Mining system

Description

FIELD OF THE INVENTION

[0002] The present invention relates, in general, to a mining system for extracting mineral deposits, and more specifically, but without limitation, to a mining system utilizing a combination of surface contour mining and underground shortwall or longwall mining systems.

BACKGROUND OF THE INVENTION

[0003] Conventional surface mining systems have devastating environmental results. In hilly or mountainous regions, surface contour mining is accomplished by removing timber and clearing the area to be mined, making a strip cut to form a substantially horizontal bench and a vertical highwall that exposes the seam of mineral deposits to be removed. Another technique is to simply remove the entire top portion of the mountain to extract the minerals deposited below.

[0004] Underground mining systems are less damaging to the environment, but more costly and inefficient with lower production rates. When underground mining systems are used to extract mineral or coal deposits from a mineral or coal reserve 10, the reserve 10 is divided into panels 12 as shown in FIG. 1 which are laid out and developed for both shortwall mining and longwall mining operations. Coal reserves conducive to mining adjacent parallel panels (Panels 1 to 8 as shown in FIG. 1) are most desirable because they facilitate panel development and allow shorter equipment moves. As can be seen, the panels 12 are generally rectangular in shape having gate entries 14 (a headgate and tailgate) extending along each length, and are all connected at one end by main entries 16. In modern mining systems, these panels 12 are developed using continuous miner units. In modern longwall mining systems, panels typically range from 400 to 1200 feet in width and from 4,000 to 15,000 feet in length. In modern shortwall mining systems, the shortwall panels typically range from 100 to 200 feet in width and from 2,000 to 4,000 feet in length. Production of coal or other sedimentary deposits begins at one end of the panel 12, the starter entry 18, to mine the seam along its face or wall in the direction indicated by the arrow 19.

[0005] Referring more specifically to FIG. 2, panel 1 of FIG. 1 is shown in more detail as panel 20 having headgate entries 22a-c, collectively the headgate 22, and the tailgate entries 24a-c, collectively the tailgate 24, referred to above. While the direction of mining proceeds in the direction indicated by the arrow 19, production or plowing of the coal always proceeds from the headgate 22 to the tailgate 24 in the direction shown by the arrow 25 for both longwall and shortwall mining systems as will be described below in more detail. A “three-entry” development system utilizes the three maingate entries 16a-c, collectively the maingate 16, the three headgate entries 22a-c, and the three tailgate entries 24a-c that are commonly used to provide the necessary airways and escapeways and other functions. The system permits installation of belt and track in the center entry, and allows one outer entry to be used as a return airway. This system is complex and expensive to develop, and is well-known in the mining business.

[0006] Upon completing development of the panels 12, the longwall or shortwall mining of the panel 20 commences as shown in FIGS. 3 and 4, respectively. Referring more specifically to FIG. 3, longwall machinery 30 and miners are protected by roof supports 32, 33 designed to withstand tremendous overburden pressures. The material containing the minerals is cut from the face of the seam by a plough or shearer 34 of the longwall machinery 30 and drops onto an armored chain conveyor system (not shown) for transport to a main conveyor system 36, which in turn transports the material to the surface. As successive cuts are made along the face of the seam from the headgate 22 to the tailgate 24 in the direction of production indicated by the arrow 25, the roof supports 32, 33 and armored chain conveyor are advanced into the seam in the direction of mining indicated by the arrow 19, allowing the overburden to collapse or cave-in behind the roof supports 32,33 to form what is known as a gob 38 of loosely-packed material. The roof supports 32,33 not only advance in the mining direction, but also are extendable as known in the art with the supports 32 being shown in the extended configuration and the supports 33 being shown in the retracted configuration.

[0007] Referring more specifically to FIG. 4, shortwall machinery 40 and miners are also protected by roof supports 42,43 designed to withstand tremendous overburden pressures. Unlike the longwall miner which ploughs the seam parallel to its face, a shortwall miner cutting head 44 of the shortwall machinery 40 which is approximately 10 to 12 feet in width plows in a direction generally perpendicular to the face of the seam and drops the material onto an armored chain conveyor system (not shown) or mobile shuttle cars for transport to a main conveyor systems 46, which in turn transports the material to the surface. As successive cuts are made along the face of the seam from the headgate 22 to the tailgate 24 in the direction of production indicated by the arrow 25, the roof supports 42,43 and armored chain conveyor are advanced into the seam in the direction of mining indicated by the arrow 19, allowing the overburden to collapse or cave behind the roof supports 42,43 forming the gob 48. The roof supports not only advance in the mining direction as shown by supports 42a and 42b, but also are extendable as known in the art with supports 42 being shown in the extended configuration and supports 43 being shown in the retracted configuration. The shortwall mining system requires significantly less capital and is more flexible in handling geological conditions that vary through the mineral reserve. The only significant disadvantage of the shortwall mining system is that the production rate is somewhat lower as compared to the longwall mining system.

[0008] It should be apparent from the above, the primary problem associated with underground longwall and shortwall mining systems is the cost and time associated with developing and creating the panels, and then moving either system from panel to panel underground to mine the entire mineral reserve 10. The moves from panel to panel result in many days of downtime at a high cost to the mining operation. The ingress and egress entries and ventilation associated with the system are all expensive. Time travel to the seam face for the miners is also a significant cost associated with these systems.

[0009] Moreover, federal legislation (e.g., Clean Water Act) restricts the use of waste rock produced by large scale surface mining systems as “fill material” legitimately disposed of at other locations. Recent court decisions have held that excess spoil generated by mining operations is waste that does not qualify as fill material that can disposed of as valley fills. Thus, the disposal of excess spoil is a significant problem.

[0010] Finally, certain mining areas may have property limitations, such that only one side of the mining area is controlled through lease or ownership, while the other side of the mining area is not controlled. This creates a tremendous burden on miners who wish to utilize mineral reserves under their control.

SUMMARY OF THE INVENTION

[0011] Apparatus and method for extracting mineral deposits is provided by combining surface contour mining with underground longwall or shortwall mining techniques. More specifically, such apparatus and method uses surface contour mining to create a staging bench and highwall for inserting either shortwall or longwall mining equipment into the seam of a mineral reserve to commence a continuous mining operation without the need for developing separate underground panels. The highwall formed at the point of insertion, the insertion highwall, extends between opposing highwalls formed on either side of the insertion highwall and generally in parallel to the direction of production and perpendicular to the direction of mining. A continuous miner is used to develop a starter entry cut into the seam extending along the entire length of the insertion highwall. Roof supports are advanced into the starter entry cut as formed by the continuous miner across the insertion highwall, and are then covered with spoil as they advance into the starter entry cut to form a starter passage sealed at both ends by a canopy. The longwall or shortwall mining commences inside the starter passage moving in either direction between the opposing highwalls that operate as “endgates” and function as either a headgate or a tailgate for the mining system depending upon the direction of production travel.

[0012] The above-identified problems are solved because the mining system is easily inserted, accessed and extracted from the surface by means of stable opposing highwalls and bench area created by contour surface mining. In addition to reducing the move time, such apparatus and method nearly eliminates travel time of the miners to the face of the seam and eliminates the need for developing panels and entries to the panels. Ingress and egress entries and ventilation entries are all much simpler and more efficient because they are provided at the opposing highwalls formed above ground on the bench rather than underground moving with successive passages formed therebetween by the face of the seam, the roof support, and the gob as the mining progresses into the seam.

[0013] Additionally, the mining operation is not restricted to production from the headgate to the tailgate, but can be adapted to move back and forth in both directions between the opposing highwalls on both sides of the ridge or mountain with full seam extraction across the entire length of the face. This eliminates the need for development entries and permanent roof supports and simplifies face ventilation. Furthermore, roof supports can be easily added or removed from the mining system to accommodate changes in the face width of the entire mineral deposit of the mineral reserve. The instant invention also reduces the volume of excess spoil that must be disposed of as a result of the mining operation.

[0014] Both sides of the mineral reserve must be accessible to form opposing highwalls on both sides of the insertion highwall. If both sides are not accessible, e.g., blocked by an adverse property line, geological anomaly, or other physical barrier, then a continuous or single gate entry is formed as a continuous underground tunnel or gate to replace one of the opposing highwalls and function as an endgate for the inaccessible side of the mineral reserve in accordance with the principles of the present invention. The single gate entry functions as either a headgate or a tailgate for the mining system in the same way as the opposing highwall being replaced. According to the principles of the present invention, the shortwall continuous miner commences formation of the single gate entry by cutting into the end portion of the insertion highwall adjacent the inaccessible side of the mineral reserve to create effectively an opposing highwall or face along the inaccessible side of the mineral reserve.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] A more complete understanding of the method and apparatus of the present invention may be obtained by reference to the following Detailed Description, with like reference numerals denoting like elements, when taken in conjunction with the accompanying Drawings wherein:

[0016]
FIG. 1 is a top plan view of an exemplary mineral reserve laid out in parallel panels;

[0017]
FIG. 2 is an enlarged top plan view of one of the panels of the mineral reserve of FIG. 1;

[0018]
FIG. 3 is an enlarged top plan, partial view of the panel of FIG. 2 after the commencement of longwall mining;

[0019]
FIG. 4 is an enlarged top plan, partial view of the panel of FIG. 2 after the commencement of shortwall mining;

[0020]
FIG. 5 is an enlarged top plan view of the mining system according to one embodiment of the present invention;

[0021]

FIG. 5

a
is a cross-sectional view taken along line 5a-5a of FIG. 5;

[0022]
FIG. 6 is an enlarged top plan view of the mining system of FIG. 5 during an initial setup and equipment insertion phase according to one embodiment of the present invention;

[0023]

FIG. 6

a
is a cross-sectional view taken along line 6a-6a of FIG. 6;

[0024]

FIGS. 7

a
and 7b are respective front and side views of an embodiment of an intake canopy; and

[0025]

FIGS. 8

a
and 8b are respective front and side views of an embodiment of an exhaust canopy.

[0026]
FIG. 9 is a top plan view of an initial production phase according to one embodiment of the present invention, which follows the initial setup and equipment insertion phase of FIG. 6;

[0027]

FIG. 9

a
is a cross-sectional view taken along line 9a-9a of FIG. 9;

[0028]
FIG. 10 is a top plan view of an exemplary initial system reversal phase according to one embodiment of the present invention, which follows the initial production phase of FIG. 9;

[0029]

FIG. 10

a
is a cross-sectional view taken along line 10a-10a of FIG. 10;

[0030]
FIG. 11 is a top plan view of a full production phase according to one embodiment of the present invention, which follows the initial system reversal phase of FIG. 10;

[0031]

FIG. 11

a
is a cross-sectional view taken along line 11a-11a of FIG. 11;

[0032]
FIG. 12 is a top plan view of an equipment extraction phase according to one embodiment of the present invention, which follows the full production phase of FIG. 11;

[0033]

FIG. 12

a
is a cross-sectional view taken along line 12a-12a of FIG. 12;

[0034]
FIG. 13 is a top plan view of an embodiment of the present invention utilizing a longwall miner;

[0035]

FIG. 13

a
is a cross-sectional view taken along line 13a-13a of FIG. 13;

[0036]
FIG. 14 is an overall plan view of an alternate embodiment of a mining system according to the principles of the present invention;

[0037]
FIG. 15 is a top plan view of the mining system of FIG. 14 during an initial setup and equipment insertion phase according to one embodiment of the present invention;

[0038]

FIG. 15

a
is a cross-sectional view taken long the line 15a-15a of FIG. 15;

[0039]
FIG. 16 is a top plan view of an initial production phase according to one embodiment of the present invention, which follows the initial setup and equipment insertion phase of FIG. 15;

[0040]
FIG. 17 is a top plan view of an exemplary initial uni-gate extension phase according to one embodiment of the present invention, which follows the initial production phase of FIG. 16;

[0041]
FIG. 18 is a top plan view of the exemplary initial production phase of FIG. 16, following the uni-gate extension phase of FIG. 17;

[0042]
FIG. 19 is a top plan view of an exemplary initial system reversal phase according to one embodiment of the present invention, which follows the initial production phase of FIG. 18;

[0043]

FIG. 19

a
is a cross-sectional view taken along the line 19a-19a of FIG. 19.

[0044]
FIG. 20 is a top plan view of a full production phase according to one embodiment of the present invention, which follows the initial system reversal phase of FIG. 19; and

[0045]
FIG. 21 is a top plan view of an equipment extraction phase according to one embodiment of the present invention, which follows the full production phase of FIG. 20.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0046] The present invention provides an economical, convenient mining system adapted to quickly and efficiently remove mineral deposits from a mineral reserve with minimal downtime. Apparatus and methods for extracting the mineral deposits are provided by combining surface contour mining with underground longwall or shortwall mining techniques. Referring more specifically to a mineral reserve 501 in FIG. 5, the mining system of the present invention utilizes surface contour mining to create a stable highwall 502 and bench area 503 around the mineral reserve 501 to allow insertion of the mining system underground. The surface contour mining, however, is conducted in stages commencing with mining area A between lines a and a′, then mining area B advancing to lines b and b′, followed by subsequent surface contour cuts advancing in increments of about 200 feet to 500 feet for each mining area to the end of the mineral reserve 501. The bench area 503 is typically between 80 to 100 feet wide.

[0047] Referring also to FIG. 5a, the mining system commences by using surface contour mining to make the initial surface contour cut in mining area A by creating a bench for supporting mining equipment, the staging bench 510, and a stable highwall to allow insertion of the equipment into a seam 504 of the mineral reserve 501 underground, the insertion highwall 520, to commence a continuous mining operation without the need for developing separate underground panels 12 (see FIG. 1). Although a longwall or shortwall mining system can be used, a shortwall continuous mining operation is disclosed in complete detail, and a longwall mining operation is disclosed (FIGS. 13 and 13a) to the extent different from the shortwall operation. Material excavated from the initial cut in mining area A will be disposed of on an existing bench or used as excess spoil fill. The height of the insertion highwall 520 may be about 40 feet with a safety bench 530 cut above the insertion highwall 520. It is important that this initial cut be laid out as straight as possible to eliminate any problems with equipment insertion underground.

[0048] Referring back to FIG. 5, the insertion highwall 520 is generally perpendicular to the direction that the mining will advance as indicated by the arrow M and generally parallel to the direction of mineral production as indicated by the double arrow P. With respect to shortwall mining, the cutting bits of the shortwall miner will be oriented in a direction generally perpendicular to arrow M. The initial surface contour cut includes a stable highwall and bench area on both sides of the staging area, i.e., the bench 550 and opposing highwall 555 on one side, and the bench 560 with opposing highwall 565 on the other side. The insertion highwall 520 extends between the opposing highwalls 555, 565. Although the system as described above proceeds generally in the direction indicated by arrow M, in certain situations, it may be necessary to shift the direction of production P as indicated by the double arrow P′ so that the production path is as short as possible. The opposing highwalls 555, 565 are still generally perpendicular to the shifted direction of mining as indicated by the arrow M′. It is appreciated that this system provides for shifts in relatively any direction, and therefore is completely adaptable to the changes in the mineral seam 504 in a selected region. Because the system is designed for quick relocation, a user can appreciate the advantages of the present system.

[0049] As the mining system advances into the mineral seam 504 (FIG. 5a), with changes in production direction being implemented in a manner as described above when necessary, contour mining continues in advance of production until the end of the mineral seam 504 is reached. The contour mining establishes an exit bench 590, which has been formed in accordance with the principles discussed above with respect to the staging bench 510. An equipment extraction highwall 540 has also been formed, and is made in accordance with the insertion highwall 520 and shown in FIG. 5A. As the miner makes its final cut through the mineral seam 504, the mining equipment is removed from the mineral reserve 501 in a manner described in more detail below. Note that the entire mineral reserve 501 does not have to be completed (i.e., the mining operation could commence with mining area A and move to mining area Z to avoid any destruction of mining area X in accordance with ordinary mining design methods).

[0050] Referring now to FIGS. 6-12a in general, there is shown differing phases for the use of the mining system according to the principles of the present invention as described above and utilizing exemplary shortwall mining techniques. Referring specifically to FIG. 6, a top plan view of the initial setup and equipment insertion phase 600 for an exemplary shortwall mining system is shown. A staging bench 610 is first formed after contour mining the mineral seam 604 in accordance with the principles discussed above. An equipment staging area 615 is formed at an insertion highwall 620. As described above, the contour mining includes a stable highwall, which are also referred to as endwalls, and bench area on both sides of the equipment staging area 615, i.e. the bench 650 and highwall 655 on one side, and the bench 660 and highwall 665 on the other side. The opposing highwalls 655, 665 in the area being mined operate as endgates, and may function as either a headgate or a tailgate, described above. This is an important advantage, as the invention described herein eliminates the necessity of independent headgates or tailgates required by prior art systems, which reduces mining costs considerably. A mobile power substation 670 may be set up in the equipment staging area 615 to provide power to various parts of the system.

[0051] In the equipment insertion phase 600, a continuous miner 675 makes initial cuts in the mineral seam 604 to form a starter entry 680. After several successive cuts are made beginning at the starter entry 680, and moving from one highwall 655 to the opposing highwall 665, an insertion passage 685 is formed. Shield carrier 672 is allowed to insert roof supports 674 behind the area mined by the continuous miner 675. The roof supports 674 are shown in the equipment staging area 615 after being placed in the starter entry 680 and starter passage 685, and also ready for placement by the shield carrier 672. An intake canopy 700 and an exhaust canopy 800 are placed at the substantially opposing highwalls 655, 665 as defined by the insertion highwall 620.

[0052] Mine spoil 720 developed during creation of the access benches 650, 660 is placed on and around the roof supports 674 to complete the formation of the starter passage 685. This use of excess mine spoil 720, which effectively seals the starter passage 685 and creates a ventilation pathway within the starter passage 685, eliminates the need to transport the mine spoil 720 to disposal locations. This expedient use of the mine spoil 720 complies with recent court decisions, particularly those involving the Clean Water Act, by providing an immediate use for the mine spoil 720, as opposed to prior systems which typically dispose of mine spoil 720 within valley fills. Accordingly, an immediate benefit of the present invention is to eliminate the need for disposal locations by placement and use of the mine spoil 720 generated during the mining process.

[0053] Referring now to FIG. 6a, a cross-section of the phase 600 taken along lines 6a-6a of FIG. 6 is shown. The staging bench 610 is shown formed below the equipment insertion highwall 620. A safety bench 630 is shown formed adjacent the equipment insertion highwall 620 and the existing mountaintop 601. The mine spoil 720 is shown surrounding the starter passage 685 adjacent the roof supports 674 as the continuous miner 675 (FIG. 6) completes cuts between the highwall 655 and opposing highwall 665 (FIG. 6). The mine spoil 720 creates an effective seal of the starter passage 685, which allows proper ventilation of the starter passage 685 and successive cuts into the mineral seam 604. Roof supports 674 are shown in the starter passage 685 adjacent to the mineral seam 604 and supporting the safety bench 630 in the area adjacent the equipment insertion highwall 620. As can be seen, the roof supports 674 have been advanced into the area mined by the continuous miner 675 (FIG. 6).

[0054] Referring now to FIGS. 7a-7b, and FIGS. 8a-8b, the intake canopy 700 and exhaust canopy 800 are shown in exemplary front and side views, respectively. The placement of the intake canopy 700 and exhaust canopy 800 during mining operations facilitates ventilation during operation of the present invention, and provides a convenient location for insertion and removal of the continuous miner 675, and also provides for safe ingress and egress into the mining area as required by the Mine Safety and Health Administration (MSHA). Accordingly, it is preferable that both the intake canopy 700 and exhaust canopy 800 allow air to flow between the intake canopy 700 and exhaust canopy 800 in order to facilitate ventilation of the area between the intake canopy 700 and exhaust canopy 800.

[0055] The intake canopy 700 includes a roof 750, preferably comprised of steel plating, support columns 755 coupled to the roof 750, at least one door 760 for sealing the canopy 700. The door 760 may be coupled to the intake canopy 700 via hinges 765 or other suitable coupling means. A base 770 is coupled to the columns 755 opposite the roof 750. A mining belt 775 may be coupled to the doors and extending along the base 770 to facilitate an air seal during operation to insure proper ventilation. The exhaust canopy 800 includes a roof 812, preferably comprised of steel plating, a base 814, and columns 816 coupling the roof 812 to the base 814 In certain preferred embodiments, the columns are I-beams comprised of steel. Likewise, the roof 812 and base 814 may be I-beams for structural integrity.

[0056] Although not specifically shown, the exhaust canopy may include doors in a manner described above. Because the intake canopy 700, exhaust canopy 800, and mine spoil 720 (FIGS. 6 and 6A) create an effective air seal, the intake canopy 700 and, if desired, the exhaust canopy 800 may be provided with a reversible ventilation fan such that the direction of ventilation may be reversed or reoriented depending on the production direction. The ventilation fan is described in more detail below.

[0057] Referring now to FIG. 9, a top plan view of an initial production phase 900, which follows the initial setup and equipment insertion phase 600 for the exemplary mining system of FIG. 6 is shown. In the initial production phase 900, the starter passage 685 (not shown) has been completed and mine spoil 720 has been placed in the manner described above to form an air seal between substantially opposing highwalls 655, 665. A ventilation fan 910 is shown attached to the intake canopy 700 to effectively ventilate the cutting area between the intake canopy 700 and exhaust canopy 800. A conveyor system 920 is shown at one end of the roof supports 674 for conveying mined material to the exhaust canopy 800, and is coupled to a second conveyor system 930 for transport of the mined material to an outside stockpile 940. The intake canopy 700 and exhaust canopy 800 are shown advanced forward along the outside of the mineral seam 604 relative to FIG. 6, but such advancement is not required during this phase 900. The continuous miner 675 advances into the mineral seam 604 and moving from one highwall 655 to the opposing highwall 665. The roof supports 674 behind the continuous miner 675 advance from highwall 655 in the direction indicated by arrow M after the continuous miner 675 has advanced into mineral seam 604 towards highwall 665 in the direction indicated by arrow P1 to form a first production passage 950. The continuous miner 675 may have a boom 960 or the like to transport mined material to the conveyor system 920. The mine spoil 720 has been placed along the opposing highwalls 655, 665 immediately behind the intake canopy 700 and exhaust canopy 800 after they have been advanced thereby closing off and sealing the starter passage 685. Referring now to FIG. 9a, a cross-section of the phase 900 taken along line 9a-9a of FIG. 9 is shown. The mine spoil 720 is shown surrounding the roof supports 674 to facilitate the formation of the air seal along the equipment insertion highwall 620 and between opposing highwalls 655, 665, which allows the ventilation fan 910 (not shown) to effectively ventilate the area between the intake canopy 700 and the exhaust canopy 800 (FIG. 9) as the first production passage 950 is being formed.

[0058] Referring now to FIG. 10, a top plan view of the second production phase 1000, which follows the initial production phase 900 of FIG. 9 is shown. In this phase 1000, a “gob” 1010 of loose material has collapsed behind the roof supports 674. The continuous miner 675 has progressed through the mineral seam 604 to the exhaust canopy 800 at the endgate area adjacent highwall 665 to complete the first production passage 950. The miner 675 is then turned around as indicated by the dashed-line R and re-enters the mineral seam 604 for a second production cut in the direction of arrow P2. Because the mining equipment does not need to be removed and repositioned at highwall 655 due to the innovations of the present invention, significant cost savings and efficiency increases are realized as a result of the elimination of downtime, the reduction in manpower, and the existing location for beginning of the second production cut indicated by arrow P2. In accordance with these advantages, the exhaust canopy 800 has been moved from position A to position B to account for the first production cut (FIGS. 10 and 10a) through the mineral seam 604. The roof supports 674 behind the continuous miner 675 have advanced into the mineral seam 604 in the direction indicated by arrow M to support the roof in the area behind the continuous miner 675. The ventilation fan 910 is reversed upon re-entry of the continuous miner 675 to facilitate ventilation in the proper direction. Mine spoil 720 continues to be placed along the opposing highwalls 655, 665 in the area behind the canopies 700, 800 to maintain the air seal.

[0059] Referring now to FIG. 10a, a cross-section of the second production phase 1000 taken along line 10A-10A of FIG. 10 is shown. The original air seal created by the mine spoil 720 is shown in the same position relative to the equipment insertion highwall, however, the gob 1010 is shown collapsed behind the roof supports 674. The collapse of the gob 1010 behind the roof supports 674 further facilitates formation of an air seal between the intake canopy 700 and exhaust canopy 800 adjacent the mineral seam 604 where the continuous miner 675 is operating. In this regard, it can be appreciated that no mountaintop removal is required, as the mountaintop collapses to form the gob 1010, with strata above the gob 1010 bending or breaking but not completely collapsing, thereby eliminating the need to transport portions of the mountaintop that are removed in prior systems. This in combination with continual use of the mine spoil 720 as the continuous miner 675 advances into the mineral seam 604 equates to tremendous reductions in environmental impact, yet complete or almost complete recovery of the mined material.

[0060] Referring now to FIG. 11, a top plan view of a continuing production phase 1100, which follows the second production phase 1000 of FIG. 10 is shown. The continuous miner 675 has advanced significantly into the mineral seam 604 at this point of the phase 1100 in the direction indicated by arrow M. Production occurs in the direction of the line indicated by arrow Px forming another production passage 1150 through the mineral seam 640. Mine spoil 720 has been used to backfill the equipment insertion highwall 620 adjacent the equipment staging area 615 and along opposing highwalls 655, 665 up to the canopies 700, 800 to allow reclamation of the mining area with minimal environmental impact. The backfilling continues as the continuous miner 675 advances further into the mineral seam 604. For example, in this phase 1100 mine spoil 720 has been placed along opposing highwalls 655, 665 to facilitate formation of the air seal and deposit the fill material thereby allowing recovery in short 200 foot to 500 foot sections to approximate original contour without creating waste. Accordingly, recent legislative and judicial decisions restricting the types of waste created no longer apply to the present invention, unlike prior systems. The present invention thus accounts not only for mountaintop removal waste through the allowability of gob collapse in the production passage 685, 950, 1150 formed by the continuous miner 675, but also accounts for mine spoil 720 created by providing a placement and use which improves mining efficiency and production. The intake canopy 700 and exhaust canopy 800 have each been advanced along substantially opposing highwalls 655, 665 of the mineral seam 604. The gob 1010 has formed due to overburden collapse rather than removal and fill, as required in prior systems in the areas behind the roof supports 674 recently mined by the continuous miner 675, thereby offering significantly less environmental impact than prior systems.

[0061] Referring now to FIG. 11a, a cross-section of the continuing production phase 1100 taken along line 11a-11a of FIG. 11 is shown. The gob 1010, which represents material that did not have to be removed during the mining operation is shown as collapsed in the area behind the roof supports 674. The continuous miner 675, roof supports 674, and conveyor system 920 are shown as advanced into the mineral seam 604 in the direction indicated by arrow M.

[0062] Referring now to FIG. 12, a top plan view of an equipment extraction phase 1200, which follows the continuing production phase 1100 of FIG. 11 is shown. In the extraction phase 1200, the continuous miner 675 has reached an equipment extraction highwall 540, adjacent an equipment extraction area 590 between endgate 1210 and endgate 1220. The canopies 700, 800 have been advanced to endgates 1210, 1220 to assist in ventilation and removal and repositioning of the continuous miner 675. During this phase 1200, the continuous miner 675 makes its final cut through the remaining portion of the mineral seam 604 (not shown) and exits the mineral seam 604 via the exhaust canopy 800. The orientation of the final cut may be reversed depending on the size of the mineral seam 604 and the position of the continuous miner 675 in the next-to-last cut. The gob 1010 is completely collapsed and re-fills the remaining production passages, and mine spoil 720 continues to be used to reclaim the area recently mined. Strata above the gob 1010 may break and bend, but does not completely collapse. In fact, when viewed from the surface, external surfaces of the mountaintop show little to no signs of underground mining operations conducted in accordance with the principles of the present invention. The power substation 670 has advanced with the continuous miner 675 to provide a continuous power supply to the system. It can clearly be seen that the removal of the continuous miner 675 may be achieved with little effort due to the location of the intake canopy 700, exhaust canopy 800, and methods as described above. Tremendous cost savings and increases in production efficiency are thus achievable with little to no environmental impact.

[0063] Referring now to FIG. 12a, a cross-section of the phase 1200 taken along line 12a-12a of FIG. 12 is shown. The roof supports 674 are shown supporting the equipment extraction highwall 540 and safety bench 1230 during the final cut and removal of the continuous miner 675, conveyor 920 and roof supports 674.

[0064] Referring specifically to FIG. 13, a top plan view of an first production cut 1300 for an exemplary longwall mining system is shown. As described above, the longwall mining system shares many similarities to the shortwall mining system discussed above. For example, prior to the first production cut 1300, a staging bench 1310 is first formed after contour mining the mineral seam 1304 in accordance with the principles discussed above. An equipment staging area 1315 is formed at an insertion highwall 1320. As described above, the contour mining includes a stable highwall 1320, and bench area on both sides of the equipment staging area 1315, i.e. the bench 1350 and opposing highwall 1355 on one side, and the bench 1360 and opposing highwall 1365 on the other side. The opposing highwalls 1355, 1365 in the area being mined operate as endgates, and may function as either a headgate or a tailgate, described above, for the mining system depending on the direction of production travel. This is an important advantage, as the invention described herein eliminates the necessity of independent headgates or tailgates required by prior art systems, which reduces mining costs considerably. A power substation 1370 may be set up in the equipment staging area 1315 to provide power to various parts of the system.

[0065] Prior to the first production cut 1300 of the longwall mining system, a continuous miner 1375 makes initial cuts in the mineral seam 1304 to form a starter entry 1380 in the manner described above with respect to the shortwall mining system. After several successive cuts are made beginning at the starter entry 1380, moving from one opposing highwall 1355 to the other opposing highwall 1365, an insertion passage 1385 is formed. Roof supports 1374 are placed behind the area mined by the longwall miner 1375 in a manner described above. An intake canopy 1390 and an exhaust canopy 1392 are placed at the substantially opposing highwalls 1355, 1365 as defined by the insertion highwall 1320.

[0066] Mine spoil 1395 developed during creation of the access bench 1350, 1360 is placed on and around the roof supports 1374 to complete the formation of the starter passage 1385. This use of excess mine spoil 1395, which effectively seals the starter passage 1385 and creates a ventilation pathway within the starter passage 1385 eliminates the need to transport the mine spoil 1395 to disposal locations This expedient use of the mine spoil 1395 complies with recent court decisions, particularly those involving the Clean Water Act, by providing an immediate use for the mine spoil 1395, as opposed to prior systems which typically dispose of mine spoil 1395 within valley fills. Accordingly, an immediate benefit of the present invention is to eliminate the need for disposal locations by placement and use of the mine spoil 1395 generated during the mining process.

[0067] In the first production cut 1300, after the starter passage 1385 has been created in the manner described above, a longwall miner 1375 is placed within the starter passage 1385 and proceeds to cut into the mineral seam 1304 in the direction indicated by arrow M1, but in smaller increments than that for the continuous miner described above, into the mineral seam 1304. Production occurs in a direction indicated by arrow P1. Cutting bits on the longwall miner 1375 are oriented in a direction parallel to M1. As successive cuts are made into the mineral seam 1304, the roof supports 1374 are advanced into the recently mined area. Ventilation is provided through the use of a ventilation fan 1397 coupled to the intake canopy 1390. Ventilation thus occurs between opposing highwalls 1355, 1365 beginning at endgate 1398 and proceeding towards endgate 1399. It is appreciated that ventilation orientation may be reversed, depending on the circumstances. Because the longwall miner 1375, upon reaching endgate 1399, does not have to leave the cutting area of the mineral seam 1304, once the first production cut 1300 has been completed, additional cuts may be made with decreases in downtime due to the elimination of equipment relocation.

[0068] Referring now to FIG. 13a, a cross-section of the first production cut 1300 taken along lines 13a-13a of FIG. 13 is shown. The staging bench 1310 is shown formed below the equipment insertion highwall 1320. A safety bench 1330 is shown formed adjacent the equipment insertion highwall 1320 and the existing mountaintop 1301. The mine spoil 1395 is shown surrounding the starter entry 1385 adjacent the roof supports 1374 as the longwall miner 1375 completes cuts between the highwall 1355 and opposing highwall 1365 (FIG. 13). The mine spoil 1395 creates an effective seal of the starter passage 1385, which allows proper ventilation of the starter passage 1385 and successive cuts into the mineral seam 1304. Roof supports 1374 are shown in the starter passage 1385 adjacent to the mineral seam 1304 and supporting the safety bench 1330 in the area adjacent the equipment insertion highwall 1320. As can be seen, the roof supports 1374 have been advanced into the area mined by the longwall miner 1375.

[0069] Referring back to FIGS. 5 and 5a, the mining system shown utilizes surface contour mining to create the stable highwall 502 and bench area 503 around the entire mineral reserve 501 to allow insertion and extraction of the mining system underground. It should be understood, however, that both the insertion highwall 520 and the extraction highwall 540 are one embodiment of an insertion/extraction technique to be used in conjunction with the surface contour mining that creates the stable highwall 502 around the remainder of the mineral reserve 501 that ultimately forms the opposing highwalls 555, 565. Any insertion or extraction technique can be used in lieu of the insertion highwall 520 or the extraction highwall 540. For example, the starter entry 18 described above may be used as the insertion technique in conjunction with the main gates 16 for extraction as shown in FIG. 2. Both sides of the mineral reserve 501 remain accessible for using contour mining to form the opposing highwalls 555, 565 on either side of the insertion and/or extraction locations in accordance with the principles of the present invention.

[0070] Although both sides of the mineral reserve 501 must be accessible to form the opposing highwalls or endwalls 555, 565, it is possible that one side of the mineral reserve 501 might not be accessible because it is blocked by an adverse property line, geological anomaly, or other physical barrier. If one side is not accessible as a result of such barrier, then a continuous or single gate entry is formed as a underground tunnel or passage to replace that opposing highwall and function as an endgate for the inaccessible side of the mineral reserve 501 in accordance with the principles of the present invention as shown in FIG. 14. This alternative embodiment of the mining system utilizes surface contour mining around one side of a mineral reserve 1401 to create a stable highwall 1402 and bench area 1403 in accordance with the principles of the present invention as described above. In this embodiment, however, the mineral reserve 1401 is inaccessible on the other side as a result of a physical barrier indicated by the dash line PB. Therefore, a continuous or single-gate entry is formed as a continuous underground tunnel or passage to replace the opposing highwall and to function as an endgate for the inaccessible side of the mineral reserve 1401 along the line PB in accordance with the principles of the present invention.

[0071] The mining system of the present invention utilizes surface contour mining to create the stable highwall 1402 and the bench area 1403 around the accessible side of the mineral reserve 1401 to allow insertion of the mining system underground from that side of the reserve 1401. The single-gate entry which functions either as a headgate or a tailgate for the mining system in the same way as the opposing highwall being replaced. Hence, both the highwall 1402 and the single-gate passage operate as endgates for the mining system. The mining system commences by using surface contour mining in mining area A and creating a bench for supporting the mining equipment, the staging bench 1410 and a stable insertion highwall 1420 as described above. According to the principles of the present invention, the shortwall continuous miner commences formation of the single-gate entry by cutting into the end portion of the insertion highwall 1420 adjacent the inaccessible side of the mineral reserve at gate-insertion point X. The wall of the tunnel opposite the property barrier PB effectively functions as the other opposing highwall along the inaccessible side of the mineral reserve 1401, hereinafter the opposing gate-wall 1404. The surface contour mining on the accessible side is conducted in stages as described above commencing with mining area A between lines a and a′, then mining area B advancing to lines b and b′ followed by subsequent surface contour cuts advancing in increments of about 200 feet to 500 feet for each mining area to the end of the mineral reserve 1401. Thus, the shortwall continuous miner creates the opposing gate-wall 1404 and a bench area 1405 makes the inaccessible side of the mineral reserve 1401 accessible according to the principles of the present invention so that both shortwall mining and longwall mining can be accomplished as generally described above and more specifically below.

[0072] The insertion highwall 1420 is generally perpendicular to the direction that mining will advance as indicated by the arrow M and generally parallel to the direction of mineral production as indicated by the double arrow P. The initial surface contour cut includes the stable highwall 1402 and bench area 1403 on the accessible side of the staging area 1410, i.e., the bench 1450 and opposing highwall 1455 on one side, while the shortwall miner (not shown) forms the bench 1460 with the opposing gate-wall 1465 on the inaccessible side of the staging area 1410 at the gate-insertion point X. The insertion highwall 1420 extends between the opposing highwall 1455 and the opposing gate-wall 1465, both of which operate as endgates according to the present invention. Although the system as described above proceeds generally in the direction indicated by arrow M, in certain situations it may be necessary to shift the direction of production P as indicated by the double arrow P′ so that the production path is as short as possible as described above. The opposing highwall 1455, and gate-wall 1465 are still generally perpendicular to the shifted direction of mining as indicated by the arrow M′.

[0073] As the mining system advances into the mineral seam, with changes in production direction being implemented in a manner as described above when necessary, contour and single-gate mining continue in advance of production until the end of the mineral seam is reached at the end of the mineral reserve 1401. The contour mining forms an exit bench 1490, which is formed in accordance with the principles discussed above with respect to the staging bench 1410, and equipment extraction highwall 1440 in accordance with the techniques used to form the insertion highwall 1420. As the miner makes its final cut through the mineral seam, the mining equipment is removed from the mineral reserve 1401 in a manner described in more detail below.

[0074] Referring now to FIGS. 15-21 in general, there is shown differing phases for the use of the mining system according to the principles of the present invention as described with respect to FIG. 14 and utilizing shortwall mining techniques. Referring more specifically to FIG. 15, a top plan view of the initial setup and equipment insertion phase 1500 for an exemplary shortwall mining system is shown for mining a mineral reserve 1501 with a mineral seam 1504 (See FIG. 15a, a cross-section taken along line 15a-15a of FIG. 15). A staging bench 1510 is first formed after contour mining the mineral seam 1504 in accordance with the principles discussed above. An equipment staging area 1515 is formed at an insertion highwall 1520. As described above, the contour mining creates a stable highwall and bench area on one side of the equipment staging area 1515, i.e., the bench 1550 and highwall 1555. The highwall 1555 in the area being mined operates as an endgate, and may function as either a headgate or a tailgate as described above. This is an important advantage, as the invention described herein eliminates the necessity of independent headgates or tailgates required by prior art systems, which reduces mining costs considerably. A power substation 1570 may be set up in the equipment staging area 1515 to provide power to various parts of the system.

[0075] In the equipment insertion phase 1500, a continuous miner 1575 makes initial cuts in the mineral seam 1504 to form a starter entry 1580. After several successive cuts are made beginning at the starter entry 1580, and moving from one highwall 1555 to an area adjacent the property barrier PB, an starter passage 1585 is formed. Shield carrier 1572 inserts roof supports 1573 behind the area mined by the continuous miner 1575 as shown in position at 1574. A mobile canopy 1590 and a stationary canopy 1595 are placed at the highwall 1555 and the area X adjacent the property barrier PB at the other end of the insertion highwall 1520.

[0076] Mine spoil 1525 developed during creation of the access bench 1515 is placed on and around the roof supports 1574 to complete the formation of the starter passage 1585. This use of excess mine spoil 1525, which effectively seals the starter passage 1585 and creates a ventilation pathway within the starter passage 1585, eliminates the need to transport the mine spoil 1525 to disposal locations. This expedient use of the mine spoil 1525 complies with recent court decisions, particularly those involving the Clean Water Act as described above. The mobile canopy 1590 and the stationary canopy 1595 are similar to those described in detail above.

[0077] Referring now to FIG. 16, a top plan view of an initial production phase 1600 according to one embodiment of the present invention is shown, which follows the equipment insertion phase of FIG. 15. In the initial production phase 1600, the starter passage 1585 has been completed and mine spoil 1525 has been placed in the manner described above to form an air seal between highwall 1555 and the mined area adjacent the stationary canopy 1595. A ventilation fan 1610 is shown attached to the stationary canopy 1595 to effectively ventilate the cutting area between the mobile canopy 1590 and stationary canopy 1595. A conveyor system 1620 is shown at one end of the roof supports 1574 for conveying mined material to the mobile canopy 1590, and is coupled to a second conveyor system 1630 for transport of the mined material to an outside stockpile 1640. The mobile canopy 1590 is shown advanced forward along the outside of the mineral seam 1504 (not shown) relative to FIG. 15, but such advancement is not required during this phase 1600. The continuous miner 1575 advances into the mineral seam 1504 and moves from the highwall 1555 to the area adjacent the stationary canopy 1595. The roof supports 1574 behind the continuous miner 1575 advance from highwall 1555 in the direction indicated by arrow M after the continuous miner 1575 has advanced into mineral seam 1504 towards the area adjacent the stationary canopy 1595 in the direction indicated by arrow P1 until it reaches the gate insertion position X thereby completing the first production passage 1585. The continuous miner 1575 may have a boom 1650 or the like to transport mined material to the conveyor system 1620. The mine spoil 1520 has been placed along the highwall 1555 at the immediate area previously mined during creation of the starter passage 1585, and behind the mobile canopy 1590 after it has been advanced, thereby closing and sealing the first production passage 1585. A scoop 1660 and roof bolter 1670 are shown positioned in the equipment staging area 1515 for use in the area adjacent the stationary canopy 1595.

[0078] Referring now to FIG. 17, a top plan view of the first step for an exemplary single-gate mining phase 1700 according to one embodiment of the present invention, which follows the initial production phase 1600 of FIG. 16, is shown. When the miner 1575 reaches the end of the first production cut at the end of the stationary canopy 1595, it is rotated about 90° and generally parallel to the property barrier PB and moved forward in a direction indicated by an arrow M1 to form a single-gate entry 1710. The single-gate entry 1710 formed by the miner 1575 comprises a floor or bench area 1760 and a newly formed gate-wall 1765 which will be extended along the paths indicated by 1560 and 1565, respectively, as the miner 1575 moves in the direction of the arrow M, to form a single gate passage 1775. The single-gate entry 1710 may be about 20 feet in width and extent about 12 to 18 feet into the mineral seam 1504. While the miner 1575 cuts into the mineral seam 1504, it discharges material onto the scoop 1660 positioned directly behind the continuous miner 1575. A battery tractor may be provided instead of a scoop 1660, should circumstances dictate. The scoop 1660 then proceeds to dump the cut material onto the conveyor 1620 for removal.

[0079] Referring now to FIG. 18, a top plan view of a second production phase 1800 following the first step of the single-gate mining phase 1700 of FIG. 17 is shown. After the single-gate entry 1710 is formed, the continuous miner 1575 backs up away from the face of the single-gate entry 1710 and rotates about 90° so that the miner 1575 faces in the direction indicated by arrow P2 to continue mining in the reverse direction. The fan 1610 in the stationary canopy 1595 reverses direction to blow air toward the mobile canopy 1590 (not shown), thus completing the system reversal in the same manner as described above. The continuous miner 1575 then advances across the mineral seam 1504 toward the mobile canopy 1590, discharging mined material onto the conveyor belt 1620. Prior to the return of the continuous miner 1575, the roof bolter 1670 enters the single-gate entry 1710 and bolts the roof of the single-gate entry 1710 for support. Although not specifically shown in this FIG., a series of cribs may be set on the side of the single-gate entry 1710 adjacent the mineral seam 1504 and mined area to add additional support to the single-gate entry 1710 and to provide a “break line” to encourage uniform and controlled collapse of the gob (see FIG. 9) adjacent the single-gate entry 1710. The scoop 1660 is placed at a convenient location for future use, such as the equipment staging area 1515.

[0080] Referring now to FIG. 19, a top plan view of an exemplary initial system reversal phase 1900 according to one embodiment of the present invention, which follows the second production phase 1800 of FIG. 18 is shown. When the continuous miner 1575 reaches the highwall side 1555 of the mineral seam 1504 (see FIG. 19a), as shown at position 1575′, the continuous miner 1575′ exits via the mobile canopy 1590 and then turns around as indicated by dotted line R. The continuous miner 1575 begins cutting back across the face of the mineral seam 1504 in the direction indicated by arrow P3 toward the gate-wall 1765. The fan 1610 is reversed again so that proper face ventilation is established underground. Once this second full face cut is completed, the single-gate entry 1710 is advanced in the direction of the arrow indicated by M2 to form the single-gate passage 1710 (See FIG. 20) Gob 1910 is shown adjacent the roof supports 1574 as it collapses as described above and in more detail below.

[0081] Referring now to FIG. 20, a top plan view of a continuing production phase 2000, which follows the system reversal phase 1900 of FIG. 19, is shown. After the continuous miner 1575 advances significantly into the mineral seam 1504 (not shown) in the direction indicated by the arrow M, production continues moving back and forth as shown, for example, in the direction of the line indicated by arrow Px forming another production passage 2050 through the mine seam 1504 (not shown). Mine spoil 1525 has been used to backfill the equipment insertion highwall 1520 adjacent the equipment staging area 1515 and along the highwall 1555, up to the area most recently mined to allow reclamation of the mining area with minimal environmental impact. The backfilling continues as the miner 1575 advances further into the mineral seam 1504. For example, in this phase 2000 the mine spoil 1525 has been placed along highwall 1555 to facilitate formation of the air seal and deposit the fill material thereby allowing recovery in short 200 to 500 foot sections to approximate original contour without creating waste. Accordingly, recent legislative and judicial decisions restricting the types of waste created are obviated by the present invention, unlike prior systems. The present invention, eliminates mountaintop removal waste because the gob 1910 simply collapses in the production passages 1585, 2050 formed by the continuous miner 1575, and also utilizes the mine spoil 1525 to reclaim the contour of the landscape which also improves mining efficiency and production.

[0082] The mobile canopy 1590 has been advanced along highwall 1555, and the single-gate passage 1775 has been advanced in the direction indicated by arrow M to continue forming the opposing gate-wall 1765. The gob 1910 has formed due to overburden collapse rather than removal and fill, as required in prior systems in the areas behind the roof supports 1574 after being mined by the continuous miner 1575, thereby causing significantly less damage to the environment than prior systems. Cribs 2010 are installed adjacent the gate-wall 1765 to support the single-gate entry passage 1775 as the gob 1910 forms as described above.

[0083] Referring now to FIG. 21, a top plan view of an equipment extraction phase 2100, which follows the continuing production phase 2000 of FIG. 20 is shown. In the extraction phase 2100, the continuous miner 1575 has reached an equipment extraction highwall 2110, adjacent an equipment extraction area 2120 between the end of the highwall 1555 and the end of the gate-wall 1765. The mobile canopy 1590 has advanced to assist in ventilation and removal and repositioning of the continuous miner 1575. During this phase 2100, the continuous miner 1575 makes its final cut through the mineral seam 1504 traveling from the gate-wall 1765 and exiting from the highwall 1555 via the mobile canopy 1590. The orientation of the final cut may be reversed depending on the size of the mineral seam 1504 and the position of the continuous miner 1575 in the next-to-last cut. The gob 1910 is completely collapsed and re-fills the remaining production passages, except for the single-gate passage 1775 which continues to be supported by cribs 2010, and mine spoil 1525 continues to be used to reclaim the area recently mined. Strata above the gob 1910 may break and bend, but does not completely collapse. In fact, when viewed from the surface, external surfaces of the mountaintop show little to no signs of underground mining operations conducted in accordance with the principles of the present invention. It can clearly be seen that the removal of the continuous miner 1575 may be achieved with little effort due to the location of the intake canopy 1590 and methods as described above. Tremendous cost savings and increases in production efficiency are thus achievable with little to no environmental impact.

[0084] The present invention according to FIGS. 5-13 provides many advantages over prior mining systems. These include advantages as compared to conventional underground longwall/shortwall systems and advantages as compared to conventional surface mining operations. With respect to conventional underground longwall/shortwall systems, the mining system of the present invention operates from continuous surface access, and does not require panel formation, headgate and tailgate entries, shuttle cars, roof bolter, scoop and a personnel carrier. Estimated capital cost reductions of about 25-30% over conventional longwall systems and about 15-20% reduction over conventional shortwall systems of equivalent production capacity may be realized. Second, directly proportional to the reduction in equipment requirements discussed above is a reduction in manpower requirements, which results in an estimated personnel cost reduction of about 30-40% over conventional longwall systems and about 20-30% over conventional shortwall systems of equivalent production capacity. Third, due to the reductions in personnel requirements, the reduction in travel time to the mineral seam and the elimination of panel moves results in about a 10-15% increase in production. Finally, through the unique and novel combination of surface and underground mining technologies and the elimination of underground development entries, the present invention may achieve nearly 100% recovery of the mineable resources, a tremendous improvement in the typical 75-85% overall recovery achieved in conventional longwall and shortwall systems.

[0085] As compared to conventional surface mining operations for the embodiment as disclosed in FIGS. 5-13, similar efficiency increases and production increases are realized. First, the present invention requires a relatively small bench area due to the relatively small earthmoving equipment as compared to the larger equipment required in conventional surface mining operations. Second, manpower requirements are greatly reduced due to the reduction in equipment requirements as compared to the conventional large-scale surface mining operations, which results in about a 10-20% personnel cost reduction over conventional surface mining systems of equivalent production capacity and resource recovery potential. This results in a proportional increase in productivity (on a tons per man-hour basis) of about 10-20%. Fourth, because the present invention may achieve about 100% recovery of the mineable resource, this is equivalent to recovery achieved by large-scale mountain top removal operations and significantly better than the typical 65-85% recovery achieved in conventional surface/auger or surface/highwall-miner systems. Finally, because of the small surface mining bench requirement which is subsequently completely reclaimed to approximate original contour, the surface disturbance and associated environmental impacts are significantly less than those associated with typical large-scale surface mining (especially mountain top removal) operations. Such improvement results in about a 70% reduction in total surface area disturbance as compared to mountain top removal operations.

[0086] With respect to the embodiments as disclosed in FIGS. 15-21, similar advantages are achieved. These likewise include advantages as compared to conventional underground longwall/shortwall systems and advantages as compared to conventional surface mining operations. With respect to conventional underground longwall/shortwall systems, the mining system of the present invention operates from continuous surface access, and does not require panel formation, and a personnel carrier. Estimated capital cost reductions of about 15-25% over conventional longwall systems and about 10-20% reduction over conventional shortwall systems of equivalent production capacity may be realized. Second, directly proportional to the reduction in equipment requirements discussed above is a reduction in manpower requirements, which results in an estimated personnel cost reduction of about 25-30% over conventional longwall systems and about 15-20% over conventional shortwall systems of equivalent production capacity. Third, due to the reductions in personnel requirements, the reduction in travel time to the mineral seam and the elimination of panel moves results in about a 10-15% increase in production. Finally, through the unique and novel combination of surface and underground mining technologies and the elimination of underground development entries, the present invention of FIGS. 15-21 may achieve nearly 90-95% recovery of the mineable resources, a tremendous improvement in the typical 75-85% overall recovery achieved in conventional longwall and shortwall systems.

[0087] As compared to conventional surface mining operations for the embodiment as disclosed in FIGS. 15-21, similar efficiency increases and production increases are realized. First, the present invention requires a relatively small bench area due to the relatively small earthmoving equipment as compared to the larger equipment required in conventional surface mining operations. Second, manpower requirements are greatly reduced due to the reduction in equipment requirements as compared to the conventional large-scale surface mining operations, which results in about a 10-15% personnel cost reduction over conventional surface mining systems of equivalent production capacity and resource recovery potential. This results in a proportional increase in productivity (on a tons per man-hour basis) of about 10-15%. Fourth, because the present invention may achieve about 90-95% recovery of the mineable resource, this is equivalent to recovery achieved by large-scale mountain top removal operations and significantly better than the typical 65-85% recovery achieved in conventional surface/auger or surface/highwall-miner systems. Finally, because of the small surface mining bench requirement which is subsequently completely reclaimed to approximate original contour, the surface disturbance and associated environmental impacts are significantly less than those associated with typical large-scale surface mining (especially mountain top removal) operations. Such improvement results in about a 70% reduction in total surface area disturbance as compared to mountain top removal operations. Overall, the embodiments as disclosed in FIGS. 15-21 makes mining much easier, especially when property zones prevent the miner from using the embodiments disclosed in FIGS. 5-13.

[0088] Other advantages include the elimination of the need for large valley fills and in-stream sediment ponds. If blasting is necessary, the number and size of blasts are greatly reduced. Safety is ensured through the use of the roof supports, canopies, roof bolts, cribs or other shields.

[0089] Importantly, federal legislation (i.e. the Clean Water Act) and judicial decisions have raised concerns of many miners in the industry due to, among other things, restrictions placed on waste removal operations at the mining site. The present invention offers an economical, efficient and highly productive system which complies with federal legislation and judicial systems by imposing little to no environmental impact at the mining area. This is accomplished through the principles discussed above, with particular emphasis on the elimination of unused mine spoil, which in the present invention is used to facilitate creation of an air seal and re-contour the exterior surface of the mine. This is further accomplished through the collapsing of the gob behind the longwall or shortwall miner, which eliminates the need to remove the gob after mining. Finally, it is important to note that the system of the present invention accomplishes these goals and advantages without compromising miner safety.

[0090] The previous description is of preferred embodiments for implementing the invention, and the scope of the invention should not necessarily be limited by this description. The scope of the present invention is instead defined by the following claims.

Claims

1. A method for extracting mineral deposits in a mineral reserve, a portion being accessible from a sloping surface and the remaining portion being inaccessible, comprising: mining the sloping surface to create a bench and highwall for providing access to the mineral reserve around the accessible portion of the mineral reserve; forming a surface in the highwall generally perpendicular to a desired direction of mining the mineral reserve to create an insertion highwall between an endwall extending from the insertion highwall and the inaccessible portion of the mineral reserve; cutting a starter entry into the mineral reserve across the entire length of the insertion highwall from the endwall to the inaccessible portion of the mineral reserve; inserting roof supports into the starter entry and backfilling the starter entry with spoil to form a starter passage from the endwall to the inaccessible portion of the mineral reserve; mining the inaccessible portion of the mineral reserve to form a single-gate entry for providing access to the mineral reserve by creating another opposing endwall extending from the insertion highwall; mining the mineral reserve in the starter passage moving along the insertion highwall from one endwall to the other endwall in a direction of production to extract mineral deposits therefrom; successively mining the mineral reserve moving from one endwall to the other endwall in the direction of production to continue extracting mineral deposits therefrom thereby forming at least one successive passage advancing in the direction of mining; and providing roof support for successive passages resulting from the extraction of mineral deposits from the mineral reserve.
2. The method of claim 1, wherein the direction of production reverses direction between the endwalls for successive passages.
3. The method of claim 1, wherein the roof support for successive passages is provided by advancing the roof supports inserted into the starter entry, whereby the roof collapses behind the roof support to form the next successive passage.
4. The method of claim 1, wherein mining the mineral reserve along the insertion highwall is accomplished by shortwall mining in the direction of production.
5. The method of claim 1, wherein mining the mineral reserve along the insertion highwall is accomplished by longwall mining in the direction of production.
6. The method of claim 1, wherein the bench and highwall extend a first predetermined distance from the endwall to form a first mining stage for mining a first predetermined number of successive passages, and further comprising: mining the mineral reserves using the first mining stage to extract mineral deposits from the first predetermined number of successive passages through the mineral reserve.
7. The method of claim 6, further comprising: extending the bench and highwall a second predetermined distance from the first predetermined distance to form a second mining stage for mining a second predetermined number of successive passages; and backfilling the first mining stage to recontour the surface with spoil resulting from mining the sloping surface of the second mining stage.
8. The method of claim 1, further comprising: ventilating the starter passage at one of the endwalls and at least one of the successive passages at one of the endwalls for each passage.
9. The method of claim 1, further comprising: positioning one canopy at one endwall and another canopy at the other endwall to provide safe access to the passage.
10. The method of claim 9, wherein one canopy is sealed and further comprising: ventilating the passage from the unsealed canopy.
11. The method of claim 9, wherein one canopy is positioned at one end of the starter passage adjacent an endwall, and one canopy is positioned at the other end of the starter passage adjacent the other endwall.
12. The method of claim 10, further comprising: coupling a reversible ventilation fan to at least one of the canopies.
13. The method of claim 12, wherein the ventilation fan is coupled to the sealed canopy.
14. The method of claim 12, further comprising: reversing the reversible ventilation fan after creation of each successive passage.
15. The method of claim 9, wherein the canopies are mobile.
16. The method of claim 15, wherein the step of successively mining the mineral reserve is accomplished by a miner, and further comprising: removing the miner from the successive passage through one of the canopies at one of the endwalls after creation of the successive passage, reversing the orientation of the miner; reversing the orientation of the ventilation; and re-inserting the miner into the mineral reserve adjacent the completed successive passage through the one of the canopies at one of the endwalls.
17. The method of claim 16, further comprising: advancing the canopies along the endwalls after creation of the successive passage.
18. The method of claim 16, further comprising: backfilling the created successive passages with spoil.
19. The method of claim 1, further comprising: allowing gob behind the roof supports to collapse in an area behind the roof supports after the step of providing roof support for successive passages.
20. The method of claim 1, further comprising: forming a surface in the highwall generally perpendicular to the desired direction of mining the mineral reserve to create an extraction highwall between opposing endwalls of the highwall extending therefrom, the extraction highwall being on a generally opposite side of the mineral reserve from the insertion highwall.
21. The method of claim 20, further comprising: mining the mineral reserve moving from one endwall to the other in the direction of production to continue extracting mineral deposits therefrom thereby forming an extraction passage; removing mining equipment from the extraction passage; and re-contouring an extraction highwall formed adjacent the extraction passage to proximate an original contour of the sloping surface.
22 The method of claim 1, further comprising: manually advancing the roof supports in the direction of mining after the creation of each successive passage.
23. The method of claim 1, wherein the step of mining the sloping surface is accomplished by contour mining.
24. The method of claim 7, wherein the steps of extending the bench and highwall and backfilling the first mining stage are repeated until a desired termination point of the mineral reserve is reached.
25. The method of claim 24, wherein the repeated steps of extending the bench and highwall and backfilling the first mining stage are conducted in stages.
26. The method of claim 1, wherein the bench is adapted to support mining equipment.
27. The method of claim 1, further comprising: creating at least one power substation disposed on the bench to provide power to mining equipment.
28. The method of claim 27, wherein the at least one power substation is mobile.
29. The method of claim 27, further comprising: advancing the at least one power substation in the direction of mining relative to the step of successively mining the mineral reserves.
30. The method of claim 1, wherein the roof supports are inserted via a shield carrier.
31. The method of claim 1, further comprising: forming a safety bench above the insertion highwall and parallel to the bench.
32. The method of claim 1, further comprising: conveying the mineral deposits from the mineral reserve to a stockpile.
33. The method of claim 1, wherein the backfilling occurs along the roof supports and endwalls.
34. The method of claim 33, wherein the backfilling creates an air seal along the insertion highwall between opposing endwalls.
35. The method of claim 1, wherein the insertion highwall is generally straight between the opposing endwalls.
36. A method for extracting mineral deposits in a mineral reserve, a portion being accessible from a sloping surface and the remaining portion being inaccessible, comprising: mining the sloping surface to create a bench and highwall for providing access to the mineral reserve around the accessible portion of the mineral reserve; forming a surface in the highwall generally perpendicular to a desired direction of mining the mineral reserve to create an insertion highwall between an endwall extending from the insertion highwall and the inaccessible portion of the mineral reserve; cutting a starter entry into the mineral reserve across the entire length of the insertion highwall from the endwall to the inaccessible portion of the mineral reserve; inserting roof supports into the starter entry and backfilling the starter entry with spoil to form a starter passage from the endwall to the inaccessible portion of the mineral reserve; mining the inaccessible portion of the mineral reserve to form a single-gate entry for providing access to the mineral reserve by creating another opposing endwall extending from the insertion highwall, mining the mineral reserve in the starter passage moving a shortwall miner along the insertion highwall from one endwall to the other endwall in a direction of production to extract mineral deposits therefrom; successively mining the mineral reserve moving the shortwall miner from one endwall to the other endwall in the direction of production to continue extracting mineral deposits therefrom thereby forming at least one successive passage advancing in the direction of mining; and providing roof support for successive passages resulting from the extraction of mineral deposits from the mineral reserve.
37. The method of claim 36, wherein the direction of production reverses direction between the endwalls for successive passages.
38. The method of claim 36, wherein the roof support for successive passages is provided by advancing the roof supports inserted into the starter entry, whereby the roof collapses behind the roof support to form the next successive passage.
39. The method of claim 36, wherein the bench and highwall extend a first predetermined distance from the endwall to form a first mining stage for mining a first predetermined number of successive passages, and further comprising: mining the mineral reserves using the first mining stage to extract mineral deposits from the first predetermined number of successive passages through the mineral reserve.
40. The method of claim 39, further comprising: extending the bench and highwall a second predetermined distance from the first predetermined distance to form a second mining stage for mining a second predetermined number of successive passages; and backfilling the first mining stage to recontour the surface with spoil resulting from mining the sloping surface of the second mining stage.
41. The method of claim 36, further comprising: ventilating the starter passage at one of the endwalls and at least one of the successive passages at one of the endwalls for each passage.
42. The method of claim 36, further comprising: positioning one canopy at one endwall and another canopy at the other endwall to provide safe access to the passage.
43. The method of claim 42, wherein one canopy is sealed and further comprising: ventilating the passage from the unsealed canopy.
44. The method of claim 42, wherein one canopy is positioned at one end of the starter passage adjacent an endwall, and one canopy is positioned at the other end of the starter passage adjacent the other endwall.
45. The method of claim 42, further comprising: coupling a reversible ventilation fan to at least one of the canopies.
46. The method of claim 45, wherein the ventilation fan is coupled to the sealed canopy.
47. The method of claim 45, further comprising: reversing the reversible ventilation fan after creation of each successive passage.
48. The method of claim 42, wherein the canopies are mobile.
49. The method of claim 48, further comprising: removing the shortwall miner from the successive passage through one of the canopies at one of the endwalls after creation of the successive passage; reversing the orientation of the shortwall miner; reversing the orientation of the ventilation; and re-inserting the shortwall miner into the mineral reserve adjacent the completed successive passage through the one of the canopies at one of the endwalls.
50. The method of claim 49, further comprising: advancing the canopies along the endwalls after creation of the successive passage.
51. The method of claim 49, further comprising: backfilling the created successive passages with spoil.
52 The method of claim 36, further comprising: allowing gob behind the roof supports to collapse in an area behind the roof supports after the step of providing roof support for successive passages.
53. The method of claim 36, further comprising: forming a surface in the highwall generally perpendicular to the desired direction of mining the mineral reserve to create an extraction highwall between opposing endwalls of the highwall extending therefrom, the extraction highwall being on a generally opposite side of the mineral reserve from the insertion highwall.
54. The method of claim 53, further comprising: mining the mineral reserve moving from one endwall to the other in the direction of production to continue extracting mineral deposits therefrom thereby forming an extraction passage; removing the shortwall miner and roof supports from the extraction passage; and re-contouring an extraction highwall formed adjacent the extraction passage to proximate an original contour of the sloping surface.
55 The method of claim 36, further comprising: manually advancing the roof supports in the direction of mining after the creation of each successive passage.
56. The method of claim 36, wherein the step of mining the sloping surface is accomplished by contour mining.
57. The method of claim 36, wherein the steps of extending the bench and highwall and backfilling the first mining stage are repeated until a desired termination point of the mineral reserve is reached.
58. The method of claim 57, wherein the repeated steps of extending the bench and highwall and backfilling the first mining stage are conducted in stages.
59. The method of claim 36, wherein the bench is adapted to support mining equipment.
60. The method of claim 36, further comprising: creating at least one power substation disposed on the bench to provide power to mining equipment.
61. The method of claim 60, wherein the at least one power substation is mobile.
62. The method of claim 61, further comprising: advancing the at least one power substation in the direction of mining relative to the step of successively mining the mineral reserves.
63. The method of claim 36, wherein the roof supports are inserted via a shield carrier.
64. The method of claim 36, further comprising: forming a safety bench above the insertion highwall and parallel to the bench.
65. The method of claim 36, further comprising: conveying the mineral deposits from the mineral reserve to a stockpile.
66. The method of claim 36, wherein the backfilling occurs along the roof supports and endwalls.
67. The method of claim 66, wherein the backfilling creates an air seal along the insertion highwall between opposing endwalls.
68. The method of claim 36, wherein the insertion highwall is generally straight between the opposing endwalls.
69. A method for extracting mineral deposits in a mineral reserve, a portion being accessible from a sloping surface and the remaining portion being inaccessible, comprising: mining the sloping surface to create a bench and highwall for providing access to the mineral reserve around the accessible portion of the mineral reserve; forming a surface in the highwall generally perpendicular to a desired direction of mining the mineral reserve to create an insertion highwall between an endwall extending from the insertion highwall and the inaccessible portion of the mineral reserve, cutting a starter entry into the mineral reserve across the entire length of the insertion highwall from the endwall to the inaccessible portion of the mineral reserve, inserting roof supports into the starter entry and backfilling the starter entry with spoil to form a starter passage from the endwall to the inaccessible portion of the mineral reserve; mining the inaccessible portion of the mineral reserve to form a single-gate entry for providing access to the mineral reserve by creating another opposing endwall extending from the insertion highwall; mining the mineral reserve in the starter passage moving a longwall miner into the insertion highwall from one endwall to the other endwall in a direction of production to extract mineral deposits therefrom; successively mining the mineral reserve moving the longwall miner from one endwall to the other endwall in the direction of production to continue extracting mineral deposits therefrom thereby forming at least one successive passage advancing in the direction of mining; and providing roof support for successive passages resulting from the extraction of mineral deposits from the mineral reserve.
70. The method of claim 69, wherein the direction of production reverses direction between the endwalls for successive passages.
71. The method of claim 69, wherein the roof support for successive passages is provided by advancing the roof supports inserted into the starter entry, whereby the roof collapses behind the roof support to form the next successive passage.
72. The method of claim 69, wherein the bench and highwall extend a first predetermined distance from the endwall to form a first mining stage for mining a first predetermined number of successive passages, and further comprising: mining the mineral reserves using the first mining stage to extract mineral deposits from the first predetermined number of successive passages through the mineral reserve.
73. The method of claim 72, further comprising: extending the bench and highwall a second predetermined distance from the first predetermined distance to form a second mining stage for mining a second predetermined number of successive passages; and backfilling the first mining stage to recontour the surface with spoil resulting from mining the sloping surface of the second mining stage.
74. The method of claim 69, further comprising: ventilating the starter passage at one of the endwalls and at least one of the successive passages at one of the endwalls for each passage.
75. The method of claim 69, further comprising: positioning one canopy at one endwall and another canopy at the other endwall to provide safe access to the passage.
76. The method of claim 75, wherein one canopy is sealed and further comprising: ventilating the passage from the unsealed canopy.
77. The method of claim 75, wherein one canopy is positioned at one end of the starter passage adjacent an endwall, and one canopy is positioned at the other end of the starter passage adjacent the other endwall.
78. The method of claim 75, further comprising: coupling a reversible ventilation fan to at least one of the canopies.
79. The method of claim 78, wherein the ventilation fan is coupled to the sealed canopy.
80. The method of claim 78, further comprising: reversing the reversible ventilation fan after creation of each successive passage.
81. The method of claim 75, wherein the canopies are mobile.
82. The method of claim 81, further comprising: reversing the direction of the longwall miner; reversing the direction of the ventilation; and re-inserting the longwall miner into the mineral reserve adjacent the completed successive passage through the one of the canopies at one of the endwalls.
83. The method of claim 82, further comprising: advancing the canopies along the endwalls after creation of the successive passage.
84 The method of claim 82, further comprising: backfilling the created successive passages with spoil.
85 The method of claim 69, further comprising: allowing gob behind the roof supports to collapse in an area behind the roof supports after the step of providing roof support for successive passages.
86. The method of claim 69, further comprising: forming a surface in the highwall generally perpendicular to the desired direction of mining the mineral reserve to create an extraction highwall between opposing endwalls of the highwall extending therefrom, the extraction highwall being on a generally opposite side of the mineral reserve from the insertion highwall.
87. The method of claim 86, further comprising: mining the mineral reserve moving from one endwall to the other in the direction of production to continue extracting mineral deposits therefrom thereby forming an extraction passage, removing the longwall miner and roof supports from the extraction passage; and re-contouring an extraction highwall formed adjacent the extraction passage to proximate an original contour of the sloping surface.
88. The method of claim 69, further comprising: manually advancing the roof supports in the direction of mining after the creation of each successive passage.
89. The method of claim 69, wherein the step of mining the sloping surface is accomplished by contour mining.
90. The method of claim 69, wherein the steps of extending the bench and highwall and backfilling the first mining stage are repeated until a desired termination point of the mineral reserve is reached.
91. The method of claim 90, wherein the repeated steps of extending the bench and highwall and backfilling the first mining stage are conducted in stages.
92. The method of claim 69, wherein the bench is adapted to support mining equipment.
93. The method of claim 69, further comprising: creating at least one power substation disposed on the bench to provide power to mining equipment.
94. The method of claim 93, wherein the at least one power substation is mobile.
95. The method of claim 94, further comprising: advancing the at least one power substation in the direction of mining relative to the step of successively mining the mineral reserves.
96. The method of claim 69, wherein the roof supports are inserted via a shield carrier.
97. The method of claim 69, further comprising: forming a safety bench above the insertion highwall and parallel to the bench.
98. The method of claim 69, further comprising: conveying the mineral deposits from the mineral reserve to a stockpile.
99. The method of claim 69, wherein the backfilling occurs along the roof supports and endwalls.
100. The method of claim 99, wherein the backfilling creates an air seal along the insertion highwall in the starter passage between opposing endwalls.
101. The method of claim 69, wherein the insertion highwall is generally straight between the opposing endwalls.
102. The method of claim 69, wherein the step of cutting is accomplished by a shortwall miner.
103. A mining system for extracting mineral deposits in a mineral reserve, a portion being accessible from a sloping surface and the remaining portion being inaccessible, comprising: means for mining the sloping surface and thereby creating a bench and highwall for providing access to the mineral reserve around the accessible portion of the mineral reserve; means for forming a surface in the highwall generally perpendicular to a desired direction of mining the mineral reserve to create an insertion highwall between an endwall extending from the insertion highwall and the inaccessible portion of the mineral reserve; means for creating a starter entry into the mineral reserve across the entire length of the insertion highwall from the endwall to the inaccessible portion of the mineral reserve; means for mining the inaccessible portion of the mineral reserve to form a single-gate entry for providing access to the mineral reserve by creating another opposing endwall extending from the insertion highwall; means for supporting a roof in the starter entry and for backfilling the starter entry with spoil to form a starter passage from the endwall to the inaccessible portion of the mineral reserve; means for mining the mineral reserve in the starter passage moving along the insertion highwall from one endwall to the other endwall in a direction of production to extract mineral deposits therefrom; means for successively mining the mineral reserve moving from one endwall to the other endwall in the direction of production to continue extracting mineral deposits therefrom thereby forming at least one successive passage advancing in the direction of mining; and means for providing roof support for successive passages resulting from the extraction of mineral deposits from the mineral reserve.
104. The system of claim 103, wherein the means for mining the sloping surface comprises a shortwall miner.
105. The system of claim 103, wherein the means for mining the mineral reserve comprises longwall mining.
106. The system of claim 103, wherein the means for successively mining the mineral reserve comprises longwall mining.
107. The system of claim 103, wherein the means for mining the mineral reserve comprises shortwall mining.
108. The system of claim 103, wherein the means for successively mining the mineral reserve comprises shortwall mining.
109. The system of claim 103, further comprising: means for reversing the direction of production between the endwalls for successive passages.
110. The system of claim 103, wherein the means for providing roof support for successive passages comprises advancing roof supports inserted into the starter entry, whereby the roof collapses behind the roof supports to form the next successive passage.
111. The system of claim 103, further comprising: means for extending the bench and highwall a first predetermined distance from the endwall to form a first mining stage for mining a first predetermined number of successive passages, and further comprising: means for mining the mineral reserves using the first mining stage to extract mineral deposits from the first predetermined number of successive passages through the mineral reserve.
112. The system of claim 111, further comprising: means for extending the bench and highwall a second predetermined distance from the first predetermined distance to form a second mining stage for mining a second predetermined number of successive passages; and means for backfilling the first mining stage to recontour the surface with spoil resulting from mining the sloping surface of the second mining stage.
113. The system of claim 103, further comprising: means for ventilating the starter passage at one of the endwalls and at least one of the successive passages at one of the endwalls for each passage.
114. The method of claim 103, further comprising: means for positioning one canopy at one endwall and another canopy at the other endwall to provide safe access to the passage.
115. A method for extracting mineral deposits in a mineral reserve, a portion being accessible from a sloping surface and the remaining portion being inaccessible, comprising: mining the sloping surface to create a bench and highwall for providing access to the mineral reserve around the accessible portion of the mineral reserve; forming a surface in the highwall to create an insertion highwall between a first endwall extending from the insertion highwall and the inaccessible portion of the mineral reserve; cutting a starter entry into the mineral reserve across the entire length of the insertion highwall from the first endwall to the inaccessible portion of the mineral reserve; inserting roof supports into the starter entry and backfilling the starter entry with spoil to form a starter passage from the first endwall to the inaccessible portion of the mineral reserve; forming a single-gate passage adjacent the inaccessible portion of the mineral reserve and extending from the insertion highwall to form a second endwall opposing the first endwall, thereby providing access to the mineral reserve; mining the mineral reserve in the starter passage moving along the insertion highwall between the endwalls to extract mineral deposits therefrom thereby forming a production passage resulting from the extraction of the mineral deposits; and advancing the roof supports from the starter passage into the production passage during the extraction of mineral deposits from the mineral reserve, whereby gob begins collapsing into the starter passage behind the roof supports.
116. The method of claim 115, wherein mining the mineral reserve in the starter passage commences in a direction of production from the second endwall toward the first endwall to form a first production passage after extraction of the mineral deposits.
117. The method of claim 115, wherein mining the mineral reserve in the starter passage forms a first production passage and further comprising: mining the mineral reserve in the first production passage moving between the endwalls to extract mineral deposits therefrom, thereby forming a second production passage resulting from the extraction of the mineral deposits.
118. The method of claim 117, wherein mining the mineral reserve in the starter passage commences in a direction of production from the second endwalls toward the first endwall to form a first production passage after extraction of the mineral deposits.
119. The method of claim 1117, further comprising: advancing the roof supports into the second production passage after the extraction of mineral deposits from the mineral reserve, whereby gob material collapses into the first production passage behind the second production passage.
120. The method of claim 117, wherein the direction of mining between the endwalls for the second production passage is reversed from the direction of mining for the first production passage.
121. The method of claim 120, further comprising: advancing the roof supports into the second production passage after the extraction of mineral deposits from the mineral reserve, whereby gob material collapses into the first production passage behind the second production passage.
122. The method of claim 115, further comprising: continue mining the mineral reserve between the endwalls to extract mineral deposits therefrom thereby forming successive production passages resulting from the extraction of mineral deposits.
123. The method of claim 12, wherein the direction of mining between the endwalls for successive production passages reverses from one production passage to the next production passage.
124. The method of claim 122, further comprising: advancing the roof supports into successive production passages after the extraction of mineral deposits from the mineral reserve, whereby gob material collapses behind the active one of the successive production passages being mined.
125. The method of claim 115, wherein mining the mineral reserve between the endwalls is accomplished by shortwall mining.
126. The method of claim 115, wherein mining the mineral reserve between the endwalls is accomplished by longwall mining.
127. The method of claim 115, wherein the bench and highwall extend a first predetermined distance from the first endwall to form a first mining stage for mining a first predetermined number of successive passages, and further comprising: mining the mineral reserves using the first mining stage to extract mineral deposits from the first predetermined number of successive passages through the mineral reserve.
128. The method of claim 127, further comprising: extending the bench and highwall a second predetermined distance from the first predetermined distance to form a second mining stage for mining a second predetermined number of successive passages; and backfilling the first mining stage to recontour the surface with spoil resulting from mining the sloping surface of the second mining stage.
129. The method of claim 115, further comprising: ventilating the starter passage at the first endwall and the production passage at either one of the endwalls.
130. The method of claim 115, further comprising: positioning one canopy at one endwall and another canopy at the other endwall wherein one canopy is sealed to close the production passage and the other is unsealed; and ventilating the production passage from the unsealed canopy.
131. The method of claim 130, wherein one canopy is positioned at one end of the starter passage adjacent an endwall, and one canopy is positioned at the other end of the starter passage adjacent the other endwall.
132. The method of claim 130, further comprising: coupling a reversible ventilation fan to at least one of the canopies.
133. The method of claim 132, wherein the ventilation fan is coupled to the sealed canopy.
134. The method of claim 132, further comprising: reversing the reversible ventilation fan after creation of each successive passage.
135. The method of claim 130, wherein the canopies are mobile.
136. The method of claim 135, wherein the step of successively mining the mineral reserve is accomplished by a miner, and further comprising: removing the miner from the successive passage through one of the canopies at one of the endwalls after creation of the successive passage; reversing the orientation of the miner; reversing the orientation of the ventilation, and re-inserting the miner into the mineral reserve adjacent the completed successive passage through the one of the canopies at one of the endwalls.
137. The method of claim 136, further comprising: advancing the canopies along the endwalls after creation of the successive passage.
138. The method of claim 136, further comprising: backfilling the created successive passages with spoil.
139. The method of claim 115, further comprising allowing gob behind the roof supports to collapse in an area behind the roof supports after the step of providing roof support for successive passages
140. The method of claim 115, further comprising: forming a surface in the highwall generally perpendicular to the desired direction of mining the mineral reserve to create an extraction highwall between opposing endwalls of the highwall extending therefrom, the extraction highwall being on a generally opposite side of the mineral reserve from the insertion highwall.
141. The method of claim 140, further comprising: mining the mineral reserve moving from one endwall to the other in the direction of production to continue extracting mineral deposits therefrom thereby forming an extraction passage; removing mining equipment from the extraction passage; and re-contouring an extraction highwall formed adjacent the extraction passage to proximate an original contour of the sloping surface.
142. The method of claim 115, further comprising: manually advancing the roof supports in the direction of mining after the creation of each successive passage.
143. The method of claim 115, wherein the step of mining the sloping surface is accomplished by contour mining.
144. The method of claim 128, wherein the steps of extending the bench and highwall and backfilling the first mining stage are repeated until a desired termination point of the mineral reserve is reached.
145. The method of claim 144, wherein the repeated steps of extending the bench and highwall and backfilling the first mining stage are conducted in stages.
146. The method of claim 115, wherein the bench is adapted to support mining equipment.
147. The method of claim 115, further comprising: creating at least one power substation disposed on the bench to provide power to mining equipment.
148. The method of claim 147, wherein the at least one power substation is mobile.
149. The method of claim 147, further comprising: advancing the at least one power substation in the direction of mining relative to the step of successively mining the mineral reserves.
150. The method of claim 115, wherein the roof supports are inserted via a shield carrier.
151. The method of claim 115, further comprising: forming a safety bench above the insertion highwall and parallel to the bench.
152. The method of claim 115, further comprising: conveying the mineral deposits from the mineral reserve to a stockpile.
153. The method of claim 115, wherein the backfilling occurs along the roof supports and endwalls.
154. The method of claim 153, wherein the backfilling creates an air seal along the insertion highwall between opposing endwalls.
155. The method of claim 115, wherein the insertion highwall is generally straight between the opposing endwalls.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This Nonprovisional Application for Patent is a Continuation-In-Part of U.S. Nonprovisional Application for patent Ser. No. 10/183,741, filed on Jun. 26, 2002, and is hereby incorporated by reference in its entirety herein.

Continuation in Parts (1)

	Number	Date	Country
Parent	10183741	Jun 2002	US
Child	10315275	Dec 2002	US

Mining system

Information

Publication Number

Date Filed

Date Published

Inventors

CPC

US Classifications

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATION

Continuation in Parts (1)