• Energy Research

The determination of methane content of coal seams is conducted in hard coal mines in order to assess the state of methane hazard but also to evaluate gas resources in the deposit. In the world’s mining industry, natural gas content in coal determination is usually based on direct methods. It remains the basic method in Poland as well. An important element in the determination procedure is the gas loss that occurs while collecting a sample for testing in underground conditions. In the method developed by the authors, which is a Polish standard, based on taking a sample in the form of drill cuttings, this loss was established at a level of 12%. Among researchers dealing with the methane content of coal, there are doubts related to the procedures adopted for coal sampling and the time which passes from taking a sample to enclosing it in a sealed container. Therefore, the studies were designed to evaluate the degree of degassing of the sample taken in the form of drill cuttings according to the standard procedure and in the form of the drill core from a coal mine roadway. The results show that the determinations made for the core coincide with the determinations made for the drill cutting samples, with the loss of gas taken into account.

Transporting materials and mine staff is a vital link necessary to the production process in underground mines. Deteriorating climatic conditions, mainly due to the increasingly deep mining and the usage of machines, force us to look for solutions to improve the underground mine environmental situation. Another essential factor responsible for deteriorating working conditions is harmful substances and exhaust fumes emitted from diesel engines. Supplying the workplaces with air quantity exceeding requirements such as the minimum velocity of air movement or gas and climatic conditions will allow for maintaining the gas concentration at the appropriate level. One possible way to solve the problems mentioned above is to replace suspended monorails powered by internal combustion engines with new solutions of electrically battery-powered monorails. Electric monorails are not yet widely used in mines; nevertheless, they have many advantages. This article analyzes the exhaust gas parameters from monorail locomotives operating in a hard coal mine and determines the required airflow to maintain permissible concentrations of harmful gases. It also focuses on a comparative analysis of climatic conditions in the development heading, considering the roadway’s functioning with and without using diesel or electric monorail. The study consists of the methodology for predicting climate conditions. Based on the performed analysis, it was shown that using electric monorails could significantly improve working conditions.

Several natural threats characterize hard coal mining in Poland. The coexistence of methane and rock-burst hazards lowers the safety level during exploration. The most dangerous are high-energy bumps, which might cause rock-burst. Additionally, created during exploitation, safety pillars, which protect openings, might be the reason for the formation of so-called gas traps. In this part, rock mass is usually not disturbed and methane in seams that form the safety pillars is not dangerous as long as they remain intact. Nevertheless, during a rock-burst, a sudden methane outflow can occur. Preventing the existing hazards increases mining costs, and employing inadequate measures threatens the employees’ lives and limbs. Using two longwalls as examples, the authors discuss the consequences of the two natural hazards’ coexistence. In the area of longwall H-4 in seam 409/4, a rock-burst caused a release of approximately 545,000 cubic meters of methane into the excavations, which tripled methane concentration compared to the values from the period preceding the burst. In the second longwall (IV in seam 703/1), a bump was followed by a rock-burst, which reduced the amount of air flowing through the excavation by 30 percent compared to the airflow before, and methane release rose by 60 percent. The analyses presented in this article justify that research is needed to create and implement innovative methods of methane drainage from coal seams to capture methane more effectively at the stage of mining.

Underground excavations in which an airflow is present are affected by both natural and technological sources of heat. As a result, the air flowing through the mine excavations is characterised by high temperatures, which—combined with high humidity—causes microclimatic conditions to deteriorate. Bad microclimatic conditions affect miners underground, causing a reduction of perception, concentration, attention, and perceptiveness. This negative influence of temperature and humidity on the human body is referred to as the climatic hazard. For this reason, the design of ventilation and air conditioning systems to be implemented in underground mining plants is an issue of increasing significance. This article investigates the performance of cooling systems in the Polish hard-coal mining industry. Based on the conducted research on air-cooling installations in six hard-coal mines, the actual efficiency of air-cooling is presented. The calculated values of cooling power were compared with the design intent. The obtained results have allowed identifying with greater precision the factors that diminish the efficiency of cooling systems in the mining plants under analysis. These factors may be treated on equal terms with key performance indicators (KPIs), which can be used to monitor the performance of cooling system components and to provide managers with high-level indicators on which decisions can be based.

Carrying out exploitation in coal mines with a methane hazard imposes the use of special procedures and the analyses of numerous parameters in order to secure mining teams working underground. The article presents a method of coal seam exploitation design under conditions of a methane hazard for the newly prepared coal seams 404/1 and 403/1 in the years 2022 to 2030 in a coal mine in southern Poland as a case study. It primarily focuses on the preparation of the methane hazard prognosis. When adequately prepared, this is key to correctly designing the mining system in the newly opened parts of the deposit. Based on the obtained results, the appropriate methane drainage system and detection systems can be selected. The calculations led to the definition in which the longwall panel emissions of methane would be the highest. The estimates showed that, from 2022 to the beginning of 2028, even methane emissions between approximately 30 m3/min and 45 m3/min are forecast, with a significant increase for half of 2028 to a value between 57.58 m3/min and 100.00 m3/min. The highest value of methane emission was forecast for the A4 and A5 longwall panels in the 403/1 coal seam at 13.53 and 49.67 m3/min, respectively, and for the A2 and B1 longwall panels in the 404/1 seam at 41.85 m3/min and 25.46 m3/min, all with advance equal 7 m/d. Therefore, a drainage system will be required in all designed longwall panels. Considering the methane emission into the longwalls and the designed U-type ventilation, the calculated drainage effectiveness will vary between 38.3 and 40.6%. Higher effectiveness values require the application of a U-type ventilation with drainage, which allows obtaining effectiveness reaching 60.2%, with the methane emission between 20 and 30 m3/min, or even up to 62.6%, with the methane emission at the level of 30–40 m3/min. Another critical design stage is utilizing the gathered methane; the proposition is to use it in the cogeneration system. The heat generated by gas-powered engines should be used in the absorbent coolers that are used for chilling the water for the central air-conditioning system of the mine.

Methane present in coal seams is a natural hazard present during the exploitation of underground mining plants. It is an explosive and flammable gas that is released into mining excavations, and it is necessary to reduce its concentration. Capturing methane while preparing extraction is virtually impossible due to the low permeability of coal resulting from its deposition depth. After the beginning of exploitation and disrupting the seam’s structure, methane is released into mine air. The most common method of minimizing gas released into ventilation air is draining the rock mass. This method allows achieving the desired ventilation parameters but requires appropriate mining techniques in hazardous areas. The article presents the example of methane capture during the operation in the longwall B-15 with an overlying drainage gallery. The authors have highlighted an example of the longwall B-15 that when using this particular drainage method, allowed capturing twice the amount of methane forecasted, thus increasing the efficiency of methane drainage. At the preliminary stage of longwall development, the amount of methane charged by the drainage system had relatively low values, reaching 15 m3/min. In the next few months, these parameters increased and varied between 35 to 55 m3/min. A significant difference in methane capture appeared in the second stage of exploitation, where the highest value of captured methane reached 82 m3/min. This particular longwall example shows that it is crucial to properly design the drainage system for seams with high forecasted methane release. It is worth remembering that using a drainage gallery provides an increase in the methane capture from the desorption zone areas, thus increasing total methane capture in comparison to forecasts.

Ventilation plays a key role in underground mining. It is essential due to the natural hazards and technological processes that come with the nature of mining. However, it is highly energy consuming and generates significant operating expenditures. Fan station parameters are selected based on the needs of a particular mine but mainly consider the requirements for the period of developed mining activities. When the period of mine decommissioning begins, the parameters of the main fan station often exceed its needs. In Poland, many mines have been closed in recent years. However, sometimes, due to the necessity of pumping underground water, it cannot be done thoroughly. In such a situation, it usually turns out that the parameters of the existing fan station significantly exceed the mine’s needs. The main fan stations are devoid of control systems, and even if they have them, they do not allow for a significant reduction of their volume flow rate. Modernising of the station to meet new requirements of the mine is expensive and time consuming. Solving the presented problem is possible by developing a fan station to replace main fans that are too big. The idea is easy to implement and consists of connecting it to an existing upcast shaft or downcast shaft, which will then be changed to upcast. The solution presented in the article has been implemented in two Polish coal mines and is in progress in a third mine. The examples presented in the article clearly show the energy benefits of replacing main fans that are too large.

The article compares the climate conditions in an excavation with thermally insulated roof and sidewalls to the conditions when such insulation is absent. The analysis of the temperatures presented in the article consisted of limiting the heat transfer from the rock mass to the heading in one of the Polish coal mines. It is widely believed that the thermal insulation of heading sidewalls, through which fresh air is supplied, can substantially improve climate conditions. The article’s objective is to evaluate the impact of thermal insulation on the surface of the roof and sidewalls on the reduction in heat transfer from the strata with a high virgin temperature to mine air. Preventing the existing climate hazard involves higher costs of coal extraction, whereas the consequences of inadequate prevention threaten the health or life of the miners.