Extremely loose and soft coal seams, with a Platts coefficient of less than 0.3, are easy to break in the process of integrated mechanized roof coal mining and are prone to spilling and piling up between the hydraulic supports, which is a safety hazard for the movement of equipment. The coal particles must be cleaned up manually, resulting in reduced resource recovery rates and lower mining face efficiency. To effectively mitigate and control the problem of coal spillage accumulation amidst hydraulic supports, this study utilizes discrete element numerical simulation to examine the characteristics of block size distribution and the spilling process during the crushing of highly loose and soft top coal. By taking into account various parameters associated with shelf spacing, this research identifies key factors for controlling arching and self-stopping phenomena in top coal particles. The study findings suggest that the uppermost coal layer undergoes significant fragmentation during the integrated mining process of loosely packed and soft coal seams, resulting in a higher probability of coal leakage issues observed near the rack's coal wall side and at the end of the roof control area. The key factors contributing to the self-arresting of spilled coal particles include inherent characteristics of the coal body, particle diameter, and stand spacing. In this specific mine under investigation, an arch formation naturally occurs to prevent further leakage when the distance between stands is less than eight times the diameter of particles, and after process correction, the average time saving for a single shift of manual floating coal cleaning at the working face is about 2 h, and the proportion of time saving is more than 50 similar to 75%.
