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By Nikhil Dhawan, Shrey Agrawal

Feldspar, a low-alumina, and abundantly available aluminosilicate source, is explored in this study to extract aluminum and potassium values. The sample comprises lamellar layers of microcline and albite with quartz containing 17.4% Al2O3, 9.67% K2O, and 66.3% SiO2. Mechanical (milling) and thermal (alkali and acid baking) activation are investigated, followed by HCl leaching. The milling treatment up to 6 h is inefficient in phase dissociation and results in ~ 40% Al and K dissolution. The alkali thermal treatment yielded 80% Al and 71% K extraction. Direct precipitation of the dissolved Al and Si values yielded alumina purity of ~ 29%, and silica gelation separated SiO2 and improved alumina product (94% purity, 71% recovery). Acid baking yielded 98% pure alumina precipitate; however, Al and K extraction were limited to ~ 45% and 65%, respectively. The microwave-assisted alkali treatment was optimal with 800 W and 10 min processing conditions yielding 80% Al and 71% K recovery with 2.26 kWh/kg alumina of thermal energy consumption. The final product contains γ-alumina with a specific surface area of 87 m2/ g. Keywords Feldspar · Alumina · Potassium ·

May 18, 2022

By Sunil Vytla, Agus Sasmito, Akash Adhikari, Srivatsan Jayaraman Sridharan, Purushotham Tukkaraja

Previous studies on blast fumes (carbon monoxide and nitrogen dioxide) clearance and workplace reentry time have overlooked the effects of toxic gases trapped in the muck pile. The currently available models for calculating the mine reentry times assume that all post-blast fumes are emitted upon detonation. However, recent studies reported that as much as 60 to 70% [1–5] of the fumes or gases produced during an underground development blasting could remain trapped in the adjacent rock mass or in the muck pile. Trapped fumes are slowly released [1–5], and when disturbed, high concentrations are released, representing a possible risk during the loading and transportation of the muck pile. In this study, mathematical models were developed using computational fluid dynamics to understand the behavior of the trapped fumes and their effect on mine reentry time. The three scenarios considered for this study include (i) gas emission source with no muck pile volume, (ii) gas emission source with non-porous muck pile volume, and (iii) gas emission source with porous muck pile volume. The estimated reentry times in all three scenarios were compared to see how porous media affects dilution time. It was observed that scenario 3, with fumes trapped in the muck pile, took a significantly longer clearance time (more than double) as compared to scenarios 1 and 2.

May 17, 2022

By Y. Pan, V. V. S. Vytla, P. Tukkaraja, R. BHARGAVA, S. Jayaraman Sridharan

Panel caving is an underground bulk mining method that utilizes gravitational force for mining massive, steeply dipping, and deep-seated ore deposits at a lower operating cost. To control dust and gas emissions entering the production level during the extraction of ore from the draw points in a panel cave, relatively negative pressure is created in the cave by installing an exhaust fan in the exhaust drift located on top of the cave. Since caving is a dynamic process, the design of an effective ventilation system is a challenging task, and therefore, estimation of airflow resistance offered by the broken rock inside the cave is critical. The complex and dynamic nature of caving also makes it difficult to predict the airflow resistance by using traditional approaches. This study investigates the effect of changes in the bulk porosity of the broken rock on the cave airflow resistance using computational fluid dynamics (CFD) approach. The results show an inverse relationship between the cave airflow resistance and the bulk cave porosity. The pressure-quantity characteristic curves presented in this paper provide valuable information for sizing and operating an exhaust fan used for a mature panel cave ventilation.

May 17, 2022

By HONGWEI YANG, Lili Zhang

The oxidation behavior of copper smelting slag under non-isothermal conditions was studied by thermal analysis. The results indicate that the copper slag is mainly composed of fayalite ( Fe2SiO4) and magnetite ( Fe3O4). The oxidation behavior can be divided into two reaction stages with the increase in temperature; the first stage is the oxidation of fayalite to magnetite, and the second stage is the oxidation of magnetite to hematite. The two reaction stages cannot be strictly separated; that is, the reaction of fayalite is not complete, and magnetite has begun to transform into hematite. Based on the TG (thermogravimetric) curves, the ABS (Achar–Brindley–Sharp–Wendworth) differential and the Coats–Redfern integral methods were employed to investigate the oxidation kinetics of copper slag during the continuous heating process. The oxidation of fayalite into magnetite and amorphous silica phases occurs mainly in the temperature range of 673 to 1083 K. The activation energies calculated by the two methods are 193.69 and 195.52 kJ mol− 1, respectively. The reaction is consistent with Avrami–Erofeev equation, and the mechanism of oxidation is random nucleation and growth. The oxidation of magnetite to hematite occurs at 1083–1303 K. The activation energies are 308.79 and 328.77 kJ mol− 1, respectively. The mechanism conforms to the Jander equation and is controlled by the two-dimensional diffusion.

May 16, 2022

By Yong Pan, Srivatsan Jayaraman Sridharan, Purushotham Tukkaraja

Block cave mining method poses unique ventilation challenges compared to other underground metal mining methods. This research study focuses on assessing the airflow behavior in regulated airflow distribution systems by developing a 1:100 scaled block cave experimental model and a numerical model. This study also investigated gas flow behavior under various airflow conditions. Based on our findings, we observed that reduction in particle size and porosity of caved materials, decrease in cave footprint, and closure of undercut drifts would increase cave airflow resistance. The increased airflow is found beneficial for gas dilution regardless of its source locations, while the regulated airflow distribution system might deteriorate gas dilution situation when the source is located in the extraction drifts.

May 12, 2022

By G. Roberts, S. S. Klima, W. R. Reed, J. Deluzio, G. Ross, A. Mazzella

The abstract discusses the problem of silicosis among roof bolter operators in coal mines due to respirable quartz dust (RCS) exposure. It presents a study comparing a new wet box collection system to the traditional dry box system. The wet box system uses water to saturate collected material, reducing RCS exposure during cleaning. The study found that the wet box system significantly reduced RCS exposures and quartz content in samples compared to the dry box system.

May 11, 2022

By Shailendra Chawla, Ashok Jaiswal, B. K. Shrivastva

The study aims to evaluate the pillar behavior during the depillaring operation by continuous miner (CM) technology. A panel with five headings developed as per the coal mine regulation of Indian coal mines [2] has been selected for the study. The depillaring operation has been carried out using CM technology after widening and heightening the original entries. An extensive field investigation has been carried out throughout the depillaring operation to access the mining conditions. Depillaring operation has been performed smoothly up to the middle of the panel (fourth row out of eight rows of four pillars each). Advanced blinking of the auto warning tell-tale (AWTT ) has also been observed on some of the instruments during the splitting of pillar no. 18. The panel shows extremely difficult mining conditions at this stage. The case has been numerically simulated using three-dimensional numerical techniques. The simulation result has indicated the high stress and yield condition on the working and the barrier pillar (surrounding goaf from both sides) after the extraction of pillar no. 18. The analysis has also indicated the marginal stability of the 2nd barrier pillar (namely “pillar B”). The failure of the barrier pillar could be the responsible for global instability of the panel as observed in the field. Understanding the importance of the barrier pillars, panel design has been modified by incorporating an additional row of barrier pillars. The stability of the modified panel has been evaluated. Both working and barrier pillars have been observed stable in the modified panel. This could be an alternative layout considering safety at the working face.

May 8, 2022

By M S. Tuohy

Since the independent review of fatal accidents in the mining industry carried out by Dr Sean Brady (the ‘Brady Review’), High Reliability Organisations (HROs) and their operating principles have been discussed across the Queensland mining sector. HROs are organisations said to consistently avoid serious failures, reliably delivering their organisational objectives despite operating in environments characterised by high levels of inherent risk and/or operational complexity. HRO concepts have previously found application in other similarly hazardous industries to mining. However, as Hopkins (2009) pointed out, HROs ‘are very elusive creatures that inhabit the realm of theory more than the real world’. The Queensland Resources Council (QRC) with support from the Commissioner for Resources Safety and Health initiated a review of how HRO principles can be translated to the mining industry. The review was conducted by Noetic, an Australian management consulting company that specialises in hazardous industries, including mining and metals, and has prior experience applying HRO theory.

May 5, 2022

By N LaBranche

The resurgence of Silicosis and Coal Worker’s Pneumoconiosis (CWP) in coalmines has placed the spotlight back on the management of worker exposure to particulate matter across all mining sectors (Coal Workers Pneumoconiosis Select Committee, 2017). There already exists a substantial body of knowledge on particulate matter and its impacts upon human health (National Academies of Sciences, Engineering and Medicine, 2018). The contribution of silica to respiratory disease is well known. However, it is also clear that there are major gaps in our understanding. In part, those gaps relate to the contribution to adverse health effects of mineralogical constituents in the dust (LaBranche et al, 2021a). It is also becoming evident that the size and shape of the particulate matter can affect its potential impact on human health. The University of Queensland has developed a methodology for characterising respirable and inhalable dust samples using scanning electron microscopy. Multiple samples from numerous mining operations have already been analysed using the UQ methodology. The process has been successful in showing the variety of mineralogical components and particle size distributions present in various areas of the mines.

May 5, 2022

By T Kilpatrick

Managing heat stress on Australian mine sites is a complex and enduring challenge due to the combined and variable contribution of environmental conditions, physical activities, and protective equipment. Inappropriately managed, heat stress can place significant physical strain on workers, leading to serious and chronic health issues. Additionally, excessive heat stress can dramatically reduce productivity, with 30 per cent of workers reporting a loss of productivity due to occupational heat strain. In Australia, due to increased absenteeism and reduced work performance, heat strain is estimated to have an annual economic burden of over $8 billion.

May 5, 2022

By A Atkins

Six recent case studies were selected based on the eight main causes of mine disasters (Table 1; Quinlan, 2014) and where credible information sources, such as Royal Commission Reports, Coronial Investigations and textbooks, were available. The six case studies are listed below. Details are available via this link or the conference PowerPoint accompanying this paper. 1. Beaconsfield, Tasmania – 2006 Fall of Ground/Seismic Event (Chandler, 2009; Melick, 2007; Wright, 2012). 2. Bingham Canyon, USA – 2013 Manefay Slide (Ross, 2017). 3. Bronzewing, WA – 2000 Hydraulic Fill Inrush (Hope, 2002). 4. Brumadinho and Samarco, Brazil – 2015 and 2019 Tailings Storage Facility (TSF) failures (Bowker, 2019; Darlington et al, 2019; Demajorovic, Lopes and Santiago, 2019; Morgenstern, 2016). 5. Northparkes, NSW – 1999 Cave Air-blast (Bailey, 2003; Hebblewhite, 2003). 6. Pike River, NZ – 2010 Methane Gas Explosion (Macfie, 2013; Panckhurst, Bell and Henry, 2012.

May 5, 2022

By A G. Guinea

Every person in an organisation has what could be called ‘a different take’ on what it means to be a safety leader. The directors will tell you they are ultimately responsible for everyone’s safety and that they can be imprisoned as a consequence of a workplace fatality. Managers, take more of a focused approach and would explain that they are totally responsible for the safety of their teams. And then there are front-line leaders. Those that not only have the responsibility (like directors and managers) but they also have the accountability, and the ability, to influence how safely their teams work. But it is not just physical safety that leaders should be concerned with.

May 5, 2022

By K Biegaj

During the author’s 25+ year career in mine management in various parts of the world (mostly in Australia), the author has been privileged to live and work in mining towns (not FIFO) for more than 20 years. And has personally observed other people from the mining industry carrying out work at home in an unsafe manner, eg pushing lawn mowers whilst wearing thongs or performing electrical jobs whilst standing on aluminium ladders, as well as many others. It is common that injuries sustained at home whilst on break are not reported upon arrival back on a mine site. A large number of compensation claims for injuries at work, which in fact had been sustained at home, come at substantial extra costs to mining companies.

May 5, 2022

By Emily Sarver, Cigdem Keles, Jonathan Gonzalez, Nishan Pokhrel, Lizeth Jaramillo

This paper presents a case study of respirable dust characterization in a thin-seam coal mine in southern West Virginia. Samples were collected in various locations within the mine and analyzed using scanning electron microscopy with energy-dispersive X-ray (SEM-EDX), thermogravimetric analysis (TGA), and Fourier transform-infrared (FT-IR) spectroscopy. The study found high non-carbonate mineral content, particularly aluminosilicates and silica, in the dust. The results indicate that fine aluminosilicate particles may interfere with SEM-EDX analysis, leading to an underestimation of coal content. The findings highlight the importance of using multiple analytical methods to accurately characterize respirable coal mine dust.

May 5, 2022

By Neha Shukla, Nikhil Dhawan

The current study examines the extraction of rare-earth elements from trichromatic phosphor of discarded tube lights via baking processes. The Y2O3: Eu3+ (YOX) and BaMgAl10O17: Eu2+ (BAM) phases completely decomposed during acid and alkali baking with > 90% Eu and Y extraction. Prior, selective acid leaching of the YOX phase enhanced the acid baking process at a lower temperature (< 230 ℃). Feed acid baking showed a maximum 87% Tb, 36% La, and 17% Ce extraction at 500 °C, 0.5 h, 1 ml/g H2SO4, and alkali baking yielded 16.1% Tb, 86% La, and 73% Ce at 300 ℃, 0.5 h, 50 wt.% NaOH. The acid baking of the acid-leached phosphor yielded 72% Tb, 95% La, 63% Ce, ~ 95% Y, and Eu extraction at 300 °C, 0.5 h, 1.05 mL/g H2SO4. Lower Tb extraction during the acid baking of acid-leached phosphor can be attributed to the formation of Ba3Tb( PO4)3 and BaTbO3 phases. Insoluble Si3Tb5 phase formation and partial decomposition of CeMgAl11O19: Tb3+ (CMAT) phase in the alkali baking route leads to lower Tb extraction. The acid baking process is suitable for extracting Tb, Eu, and Y, whereas the alkali baking process is suitable for La and Ce. The thermal analysis of phosphor and flux interaction depicts that alkali baking is less energy-intensive than acid baking. In comparison, the one-step acid baking process and the two-step alkali baking process yielded desirable extraction results (87% Tb, total RE (rare earth) 78.5% and 50.4% Tb, total RE 59.3%). The product yield in the acid and alkali baking route of feed, acid-leach phosphor is 36%, 29%, and 39%, 28.2%, respectively, with ~ 98% mixed rare-earth oxide purity.

May 5, 2022

By Menglong Bian, Xiaotong Dong

Thermal damage is an urgent problem faced by deep mining. High-temperature rock mass, hot water and electromechanical equipment are the sources of the thermal damage. The increase in air temperature in mine tunnel is the result of fluid–solid coupling heat transfer from various heat sources. This paper takes a roadway with hot water and a mine car as the research object. Based on the Fluent, Static Structural and Steady-State Thermal modules in ANSYS, the thermal-fluid–structure coupling analysis in the roadway is carried out. It is found that the hot water has a significant effect on the thermal environment of the mine. Under the experimental parameters, the maximum heat flux density and equivalent elastic strain at the interface between the hot water and the rock are 9789.3 W/m2 and 0.00054532 m/m, respectively. The heat flux distribution in the rock area near the mine car does not change much, and the equivalent elastic strain value in this area is high. After the air is heated in the hot water area, the temperature curve changes gradually and then rises steadily. By changing the inlet air temperature parameter, it is found that the lower the inlet air temperature, the better the cooling effect, and the change of the inlet air temperature can change the air temperature field in the roadway as a whole. By changing the parameter of inlet air speed, it is found that higher wind speed brings better cooling effect, but with the increase in wind speed, the cooling effect of roadway thermal environment is very limited. When the wind speed increases from 5 m/s to 10 m/s, the air temperature of most measuring points drops by more than 2℃; when the wind speed increases from 15 m/s to 20 m/s, the air temperature of most measuring points drops below 0.7℃. After the wind speed reaches a certain value, the cooling effect of ventilation is very limited.

May 5, 2022

By Liming Yuan, Wei Tang, RICHARD THOMAS, JOHN SOLES, DAVOOD BAHRAMI

The abstract discusses the issue of mine equipment fires caused by hot surface ignition of flammable liquids. The research investigates the ignition probability of liquid fuels (diesel, engine oil, hydraulic fluid) on different metal surfaces (stainless steel, cast iron, carbon steel) under various ventilation speeds. The results show that the type of metal and ventilation speed influence the ignition temperature, with diesel being the most easily ignited fuel and carbon steel requiring a higher ignition temperature. The study provides data for understanding equipment mine fires and developing mitigation strategies.

May 4, 2022

By Shi Wang, Hongbin Liu, Meiliang Wei, Wu Liu, Xiaojun Wang, Yuxian Ke, Xuepeng Song, Tiejun Tao

The study investigates the influence of water migration on the fluidity of fresh cemented paste backfill (CPB) with and without flocculant under variable shear rates. The research utilizes nuclear magnetic resonance (NMR), rheological tests, and scanning electron microscopy (SEM) to analyze water migration, rheological properties, and microstructure evolution. The findings reveal that water migrates to more stable states as shear rate increases, and the addition of flocculant enhances water migration and increases shear stress and apparent viscosity. The study establishes relationships between water content and rheological parameters, providing insights into the flow characteristics of fresh CPB for pipeline transportation.

May 4, 2022

By X. Chen, F. An, H. Chen, Z. Wang

The bottom drainage roadway plays a crucial role in preventing coal and gas outbursts by using underground gas drainage methods. Therefore, it is essential to select the ideal position of the bottom drainage roadway. In this paper use a combination of geological data and numerical simulation to study the ideal position of the bottom drainage roadway, we taking the gas drainage of the first workface of No. 3 coal seam in the Yuxi coal mine in China as an example. The geological study showed a limestone marker layer at an average vertical distance of 14 m from the first mining face. Using this marker layer, the bottom drainage roadway could be excavated without the risk of accidentally exposing the coal seam, and less crosscutting borehole drilling from the bottom drainage roadway would be required. Based on the needs of gas control, the layout of the bottom drainage roadway was selected as an external stagger type. Combined with the numerical simulation results, when located 20 m outside of the mining workface ‘footprint’ on the horizontal projection, the bottom drainage roadway was a sufficient distance from the stress concentration area during mining of workface 1301, which facilitated roadway maintenance. Furthermore, the length of the crosscutting boreholes is also relatively short, which reduces the amount and cost of drilling. The results of this study are expected to provide a reference for the selection of an ideal position of the bottom drainage roadway in field engineering.

May 2, 2022

By S. Sekhar, S. Bhargava, A. K. Godugu, J. L. Porathur

Cemented backfilling has enabled underground hard rock mines to extract orebodies more safely with improved ore recovery. It is important to estimate the minimum required strength parameters for a backfill mix by optimizing the binder percentage to enable cost-effective and safe stoping operations. We conducted three-dimensional numerical modelling to study the effect of various stoping parameters on the stability of a free-standing backfill wall. A Mohr-Coulomb material model was used for the backfill material and the rock-fill interface. A strength reduction technique, excluding friction angle, was employed to arrive at a minimum stable strength value for the backfill. For a given combination of strength values, the stability state of the backfill wall could be demarcated using a displacement and yield zone tracking method. The numerical modelling results are compared to some earlier theoretical models. From the simulations, a predictive equation is developed to predict the required strength parameters for a backfill mix to ensure a stable free-standing wall. Examples are given of the successful use of the predictive equation at some underground hard rock mine sites in India.

May 2, 2022