Design of Underground Hard-Coal Mines

238 Pages·1988·12.021 MB·English

by  Józef Paździora (Eds.)

Advances in Mining Science and Technology
Advisory Editor: B.N. Whittaker
Mining Engineering Department, University of Nottingham
Nottingham, Great Britain
Volume 1 Underground Mining Methods and Technology
(Szwilski and Richards, Editors)
Volume 2 Reclamation, Treatment and Utilization of Coal Mining Wastes
(Rainbow, Editor)
Volume 3 Design of Underground Hard-Coal Mines
(Pazdziora)
Advances in Mining Science and Technology, 3
Design of Underground
Hard-Coal Mines
Jozef Pazdziora
Central Mining Institute, Katowice, Poland
Amsterdam — Oxford — New York—Tokyo
PWN—POLISH SCIENTIFIC PUBLISHERS
Warszawa
1988
Translated from the Polish by Mauriel Mierzynska and Stanislaw Bochniak
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Library of Congress Cataloging-in-Publication Data
Pazdziora, Jozef.
Design of underground hard-coal mines.
(Advances in mining science and technology; 3)
Translation of: Wybrane zagadnienia projektowania kopaln.
Bibliography: p.
1. Mining engineering. I. Title. II. Series.
TN145.P3513 1988 622'.334 87-27441
ISBN 0-444-98938-2 (Vol. 3)
ISBN 0-444-42846-1 (Series)
Copyright © by PWN—Polish Scientific Publishers—Warszawa 1988
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Printed in Poland
Preface
The escalating worldwide demand for energy has had the effect, among other
things, of promoting the development of coal mining. This development, on
a world scale, has not been hampered either by the growing production of
crude oil and natural gas or by the advances made in the last three decades
by nuclear energy. Everything appears to indicate that coal's contribution
in satisfying world energy requirements will be of signal importance for a long
time yet. This is particularly true of those regions of the world, or of par-
ticular countries, where there are substantial reserves of this valuable fuel.
The part played by coal in the world economy seems likely to be enhanced
in view of the development prospects for methods of coal utilization, especially
coal processing to obtain liquid and gaseous fuels.
These factors, coupled with the necessity of ensuring essential technical
and economic effectiveness in mining investment projects have, over the last
thirty years, resulted in increasing interest being shown by economists and
theoretical and practical mining experts in plans for the exploitation of mining
regions, and for the construction of new mines and the reconstruction of
working mines. The major problems in this field were seen to be the technical
and economic optimization of the project designs and raising the level of
work safety in the mines. Thus mine design became a new area in mining
sciences and also a specialist field in design theory. In some countries specialist
design offices were set up, while in the universities and technical schools,
students were trained as specialists in mine design and construction. Poland,
a country having mining traditions stretching over many centuries, may be
cited as an example. Thirty-five years ago the Chief Mine Design and Studies
Office was organized here, followed a few years later by the Chief Coal Prep-
aration Design and Studies Office, backed up by enterprises specializing in
the implementation of mine investment projects, both underground and on
the surface; meanwhile, institutes for mine design and construction were set
up at the Academy of Mining and Metallurgy in Krakow and at the Silesian
Polytechnic University in Gliwice. In the period from the end of World War
II up to 1984, twenty new hard-coal mines, together with coal preparation
VI PREFACE
plants, were constructed in Poland, including mines with a daily production
of 24 000 tonnes. Reconstruction and modernization projects have been
carried out for more than 60 working hard-coal mines and preparation plants,
while complex development of the new Rybnik Coal Region has been com-
pleted, complex development of the Lublin Coal Region is currently being
implemented, and the development of the Upper Silesian Coal Basin is a con-
tinuing process. Working to Polish designs and with the active assistance of
Polish mining experts, new mines and various mining facilities have been
built or are in the course of construction in many foreign countries. Poland
has gained a place in the forefront, not only as a coal producer and exporter,
but also as an originator and exporter of technical mining know-how, par-
ticularly in the field of the design and construction of hard-coal mines.
My 25 years of practical experience in mine design, in the supervision of
mining investment implementation both at home and abroad, and also in
directing the activities of the Chief Mine Design and Studies Office in Poland,
plus more than 20 years' teaching experience in the training of mining en-
gineers, in particular as head of the Mine Design Department of the Mining
Faculty at the Silesian Polytechnic University in Gliwice, prompted me to
write this present book, which discusses the basic problems met with in the
design of underground hard-coal mines. The book is not a classic textbook
offering a collection of formulae for the calculation of specific physical values
and giving precise principles for the selection of appropriate designs, magni-
tudes and technical parameters. All these may be found in specialist mining
textbooks. My primary endeavour here has been to deal with all those ques-
tions in mine design which have not yet been answered in mining textbook
publications and which, from my personal experience, I consider to be of
importance. Pursuing this course, I have presented the general principles
governing the design of new mines and the reconstruction of working mines,
the development of mining regions, the design of coal-preparation plant,
and energy economy in mines. Making use of the broad experience gained
by the Polish mining industry in the implementation of mining investment
projects, I have quoted several examples of technical and organizational
solutions which effectively shorten the mine construction cycle. In many of
the developing countries, difficulties are encountered in ensuring the regular
supply of the materials, equipment and spare parts essential to maintain
normal mine production. Bearing this problem in mind, I have put forward
a conception for the organization of a stores-transport system for such con-
ditions. Finally, I have given an account of the economics of mining invest-
ment.
I fully realize that the material given here by no means covers the whole
PREFACE VII
spectrum of mine design. I hope, however, that it proves of use to readers
when taking investment decisions. The book is addressed chiefly to investors
and engineers engaged in preparing plans for the development of mining
regions, plans for the construction of new mines and the reconstruction of
existing mines and preparation plants, and to students in the mining depart-
ments of technical schools and universities. I hope that the information
offered here will be of genuine practical value, and moreover that it may
stimulate the development of new ideas for design and implementation con-
cepts.
I should like to express my thanks to the colleagues and co-workers who
favoured me with their valuable help in preparing this book, and especially
to Professor Miroslaw Chudek, who reviewed it.
Jozef Pazdziora
Chapter 1
Introduction
1.1 World Prospects for Hard-Coal Production Expansion
Coal mining, initiated in the 18th century for use in the ferrous and non-
ferrous metals industries, shows a continuous dynamic development right
up to the present day and most probably will do so well beyond the 21st
century. The more than 100 years-old career of crude oil, which has revol-
utionized many technologies and sectors of industry, enabled significant devel-
opments in transport of all kinds and found a wide application as an energy
and chemical raw material, has by no means eliminated coal from the global
world energy balance. Neither has coal mining been appreciably affected by
the growth of nuclear energy over the three decades of its existence or by the
substantial increase in natural gas production.
Although both these energy sources play an increasingly important role
they have not seriously challenged coal's share in meeting the escalating world
energy demand. Furthermore, as no effective substitute for coking coal has
yet been found, its production is essential for the metallurgical industry.
In the 'fifties and 'sixties certain circles in Western countries confidently
prophesied the "twilight of coal". This prophesy was based on a belief in the
infinite potential of nuclear energy and an uncritical fascination with the
apparently unlimited availability and low price of crude oil on world markets
at that time. The well-known political events of 1973, with their economic
repercussions for importers of crude oil, forced a reappraisal of oil strategies
and practical measures were taken to meet the crude-oil demand. As a con-
sequence, the role and importance of coal took on a new look (or more pre-
cisely regained its "old" look) in the current and future world energy balance.
The practical development prospects for nuclear energy give no support to
the voices proclaiming the "twilight of coal". The need for rational expansion
2 INTRODUCTION Ch. 1
of coal production is at present generally accepted and, although opinions may
differ as to optimum projected growth of production, the necessity for such
growth is no longer questioned.
The most reliable projections for the future of hard coal appear to be those
found in the data presented by World Coal Study—WOCOL, which have
been used to a certain extent in this book.
Factors favouring the expansion of coal production are both the growing
demand for energy raw materials and the large coal reserves. Coal now takes
second place after crude oil in supplying world requirements for energy raw
materials. In 1977 world hard-coal production was about 2500 million tonnes
and its share in the world energy balance was about 26%. At that time
the share of the remaining energy raw materials and sources was as follows:
crude oil—50%, natural gas—17%, hydroenergy—4.6% and nuclear energy—
2.4%.
In 1981 world coal production was about 2800 million tonnes, of which
some 40% was utilized in economically developed Western countries, 55% in
the Socialist countries and about 5% in developing countries. Figures showed
a clear increase in the share of coal and a marginal increase in that of hydro-
and nuclear energy at the expense of crude oil and natural gas (no exact
and reliable data available).
Long-term prognoses (up to the year 2000) foresee a considerable increase
in the share of coal in meeting world energy needs and an appreciable decrease
for the remaining energy raw materials and sources. Two variants of increase
in coal demand are considered, i.e. moderate and large. It is estimated that
assuming moderate increase in demand for coal, its share in meeting the
increased world energy requirements in the year 2000 will be 37% and the
corresponding figures for the remaining energy raw materials and sources
will be: crude oil—10%, natural gas—8%, hydroenergy—13% and nuclear
energy—32%. The large variant demand predicts an increase of 55% for coal
assuming a reduction of 20% for crude oil and maintaining the increase of
32% for nuclear energy. Should nuclear energy's share drop by 10% then
that of coal would increase to 67%. This means that in the year 2000 the share
of hard coal in the world energy balance will be over 35% for moderate de-
mand and 40% or even 43% for large demand.
Projections up to the year 2000 show an increase in hard coal consumption
from about 2500 million tonnes in 1977 and about 2800 million tonnes in
1981 to 6000-7000 million tonnes. This increased demand for coal will take
various forms in different parts of the world. For member countries of the
Organization of Economic Cooperation and Development (Canada, USA,
Denmark, Finland, France, FRG, Italy, Holland, Sweden, United Kingdom
WORLD PROSPECTS FOR HARD-COAL PRODUCTION 3
and the remaining Western European countries, also Japan and Australia)
demand for steam coal will rise from about 740 million tonnes in 1977 to
about 1670 million tonnes (moderate variant) or about 2650 million tonnes
(large variant) in the year 2000. As an example, figures are given for 1977
and 2000 (both variants) in million tonnes:
1977 2000
moderate large
variant variant
Canada 18.0 67.0 106.0
USA 432.0 975.0 1590.0
Italy 2.4 19.5 48.5
Japan 10.0 64.0 132.0
Australia 29.7 124.0 149.0
Similarly, a two- or threefold overall increase in demand for coal (steam
and coking) from the OECD countries is foreseen, i.e. an increase from about
990 million tonnes in 1977 and about 1180 million tonnes in 1981 to about
2000 million tonnes (moderate demand) or 3000 million tonnes (large demand)
in the year 2000.
Countries outside OECD utilized about 1500 million tonnes of steam coal
in 1977, the biggest consumers being: USSR (490 million tonnes), People's
Republic of China (368 million tonnes), Poland (159 million tonnes), India
(72 million tonnes), and South Africa (61 million tonnes). It is expected that
the total demand for coal (steam and coking) for countries outside OECD
will increase by the year 2000 to 3-4 thousand million tonnes and the corre-
sponding figures for the developing countries will be: about 150 million
tonnes in 1977 to about 600-700 million tonnes in the year 2000. In this period
the People's Republic of China plans to reach an annual coal production of
1.5 thousand million tonnes while the figure for the Socialist countries is
1.5-2 thousand million tonnes. Poland plans to produce about 260 million
tonnes of hard coal in the year 2000.
Table 1.1 shows world coal producers and level of coal production in the
years 1977, 1981 and projected production for the year 2000 taking the large
coal demand variant for the year 2000.
Bearing in mind the escalating world demand for energy, in a situation
where alternative energy sources suffer from lack of availability, inadequate
development or lack of technical/economic feasibility of production develop-
ment, the substantial proved resources of coal and advanced technology
speak clearly in favour of hard-coal production expansion.
4 INTRODUCTION Ch. 1
TABLE 1.1 World hard-coal production
Coal production, million t % of world total
Country or region
1977 1981 2000 1977 1981 2000
Canada 23 33.3 159 0.94 1.19 2.3
United States 560 697.4 1883 22.9 24.87 27.8
Total North America 583 730.7 204.2 23.8 26.06 30.1
Denmark <1 <0.1
France 21 20.3 10 0.85 0.72 0.15
FRG 120 95.5 150 4.85 3.39 2.23
Italy <1 <1 3 <0.1 <0.1 <0.1
Great Britain 108 127.4 162 4.37 4.53 2.4
Other western Euro-
pean countries 38 25.4 101 1.54 0.93 1.5
Japan 18 17.7 18 0.72 0.62 0.26
Australia 76 92.1 326 3.07 3.27 4.84
Total OECD coun-
tries 964 1110.1 2813 39.0 39.47 41.84
South Africa 73 131.2 228 2.95 4.66 3.39
India 72 121.1 285 2.91 4.30 4.23
Indonesia <1 <1 20 <0.1 <0.1 0.29
Asian countries j 15 , 68.3 11 0.6 2.42 0.16
Africa and Latin
America 25 24.4 180 1 0.86 2.67
People's Republic of
China 373 598.6 1450 15.1 21.28 21.57
Poland 186 163 260 7.53 5.79 3.86
USSR 510 544.2 1100 20.6 19.35 16.36
Other socialist coun-
tries 250 50 375 10.1 1.77 5.57
World total 2469 2812 6722 100 100 100
Table 1.2 gives world geological and industrial hard-coal reserves for the
latter half of the seventies. The figures may be taken as approximately true
also for the mid-eighties since losses due to extraction have no doubt been
compensated for by the increase in reserves resulting from geological pros-
pecting. According to the World Coal Study (WOCOL) total world hard-
coal production in the period 1977-2000 will reach 103 thousand million
tonnes, assuming large coal demand (variant two). This means that in this