The goal of coal mining is to remove coal from the ground. Coal is valued for its energy content, and since the 1880s is widely used to generate electricity. Steel and cement industries use coal as a fuel for extraction of iron from iron ore and for cement production. In the United States, United Kingdom, and South Africa, a coal mine and its structures are a "colliery". In Australia, "colliery" generally refers to an underground coal mine.
Coal-cutting machines were invented in the 1880s. Before the invention, coal was mined from underground with a pick and shovel. By 1912 surface mining was conducted with steam shovels designed for coal mining.
The most economical method of coal extraction from coal seams depends on the depth and quality of the seams, and the geology and environmental factors. Coal mining processes are differentiated by whether they operate on the surface or underground. Many coals extracted from both surface and underground mines require washing in a coal preparation plant.
Technical and economic feasibility are evaluated based on: regional geologic conditions; overburden characteristics; coal seam continuity, thickness, structure, quality, and depth; strength of materials above and below the seam for roof and floor conditions; topography (especially altitude and slope); climate; land ownership as it affects the availability of land for mining and access; surface drainage patterns; ground water conditions; availability of labor and materials; coal purchaser requirements in terms of tonnage, quality, and destination; and capital investment requirements.
Surface mining and deep underground mining are the two basic methods of mining. The choice of mining method depends primarily on depth of burial, density of the overburden and thickness of the coal seam. Seams relatively close to the surface, at depths less than approximately 180 ft (50 m), are usually surface mined. Coal that occurs at depths of 180 to 300 ft (50 to 100 m) are usually deep mined but, in some cases, surface mining techniques can be used. For example, some western U.S. coal that occur at depths in excess of 200 ft (60 m) are mined by open pit methods, due to thickness of the seam 60–90 feet (20–30 m). Coals occurring below 300 ft (100 m) are usually deep mined. Although there are open pit mining operations working on coal seams up to 1000–1500 feet (300–450 m) below ground level, for instance Tagebau Hambach.
When coal seams are near the surface, it may be economical to extract the coal using open cut (also referred to as open cast, open pit, or strip) mining methods. Open cast coal mining recovers a greater proportion of the coal deposit than underground methods, as more of the coal seams in the strata may be exploited. Large Open Cast mines can cover an area of many square kilometers and use very large pieces of equipment. This equipment can include the following: Draglines which operate by removing the overburden, power shovels, large trucks in which transport overburden and coal, bucket wheel excavators, and conveyors.
In this mining method, explosives are first used in order to break through the surface, or overburden, of the mining area. The overburden is then removed by draglines or by shovel and truck. Once the coal seam is exposed, it is drilled, fractured and thoroughly mined in strips. The coal is then loaded on to large trucks or conveyors for transport to either the coal preparation plant or directly to where it will be used.
Equipment to be used depends on geologic conditions. For example, to remove overburden that is loose or unconsolidated, a bucket wheel excavator might be the most productive. The life of some area mines may be more than 50 years.
The contour mining method consists of removing overburden from the seam in a pattern following the contours along a ridge or around a hillside. This method is most commonly used in areas with rolling to steep terrain. It was once common to deposit the spoil on the downslope side of the bench thus created, but this method of spoil disposal consumed much additional land and created severe landslide and erosion problems. To alleviate these problems, a variety of methods were devised to use freshly cut overburden to refill mined-out areas. These haul-back or lateral movement methods generally consist of an initial cut with the spoil deposited downslope or at some other site and spoil from the second cut refilling the first. A ridge of undisturbed natural material 15 to 20 ft (5–6 m) wide is often intentionally left at the outer edge of the mined area. This barrier adds stability to the reclaimed slope by preventing spoil from slumping or sliding downhill.
The limitations on contour strip mining are both economic and technical. When the operation reaches a predetermined stripping ratio (tons of overburden/tons of coal), it is not profitable to continue. Depending on the equipment available, it may not be technically feasible to exceed a certain height of highwall. At this point, it is possible to produce more coal with the augering method in which spiral drills bore tunnels into a highwall laterally from the bench to extract coal without removing the overburden.
Mountaintop coal mining is a surface mining practice involving removal of mountaintops to expose coal seams, and disposing of associated mining overburden in adjacent "valley fills." Valley fills occur in steep terrain where there are limited disposal alternatives. Mountaintop removal combines area and contour strip mining methods. In areas with rolling or steep terrain with a coal seam occurring near the top of a ridge or hill, the entire top is removed in a series of parallel cuts. Overburden is deposited in nearby valleys and hollows. This method usually leaves ridge and hill tops as flattened plateaus. The process is highly controversial for the drastic changes in topography, the practice of creating head-of-hollow-fills, or filling in valleys with mining debris, and for covering streams and disrupting ecosystems.
Room and pillar mining consists of coal deposits that are mined by cutting a network of rooms into the coal seam. Pillars of coal are left behind in order to keep up the roof. The pillars can make up to forty percent of the total coal in the seam, however where there was space to leave head and floor coal there is evidence from recent open cast excavations that 18th century operators used a variety of room and pillar techniques to remove 92% of the in situ coal. However, this can be extracted at a later stage (see Retreat Mining, below).
Most coal seams are too deep underground for opencast mining and require underground mining, which method currently accounts for about 60% of world coal production. In deep mining, the room and pillar or bord and pillar method progresses along the seam, while pillars and timber are left standing to support the mine roof. Once room and pillar mines have been developed to a stopping point (limited by geology, ventilation, or economics), a supplementary version of room and pillar mining, termed second mining or retreat mining, is commonly started. Miners remove the coal in the pillars, thereby recovering as much coal from the coal seam as possible. A work area involved in pillar extraction is called a pillar section. Modern pillar sections use remote-controlled equipment, including large hydraulic mobile roof-supports, which can prevent cave-ins until the miners and their equipment have left a work area. The mobile roof supports are similar to a large dining-room table, but with hydraulic jacks for legs. After the large pillars of coal have been mined away, the mobile roof support's legs shorten and it is withdrawn to a safe area. The mine roof typically collapses once the mobile roof supports leave an area.
There are five principal methods of underground mining:
- Longwall mining accounts for about 50% of underground production. The longwall shearer has a face of 1,000 feet (300 m) or more. It is a sophisticated machine with a rotating drum that moves mechanically back and forth across a wide coal seam. The loosened coal falls on to a pan line that takes the coal to the conveyor belt for removal from the work area. Longwall systems have their own hydraulic roof supports which advance with the machine as mining progresses. As the longwall mining equipment moves forward, overlying rock that is no longer supported by coal is allowed to fall behind the operation in a controlled manner. The supports make possible high levels of production and safety. Sensors detect how much coal remains in the seam while robotic controls enhance efficiency. Longwall systems allow a 60-to-100% coal recovery rate when surrounding geology allows their use. Once the coal is removed, usually 75 percent of the section, the roof is allowed to collapse in a safe manner.
- Continuous mining utilizes a machine with a large rotating steel drum equipped with tungsten carbide teeth that scrape coal from the seam. Operating in a “room and pillar” (also known as “bord and pillar”) system—where the mine is divided into a series of 20-to-30 foot (5–10 m) “rooms” or work areas cut into the coalbed—it can mine as much as five tons of coal a minute, more than a non-mechanised mine of the 1920s would produce in an entire day. Continuous miners account for about 45% of underground coal production. Conveyors transport the removed coal from the seam. Remote-controlled continuous miners are used to work in a variety of difficult seams and conditions, and robotic versions controlled by computers are becoming increasingly common. Continuous mining is truly a misnomer, as room and pillar coal mining is very cyclical. In the US, one can generally cut 20 ft (or a bit more with MSHA permission), after which, the face has to be serviced, before it can be advanced again. During servicing, the "continuous" miner moves to another face. Some continuous miners can bolt and dust the face (two major components of servicing) while cutting coal, while a trained crew may be able to advance ventilation, to truly earn the "continuous" label. However, very few mines are able to achieve it. Most continuous mining machines in use in the US lack the ability to bolt and dust. This may partly be because incorporation of bolting makes the machines wider, and therefore, less maneuverable.
- Blast mining or conventional mining, is an older practice that uses explosives such as dynamite to break up the coal seam, after which the coal is gathered and loaded on to shuttle cars or conveyors for removal to a central loading area. This process consists of a series of operations that begins with “cutting” the coalbed so it will break easily when blasted with explosives. This type of mining accounts for less than 5% of total underground production in the U.S. today.
- Shortwall mining, a method currently accounting for less than 1% of deep coal production, involves the use of a continuous mining machine with movable roof supports, similar to longwall. The continuous miner shears coal panels 150–200 feet (40–60 m) wide and more than a half-mile (1 km) long, having regard to factors such as geological strata.
- Retreat mining is a method in which the pillars or coal ribs used to hold up the mine roof are extracted; allowing the mine roof to collapse as the mining works back towards the entrance. This is one of the most dangerous forms of mining owing to imperfect predictability of when the ceiling will collapse and possibly crush or trap workers in the mine.
Coal production has grown fastest in Asia, while Europe has declined. The top coal mining nations (figures in brackets are 2009 estimate of total coal production in millions of tons) are:
- China (3,050 Mt)
- USA (973 Mt)
- India (557 Mt)
- Australia (409 Mt)
- South Africa (250 Mt)
- Russia (298 Mt)
- Indonesia (252 Mt)
- Poland (135 Mt)
- Kazakhstan (101 Mt)
- Colombia (72 Mt)
Technological advancements have made coal mining today more productive than it has ever been. To keep up with technology and to extract coal as efficiently as possible modern mining personnel must be highly skilled and well trained in the use of complex, state-of-the-art instruments and equipment. Many jobs require four-year university degrees. Computer knowledge has also become greatly valued within the industry as most of the machines and safety monitors are computerized. The use of sophisticated sensing equipment to monitor air quality is common and has replaced the use of small animals such as canaries, often referred to as "miner's canaries".
In lesser developed countries and some developing countries, many miners continue to die annually, either through direct accidents in coal mines or through adverse health consequences from working under poor conditions. China, in particular, has the highest number of coal mining related deaths in the world, with official statistics claiming that 6,027 deaths occurred in 2004. To compare, 28 deaths were reported in the U.S. in the same year. Coal production in China is twice that in the U.S., while the number of coal miners is around 50 times that of the USA, making deaths in coal mines in China 4 times as common per worker (108 times as common per unit output) as in the USA.
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