Explosives & Blasting in Underground Coal Mines

Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

Explosives and Blasting in Underground Coal Mines

Author: Partha Das Sharma (E.Mail: sharmapd1@gmail.com)

Introduction
All seams in underground coal mines, now a days, are considered gassy, the degree of gassiness
may vary from I to III. Methane gas present in the originally formed coal seam gets released in to
the mine atmosphere during excavation of coal. Methane when mixed with air in the proportions
between 5-14 % forms an explosive mixture. Hence, there is possibility of a Methane-air mixture
being dangerously formed in the galleries and working areas. In underground coal mines, there is
also an additional risk as coal dust, when mixed with air, can undergo a dust explosion when
suitably ignited. Both methane-air and coal dust explosions cause loss of life and extensive damage
to the underground mines. Methane ignition is known to take place due to the following reasons
when explosive is in use:

a. Direct action of shock wave from the explosive.

b. Indirect action of the shock wave after it has been reflected from solid surfaces in the
vicinity of explosives.
c. Hot gaseous products of detonation mixing with the methane-air mixture.
d. Hot reacting solid particles of explosives getting ejected in to the methane-air mixture.

Hence, specially designed explosives and detonators are required for use in underground coal mines.
Such products come under the ‘Permitted’ category and have to pass critical tests in simulated
conditions of field usage. Explosives and detonators are tested in both methane-air and coal dust-air
mixtures before being certified fit for use in underground coal mines/seams of various degree of
gassiness. Thus these require special properties, mainly a high degree of safety against methane-air
and coal dust-air mixture ignition.

Hence, they should have reduced flame temperature and duration of flame, have good continuity of
detonation properties, maintain its sensitivity and ensure reliable propagation even after being
subjected to the compressive shock wave generated by the earlier fired shot holes and be of non-
deflagrating type. Explosives should also be water proof, generate low level of toxic post - blast
fumes and be relatively insensitive to impact and friction.

Risk of ignition of methane-air mixture due to blown out shots is inherent danger during blasting in
underground coal mines. Blown out shots occur due to inadequate and proper stemming, excessive
burden or spacing between shot holes, improper use of delay detonators and incorrect sequence of
firing of shot holes.

Deflagrating of explosives is more prone for risk in underground coal mines, since they burn for
longer period comparative to explosive which detonate. High strength explosive readily ignites
methane-air mixture in view of their high reaction temperatures. Weak explosives, inspite of having
higher velocity of detonation are found to be relatively safer (present day Permitted explosives are
relatively weaker), have low detonation temperature and do not contain any ingredient which
continues to burn after the detonation reaction is completed.

Permitted Explosives

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

Only those explosives, which are included in the official list of authorised explosives issued by the
Chief Controller of Explosives in India, may be used for blasting in mines. Chemical and physical
stability and reliable performance are the pre-requisites for inclusion in this list. Further testing and
approval of the Director General of Mines Safety is required for an authorized explosive to be
classified as a permitted explosive suitable for use in underground coal mines.

Explosive to be used in coal seams must be safe for use in methane-air mixtures or coal-dust
mixtures encountered in underground coal mines. To meet these requirements stipulated official
tests are carried out to assess the safety of the explosives under these conditions. Only on passing
these tests in an explosive approved as a ‘permitted’ explosive.

In India there are 3 types of permitted explosives, each group being designed for a particular type of
operation to give maximum safety.

P-1 Type Permitted Explosives: These explosives can be used for drifting or ripping and
simultaneous firing in an undercut / middlecut / overcut and in depillaring faces, in coal seams of
first degree of gassiness.

P-3 Type Permitted Explosives: These are Equivalent-to-Sheathed Explosives (which have
replaced the earlier Group P-2 Sheathed Permitted Explosives) used for drifting or ripping and
simultaneous firing in an undercut / middlecut / overcut and in depillaring faces, in all coal seams.

P-5 Type Permitted Explosives: These are special type of explosives with a high degree of
intrinsic safety against all types of likely hazards in delay blasting in coal and specially designed for
Solid Blasting in conjunction with non-incendive copper short delay detonators.

All Indian coal seams have been classified according to their degree of gassiness. This classification
of coal seams and the explosives that can be used in different seams are summarized below.

Degree of Classification of Gassiness Type of Permitted

Gassiness of Explosives
Coal seam
I < 0.1% of gas in the general body of air P1 / P3 / P5
and rate of emission of such gas is less
than 1 cu. m/t of coal production
II > 0.1% of gas in the general body of air P3 / P5
and rate of emission of such gas is
greater than but less than 10 cu. m/t of
coal production
III Rate of emission of the gas is greater P3 / P5
than 10 cu. m/t pf coal production

DGMS (India) Stipulations on Maximum Permissible Charge in a Shot Hole.

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

Types of Explosives Degree of gassiness / Type of Max

Application Permissible charge per
Shot hole (gms)
P1 Degree 1 mines, Cut face, Depillaring 800

P3 Degree I, II & III mines, Cut face, Depillaring 1000

P5 Degree I-‘BOS’, 1000

P5 Degree II &III-‘BOS’ 565

Non Permitted Explosives

For certain operations such as shaft sinking and stone drifting, where there is no gas or coal dust
present, explosives other than permitted explosives can be used, subject to such conditions as may
be laid down by the DGMS in specific instances.

Detonators

In conjunction with Permitted explosives, only approved detonators may be used for coal blasting.
Only electric detonators with copper tube are permitted for use in coal blasting. These are of two
types (both of N0.6 strength).

1.Instantaneous Copper Electric Detonators (CED): These are Instantaneous Electric

Detonators with a copper shell. P1 and P3 Explosives can only be used in conjunction with CEDs.

2. Copper Non-Incendive Short Delay Detonators (CDD): These are copper tube
detonators, used for delay firing when solid blasting in coal is done. These are used along with P5
explosives. These are specially designed to meet the stringent safety requirements for solid blasting
in coal, for which they have to undergo statutory tests at CMRI as stipulated by DGMS. The
nominal delay of 25ms between two successive delay intervals (from 0 to6) is available to the
maximum delay period of 150ms.

Principles of blasting in coal

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

From the point of view of blasting, underground coal mining operations could be divided into two
categories, namely, Development and Depillaring. The techniques of blasting in each case are
widely different.

Both for bord-and-pillar as well as for longwall mining, driving galleries through coal seams are
done. There are two techniques employed for blasting in development galleries.
a. Blasting on pre-cut face.
b. Solid blasting of coal.

Blasting on a pre-cut face

In many mines coal-cutting machines are used to provide an additional free face for blasting. While,
this may be under, over, middle or side cut, the most common practice in Indian mines is to have
undercut face. For blasting on cut faces the fallowing conditions must be complied with:

• The length of the shot hole should be at least 15cm (6 inchs) less than the depth of the cut.
• The detonators in a round should be fired simultaneously, preferably in series.
• The maximum charge in hole should not exceed 800gms for P1 explosives and 1000gms for
P3 and P5 explosives.

While blasting on cut face, the following guidelines should be borne in mind for best blasting
results:

• Depth of cut: The jib should be properly ‘sumped in’, and it must be ensured that cut is of
uniform depth. It should also be ensured that the cutting is done to the maximum possible
depth to get the best advantage out of cut face blasting. Generally, the cut depths vary from
1.2 to 1.8 m.
• Cleaning of the cut: The purpose of cut is to provide an additional free face for the blast.
The maximum advantage of the cut can be taken only if it is properly cleaned and all the
gummings are removed.
• Depth and placement of shot holes: As mentioned the depth of shot holes should
always be at least 15cms less than the cut depth. Holes should not be too short, otherwise un
blasted coal would be left hanging. Moreover, the burden on any hole should always be less
than the depth of shot hole, preferably the burden should be kept 2/3 the depth of shot hole
for getting optimum results.

Some of the optimum drilling and blasting patterns with undercut are given below:
Thumb rules for u/g coal blasting in Cut Faces :
1. No. of holes For each 1 square meter area = 1 hole
2. Depth of hole 15cm less than cut length
3. Charge per hole 40% of hole length
4. Stemming 60% of hole length
5. Explosive P1 type (Solarcoal-1) for degree 1 mines
P3 type (Solarcoal-3) for degree 2/3 mines

A typical round of hole used in blasting an under cut face is shown below:

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

(Numbers shown sequence of firing rounds)

Depth of Hole - 1.5 Meters
No. of Holes - 8
Charge / Holes- 300 g
Total yield of Coal - 14 tones
Yield per kg - 6.00 tones

Solid blasting of coal (BOS)

Both in Longwall and development faces coal can be blasted without giving an under cut by a
coal cutting machine. The technique of blasting of the solid is simpler, more economical and
less hazardous than conventional method of breaking coal with machine cut and blasting. The
following points are to be remembered while doing Solid Blasting in coal:

(a) To create an initial cut, holes need to be drilled in inclined position so as to provide
direction and force for coal to move outwardly, to create free face for other holes.
(Lever action theory)
(b) Wider the opening (i.e. Free face) easier it would be for other holes to perform better. It
is advisable to give zero delay for 4 to 6 cut holes in the centre.
(c) Considering Beam theory, hole length beyond 70% of seam height would not bring
expected result. Rather long sockets will be left and explosive energy will be wasted
and P.F. will be reduced.
(d) Stemming less than 60% of hole length or un proper packing may not be able to sustain
the volume / pressure of gases generated during blasting and explosive energy will be
wasted in form of a blown out shot.
(e) Cut holes should be charged more as compared to other holes.
(f) Initiation sequence should be maintained so as that cut holes give way first, nearest hole
next and farthest holes last.
The additional technical points are also to be adopted for solid blasting in coal

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

• Only P5 Permitted Explosives (Solarcoal - 5) and 'Non-incendive' copper short

delay detonators shall be used.
• Maximum charge per hole is 1000 gms for Degree I mine and 565 gms for
Degree II & Degree III.
• The estimated period of Delay between the first and last shots shall not
exceed 150 ms (100 ms for Degree III Mines).
• The estimated period of delay between any two consecutive delay shots shall
not exceed 60ms.
• The maximum distance between the two adjacent shot holes of different delays
shall not be less than 0.6m.
• Atleast 284 cu.m of air per minute shall be conducted up to every face where
solid blasting is being done.
• Test for inflammable gas should be made within the radius of 20m of the blast.
• More than 25 shots in one round should not be blasted.

Recommended Pattern for Seam Height 2.6 m

Face Size 4.6 x 2.6 Total Holes = 15
Type of Number Depth of Explosive / hole Delay Stemming
Holes Holes Number
Cut 6 1.7 m (5.6) 3 555 Z 60-65%
Holes
Other 6 1.6 m (5') 3 555 I 60%
Holes 3 1.6 m (5') 3 555 II 60%
Total Explosives Expected Pull Expected Coal Powder Factor Detonator
per Round (Insitu) T/Kg. Factor
8.32 Kg. 1.27 m (4') 19.74 M. T. 2.37 1.31
Remark 1. 2-4 holes to be increased if encountered with shale /stone band.
2. Full packaging with sand clay cartridges as stemming gives 10% better results.

In stables and development headings the technique of solid blasting is done by creating initial
opening either by (a) Wedge Cut Pattern, or (b) Fan Cut Pattern.
In a 'Wedge Cut', two or more holes are drilled so as to converge at the rear by not less than
0.3m. This arrangement provides a concentration of charge at the back. With this pattern, the

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

advance is limited. For deep pulls burden should be reduced by providing steeply inclined hole
at the centre, known as 'Stab Hole' or by giving another shallow wedge cut known as 'Baby Cut'.
This relieving hole should be fired prior to the main wedge cut pattern. Following some of the
examples given :

No. of Holes = 14+1stab hole = 15 (Total), size of gallery = 4.3m x 2.4m

Delay Number Charge (Cartridge) Explosive (gm ) Explosives
Charged (gm)
0 1 3 555 555
1 2 3 555 x 2 1110
2 2 3 555 x 2 1110
3 4 2 370 x 4 1480
4 4 2 370 x 4 1480
5 2 2 370 x 2 740

Total Charge :- 6.5 kg, Av. Pull :- 1.35m to 1.45m

Blasting Ratio (PF) :- Av. 2.6 t/kg Detonator Factor :- 1.1 to 1.2 t

In Fan Cut Pattern, the initial opening is created by firing a hole drilled at an acute angle to the
face. The inclination generally varies from 30 to 60 degree. The inclination of subsequent hole
is gradually reduced. This pattern suitable for medium hard to hard coal seams. Some
illustrations are given below :

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

No. of Holes :- 14, Size of gallery = 4.0m x 2.40m

Delay Number Charge (Cartridge) Explosive (gm ) Explosives
Charged (gm)
0 1 3 555 x 1 555
1 1 3 555 x 1 555
2 2 3 555 x 2 1110
3 2 3 555 x 2 1110
4 2 2 370 x 2 740
5 4 2 370 x 4 1480
6 2 2 370 x 2 740

Total Charge : - 6.25kg to 6.50kg Av. Pull :- 1.35m to 1.45m

Blasting Ratio (PF) :- 2.7t/kg (Av.) Detonator Factor :- 1.2 to 1.4 t

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

In Long wall mining the technique of solid blasting (BOS) offer substantial overall cost
advantages and higher out put and productivity as compare to use of coal-cutter in stables as this
technique eliminates pre-shearing. More over, it encourages additional advantages like low
capital investment, saving in man power, flexibility in deployment of drill machines, lesser
stores inventory, better maintenance of Long wall face in greater gradient and uneven/disturbed
seam and avoidance of frequent breakdown of coal cutting machines. A typical lay out of shot
hole in long wall face is shown below.

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

Code of good practices in underground blasting

A. In cut faces
1. Before drilling in cut faces, all duffs / gumming must be removed from cut.
2. The cut should be carefully examined and measured.
3. Each hole should then be drilled directly above or below the cut to terminate at aleast 15cms (6
inches) short of the cut depth. If holes are drilled too deep, it is likely that the charge will be
located in coal, which is not undercut.
4. The correct drilling of each hole with respect to placement, depth and angle is essential for safe
and efficient breaking.
5. It is important to relate the burden to mass of explosives in the hole; overburdening can result in
either inadequate fracture or blown-out shot. Under burdening will result in excessive
fragmentation of the material and dangerous flying debris. Both under-and over burdening are
more likely to cause an ignition.

B. Charging of shot hole

6. All drill cuttings should be removed from shot holes before charging, in order to avoid the
chances of drill cuttings to remain between the cartridges, which may lead to misfires. It is
recommended to place the complete charge, including primer, in the form of a ‘train’ in the
mouth of the hole. This is then pushed home as a continuous charge.

C. Stemming
7. To reduce the possibility of a gas or coal dust explosion,(as per Regulations) the shot holes to be
stemmed up to the collar.
8. Proper stemming material, preferably a mixture of sand and clay should be used. Effective
stemming is important from a practical point view as it confines the gasses from explosion
utilizing the full potential of the explosives.
9. Coal chips should not be used as stemming material, as it is a combustible material, shot may
blown-out and also shot may be misfired due to short-circuit since coal chips may damage the
insulation of Electric Detonator.

D. Deflagration
10. The detonator should be positioned at the toe of the hole, i.e. toe priming or inverse initiation
should be adopted. This reduces the risk of deflagration and chances of blown-out. As far as
possible, collar priming or direct initiation is to be avoided.
11. A distance of at least 0.6m and a maximum time interval of 60ms delay between any two
adjacent shot holes should be maintained.
12. As mentioned earlier, cartridges should be loaded in such a manner to prevent air -gaps or drill
cuttings coming between them. Careful loading of cartridges reduces the risk of deflagration.

E. Primers
13. The base of the detonators should point in the direction of the charge column.
14. It is important to attach the detonators lead wires correctly to prevent the detonator being pulled
out of the cartridges. Care must be taken not to put strain in the lead wires where they enter the
detonators.

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

F. Electric Blasting & Circuit testing

15. Care must be taken when charging up and correct procedure of testing of circuit by an
Ohmmeter to determine actual resistance should be adopted. In case of any fault correction to be
done before firing.
16. As per the firing capacity of Exploder, the numbers of detonators are to be used in the circuit.
Care should be taken to avoid having starvation of current to Electric detonators used.
17. Only approved type exploder to be used.

G. Explosives & Blasting

18. Only Permitted type explosives are to be used, as per DGMS regulations and circulars.
19. During blasting operations, proper shelter should be taken by all.
20. After the blast, only after clearing of fumes from the face persons should be allowed to enter.

• VELOCITIES OF AIR CURRENT (DGMS stipulations) : The Velocity of air

current measured in meters per minutes at the place shown in column (2) shall not be
less than that shown in column (3) for the different seams shown in column (1) of the
table giving below :

Degree of Place where velocity of air is to be Velocity of air

Gassiness measured
1 2 3
First, Second or Immediate out bye ventilation connection 30
Third Degree form the face.

First, Second (i) 4.5meters from any face whether 30

Degree working or discontinued on the in
take side of the brattice or partition.
(ii) 7.5 meters out bye of the discharge 15
end of an air pipe.
(iii) At the maximum span of a Longwall 60
face.

Third Degree (i) 4.5 meters from any face whether 45

working or discontinued on the
intake side of the brattice or partition.
(ii) 7.5 meters out bye of the discharge 25
end of an air pipe.
(iii) At the maximum span of a long wall 75
face.

[The DGMS stipulates that under no condition the presence of Carbon monoxide (CO) and
oxides of Nitrogen (NOx) in blasting fumes should be more than 50 ppm and 5 ppm
respectively with in a period of 5 minutes.]

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Explosives & Blasting in Underground Coal Mines
Author: Partha Das Sharma (E.mail: sharmapd1@gmail.com)

Author’s Bio-data: Partha Das Sharma is Graduate (B.Tech – Hons.) in Mining Engineering
from IIT, Kharagpur, India (1979) and was associated with number of mining and explosives
organizations, namely MOIL, BALCO, Century Cement, Anil Chemicals, VBC Industries, Mah.
Explosives etc., before joining the present organization, Solar Group of Explosives Industries at
Nagpur (India), few years ago.

Author has presented number of technical papers in many of the seminars and journals on varied
topics like Overburden side casting by blasting, Blast induced Ground Vibration and its control,
Tunnel blasting, Drilling & blasting in metalliferous underground mines, Controlled blasting
techniques, Development of Non-primary explosive detonators (NPED), Signature hole blast
analysis with Electronic detonator etc.

Currently, author has following useful blogs on Web:

• http://saferenvironment.wordpress.com
• http://www.environmentengineering.blogspot.com
• www.coalandfuel.blogspot.com

Author can be contacted at E-mail: sharmapd1@gmail.com, sharmapd1@rediffmail.com,

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Disclaimer: Views expressed in the article are solely of the author’s own and do not necessarily
belong to any of the Company.

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