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By C. Dirscherl

"Declining ore grade, leading to increased material transport and plant throughput requirements, is one of the major challenges in the current mining environment. This is accompanied by rising energy and labor costs, decreasing plant productivity and the requirement for highest plant availability. Siemens’ answer is the latest gearless drive technology for grinding and conveying. Gearless drive solutions are surpassing the mechanical limits of conventional drive systems serving to utilize the principle of economies of scale. By elimination of various components of the drive train, the maintenance activities and spare parts inventories are reduced. The advantages are culminating in the incomparable availability of the Siemens’ gearless drive technology of 99.46 to 99.71 percent — as confirmed by real operational data from the Antapaccay Mine in Peru. It was the first plant worldwide to use gearless drives for both applications.The gearless principleThe principal idea behind a gearless drive system is to reduce the number of components and diversity of parts, especially those components that are at the edge of current manufacturing or power limits are eliminated. The used equipment provides the possibility to scale up and increase the power transmitted to the driven machine. This finally results in a possible increase of throughput respectively transported or processed material.In order to apply this principle of simplification, the components of a conventional drive system are examined. They consist of:• Driven equipment (mill, conveyor, slurry pump).• Components altering the rated speed (gearboxes, girth gear/pinion).• The electric motor.• Starting devices for the motor (VSD, CCV, LRS, clutch), which are necessary because a direct across-the-line start of high power motors with load would result in a significant drop in the line supply voltage.• Alternatively a variable speed drive (VSD) or cycloconverter (CCV) to utilize the possibility of speed variation during operation.• The electrical supply system (cables, switchgear, transformers, protection equipment)."

Jan 1, 2015

By P. H. S. W. Kulatilake, T. Hudaverdi, C. Kuzu

Prediction of blast fragmentation plays a key role for overall productivity of mines. In this study, a new multivariate analysis procedure for prediction of blast fragmentation is presented. Several blasts performed in various mines and rock formations worldwide were brought together and evaluated. An extensive blast database was created. Blast design parameters, the modulus of elasticity and in-situ block size were considered to perform multivariate analysis. A complete multivariate analysis procedure was applied in three steps. First, a hierarchical cluster analysis was used to separate the blast data into different groups of similarity. Two different groups were formed based on the elasticity modulus values. In the second step, group memberships were checked by discriminant analysis. The dominant parameters of the occurrence of the groups were determined. Also, discriminant analysis was used to determine the group membership of the respective blasts. As the last step, the multivariate regression analysis was applied to develop prediction equations for estimation of the mean particle size of muckpiles. Two different prediction equations were developed based on the rock stiffness. Validation of the proposed equations on various mines was performed. Prediction capability of the proposed models was found to be strong. The models are not complex and are suitable for practical use at mines.

Jan 1, 2011

By J. D. McAteer

It is widely agreed throughout the mining community that federal mine safety and health legislation administered by the Mine Safety and Health Administration (MSHA) deserves significant credit for the past quarter-century's remarkable improvements in miner safety and health. Recently, however, it has been suggested that the mining industry in the United States has now evolved to a point that current mine safety and health law may be obsolete. This proposition deserves attention. Today, I propose to give it the close logical scrutiny that is its due. I conclude that the obsolescence of current mine safety and health law is not supported by the evidence. The existing mine safety and health law continues to serve as a critically important supplement to mine operators' safety programs at a modest cost to the taxpayer. At the same time, trends in a changing industry do call for responsive adaptations in the Federal mine safety and health program. I will argue that timely and appropriate responses to changing needs can be accomplished within the framework of existing legislation, provided federal officials avail themselves of the flexibility provided by existing law.

Jan 1, 1996

By Gang Yang, Manchao He, Chengzhang Gao, Jun Zhang, Yayun Li, Jun Yang, Shilin Hou, Ben Liu, Yajun Wang, Jianning Liu

To explore the mechanism of roof directional breaking in gob-side entry formed automatically without coal pillars, the numerical simulation was used to study the deformation movement of roof, the deformation evolution of roadway, and the stress distribution of roadway under roof directional breaking and non-roof directional breaking. Based on the results, the deformation movement of roof is divided into three stages: the goaf roof collapse stage, the basic roof deformation stage, and the basic roof stability stage. The goaf is filled with gangue due to the broken expansion characteristics of the collapsed rock under the roof directional breaking. Due to the supporting force of gangue, the deformation of the basic roof under the roof directional breaking is smaller than that under the non-roof directional breaking, which reduces the influence of the deformation of the basic roof on the deformation of the roadway roof and improves the integrity of the roadway. At the same time, roof directional breaking cuts off the stress transfer path of partial roof, which weakens the peak stress convergence on the arc side, transfers the peak stress convergence to deeper, and improves the stability of roadway. Finally, a field test was carried out to further verify the accuracy of the numerical simulation. The field test results are in good agreement with the numerical simulation results. The roadway deformation is small and meets the requirements of safety production. It is proved that roof directional breaking plays a positive role in improving the stability of the roadway.

Dec 22, 2022

By J. H. van Laar, C. S. L. Schutte, M. Le Roux

Highly energy-intensive systems prone to wastage are significant causes of unnecessary energy losses in industry. Deep-level mine chilled water reticulation systems fall within this category of inefficient energy-intensive systems. Some techniques (measured baselining, zero-waste baselining, leak detection, and control valves) exist to identify and reduce wastage in mine water reticulation systems. However, these techniques have not been compared, which begs the question of which is more accurate. A need, therefore, exists to compare these methods to determine the effectiveness of each. This study investigates each method and applies them to a case study mine, providing a platform for comparison. These methods identified wastage ranging between 2 and 20 l/s (3–30% of water consumption). The comparative effectiveness of the methods from best to worst was found to be zero-waste baselining, leak detection, control valves, then measure baselining. This study proposes an application procedure combining the considered methods to identify and eliminate wastage on deep-level mine systems more efficiently.

Jan 31, 2024

By Chamila Jinendra Nanayakkara, Nimila Dushyantha, Amila Sandaruwan Ratnayake, Gayithri Niluka Kuruppu

Rare earth elements (REEs) are key ingredients in many advanced materials used in energy, military, transportation, and communication applications. However, the prevailing geopolitical dynamics and the rising demand for REEs have rendered the reliance on primary REE resources susceptible to future supply disruptions, posing a substantial risk to the availability of these elements for numerous applications. Therefore, it is imperative to undertake substantial initiatives in the extraction of REEs from secondary sources on a large scale to ensure the resilience of the supply chain. Permanent magnets, lighting phosphors, and nickel-metal hydride (NiMH) batteries are among the secondary sources with high potential for sustainable REE extraction. This review assesses the extraction potential of REEs from the aforementioned three secondary sources and their leaching kinetics and thermodynamics aspects. More importantly, state-of-the-art different existing kinetic models employed in rare earth (RE) leaching were well discussed for a better understanding of the REE leaching reactions. Furthermore, the optimized leaching parameters related to this kinetics were described, and various RE recovery methods were comprehensively summarized. These processes facilitate to managing one of the fastest-growing solid waste streams by minimizing environmental impacts and producing critical metals, including REEs via circular economy approaches. The recovery of REEs from secondary sources aligns with numerous United Nations Sustainable Development Goals (SDGs), particularly in the renewable energy sector for climate change mitigation. Consequently, this trash-to-treasure urban mining concept to transforming e-waste into a valuable resource for REE recovery emerges as a pivotal element within the REE industry.

Dec 28, 2023

By SAHENDRA SINGH, SANJIT KUMAR PAL, DHARMITA HORO

The North Singhbhum Mobile Belt (NSMB) lies between two crustal-scale shear zones, the South Purulia Shear Zone (SPSZ) at the north, and the Singhbhum Shear Zone (SSZ) at the south. The Babaikundi-Birgaon Axis (BBA) is an east-west trending secondary shear zone in the NSMB lying south of SPSZ, which is known for the occurrence of gold along with other sulfide minerals within the quartz reefs. The present study has been carried out at north of Ichadih village, which lies on the BBA. The present study attempts combined electrical resistivity tomography (ERT) and self-potential methods along a profile of 470-m length in the Ichadih area to map the potential mineralized zones. Initially, ERT sections generated by Wenner, Wenner- Schlumberger, dipole-dipole, and joint inversion of the combined array have been analyzed, and results are validated through the analysis of model resolution. A prominent low resistivity (10–100 Ωm) associated with quartz reef/limonitic quartz reef at a depth of approximately 30–85 m, encircled by a high resistive (more than 10,000 Ωm) formation associated with metasedimentary rock, has been delineated using joint inversion of the combined array. Further, analysis of self-potential (SP) anomaly using particle swarm optimization inversion also confirms the prominent low SP anomaly at a depth of 77.3 m, which is analogous to the low resistivity anomaly identified in the joint inversion of the combined geo-electric array. Subsequent analysis of a complex synthetic geo-electrical model analogous to the present field situation proves the efficacy of the joint inversion of combined arrays. As a whole, joint inversion of multi-array data is established as an efficient technique for better subsurface imaging in case of the complex subsurface structure. In-depth analyses confirm the possibility of sulfide mineral-rich deposit (quartz reef/limonitic quartz reef) which requires further geological drilling and lithogeochemical sample analysis, for possible future exploration.

Oct 26, 2020

By D. Brandt

The Dos Pobres Mine is a copper oxide heap-leach operation located near Safford, AZ. Mine production is 163 kt/d (180,000 stpd) with a stripping ratio of 2:1. During the startup phase of the mine, the required fragmentation size was easy to achieve as the ore was highly weathered and fractured near the surface. As the mine depth increased, the proper fragmentation size became harder to achieve due to less weathering and different rock types. Because copper recovery increases as crusher product size decreases, achieving the appropriate product size at the crusher is the operating priority. The engineering department began a project to improve fragmentation through blasting and thus increase throughput in the crushing system. It soon became clear that input from other departments was going to be required to make this a safe and economical project. Therefore, the crush and convey and ore control departments worked together to evaluate all available data on blast patterns and explosive loads and tracked performance and results. Using image analysis, drill energy index and databases, improved fragmentation size has been achieved and results have been verified while controlling costs.

Jan 1, 2011

By Phil Shelton

What exactly does clean coal mean? Mining coal creates dust and releases methane gas. And burning coal liberates CO2 and emits particulates, including SO2 and NOx. Coal creates wastes that are often stored in unsightly and potentially dangerous slag heaps and lagoons. When clean coal technology is discussed, it sometimes seems that creating modern or ?ultra super critical? coal-fired power stations is presented as the main or even the only answer. However, there may be a more holistic approach. Using the energy potential of coal is always going to have environmental impacts. Some of these will be negative. But the need to secure future energy resources demands that society tackle these negative issues and find ways to minimize and offset them.

Jan 1, 2010

By G. ALBORNOZ, S. Utili, A. AGOSTI, C. VALDERRAMA, R. PELL, N. Morales

The steepness of the slopes of an open pit mine has a substantial influence on the financial return of the mine. The paper proposes a novel design methodology where overall steeper pitwalls are employed without compromising the safety of the mine. In current design practice, pitwall profiles are often planar in cross-section within each rock layer; i.e., the profile inclination across each layer tends to be constant. Here instead, a new geotechnical software, OptimalSlope, is employed to determine optimal pitwall profiles of depth varying inclination. OptimalSlope seeks the solution of a mathematical optimization problem where the overall steepness of the pitwall, from crest to toe, is maximized for an assigned lithology, geotechnical properties, and factor of safety (FoS). Bench geometries (bench height, face inclination, minimum berm width) are imposed in the optimization as constraints which bind the maximum local inclination of the sought optimal profile together with any other constraints such as geological discontinuities that may influence slope failure. The obtained optimal profiles are always steeper than their planar counterparts (i.e., the planar profiles exhibiting the same FoS) up to 8° depending on rock type and severity of constraints on local inclinations. The design of a copper mine is first carried out employing planar pitwalls, secondly adopting the optimal pitwall profiles determined by OptimalSlope. The adoption of optimal slope profiles leads to a 34% higher net present value and reductions of carbon footprint and energy consumption of 0.17 Mt CO2 eq and 82.5 million MJ respectively due to a 15% reduction of rockwaste volume.

Feb 9, 2022

By C. A. Rowland

The use of the Bond Work Index to size industrial grinding equipment is well known. Its use to measure grinding efficiency was presented by C.A. Rowland, Jr. at an AIME meeting in 1976. However, due to a bureaucratic error, the paper was never submitted for publication. This metric has nevertheless been adopted by industry as a widely used standard. The purpose of this paper is to re-present and update the application of this tool as a standard for measuring grinding circuit efficiency. Definition ?standard, n. something established for use as a rule or basis of comparison in measuring or judging capacity, content, extent, value, quality, etc.; as standards of weight and measure? (Webster, 1958).

Jan 1, 2008

By Vivek Priyadarshi, VIVEK KUMAR HIMANSHU, A. K. Vishwakarma, M. P. Roy, A. K. Mishra, RAVI SHANKAR

The nature and orientation of joints in rock strata affect the damage pattern under explosive loading. Most of the limestone deposits in India are found with severity of joints. Categorically, these joints may have variable orientations such as dipping out of the blast face, inside the face, horizontally or having strike parallel to the face. The damage pattern under the varying category of orientation will be different. Accordingly, a numerical model in Ansys-Explicit Dynamics was prepared to compare the damages of rock mass under different joint orientations. The physical nature of a joint reflects frictional and stiffness behaviour. Accordingly, the damages have been compared under bonded and frictional nature of joints. The output damage pattern from the model has been validated on the basis of blastability index proposed by Lilly. Different limestone mines in India show different nature of jointing in their rock strata. Accordingly, the blasting outputs from three different limestone mines, viz. Rawan limestone mine, Sagmania and Birhauli limestone mine and Injepalli limestone mine, have been compared along with their blast design parameters and the nature of joint. The comparative results show that the closely spaced horizontal joints support maximum in burden movement and rock fragmentation due to blast.

Nov 23, 2023

By Jack E. Bailey

From a start in 1957, milling 3,000 TPD of copper ore, the Cyprus Pima Mining Company, which is located 20 miles south of Tucson, has expanded its operations four times, and is currently treating over 55,000 TPD of ore.1 The most recent expansion added a 14,000 TPD semi-autogenous concentrator to the operation. Shortly after startup in January, 1972, the semi -autogenous plant exceeded the designed tonnage rate.2 Ore from the mine is delivered to a 54 inch gyratory crusher and is reduced to a minus 8 inch product. From the crusher the ore is stacked on a surge pile and then reclaimed and fed to the two parallel grinding circuits. A 28 ft. diameter by 12 ft. long semi-autogenous mill and a 16.5 ft. diameter by 19 ft. long ball mill make up each grinding circuit. The semi-autogenous mills are in closed circuit with screens and the ball mill circuits are closed with hydro- cyclones. Rougher flotation follows the grinding operation. Concentrate regrinding and cleaner flotation is performed in Mill I, the older mill. The generalized flowsheet is shown in Figure 1.

Jan 1, 1975

By H. Y. Sohn

Considering the two most important issues the ironmaking industry faces today, i.e., energy consumption and greenhouse gas emissions, it would be advantageous to utilize the concentrate-size raw materials directly without pelletizing or sintering, especially without the use of coke. This plenary lecture describes two such processes developed at the University of Utah. One is the Flash Ironmaking Technology (FIT) and the other is a moving-bed process for continuous ironmaking with gaseous reduction of iron ore concentrate (MBIT). These technologies are designed to produce iron directly from iron concentrate without requiring pelletization/sintering and cokemaking in two significantly different temperature ranges. They take advantage of the high reactivity of the concentrate particles and will considerably reduce energy consumption and carbon dioxide emissions compared with the current processes. The process of the development from the conception of the idea, to kinetic feasibility establishment, to laboratory flash furnace, and finally to the operation of a prototype facility for the development of the FIT is discussed. The development of the MBIT also started with the formulation of the process concept, followed by kinetics feasibility establishment, and the design of a potential industrial reactor. The results of economic analyses on the FIT are briefly described.

May 12, 2023

By Ernest E. Thurlow

The Geology Division of Northern Pacific Railway Company has adapted to its exploration efforts field procedures for geochemical sampling and semi-quantitative analysis which have been developed through research by the U. S. Geological Survey. The sampling is done in conjunction with reconnaissance geologic mapping on aerial photographs or during field checking of maps which have been prepared largely by photogeologic interpretation.. Stream sediment or soil samples are taken and readily soluble combined heavy metals are extracted with ammonium citrate followed by colorimetric titration with dithizone at the sample site. The effectiveness of this approach has been demonstrated both in positive and negative results, thereby assisting in the elimination of large areas of land from further immediate attention and in providing targets for followup exploration. An occasional sample is submitted for spectrographic analysis as a check on the possible presence of other elements of economic significance. Field laboratory procedures are also being implemented for determining molybdenum, mercury, and other metals which may be valuable in themselves or useful as pathfinder elements in outlining mineralized areas. A lead-zinc occurrence in Oregon and a copper deposit in Montana were readily detected and outlined by stream sediment and soil sampling and a heavy metal anomaly that lacks obvious interpretation has been found in northwestern Montana. Detailed mapping and additional sampling are followed by other exploration techniques if warranted.

Jan 1, 1964

By D. Pearson

About 15,000 tonnes of zinc per year is present in the dusts and fumes produced in electric arc and BOS steelmaking, secondary copper refining and brass ingot making. Apart from the use of some copper-smelter fumes for zinc chemicals manufacture, zinc is not recovered and their disposal by landfill entails some risk of pollution by leach-out. The paper describes processes for recovering the zinc based on leaching and electrowinning. It was shown that the procedures normally employed for purifying zinc-electrolytes derived from primary sources are sometimes ineffective for secondary materials. Alternative process routes are proposed. Source materials were leached with acidic or alkaline reagents and solvent extraction was employed for electrolyte purification in addition to the usual techniques involving precipitation. Examples of integrated flow sheets for specific source materials are presented.

Jan 1, 1980

By Robert Essler, Paul Marsden, Paul Pandrea

"1. THE VICTORIA STATION TRANSPORT HUB Victoria Underground station is part of the Victoria transport hub, which comprises one of London’s main train termini and a major bus station. At the Underground station, the District Line running in the older shallow brick tunnels dating back to 1868 cross the Victoria Line running in the lower tunnels, which were opened in 1969. After Waterloo, Oxford Circus and King’s Cross/St. Pancras Tube stations, Victoria is the most frequented station on the London Underground network and is used by over 80 million passengers per year. Capacity at Victoria Tube station has been inadequate for many years with passenger numbers steadily rising. Overcrowding is a constant challenge and the station has to be closed regularly during morning and evening peaks until sufficient trains pass through to clear the platforms. For this reason an extension has been debated since the 1990s. After intensive preliminary investigations and feasibility studies covering many variants, which included a large-scale jet grouting test to determine the applicability of this technology as a protective measure for the tunnelling works, the project was officially started with the Victoria Station Transport and Works Act Order (Secretary of State, 2009) effective on the 18th of September 2009. Following a competitive tender process a joint venture of Taylor Woodrow and BAM Nuttall were awarded the contract by London Underground, with their design being carried out by Mott MacDonald Ltd. Ensuring the busy station remained open to the public was a key requirement of the Victoria Station Upgrade. Jet grouting works, which were executed from ground surface, were also carried out while the station was fully operational 2. OVERVIEW The Victoria Station Upgrade aims to increase the capacity of the Underground station significantly and one of its major design objectives is to optimise the transfer between the Underground lines. In order to achieve this, the following new structures are currently under construction: •,A new North Ticket Hall •,Extension of the existing South Ticket Hall •,Nine new escalators •,Connecting tunnels between the North and the South Ticket Hall •,8 new lifts providing step free access to all platforms •,An improved connection between the rail/bus terminus and the Underground station As the elevation and geometry of the existing structures cannot be changed, the new structures need to be adapted to the existing structures (see Figure 1)."

Jan 1, 2016

By B. Boutilier, R. Mendoza

"First Majestic Silver Corp. (FMS) is a silver mining company founded in 2002 that operates exclusively in Mexico. It has six producing silver mines, one of which is the La Encantada silver mine (La Encantada) located in the state Coahuila. La Encantada is located near the southern United States border and 708 km (440 miles) north of the city Torreon.La Encantada is located in the Sierra Madre Oriental and is a high-temperature carbonate replacement deposit. Mineralization in La Encantada occurs in many different forms such as veins, chimneys, breccia pipes and reefs (mantos). Mineralization is mainly oxides of iron, zinc, lead and manganese, with high concentrations of sulfides at depth relating to two main intrusive events: the Milagros Intrusive and the La Prieta Skarn.Mining began in La Encantada during the 1950s with small vertical shafts, drifts and raises. It focuses on the high-grade silver zones using traditional hoists and extraction methods, before branching into two main separate mining camps: El Plomo and Penoles camp. Penoles, the previous owner, focused mainly on large ore bodies using post pillar cut-and-fill mining method to extract the higher-grade material. Due to the type of ground, irregularity of pillars, and rock conditions, large amounts of high-grade pillars had to be left in situ to ensure the stability of the excavations. The mined-out areas would then be filled with lower-grade material to assist in the stability of the secondary level. These room-and-pillar development entries were 2.5 m x 2.5 m (8.2 ft x 8.2 ft) and spaced every 10 m (32 ft), leaving a vertical pillar of 7.5 m (25 ft). First Majestic acquired La Encantada in 2006. After the acquisition of the mine, the company began the conversion of the surveying reference system from a local grid (Maria Isabel Shaft as 0,0) to the Nav27 coordinate system, and subsequently converted to the WGS84 coordinate system in 2015. Due to the extensive history of the mine, different areas were surveyed with different systems, causing significant challenges when designing the principal extraction levels, pillar heights and ramp locations. To overcome this difficulty, the entire mine was resurveyed and the old workings transposed to the new coordinate system, except for some inaccessible areas due to poor ground conditions or ground collapses. To further ensure pillar height and the safety of the mine workers, probe holes were drilled during the development process."

Sep 1, 2019

By Snehamoy Chatterjee, Sanjay Kumar Palei, Smarak Das

Machine manufacturers’ recommendations on maintenance strategies of capital-intensive draglines are not always based on real data and therefore lead to losses from downtime. This paper proposes a preventive maintenance strategy for a dragline deployed in an opencast coal mine based on reliability-centered maintenance and failure-mode-effects analysis using real operational data. Reliability-centered maintenance replaced a cluster of critical failure components of the dragline while satisfying two specific conditions: (i) the components should be replaced at the earliest mean time to failure (MTTF) within the group and (ii) the time taken to replace all the parts should be equivalent to the maximum downtime within the group. Estimated threshold weightage factor identified twenty-six critical failure components for the preventive maintenance strategy, and clustering of components divided them into nine groups. In a group, the loss that is expected to occur by replacing some of the components before their failure, and the gain by reducing the overall maintenance downtime, has been explained through a cost-benefit analysis. The total net profit generated is calculated as US$200,178. This clustering activity also led to a reduction of annual downtime by 231 h, whose approximate market price as equivalent coal production costs $295,365.

May 28, 2020

By W. Roggenthen, Z. J. Hladysz, G. D. Callahan, W. G. Pariseau, W. Weinig, C. Randolph-Loar, R. Popielak

A Deep Underground Science and Engineering Laboratory (DUSEL) is being planned at the site of the former Homestake Gold Mine in Lead, SD, under the sponsorship of the U.S. National Science Foundation (NSF) in cooperation with the Department of Energy (DOE). This national facility will host a variety of multidisciplinary science and engineering experiments, including physics experiments that require shielding from cosmogenic radiation. Current plans include construction of large rooms (up to 55 m in width) at depths of 1.48 km (4,850 ft) and 2.25 km (7,400 ft) below the surface. Preparation of the preliminary design required the development of a geotechnical characterization program, including preliminary drilling and coring, core logging, drill hole mapping with a televiewer, drift mapping of the geology and rock structure, in situ stress measurements, and laboratory testing of the mechanical properties of the rocks and discontinuities. Overall rock quality is very good to excellent. Site investigations included geotechnical assessments for the construction of caverns and laboratory modules. The results are favorable and reaffirm selection of the Homestake site for establishment of a Deep Underground Engineering and Science Laboratory.

Jan 1, 2011