MINING MINING MINING MINING MINING 
HORIZON SENSINGTM 
BENEFITS 
Project Fact Sheet 
• Saves energy by maximizing 
cutting efficiency 
• Increases recovery and quality of 
run-of-mine product 
• Allows for deeper mining 
• Increases mine worker safety 
APPLICATION 
Remote sensing and imaging at 
the cutting edge of mine equipment 
will be used in both surface and 
underground mines to mine 
cleaner coal, trona, and potash; 
help increase productivity; and 
ensure mine safety. 
REMOTE SENSING AND IMAGING TO CUT CLEAN-COAL AND 
B
C 
Mudstone 
OTHER MINERALS MORE EFFICIENTLY 
This project will demonstrate the feasibility and benefits of real-time horizon 
sensing and bit drag and side force measurements on cutting drums of longwall 
shearers and continuous mining machines. The sensing technology can also be 
applied to boring machines, front-end loaders, and drag lines. The application of 
cutting-edge technology to mining machines will reduce dust exposure to machine 
operators; enable mining of clean-coal, trona, and potash; minimize waste rock; 
increase energy-efficient recovery and yield; and enable automation of machines 
mining metal and nonmetal deposits. 
In both surface and underground mines there are barriers beyond which extraction 
may not occur. In undulating seam deposits, remote sensing can prevent cutting 
through thin contaminated layers next to the bounding sedimentary rock layer. 
Because of biological and chemical reactions occurring at the time of peat-coal 
burial, thin layers of boundary coal contain higher percentages of sulfur, ash, and 
heavy metal such as mercury. Leaving the boundary layer behind will result in 
clean-coal mining. Seam boundary contamination also occurs in other mineral 
deposits. A cutting-edge sensor can reduce the amount of waste rock and 
increase yield in coal, trona, and potash mining. Real-time sensor signals will 
enable automated vertical control and not require an operator to be in close 
proximity to the machine. This reduces dust exposure to mine personnel. Leaving 
the boundary layer of coal, trona, and potash will improve ground control and 
prevent roof falls. Monitoring bit forces will optimize bit location on the cutting 
drum bit for maximum cutting efficiency. All of these benefits contribute to 
increased productivity and mine safety. 
CROSS SECTION OF SEAM 
A 
Contaminated Coal 
Wireless 
Transmission 
Fire Clay 
Horizon Sensing for Continuous Miners is comprised of the following: (A) Display 
readout outby on machine, (B) Coal thickness sensor and data transmission antenna, and 
(C) Electronic package in drum end (cover plate removed). 
Sandstone 
Vertical 
Stop 
Coal 
OFFICE OF INDUSTRIAL TECHNOLOGIES 
ENERGY EFFICIENCY AND RENEWABLE ENERGY U.S. DEPARTMENT OF ENERGY
Project Description 
Objective: To test remote sensing and imaging technology on the cutting edges of 
mining equipment to make real-time measurements of mining conditions. 
Researchers hope to develop a cutting-edge sensor that will improve worker safety 
by preventing mining into high-pressure water/carbon dioxide cavities, and by 
allowing greater remote control of equipment while improving the efficiency of 
mining operations. 
Progress and Milestones 
Activities to be completed in this project include: 
• Install electronic measuring instrumentation and Resonant Microstrip 
Patch Antenna (RMPA) sensors on cutting drums, rotating arms, and 
buckets. Instrumentation will achieve Mine Safety and Health 
Administration flameproof approval for measurement electronics in coal 
and trona deposits. 
• Develop Neural Network Software and algorithm enhancements for the 
drum sensor application. Modify software as necessary to achieve the 
desired graphical presentation to machine operating personnel. Graphical 
enhancements include display of uncut coal thickness, and detection of 
hazardous conditions ahead of mining (water- and carbon dioxide-filled 
cavities). 
• Conduct in-mine tests for continuous miner, bore miner, and bucket. 
LONGWALL HORIZON/STRESS SENSOR 
RMPA Stress 
RMPA Horizon 
Proposed mounting of RMPAs and explosion-proof enclosure on shearer drum. The 
explosion-proof enclosure is welded between the face bit ring and vein of the drum. The RMPA 
sensors are protected by Lexan plates and mounted at the approximate level of the bit block. 
PROJECT PARTNERS 
Stolar Horizon, Inc. 
Raton, NM 
Colorado School of Mines 
Golden, CO 
Los Alamos National Laboratory 
Los Alamos, NM 
Mine Safety and Health 
Administration 
Pittsburgh, PA 
CONSOL, Inc. 
Library, PA 
RAG American Coal, 
Plateau Mining Corp. 
Price, UT 
FMC Corporation 
Green River, WY 
Lee Ranch Coal Co. 
Grants, NM 
FOR ADDITIONAL INFORMATION, 
PLEASE CONTACT: 
Office of Industrial Technologies 
Clearinghouse 
Phone: (800) 862-2086 
Fax: (360) 586-8303 
clearinghouse@ee.doe.gov 
Visit our home page at 
www.oit.doe.gov/mining 
Office of Industrial Technologies 
Energy Efficiency 
and Renewable Energy 
U.S. Department of Energy 
Washington, D.C. 20585 
February 2001