The Synergistic Mechanism of Blending–Mining Coordination and Ash Content Traceability Control in Fully Mechanized Top-Coal Caving Mining: A Case Study

Qun Wang, Xipeng Gu and Mengtao Cao ()
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Qun Wang: Center of Shanxi Engineering Research for Coal Mine Intelligent Equipment, Taiyuan University of Technology, Taiyuan 030024, China
Xipeng Gu: Center of Shanxi Engineering Research for Coal Mine Intelligent Equipment, Taiyuan University of Technology, Taiyuan 030024, China
Mengtao Cao: Center of Shanxi Engineering Research for Coal Mine Intelligent Equipment, Taiyuan University of Technology, Taiyuan 030024, China

Sustainability, 2026, vol. 18, issue 7, 1-18

Abstract: As a primary associated by-product of coal mining, the comprehensive utilization of coal gangue has become a core pathway for the green transformation of the energy system and the establishment of a resource recycling system. The fully mechanized top-coal caving mining method used in China lacks a quality linkage mechanism between underground matched mining and surface coal blending, resulting in significant fluctuations in coal quality, larger volumes of gangue brought to the surface, and low utilization rates of coal washing by-products. In this paper, we propose a reverse decision-making method for whole-lifecycle coal quality control and construct an ash content tracing and regulation model to coordinate coal blending and matched mining in fully mechanized caving faces. In the coal blending stage, under the constraints of calorific value balance and cost minimization, the method transforms low-calorific-value by-products, such as middlings and fine gangue, into valuable resources. In the matched mining stage, a reverse tracking model based on the surface–underground ash content balance is proposed, grounded in material flow analysis theory. The model formulates correlation equations among face length, the low calorific value of raw coal, daily advance per cycle, and caved gangue volume. It further proposes a reverse coal quality tracing theory that links commercial coal sales targets with caving process parameters. The study clarifies the deep coordination mechanism between underground matched mining and surface coal blending. The results demonstrate that the proposed method systematically establishes a closed-loop pathway integrating underground gangue reduction at the source and surface fine gangue blending. The implementation has yielded direct economic benefits totaling RMB 65.31 million, increased commercial blended coal output by 104.5 thousand tons, and reduced gangue emissions by 258.5 thousand tons. This study provides a reference for the reduction, resource utilization, and recycling of coal gangue.

Keywords: green mining; fully mechanized top-coal caving face; coal blending–matched mining coordination; daily production planning; gangue emission reduction (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2026
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