lar strength in terms of two variables; width to height ratio and
upon laboratory testing, full-scale pillar testing, and back-analysis in situ coal strength.
Bieniawski (1981) represented very good classic approach to
pillar design. He at first described the issues involved in pillar de-
⇑ Corresponding author. Address: Hafez 424, P.O. Box 15875-4413, Tehran, Iran. sign, and advantages and shortcomings of the available methods
Tel.: +98 21 6454 2972; fax: +98 21 6640 5846. and then represented a logical, step-by-step approach to determine
E-mail address: ebrahim62.gh@gmail.com (E. Ghasemi). the coal pillars dimensions in room and pillar mines.
0925-7535/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ssci.2011.11.005
580 E. Ghasemi, K. Shahriar / Safety Science 50 (2012) 579–585
Table 2 should be calculated using Eq. (13). If D is less than or equal to the
Used symbols in proposed coal pillars design method. sum of pillar width and entry width, the optimum pillar width is
Symbol Description (unit) obtained from Eq. (14). Otherwise, the number of entries is added
AMZ Active mining zone depending on D value and calculations are repeated from step 8:
H Depth of cover (m)
P Panel width (m)
D ¼ LAMZ ½ðw þ BÞ ðNE 1Þ ð13Þ
h Pillar height (m)
B Entry width (m) D
c Mean unit weight of the overburden (KN/m3) wP ¼ w þ ð14Þ
ðNE 1Þ
b Abutment angle (°)
LAMZ AMZ length (m) In the following section optimum pillar dimensions in the main
WAMZ AMZ width (m)
panel of the Tabas Central Coal Mine, located in mid-eastern part of
DL Development load (KN)
FL Maximum front abutment load (KN) Iran, is determined in order to validate the proposed method and
SL Side abutment load (KN) results are interpreted. This mine is the first mechanized one in
WSG Side gob width (m) Iran designed as a room and pillar mine. The pillars left behind
WB Barrier pillar width (m)
in this mine are supposed to be extracted as retreat mining in fu-
R Transfer rate (%)
ML Maximum load applied on AMZ (KN)
ture after the preliminary mining finishes. Therefore a proper pillar
SP Pillar strength (MPa) design can has a remarkable influence on higher safety and effi-
NE Number of entries ciency of the reserve recovery in this mine.
NP Number of pillars in AMZ
TLC Overall load-bearing capacity of AMZ (KN)
SF Safety factor 3. Tabas Central Coal Mine
w Pillar width (m)
D Width difference (m)
Tabas Central Mine (TCM) is the case studied here, located in
wP Optimum pillar width (m)
Tabas coal region approximately 85 km south of Tabas town in
Yazd province in mid-eastern part of Iran (Fig. 4). The mine is
working seam C1 by room and pillar method using continuous
miner and LHD. The C1 seam gradient is 1 in 5 (11°) and seam
thickness is about 2 m. The immediate roof above the seam typi-
cally is weak (CMRR = 37) and consist of 0.1–0.2 m thick mudstone,
siltstone/sandstone interfaces and sandstone channels in some
areas within 3 m which have potential to be water bearing. The
immediate floor is about 1–1.3 m of weak seatearth/mudstone
underlain by stronger mudstones, siltstones/sandstones. The min-
able reserve accounts for 6 million tones of coking coal (Central
Mine Design Report, 2005). The in situ strength of coal, based on
results from uniaxial compressive tests and Gaddy equations (Bie-
niawski, 1987), is 6 MPa.
As can be seen in Fig. 4 the suggested layout for this mine in-
cludes two access drifts, a main panel, and eastern and western
panels in both sides on the main panel. The main panel is initially
Fig. 3. Abutment angle concept in sub-critical and super-critical panels (Mark,
1992).
developed in 2004 with five entries and pillars with 20 20 m dis-
tance between centers. This panel is developed with a continuous
haulage system with 4.5 m wide entries and crosscuts. So, Pillars
left behind this panel are square shaped and width is 15.5 m. Be-
Table 3 cause of weak floor, the pillar height is not equal to the seam thick-
Suggested safety factors for stability of the pillars in AMZ.
ness and is 2.6 m. The current recovery rate is 40%. According to
Depth of cover Weak and intermediate roof Strong roof negotiations with the technical office and the caving behavior ob-
(m) (CMRR 6 65) (CMRR > 65) served in the mine No. 1 (near the TCM), abutment angle in TCM is
H 6 200 P1.5 P1.4 25°, so the main panel is super-critical (Ghasemi et al., 2010b).
200 < H 6 400 1:5 ½ðH 200Þ=333 1:4 ½ðH 200Þ=333 Because of extracting the pillars left behind in the eastern and
400 < H 6 600 0.9 0.8
western panels prior to beginning retreat mining in the main panel,
gob is created in both sides of this panel. Therefore side abutment
load should be considered in calculation of the maximum load ap-
plied on pillars in AMZ. The gob areas are super-critical and the bar-
ratio larger than four is reached. Of course, in order to control and rier pillar width in both sides is 30 m. According to the descriptions
avoid excessive increase of pillar width, the recovery rate is taken given in this section, the parameters required in pillar design in the
into consider. According to experiments and considering economic main panel of the TCM are summarized in Table 4.
purposes in preliminary mining stage, the most suitable recovery
rate varies from 40% to 60%. It should be notice 0.5 m is added to
4. Results
the pillar width each time in this step.
The results of proposed method for main panel of TCM are sum-
2.12. Step 12: Determining the optimum pillar width marized in Table 5. Based on TCM conditions (i.e., depth of cov-
er = 85 m and CMRR = 37) the minimum suitable safety factor for
In this step, the width obtained from previous step is corrected pillars stability is 1.5 (see Table 3). As can be seen in Table 5 the
so that the optimum pillar width is determined based on the num- number of entries equal to six and optimum pillar width equal to
ber of pillars in each row and the panel width. In order to at first D 11.6 m were obtained. In comparison with original mine layout,
584 E. Ghasemi, K. Shahriar / Safety Science 50 (2012) 579–585
Table 4 like classic method and Bieniawski method neglect abutment loads
Essential data for pillar design in the TCM. and determine pillar dimensions only based on development load
(estimated by tributary area theory). Abutment loads increase
Parameter Value Parameter Value
the overall loads applied on the pillars adjacent to the gob area.
H 85 m c 25 KN/m3
When overall load increases, pillar efficiency will decrease and
h 2.6 m b 25°
B 4.5 m P 85 m eventually leads to pillar failure. So, properly sized pillars that
S1 6 MPa CMRR 37 are designed considering abutment loads can result in safety for
miners and more efficient recovery of reserves. In this paper, by
estimation overall loads (including development load and abut-
ment loads) which may be applied on pillars during room and pil-
Table 5 lar mining, a simple method is provided to design coal pillars. One
Summary of results for the TCM.
of the most important advantages of this method is decrease of pil-
Parameter Value Parameter Value lar failure risk, especially massive pillar collapses. The result of this
LAMZ 80.5 m ML 10.87 106 KN method can be taken as the optimum pillar width which causes
WAMZ 46.1 m NE 6 stability of pillars during preliminary and secondary mining.
DL 7.89 106 KN wP 11.6 m Although this method is similar to ARMPS program in structure,
FL 2.05 106 KN Rra 48%
the main difference of proposed method with ARMPS program is
SL 0.93 106 KN
that optimum pillar width in room and pillar mining is calculated
a
Rr – Recovery rate. using this method in order to decrease the pillar failure risk during
retreat mining but in ARMPS program by inputting parameters
one unit was added to entries which can increase the production such as pillar width, panel width, depth of cover and etc., stability
rate if efficient management is applied. Furthermore pillar width of pillars in preliminary and secondary stages are evaluated. It
was decreased remarkably (about 4 m) which causes 8% increase means that in proposed method the pillar width is unknown
in recovery rate that shows the proposed layout is more economic. parameter (i.e. pillar width is main output in proposed method)
Also, it can be seen that development load, front abutment load whereas in ARMPS program the pillar width is one of inputs so
and side abutment load constitutes 73%, 19% and 8% of the total there is no need for calculation of pillar width.
load applied on pillars in AMZ respectively. The negligible side
abutment load can be attributed to the great width of barrier pil- Acknowledgments
lars. Side abutment load is transferred to barrier pillars and pillars
in AMZ so as the barrier pillars width increase, the more load will The authors would like to thank Dr. M. Sharifzadeh, Dr. H. Hash-
applied to them. emolhosseini and Dr. F. Samimi for their kind helps and construc-
To confirm the results of proposed method, optimum pillar tive suggestions during the preparation of manuscript.
width and other related parameters of the TCM were entered as in-
put data to ARMPS program and acceptable stability factors were
obtained, which indicates the mining operation, in both the preli- References
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