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By Robert J. Timko, R. Lincoln Derick

The Bureau of Mines evaluated the integrity of escapeways in a three entry underground coal mine. A center conveyor belt entry (secondary escapeway), was flanked by an intake (primary escapeway) and a return entry. Diesel equipment was used throughout the mine for material and personnel haulage. A carbon monoxide monitoring system, tied to a data recording computer on the surface, was deployed throughout the belt entry and at selected sites in the intake and return entries. Previously, the company had a fire of unknown origin in another mine, which prompted an interest in the performance of their escapeways. An initial, qua1itative evaluation was performed by burning approximately 14 kg of coal at the mouth of the intake entry. The first test was followed by a similar burn at the mouth of the belt entry. These initial trials showed a high quantity of leakage between entries. In several follow-up evaluations, simulated fires, using a tracer gas, were set in the intake and belt entries. Tracer gas concentrations were obtained in all entries at four different underground locations. The results of these tests showed that permanent stoppings could not guarantee isolated, contaminant-free escapeways.

Jan 1, 1989

By Håkan Stille, Kjeld Boye-Møller, Lars Lundström

BACKGROUND Forsmark Power Station is a nuclear power plant under construction at the Baltic abt 120 km north of Stockholm. Investigations on the Site were started in 1969. Areas were reserved for a maximum of 6 units of which the buildings for two of them, Unit 1 and 2, were nearly finished in 1976, when the investigation for Unit [3], here presented, was carried out, cf Fig. 1. [ ]

Jan 1, 1979

By F. G. Hyde

Passage of the Public Utilities Regulatory Policy Act ("PURPA") in I 978 created an entirely new industry that is referred to today as the Independent Power Producers ("IPP"). Requirements of project owners, environmental compliance, project design, the financial community and most of all, the need to be a low-cost producer presented a unique situation for the sourcing and the utilization of fuels. Depending on the specific type of project being developed, (e.g. coal-fired, wood/biomass, natural gas, petroleum coke or a blend of several fuel types) and the type of boiler design, it is important to acquire fuels that will optimize both the project's operating efficiency and flexibility. This paper will focus on the acquisition of fuel for coal-fired projects, but will describe the necessary steps in the sourcing, contracting for, and the utilization of fuels and transportation resources in the IPP industry today.

Jan 1, 1996

By J. Sidhom, W. Fourie

"As the mining industry continues to face difficult challenges the need to persistently focus on productivity and utilization of labor and equipment costs will intensify. With these challenges in mind, Joy Global is helping to bring mining performance and analytics to the next level. By evaluating underground haulage, a significant component of the Room and Pillar mining value stream, variables have been identified and sensitivities have been performed to show opportunities to balance and streamline throughput. As a result of applying operational excellence tools to the mining environment, Joy Global is seeking to optimize mining performances by limiting waste, simplifying the process, increasing productivity and machine utilization, as well as removing workers from harm’s way. These days it’s not enough to work harder; mines have to work smarter. Improving efficiency, reducing costs, increasing safety: these are no longer ‘nice to haves’, they are ‘must haves’. Starting with the best products and the right people is a first step, but then what? How do mines take their operations from just OK to being a top performer? By using operational excellence principles aimed at eliminating waste, simplifying processes, automating where possible and removing people from harm’s way. The fundamentals of operational excellence (OpEx) are based upon the DMAIC process, which stands for define, measure, analyze, improve and control. DMAIC is an improvement cycle that helps with, for example, haulage optimization by: defining the issues and problems in the process as well as the areas of improvement; measuring and collecting mining operational data by time study and equipment monitoring system; analyzing through sensitivities and production modelling to determine root causes; then improving the performance and controlling the operation. Joy Global uses Joy OpEx or ‘lean’ principles inside its organization to drive efficiency, but it also helps its customers employ them to achieve new levels of productivity and safety. These same principles can be applied in most situations to streamline processes, improve operations and deliver value. As applied to mining, OpEx is seen as moving the needle on value creation by first identifying the value stream, then analyzing the areas that are not optimized. Once defined, these areas are ‘designed out’ of operational processes to create an automated operational flow. At a US coal mine, Joy Global was brought in to apply Joy OpEx principles to optimize mining and haulage to improve productivity and reduce costs. This multi-phase process started by defining the existing systems challenges to start finding areas for improvement."

Jan 1, 2017

By Mike Schaffner, Pieter Van Aswegen

There are a significant number of refractory sulfide deposits that cannot be economically treated with conventional roasting, autoclaving, or tank biooxidation technologies. Echo Bay and Biomin have developed the Integrated Tank/Heap Biooxidation Process (T/H process) to allow treatment of these deposits. This paper reviews the flowsheet development, pilot plant results, and economics of the T/H process.

Jan 1, 2000

By Joseph W. Siefke

The Kramer borate deposit is located in the western Mojave Desert at Boron, California, about 100 miles northeast of Los Angeles (Figure 1). The deposit derives its name from the district in which it lies. Borax (Na2 B407.10H2O) is being mined from the Boron open pit to serve a major portion of the United States and world borate markets. This paper deals primarily with those geologic factors which affect slope stability in the overburden at the Boron open pit. Discussion includes slope failure history, slope monitoring techniques and the results of a dipmeter survey of overburden structure. Open pit mining was begun at Boron in 1957. The initial pit was successfully excavated at the recommended 1.5:1 (horizontal to vertical) slope in the overburden. During pit expansion in 1962, excavation of the overburden exposed beds dipping into the pit at +15 degrees and numerous high angle fractures associated with two intersecting fracture systems, the West Jenifer and Portal fault zones. Ensuing south and east wall failures indicated the need for more structural information in the arkose to establish better wall design criteria. Barnard and Kistler (1963) recognized that the many facies changes, faults and other variables in the Boron overburden make it extremely difficult to reduce prediction of slides to a simple arithmetical formula. Despite the difficulties and uncertain¬ties, special programs such as surface resistivity, refraction seismic and core drilling were conducted in an attempt to predict slope stability conditions and to gather geologic information. These early efforts while helpful, did not provide the necessary details of bedding orientations and fault locations which are of paramount importance in our slope stability program. A dipmeter survey in 1974 successfully measured these variables and data from that survey are instrumental in the design of slopes currently being excavated.

Jan 1, 1976

By J. Stowe

While there has been continual improvement in the models for predicating deposition velocity and pipeline friction losses, the fundamental design philosophy for tailings pipelines has remained the same over the previous three or four decades: design the tailings pipeline to operate in turbulent flow without a deposit on the pipe invert for all expected process conditions. Recent improvements in the understanding of slurry pipeline flows allows for the design of pipelines operating with a deposit on the pipe invert, allowing the system to operate at moderate velocities for high flow rates, optimizing system energy requirements and maximizing pipeline wear life. Tailings pipelines are increasingly operated at higher solids concentrations where there is a greater likelihood the pipeline will operate in laminar flow due to the higher tailings slurry rheology. Historically, slurry pipelines have been operated in turbulent flow. We now know that laminar flow pipeline operation is possible as there are several operational laminar flow tailings pipelines. While our understanding of laminar flow slurry pipelines is not complete, recent research provides guidance on how to approach the design of these pipelines. New sensor technology has led to the development of an instrument that provides reliable indication of bed deposit height within a pipeline. This technology is particularly helpful in operating pipelines with a deposit and has application in better understanding the operation of laminar flow pipelines. Failure of tailings pipelines can result in consequent damage to surrounding structures and unacceptable spillage into the environment. Modern pipeline leak detection technology allows operators to better manage this risk by ensuring safe and reliable operation of tailings pipelines. This paper provides an overview of the each of the above advances in the design and operation of tailings pipelines. OPERATING TAILINGS PIPELINES WITH A DEPOSIT Tailings pipelines, and slurry pipelines in general, are typically designed to operate without a deposit on the pipeline invert. Meaning, the minimum operating velocity exceeds the turbulent deposition velocity. This approach has been adopted due to concerns regarding potential blockage of a pipeline operating with a deposit. Figure 1 shows a typical design duty envelope for a tailings delivery system as a function of solids throughput and solids concentration by mass. If the pipeline is designed to operate without a deposit at the lowest duty flow rate (4,480 m3/h), the operating velocity at the highest duty flow rate (6,590 m3/h) is about 1.5 times the deposition velocity. Considering that the pipeline wear and energy requirements are roughly proportional to the square of operating velocity, this results in an operationally inefficient system when the pipeline is operated close to the maximum design flow rate. Most systems tend to operate at maximum throughput after post-startup debottlenecking optimizations. Alternative Approach An alternate design approach is to ensure the pipeline operates without a deposit for the nominal flow rate and accept that a deposit will form when operating at lower flow rates. This results in the selection of a larger diameter pipeline, but there are significant benefits in terms of reduced energy requirements and lower pipeline wear.

Jan 1, 2019

By J. S. Martin

The redesign and reinforcement of a highwall located adjacent to a $10,000,000 shopping center, destabilized by active subsidence, was conducted after an extensive geotechnical investigation. The highwall was excavated in a hillside where a coal seam had been retreat mined and augered. Engineering geological mapping, determination of the properties and behavior of the intact rock, fractured rock, and urethane grout material, and soil were required to characterize the highwall and conduct a stability analysis. Remedial measures included re-excavating portions of the highwall to reduce the slope angle, and pressure grouting of the immediate roof.

Jan 1, 1988

By S. P. Banerjee

There has been a phenomenal increase in production of coal from opencast mines in India. At the same time environmental problems caused by mining are receiving greater atttention. Deterioration in ambient air quality due to increased concentration of suspended particulate matter (SPM) in and around an opencast project is a major problem. Some measured values of SPM level around opencast mines in diff coalfields show that in many cases the TLV of 500 ug/m^3 is exceeded. The impact of dust emission from a mining project on surrounding areas are estimated by using computer models for air pollution dispersal but such treatment suffers from errors in predicting the dust load and failure to take into account the terraced nature of the opencast mine site. The haul roads have been identified as the most prolific source of dust and some recent trials on haul road dust consolidation in Indian mines are mentioned in the paper. Statistics regarding pneumoconiosis cases in Indian coal mines for the last decade are presented to show an increase in reported cases and a gist of the recently amended regulations on the subject of precaution against dust is mentioned.

Jan 1, 1991

By A. E. Ketler

Powerful, yet inexpensive, personal computers running Windows-95 operating systems provide powerful mine-wide monitoring capabilities when properly engineered. Long awaited conductivity over LAN, phone and Internet links provide new dimensions for sharing information throughout an operator's organization, in- deed around the world. On-line data analysis, archival data storage and historical trend viewing generate shared inputs to production, safety and maintenance personnel. Five years in development, Rel-Tek's new EZ-Trol/W-DX system was engineered around the pilfalls of a Windows environment. It now offers higher speeds, 3D animated graphics and long distance telemetry - all with better reliability than ever before possible. The ubiquitous DDS utility inherent in most Windows was discarded in favor of a lightning fast RAM format. Several ponderous interpretive programs were redesigned into a single compiled entity, thus avoiding the overhead from message conversion, handshaking and transfer. To make the system user friendly, a 'Wizard" utility helps operators set up and reconfigure their systems on site. In-mine data acquisition telemetry was also re- vamped, incorporating a unique noise avoidance scheme, dubbed the "DX" bus - enabling longer distances and higher reliability. 12- bit analog conversion provides the enhanced resolution needed for field scaling auto-cal sensors. By mid '96, eight EZ-TROLMI- DX systems were up and running, several for more than a year. Factory updating and assistance are possible over a phone or Internet link. Our factory testing of components routinely includes actual operation at 2400 BAUD over 14 miles of twisted pair wires.

Jan 1, 1997

By Ataç Başçetin, Hasan Çelt, Hüseyin Onur Dönmez, Kürşat Hasözdemir

Phenolic foams, known for fire resistance, show broader industrial potential, particularly in mining, through property enhancements. Adjustments to the formaldehyde-to-phenol (F/P) ratio, bio-based additives like lignin, and nano-silica improve foam strength and thermal stability. Density modifications allow foams to range from flexible, low-density forms to rigid, high-density supports. In mining, enhanced phenolic foams could reduce coal ignition risks by acting as oxygen-blocking barriers. Current findings suggest these foams offer viable, sustainable solutions for safety in hazardous environments. Continued development could make them essential for thermal and mechanical applications under extreme conditions. This paper aims to provide a comprehensive overview of the mechanical characteristics of phenolic foams, current enhancement strategies, and standardized testing methods used to evaluate foam properties.

Feb 1, 2025

By William C. McBee

A sulfur concrete technology has been developed by the U.S. Department of the Interior, Bureau of Mines, in which chemically modified sulfur is utilized with suitable mineral aggregates to produce construction materials which are resistant to corrosion by acids and salts. This report presents a summary of the basic technology and results of testing the materials under actual operating conditions in 50 corrosive environments in 40 commercial plants. After 4 years of testing, there was essentially no evidence of material degradation or loss of strength. Regular concrete materials were attacked and in some cases completely destroyed under the same conditions. Testing is continuing to establish ultimate longevity and durability of the sulfur concretes. The materials are finding widespread applications in metallurgical, chemical, and fertilizer processing plants.

Jan 1, 1983

By L. Cheng

Almost all modern cutting bits use a cemented tungsten carbide tip to provide adequate hit life against wear. Laboratory tests by the US Bureau of Mines have indicated that the number of strikes for ignition increased by a factor of three with a new non-rotating bit impacting a sandstone block when the clearance angle was increased by 10°, and that carbide-tipped bits allowed more strikes before ignition than steel-tipped bits by a factor of 7 to 10. Recent field tests in an operating coal mine indicate a dramatic reduction in the frequency of frictional ignitions and improvement in hit life by using a mushroom-shaped hit cap and a larger initial clearance angle. The latter was achieved by increasing the hit attack angle. Improved hit performance through selection of the grade of tungsten-carbide is a com¬promise between fracture resistance and wear resistance. A large clearance angle should he maintained by various techniques, such as a variable attack angle holder, or a reusable hit that can he reground.

Jan 1, 1990

The issues involved in mine closure are usually complex, and the risks are significant. Although environmental risks are paramount, other issues such as safety, community, legal, fiscal and technical factors need to he taken into account. This paper describes a simple empirical model based on the concept of the closure risk factor, which will enable decision-makers to analyze the mine closure risks at any site, regardless of the complexity of the issues and the scale, scope and location of the operation. The model enables all the issues to be captured and their individual and collective risk quantified. A number of case studies in Australia and the Pacific that illustrate the usefillness of the model are presented.

Jan 1, 2002

By Anthony D. Hammond

Geographic Information Systems (GIS) are powerful analytical and data display tools for mining industry management, capable of linking spatial features with tabular data and integrating communications across departmental boundaries. This GIS application concentrates in four technical areas of underground mining: ownership and mineral claims; exploration management; production; and mine safety. GIS provides land and exploration managers with the ability to consolidate and archive claim data and to georeference property maps defined in local coordinates into world coordinate systems. It facilitates optimal siting and querying of service installations and refuge chambers relative to production centers. GIS's proximity analysis identifies areas of potential safety concern and points to and maps the shortest routes to emergency exits, facilitating the prompt evacuation of mine personnel.

Jan 1, 2002

By Jorma Miettunen

The Plant. The annual production of the Pyhasalmi mine is 900 000 tons of copper- zinc-pyrite ore containing approximately 0.7 % Cu, 2.5 % Zn and 30 % S. During 1976...1981 altered surface ore, 850 000 tons in all, was also treated at the concentrator. The surface ore was crushed and ground in a separate plant and was then fed into the copper or zinc flotation or was flotated in its own circuit, depending on the degree of alteration and the content of copper and zinc in the ore. The surface ore was exhausted in October 1981. Flotation comprises three consecutive flotation circuits; copper, zinc and pyrite circuit. The zinc circuit includes an open circuit roughing and scavenging. The scavenger concentrate and cleaner tailing are pumped to the middlings flotation. Rougher concentrates of the open circuit and the middlings flotation are pumped to cleaning which includes four stages. Figure 1 describes the flowsheet of the zinc circuit.

Jan 1, 1982

By A. J. Lewis, P. J. Hutcheson, M. E. Robertson, P. A. Moir, K. M. Barfoot

With the content of gold and platinum in the vast majority of ore deposits typically averaging 6 parts per million and less, the accurate and precise measurement of these metals in samples of ore and mining process streams has proven very difficult to achieve by modem spectroscopic analytical techniques. Largely because no other technique has proven suitable, the basic fire assay process has become the accepted international standard for these metals. Fire assay, however, suffers a number of disadvan­tages in the modem, competitive, high technology, and increas­ingly environmentally aware world. It is a labour intensive technique that is difficult to automate, and requires high levels of skill to ensure accuracy and consistency of results. Potentially hazardous chemical reagents are employed, of which, lead, in particular, can be a serious source of contamination to both personnel and the environment if not effectively controlled. Other dangerous elements, such as mercury and arsenic, liberated in high energy furnace operations, are further sources of possible health and pollution hazards. n contrast, the energy dispersive K X-ray fluorescence (K­XRF) technique devised by K X Technology Ltd overcomes many of the technical constraints of conventional low energy X­ray analysis, and has the potential to revolutionise assay opera­tions in precious metal mining. The technology is simply automated, requires basic operator skills, uses no chemicals, consumes less than 20kW, and is capable of detecting gold and platinum to an accuracy of O .1 parts per million by mass. The new third generation design of AZTEC laboratory instrument, released in 1994, is the result of significant technical development. Capable of analysing over 1200 samples per day, and developed primarily for grade control sampling, its applica­tions have spread to gold ore accounting from on-line conveyor belt sampling; screening of exploration samples; measurement of gold in carbon granules for Carbon-in-Pulp process control; and for conducting rapid checks to support key managemen decisions. The economic, rapid, and non destructive analysis ofup to 80g of ore for large numbers of samples, reduces sampling and sub-sampling errors, and provides improved grade estimates for ore bodies. When interfaced to a LIMS, laboratory automation and cost-savings can be further enhanced. The AZTEC design is also being modified for the analysis of platinum. The GOLDSTREAM on-line analysis system is an important new application of K-XRF to the continuous monitoring of process streams in gold ( or platinum) plants and mills. Integrat­ing the technologies of K-XRF to measure total gold, and dissolved gold spectroscopy to measure gold in solution, the insoluble fraction of gold can be deduced, and the effectiveness of the extraction process determined. Slurries are sampled automatically from selected points of the plant and pumped to the system for analysis. The information produced forms the basis for plant control and optimisation.

Jan 1, 1995

Not quite a year ago, during a speech to a group of mining professionals in Washington, DC, the subject centered around the long-range importance of conducting research projects and how much that research needs to specifically apply to health and safety matters in our industry. The point was made about the critical need to work together with government, private industry, labor organizations and academia speaking with a unified voice as we all march into the future together. The fundamental benefits of competitive research were mentioned --to improve our quality of life, to develop our energy resources, to achieve a safe and healthy environment and to ensure long-term economic growth. Very importantly, emphasis was given to the natural link that makes my agency, the Mine Safety and Health Administration, and the National Institute for Occupational Safety and Health --NIOSH --the beneficiaries of each other's findings. Unquestionably, there are lines of separation. The main responsibility of the agency I represent, MSHA, is enforcement of the nation's mine safety and health laws. But we also have an additional responsibility and that is to coordinate and give priority to research in a never-ending hunt for answers.

Jan 1, 1999

By A. C. Nixon, A. D. S. Gillies, Hsin Wei Wu

Ventilation and refrigeration strategies for the 3000/3500 orebodies, Mount Isa Mines, Australia were reviewed. The orebodies lie between 1,200 and 1,800 m below surface and are characterised by steep geothermal gradients, intensively mechanised stoping methods and high ambient air temperatures in summer. Providing acceptable working conditions under these situations is difficult and costly. The ventilation air quantity required in the 3000/3500 orebodies exceeds 550 m3/s when the production rate is greater than 2.5 million tonnes per year. The maximum quantity that can be supplied and exhausted using the existing intake and return ventilation system is estimated at about 630 m3/s. For production rates greater than 3 million tonnes per year, either new intake and return airways will need to be developed or innovative approaches such as controlled partial recirculation used. A description is given of technical and economic investigations conducted at Mount Isa into controlled partial recirculation. During these investigations, a major field trial of a controlled partial recirculation system was undertaken with results indicating that an acceptable working environment can be achieved practically and economically utilising this approach. The cost involved in controlled partial recirculation for supplying the required ventilation quantity when the production of 3000/3500 orebodies exceeds 3 million tonnes per year is examined. A cost comparison between recirculation and other conventional alternatives such as new surface shaft or underground booster fans is included. The results indicate that the option of a new surface shaft will incur a high initial capital cost and moderate annual operating costs. The alternative of underground booster fans will necessitate a moderate capital cost and very high operating costs. Controlled partial recirculation, in this case, offers both the lowest capital and operating costs of the three options evaluated.

Jan 1, 1995

By Thomas G. Johnston, Garston H. Blackwell

The development of a block model for a copper molybdenum ore deposit is described. The early use of the inverse distance power estimator, and later transition to geostatistics and kr iging, produced block models suitable for global reserve estimates. Because the global reserve was inadequate for routine mine planning, the production blast hole assays were incorporated into the block model, resulting in excellent local grade prediction. The on site use of small mini, and more powerful personal computers for estimating grades is described. The development of a computer aided, interactive graphic, mine planning system utilizing the grade block model is detailed.

Jan 1, 1987