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By M. R. Shahan, W. R. Reed, S. Klima, T. W. Beck, Y. Zheng

Testing was conducted to determine the ability of foam to maintain roof coverage in a simulated longwall mining environment. Approximately 27 percent of respirable coal mine dust can be attributed to longwall shield movement, and developing controls for this dust source has been difficult. The application of foam is a possible dust control method for this source. Laboratory testing of two foam agents was conducted to determine the ability of the foam to adhere to a simulated longwall face roof surface. Two different foam generation methods were used: compressed air and blower air. Using a new imaging technology, image processing and analysis utilizing ImageJ software produced quantifiable results of foam roof coverage. For compressed air foam in 3.3 m/s (650 fpm) ventilation, 98 percent of agent A was intact while 95 percent of agent B was intact on the roof at three minutes after application. At 30 minutes after application, 94 percent of agent A was intact while only 20 percent of agent B remained. For blower air in 3.3 m/s (650 fpm) ventilation, the results were dependent upon nozzle type. Three different nozzles were tested. At 30 min after application, 74 to 92 percent of foam agent A remained, while 3 to 50 percent of foam agent B remained. Compressed air foam seems to remain intact for longer durations and is easier to apply than blower air foam. However, more water drained from the foam when using compressed air foam, which demonstrates that blower air foam retains more water at the roof surface. Agent A seemed to be the better performer as far as roof application is concerned. This testing demonstrates that roof application of foam is feasible and is able to withstand a typical face ventilation velocity, establishing this technique’s potential for longwall shield dust control.

Jan 1, 2017

By M. R. Shahan, W. R. Reed, S. Klima, T. W. Beck, Y. Zheng

Testing was conducted to determine the ability of foam to maintain roof coverage in a simulated longwall mining environment. Approximately 27 percent of respirable coal mine dust can be attributed to longwall shield movement, and developing controls for this dust source has been difficult. The application of foam is a possible dust control method for this source. Laboratory testing of two foam agents was conducted to determine the ability of the foam to adhere to a simulated longwall face roof surface. Two different foam generation methods were used: compressed air and blower air. Using a new imaging technology, image processing and analysis utilizing ImageJ software produced quantifiable results of foam roof coverage. For compressed air foam in 3.3 m/s (650 fpm) ventilation, 98 percent of agent A was intact while 95 percent of agent B was intact on the roof at three minutes after application. At 30 minutes after application, 94 percent of agent A was intact while only 20 percent of agent B remained. For blower air in 3.3 m/s (650 fpm) ventilation, the results were dependent upon nozzle type. Three different nozzles were tested. At 30 min after application, 74 to 92 percent of foam agent A remained, while 3 to 50 percent of foam agent B remained. Compressed air foam seems to remain intact for longer durations and is easier to apply than blower air foam. However, more water drained from the foam when using compressed air foam, which demonstrates that blower air foam retains more water at the roof surface. Agent A seemed to be the better performer as far as roof application is concerned. This testing demonstrates that roof application of foam is feasible and is able to withstand a typical face ventilation velocity, establishing this technique’s potential for longwall shield dust control.

Jan 1, 2018

By John M. Dale

Now that the price of sulfur has reached unexpected high levels, it is little wonder that sulfur from surface ores is again receiving attention. In most instances, it is advantageous for an ore to be at or near the surface. However, it is a distinct disadvantage for sulfur ore to be close to the surface because it precludes the use of the Frasch process. The Frasch process depends on the presence of at least 180 m of uniform overburden to allow pressure injection of superheated water into the sulfur-bearing formation to melt the sulfur. In the Frasch process, sulfur separates cleanly from the gangue underground and comes to the surface in a very pure form. Surface sulfur deposits, particularly those in the Western Hemisphere, exist largely due to volcanic activity, and sulfur separation from the gangue is a formidable technical problem. None of the surface deposits are large compared to some of the Frasch deposits, but at the present sulfur price, they are certainly of economic importance. From the turn of the century until 1975, the price of sulfur was for the most part $18-$28/t. However, with the price of sulfur now over $154/t, there are a variety of technical alternatives to consider for sulfur surface ore separation that may not have been economically attractive a few years ago.

Jan 9, 1981

By P. A. Plunkert, D. E. Morse, L. McCartan, J. F. Papp

The mineral sector is a fundamental part of the U.S. economy. It contributes to the real gross domestic product (GDP) at several levels — basic (mining), intermediate processing, manufacturing of finished goods and construction. The real GDP during 2004 increased by 4.4 percent. The nominal GDP was about $11.7 trillion. Housing starts were up by slightly more than 4 percent for the year. And the nation’s unemployment rate decreased to5.5 percent in 2004 from 6 percent in 2003. Interest rates continued to be low (prime rate was 5.25 percent at the end of 2004) but have risen gradually, following rising inflation.

Jan 1, 2005

By Colin Barratt

The East Side Access (ESA) project is the largest underground rail infrastructure project under construction in New York City, USA. The Manhattan segment of the project is to be mined through rock and consists of 4.1 miles of Tunnel Boring Machine tunnels for track work and mined excavations to house rail switches, air plenums, and other rail facilities. This paper considers different methods for concrete lining, such as the use of fixed forms, adjustable forms, and pneumatically applied shotcrete. The advantages and disadvantages of these methods are discussed and the basis for considering one over the other are illustrated. Further discussions on design development and preparation of documents to facilitate quality and constructability in the field are presented.

By M. L. Harris, J. Organiscak, S. Klima, I. E. Perera

"The Pittsburgh Mining Research Division of the U.S. National Institute for Occupational Safety and Health (NIOSH) conducted underground evaluations in an attempt to quantify respirable rock dust generation when using untreated rock dust and rock dust treated with an anticaking additive. Using personal dust monitors, these evaluations measured respirable rock dust levels arising from a flinger-type application of rock dust on rib and roof surfaces. Rock dust with a majority of the respirable component removed was also applied in NIOSH’s Bruceton Experimental Mine using a bantam duster. The respirable dust measurements obtained downwind from both of these tests are presented and discussed. This testing did not measure miners’ exposure to respirable coal mine dust under acceptable mining practices, but indicates the need for effective continuous administrative controls to be exercised when rock dusting to minimize the measured amount of rock dust in the sampling device IntroductionTwo recent regulations have modified operators’ rock dusting schedules in order to meet compliance standards. First, the 80 percent incombustible requirement in intake entries has increased both on-section and out by the- section rock dusting. Secondly, the recent change to the respirable dust regulation has increased the number of respirable dust samples taken per sampling cycle. Previously, when only five samples were needed bimonthly, rock dusting could be scheduled to not interfere with the respirable dust sampling schedule.The significant number of samples now required under new regulations, combined with the need to maintain 80 percent total incombustible content in active mining areas, require the schedules for respirable dust sampling and rock dusting to overlap. Although rock dust is considered a nuisance dust in relation to U.S. Mine Safety and Health Administration (MSHA) sampling, these overlapping schedules raise concerns about the amount of rock dust that potentially is included in the sample. Additionally, the respirable dust maximum was lowered from 2.0 mg/m3 to 1.5 mg/m3 effective Aug. 1, 2016, increasing concern that rock dust contamination may be an issue (MSHA, 2016). Currently, the acceptable practice is to apply administrative controls such as keeping the miners upwind during rock dust application, or to schedule rock dusting during a maintenance shift when the number of miners present is lower."

Jan 5, 2017

By Richard L. Stotlar

Introduction During the last decade, the metallic minerals segment of the industry could be categorized as a "feast-or-famine" business. It is no secret that metallic minerals are cyclical. Employment opportunities greatly depend on the supply and demand for its mineral products. It is also not unusual for there to be a lag between the industry's manpower requirements and academia's ability to produce new graduates. Due to this lag, there will be years with manpower shortages, as in the mid-1970s. At other times, supply will exceed demand. The question is where will the jobs be in the years to come? This presentation will review reasons why employment opportunities have declined within the metallic minerals industry. It will also predict future demand for mineral engineering graduates. And it will outline strategies for obtaining an employment offer. Historical Review - Employment From 1977 through 1983, about 75% of all metal mining employees were directly engaged in production activities, down from 83% in 1965. This decline reflects increased use of labor saving equipment, and more government regulation and foreign competition. Metal mining's employment decreased from 74,000 jobs in 1982 to fewer than 68,000 in 1983 - an 8% decline. The overall industry is having these problems because of the general downturn in the economy. For example, at the beginning of this decade, US automobile and steel industries were in trouble. Interest rates were too high and volatile. This adversely affected construction, housing starts, and manufacturing. All these industries, being large users of base metals, drastically affected the metals industry. US copper companies are still having problems. Reports indicate that many copper employers have cut production, laid-off workers, and permanently closed mines, refineries, and smelters. A decline in the demand for US produced metal products, such as copper, obviously affects some mineral engineering employment opportunities. Other factors to consider when looking at employment opportunities and why it has become difficult for US metal producers to compete in the world market include: • The grades of ore bodies of many US minerals are considerably lower than the grades of ores being mined elsewhere in the world. • The grades of ore bodies currently being mined in the US are steadily declining. • Foreign producers are largely government controlled and are not necessarily subject to the realities of supply and demand. • US environmental regulations have considerably added to production costs. Foreign producers in most countries do not have to worry about these additional costs. • US mines are getting deeper. This adds to the cost of production because of the increasing distance the ore has to be transported. • Plants and equipment are outdated. Many companies find themselves operating with equipment and plants that need modernizing or replacing. This obviously hinders competitive productivity. • Labor and management have had problems. Work stoppages in certain mining businesses and high wage and benefit costs in relation to foreign producers place US producers at a disadvantage. • Much land is unavailable. The US government owns most of the land considered to have the best potential for minerals development. Most of this land is unavailable for mining or exploration. Therefore, it appears that finding employment with a company whose primary business is mining and processing most metals, such as copper, in the US will be quite restricted and competitive. Future Demand It is difficult to anticipate what key employment opportunities within the next few years will be available to mineral engineering graduates. The Engineering Manpower Commission estimated that US engineering schools awarded 72,471 undergraduate degrees in 1983 vs. 66,990 in 1982. This was the eighth consecutive year in which the number of baccalaureates awarded has increased. On a brighter note, the US government's Occupational Outlook Quarterly stated that the growth rate through 1995 for all engineers is an encouraging 49% over present levels. The estimated number of engineers employed in 1982 is 1.2 million. The numerical in-

Jan 2, 1985

By J. Baz-Dresch

A custom-designed shotcrete system, consisting of an 8-m3 (10-cu-yd) transit mixer and a shotcrete spray boon carrier, is used by a two-man crew to transport and place up to 25 m3 (32 cu-yd) of steel fiber reinforced, dry, silica fume shotcrete per 11-hour shift. Shotcrete is custom blended by a local supplier and delivered predampened. Mix design and quality control are performed with a computer program that develops and graphs a properly balanced mix based upon the materials sieve analyses.

Jan 1, 1992

By Bruce Geller

The 2004 Prospectors and Developers Association of Canada (PDAC) conference contained an air of optimism and excitement that has not been seen since 1997. Many segments of the mining industry are alive and well. This is largely a reflection of improved metal prices, themselves due to the strong euro and improvements in Asian economies. Those factors offset higher oil prices, a weaker U.S. dollar and concerns about the Middle East. This report is an overview of the conference. It is supplemented by an examination of conference handouts, abstracts and a few complete papers that are on the PDAC’s Web site www.pdac.ca. Sixty PDAC 2004 abstracts are available at the same site, along with 15 complete papers in PDF format. The conference was held March 7-10 in Toronto, Ontario. It was attended by a record 9,200 delegates from 85 countries. About 8,000 people from 74 countries attended the 2003 conference.

Jan 1, 2004

By J. Philip Neal

Feldspar is no example of special mineralization in isolated spots: it can usually be found within a mile or so of almost anywhere. Along with silica sand, it is a major part of our world's total mineral composition. This fact imparts to it an economic status different from a sulfide ore, or potash, or phosphate. While every feldspathic "stringer" does not possess economic potential, the generous distribution does yield a high statistical frequency of good feldspar ore bodies: the adjective "good" being subject to some flexibility of interpretation. The strong chemical bonds of this alkali aluminum silicate give it certain use advantages, but under present technology its individual elements cannot practically be separated to create aluminum, potassium, sodium, silicon - or their oxides. Its present uses rely upon chemical inertness - as in fillers; and on its physical melting characteristics and their effect in glass, enamel, or ceramics.

Jan 1, 1973

By S. Pastor, S. Hahn

"As the concept of autonomous haulage systems (AHS) moves from prototypes to production-ready applications, the operating performance of the haul road will become critical to the overall success of autonomy in mining. Deterioration in road performance will require remediation, human intervention and significant, albeit temporary, changes to operating procedures, to accommodate road maintenance. With autonomous trucks comes the opportunity to reduce road formation and operating width. This will, therefore, generate potentially significant reductions in stripping ratios and improvements to mine economics, but only if the design of the road, and its associated deterioration rate, is predictable and manageable, based on the materials used to construct the road and the maintenance interventions to be carried out on the road.This article presents the assessment of a digital photogrammetric approach to the characterization of a mine haul road surfacing, or wearing course material. Design and maintenance parameters for these roads are currently determined partly from physical particle size distribution (PSD) assessments of ‘in-road’ material. However, this approach does not accommodate the need, nor leverage the benefits from, AHS. The digital imaging approach is assessed in this article, using two standard digital analysis software tools, together with in-service mine haul road wearing course samples and images that are analyzed to determine the applicability and reliability of the approach to deliver a real-time assessment of haul road surfacing conditions and thus to identify the road maintenance interventions required to address deterioration.Enhancements in mine road design, construction and management for the past 20 or more years has largely been focused on short-term tactical needs. These improvements have not been matched by advances in the fundamental technologies that underpin mine road design and management and, although the quality of mine roads have probably"

Jan 1, 2015

By G. Le Bel

The paper proposes three methods to determine optimum lifetime of a mining project1. The conclusion is that the three methods arrive at the same optimum production rate (by coincidence). It is also stated that: "The stochastic and option pricing models, in addition to providing a more realistic optimum mine life than the traditional NPV (net present value) calculation, showed that the example project has the potential for substantially higher return. By explicitly considering a project's potential risks, the stochastic or option pricing techniques can more accurately describe its probable investment performance." This discussion is intended to demonstrate that: • It is no coincidence that the three methods arrive at the same optimum production rate. • The stochastic and option pricing models do not provide a more realistic optimum mine life than the traditional NPV calculation. • The potential for a substantially higher return is misrepresented. First, a review of investment decision theory in mining is needed. Net present value is the preferred performance measure because of the flexibility offered when comparing various alternatives. However, it presents the following disadvantages: • The discount rate selection is not straightforward. • The NPV obtained represents a deterministic characterization of the variables included in the cash flow calculations, i.e. a single-point estimate.

Jan 1, 1993

By David G. Adam

Introduction Syncrude Canada Ltd. is the operating company for a consortium of industry and government participants that produce synthetic crude oil from their leases in the Athabasca Oil Sands. Production from the $2.3 billion (1978) integrated mining, extraction, and bitumen upgrading and utility complex started in September 1978. Production is currently about 6.4 Mm3/a (40 million bbl per year) of high quality synthetic crude oil. This is done by upgrading the extracted bitumen from the oil sands mined. Plans are to increase the production to 8 Mm3/a (50 million bbl pier year) by 1989. At that time, the mining operation will be required to deliver 100 Mt/a (110 million stpy) of oil sand (ore) to the extraction plants, and handle quantities of waste ranging from 50 to 75 Mt/a (55 to 83 million stpy). The Syncrude plant is located at Mildred Lake, 40 km (25 miles) north of Fort McMurray and 480 km (300 miles) north of Edmonton, Alberta. Climate, particularly winter, is therefore a major factor affecting the design and operation of all the Syncrude production facilities. Bitumen production, consisting of overburden removal, oil/sand mining, bitumen extraction, and tailings disposal, account for about half the total SCO production costs. Considerable research and development, therefore, continues to be applied to improve both material handling and bitumen recovery methods. Potential applications for feeder breakers were identified in the material handling aspects of both overburden and oil sand mining to reduce cost and to attain planned production increments. Overburden removal Overburden materials on the leases comprise thin Pleistocene sands, gravel and fill, and sands, silts and clays of the thicker Clearwater Formation with the silt to clay components predominating. The latter contains multiple leases of hard siltstone with unconfined compressive strengths up to 148 MPa and thicknesses up 0.1 to 0.9 m (1 to 3ft). Characteristics of the overburden as well as the climatic environment and scale of operation present unique problems for the efficient removal of the material. In a bucketwheel/conveyor system, the weak silty clay formations require relatively flat working slopes for safe operation, while the siltstone lenses and frozen overburden require blasting or selective removal by other equipment. These factors, combined with the normal bucketwheel/conveyor design parameters, lead to high capital investment and relatively inefficient use of that capital. Hydraulic mining alternatives, including dredging, are constrained by severe clay settling problems in the waste disposal

Jan 6, 1986

By R. A. Jankowski, J. D. Potts

Four underground respirable dust surveys were conducted to determine factors affecting belt entry dust levels and how using belt air to ventilate work areas affected dust exposures. Belt entry dust levels on the surveyed longwall and continuous miner section averaged 0.59 and 0.26 mg/m3, respectively. The stageloader/crusher contributed an additional 0.5 to 0.9 mg/m3 of dust to belt air, while the feederbreaker contributed 0 to 0.2 mg/m3 of dust. A 1000 ft (305 m) increase in belt entry length or a 200 to 500 tons/shift (181,000 to 454,000 kg/shift) increase in production resulted in roughly a 0.1 mg/m3 increase in dust. Using the belt entry as an intake entry on the continuous miner section appeared to reduce dust levels by 0.1 to 0.3 mg/m3 during cutting. Belt air was not used to ventilate the face on the longwall section.

Jan 1, 1992

By Emily Wortman-Wunder

While the mood at the 2013 annual joint meeting between the Pittsburgh Coal Mining Institute of America (127th Annual Meeting) and SME Pittsburgh Section (68th Annual Off-the-Record Meeting) in Canonsburg, PA was subdued following a rocky year in the coal industry, attendance was down only slightly, to 300, and overall, the meeting?s focus was optimistic about the future of coal. The conference began by addressing one of the central challenges of coal mining head-on with a keynote address on the status of safety in the mining industry. Noting that two more U.S. miners had died in 2013 than by the same date in 2012, the National Mining Association?s (NMA) Senior Vice President of Regulatory Affairs Bruce Watzman made a plea for a new approach to safety. He described the NMA CORESafety initiative, a program that promotes proactive safety measures versus a compliance-driven model. CORESafety, described in more detail on pp. 29 of this issue, focuses on developing successful ways to change company cultures of safety and behavior. Other industries that have adopted this approach have seen dramatic drops in fatalities, including the Australian mining industry, which has seen its annual fatality rate drop to nearly zero even while the number of people employed in the industry has soared. The rest of the morning?s sessions explored what is arguably the industry?s biggest challenge right now ? maintaining the social license to operate.

Jan 1, 2014

By Manuel Arnáiz, Pedro R. Sola, Rogelio Baudot, Manuel Herrera, Carlos S. Oteo

The aim of this paper is to describe and analyze the ground treatment performed between January and May 2002 in order to increase safety during excavation and reduce instability problems along 180 m of tunnel, during the construction works associated with line 10 extension to the Madrid Metro. The tunnel was excavated using the traditional Madrid Method and in the section considered in this paper layers of sand were detected around the tunnel crown area with a significant presence of water, the in?ow of which needed to be controlled with a minimum impact on the surrounding environment.

Jan 1, 2003

By Bruce Gellar

For the past six years, the author has made it a priority to attend the Prospectors and Developers Association of Canada’s (PDAC) annual conference. This most recent meeting took place March 10-13, 2002in Toronto, Ontario. In the three years since the author’s last PDAC report, the mining industry has undergone a severe trough. Some the industry’s woes included deeply discounted commodity prices, rampant layoffs, mergers, and overall avoidance by the investment community. However, at each of the PDAC conferences, the author has felt a heightened sense of excitement about the mining industry, more so than at other similar gatherings.

Jan 1, 2002

By V. Herman, B. Knorr, D. Whalen

"Edge effect is a condition widely observed in High Pressure Grinding Roll (HPGR) operations that gives rise to reduced comminution at the edges of the roll surfaces. This effect is caused by a reduction in the local crushing pressure at the edges of the rolls resulting from the sliding friction between the static cheek plates and HPGR feed material. Practically, this has an impact on equipment sizing, as the edge effect leads to coarser particles reporting to downstream equipment in open-circuit operations and increased circulating load and diminished HPGR circuit capacity in closed-circuit operations.To address this, Metso's HRC™ HPGR incorporates an Arch-frame to maintain a parallel relationship between the rolls and allow for the use of a flanged roll design. We conducted a series of pilot-plant tests with a 750 mm by 400 mm HRC HPGR to compare the performance of the flanged roll design against that of a traditional cheek plate arrangement under similar operating conditions. The edge effect was found to be significantly reduced with the flanged roll design. Based on the pilot-plant results, the implications for circuit design, energy efficiency and overall plant performance in a full-scale application were investigated and discussed.IntroductionGlobal trends such as lower ore grades and rising operating costs are driving the market toward more energy-efficient mineral processing solutions, most notably in comminution circuit design. High pressure grinding rolls (HPGRs) have been recognized as an energy-efficient solution relative to more conventional circuit designs. The basic operating principle of HPGRs, in which a fairly uniform pressure is applied to a bed of material in the compression zone, lends itself to this improved energy efficiency (Morley, 2006). Studies have estimated that savings of 10-15 percent are possible when comparing an HPGR circuit with a traditional SABC circuit (Rosario and Hall, 2008). While HPGRs offer a more energy-efficient solution than tumbling mills, there is still room for improvement in many aspects of the design. Edge effect, in particular, is one such aspect that limits the effectiveness of the machines. Edge effect is the impaired performance at the edge of the rolls due to a reduction in crushing pressure (Morley, 2010; van der Meer, 2010). As described in our prior work (Knorr, Herman and Whalen, 2013), edge effect is caused by the interaction between the ore entering the crusher and the relatively static cheek plates positioned at the edges of the rolls. As the material is drawn into the crushing zone, the sliding friction between the ore and the cheek plates inhibits the ability of material to be effectively drawn into the compression zone at the edges of the rolls. This reduces the crushing force in those edge regions relative to the center of the roll where material is being drawn into the compression zone at a higher rate. In addition, the cheek plates of a traditional HPGR design are held in place by spring-loaded brackets that are adjustable to manage the clearance. This spring-loaded cheek plate design prevents full compression of the material in the edge regions of the roll as there is relief at the outer edges."

Jan 1, 2016

By F. Dieu, C. Laughton

CERN, the European Laboratory for Particle Physics, is, at present, constructing an underground tunnel and cavern network to house a Large Electron Positron (LEP) colliding beam machine. This paper describes the techniques adopted to permit the excavation and temporary support of the access shafts through a series of glacial moraines, at depths of up to 80 m, to reach the bed-rock. Owing to the presence of superficial and deep water-tables, the variable nature of the moraine deposits and, above all, the tight work schedule, a combination of diaphragm walling and ground freezing was employed.

Jan 1, 1987

By Yehia M. Youssef, Nourhan Moukhtar, M. H. Abdel-Aziz, Ibrahim Hassan

Copper was recovered from copper sulfate solution in a batch-recycled galvanic reactor operated under forced convection with the generation of electrical energy during the cementation process. The divided galvanic cell consisted of parallel copper and zinc plates. The mass transfer rate and the amount of electrical energy generated were found to be directly proportional to the solution flow rate and the initial concentration of metallic ions and inversely proportional to the distance between electrodes. The experimental results were expressed in terms of a dimensionless correlation including all parameters. The wastewater treatment presented herein cell can be utilized to recover many soluble heavy metal ions from solution with high efficiency.

Oct 2, 2020