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By Fredrik Sarvell, Leo-Ville Miettinen, Veli-Matti Uotinen

"Abstract The continued concentration of building activities in cramped areas of city centres means more underground construction and facilities. Demand to minimize execution time and any kind of disturbance to business, general traffic, people and nearby technical structures is increasing. To answer these challenges foundation business has to develop schedule-wise and technically reliable deep excavation and foundation solutions in vulnerable surroundings and challenging soil conditions.Drilled pipe pile wall – RD-pile wall – is a combination of Ruukki drilled steel pipe piles and interlocking sections. Individual RD piles, typical diameters between 219 mm to 610 mm, are connected to each other with interlocks welded to the piles on the automated welding line at the workshop. The matching dimensions of the drilling system and interlocking sections allow the installation of RD piles through stones and boulders and even into the bedrock, if necessary, in a single operation. Installation is done by a down-the-hole hammer (DTH) using the centric drilling system and oversized ring bits or a drilling system consisting of a pilot bit and reamer wings.RD-pile walls have been used as permanent and temporary retaining walls for different kinds of demanding excavations and structures, such as bridge foundation, as quay wall and as sealing structure in rehabilitation of an existing dam. Rigidity and watertightness of the lower end of the RDpile wall is being researched as well as fire design issues examined. One of the most fascinating RDpile wall solution is to utilize the wall as a permanent underground basement wall. Reliable and rigid connection to bedrock decreases the bending moment and deflection of the wall and good fire resistance in addition to large variety of pile dimensions and steel grades gives possibilities to design and execute a cost-efficient basement wall and foundations without temporary retaining wall works. 1. IntroductionIn northern Scandinavian soil conditions, installation of sheet pile walls, or even secant pile walls, is often problematic due to the existence of hard and large boulders in the overburden, and especially when the retaining wall structure should penetrate to or into the hard bedrock. On the other hand, an efficient and reliable piling technique suitable for the demanding soil conditions described above, percussion drilling, has been developed since the 1960’s, and especially from the mid-1990’s, when the concentric drilling method with the ring bit and pilot was introduced. A new retaining wall application, the RD pile wall was developed by combining that drilling method with the widely used retaining wall solution based on steel pipe piles and welded interlocks (a pipe pile wall normally installed with vibratory or impact hammers)."

Jan 1, 2014

By J. Dahner

Total milling cost is composed of energy, liner and grinding media costs. In primary high ball load milling, the grinding media play the biggest role in total milling cost. This cost can be drastically reduced by improving the impact condition inside the mill. The impact condition inside the mill is influenced by shell liner design (as well as feed end and discharge design) and the type of discharge. The improvement of the impact condition will result in a significant decrease in grinding media consumption. The softened impact condition allows for better alloy optimization, resulting in a further reduction in grinding media consumption. Optimized liner design can also improve energy consumption as less energy is wasted in the projection of the grinding media. Magotteaux utilizes tools to simulate and show the grinding media trajectories for shell and end liners. This paper will present some practical examples where the media and energy consumption can be or has been reduced by optimizing liner design. Keywords Comminution, grinding, liner design, grinding media wear.

Jan 1, 2011

By Madan B. Karkee

The understanding and the development of sound theoretical basis concerning the pile foundations has been phenomenal during the past few decades, considering the thousands of years the piles have evidently been in use. The importance of the quality assurance and the need for verification of load bearing capacity is being further reinforced rather than undermined by these developments. This is evidenced by significant developments made in the pile load test technology in recent decades, making it possible to make judicious selection of a test method, or a package of test methods, suitable for a given situation. The selection depends on the objective of carrying out the test and the reliability desired. Presently, the possible selection ranges from dynamic to static methods. The extent of dynamic effect in a test can be reckoned based on a dimensionless parameter defined as the 'relative duration'. Examples of different load tests are given for illustration of the different methods currently in use.

Jan 1, 1997

Ultrasonic Extinction for High Resolution Particle Size and Concentration Analysis

Sep 13, 2010

By Pat McLaughlin

Blast design in the construction industry has often been based on past practice or powder factors. This is to some extent understandable, since construction projects do not have the longevity of mining or quarrying operations and therefore have less opportunity to pursue potential improvements. The main concern of the operator is whether or not the technique will work, and at what cost to the downstream processes. Time, not long term savings, is of the essence.

Jan 1, 1994

By Alain Bouchard, Germain Labonté, Jim Barrett

"Mill feed materials that are not run-of-mine ore are often a challenge for mineral processors and tend to accumulate in stockpiles, where they remain unprocessed for many years and become “slow moving inventories”. During a complete re-evaluation of the Clarabelle Mill operation (38,000 ton/day capacity) in 2000, it was concluded that there was an opportunity to assemble a 5,000 ton/day custom circuit to treat such stockpiles in the equipment that remained available during regularly scheduled maintenance shut-downs.This project was part of the larger Mill Redesign Project and involved testing the intended flowsheet under a number of operating scenarios for the first material to be treated: spent refractory bricks. The laboratory focus was on how to maximize returns using the available equipment and reagents.The circuit was successfully commissioned in the fall of 2000. As the brick stockpile was depleted, other potential feeds were evaluated at the laboratory, as well as in the new custom circuit itself. Processing of the spent refractory brick has yielded a significant contribution to the profitability of INCO. Significant opportunities lie ahead for generating more value from other slow moving inventories.INTRODUCTIONIntegrated mining operations tend to have slow moving inventories along the path from the mines to the finished products. Spent refractory bricks from furnaces and converters and furnace bottoms are materials that often end up in long-tern stockpiles. Such stockpiles are a challenge, although they represent small tonnages on an annual basis, because they are unique materials, which cannot be readily brought into the process at a rate anywhere near that at which they are produced, due to the high contents of deleterious components such as chromite or magnesia. Accumulation over years will eventually yield a metal inventory worthy of consideration given the right opportunity, such as availability of spare equipment or peak metal prices."

Jan 1, 2002

By François Robichaud

"The Laronde mill has been in operation since 1988. Actual milling rate ranges from 7,000 to 8,500 mtpd. Laronde uses SAG/ball mill grinding followed by copper and zinc flotation circuits. A cyanidation/Merrill-Crowe process recovers the remaining gold and silver in the flotation tails.In 1999, the carbon in pulp circuit was replaced by a Merrill-Crowe circuit in order to cope with a much higher ratio of silver/gold associated with the discovery of the Penna shaft. Marine type diatomaceous earth was used as filter aid in both clarifier pressure leaf filters and recessed pressure filter presses from 1999 to 2005. In 2005, this filter aid was gradually replaced by alpha-cellulose after several laboratory and plant filtration trials. The selected cellulose is considered to be much less sensitive to parameters such as pH and reagent concentration and have increased clarifier and filter press filtration performance. Also, since cellulose is exothermic, replacing diatomaceous earth with cellulose as filter aid in the filter presses has increased calcining and oxidation rates in the calcining ovens since cellulose is exothermic. Finally, better calcining conditions have resulted in energy and reagent savings at the arc furnaces.This paper describes how the filter aid replacement has contributed to increasing productivity and Net Smelter Return of the refinery while reducing worker’s hazards and operating cost.INTRODUCTIONAll Merrill-Crowe circuits in the world are operated with filter aids. For years, the market for precoat filter aid has been dominated by mineral filter aids such as diatomite and perlite. Flowsheet and equipment selection at the Laronde refinery were performed in the late nineties. At that time, some key parameters of the design criteria had clearly identified marine type diatomaceous earth (DE) as the most successful filter aid. Parameters such as reagent cost and availability, clarity of the filtrate solution and good historical filtration performance in other concentrators had designated DE as the best suited filter aid. Pregnant solution processed in the refinery from its start-up through 2001 was fairly stable in flow rate and reasonable in terms of impurity content (cationic and anionic compounds)."

Jan 1, 2007

By N. Mphathiwa

When slope angles are designed during open pit optimization, there is a risk factor applied in steepening the slopes. The steepening of slope angles has implications for the safety and economics of the mining operation. The steeper the slope angles, the greater the probability of slope failure. Although a slope failure will result in added costs, the challenge is to compile an accurate cost-benefit exercise optimizing the economic benefits of the project without exposing mine workers and equipment to unacceptable risk of rockfalls. A balance between the safety of the operation and the economics of the investment is therefore required. The ideal situation is to have a slope monitoring system that will predict slope failure by detecting any ground movement before the actual failure occurs. This early warning will allow the risk factor to be applied with a high degree of confidence, knowing that the risk will be adequately mitigated. The objective of this paper is to provide guidelines on how to design an optimal survey slope monitoring system. It is the authors? view that for a survey monitoring system to yield desirable results, it should adhere to survey principles such as working from the whole to part and consistently cross-checking. The case study used is Jwaneng Mine, and the design strategy outlined can be used as a guideline for developing a new slope monitoring system or to optimize an existing one.

Jan 1, 2014

By D. Fray

Electrochemical processing using molten electrolytes is undergoing a considerable renaissance due to several innovative ideas being explored both in the laboratory and also at the pilot scale. Several of these new ideas are related to developments in energy generation and storage and involve solid electrolytes. Sodium has been prepared by the electrolysis of sodium carbonate or sodium hydroxide with the transfer of sodium ions through a sodium beta" alumina membrane and magnesium oxide dissociated by the removal of the oxygen through a stabilized zirconiaelectrolyte incorporating a fuel cell electrode. By using halides with highly electropositive cations, such as molten calcium chloride, it has been found that the favoured cathodic reaction, when oxygen is present, is the ionization of oxygen and not the deposition of calcium. This approach has been applied to the reduction of many metal oxides including titanium, zirconium, niobium and rare earth oxides and, by using a mixture of oxides as the cathode, homogeneous alloys are produced. This concept can also be applied to deoxidation of solid and liquid metals. Refining of metals is possible using intercalation compounds and, in a completely different application, it has-been found that, by intercalating alkali metals by electrolysis of alkali halides into graphite, it is possible to produce carbon nanotubes and nanoparticles. The technological opportunities of these various concepts will be discussed.

Jan 1, 2004

By S. Djaroudib

Keywords: iron recovery, hematite, hydrolysis, polyvinylpyridine The precipitation of hematite (Fe2O3) from ferric chloride media at ambient pressure and at temperatures below 100°C was studied as part of a program to recover a marketable iron product form metallurgical processing streams and effluents. Hematite was formed in preference to ferric oxyhydroxides (e.g. ß-FeO?OH) by controlling the precipitation conditions, especially by adding Fe2O3 seeds. The extent of the hydrolysis reaction was found to depend primarily on temperature and on the free-acid concentration. As to the latter, the controlled addition of an adsorbent of free acid, in our case the anionic resin polyvinylpyridine (PVP), was shown to allow for the nearly complete removal of iron as readily filterable Fe2O3. The hematite product typically contains = 63% Fe and = 1.5% Cl, and its composition does not change appreciably upon repeated cycling using regenerated PVP.

Jan 1, 2005

By Brian Fulcher

The Arrowhead Tunnels Project represents the final portion of a 70 km (44-mile) long water conveyance facility that will bring up to 28 m3/sec (1,000 ft 3/sec) of water into Southern California. The 13 km (8-mile) tunnelling project is well underway and consists of two, 5.8 m (19-ft) diameter TBM bores through extremely variable geological conditions. An extensive and essential pre-excavation drilling and grouting program was performed in all reaches of the Arrowhead Tunnels Project, located north of San Bernardino, CA. This program supported the advance of two hybrid hard rock TBMs though extremely challenging ground conditions under substantial ground cover and up to 27 bar (900 ft) of ground water pressure. The well known San Andreas Fault lies nearby and has greatly influenced the local geological conditions. This paper will describe the means, methods and materials used throughout the numerous phases of the pre-excavation grouting program. It will also describe many versatile, flexible and innovative drilling and grouting methods and equipment systems utilized to improve performance, save time and costs in constantly changing geological conditions. Considerable lessons learned have been learned while overcoming some extremely formidable ground conditions and safely advancing the tunnels.

Jan 1, 2008

By Reno M. Pappas, Christopher Mark

This report presents results of a U.S. Bureau of Mines study of longwall gob material. The objective of this work was to determine material stiffness properties of the gob for use in numerical models of rock mass response to longwall mining. Photographs of actual mine gob were digitized to obtain approximate particle size gradations of gob material. The gradation curve was shifted down to a lab- oratory scale, and 20 uniaxial compression tests were conducted. Varying the maximum particle size was not found to affect the stress-strain behavior, but changing the gradation appeared to influence the stress-strain behavior. The stress-strain relationship of the simulated gob material was nonlinear, the stress-secant-modulus relationship, was approximately linear, and the stress-tangent-modulus relationship was approximately a second-order polynomial function. Equations were generated from these curves, providing numerical modelers with a means to estimate gob moduli based on the stress level. In addition, the experimental data were statistically evaluated using multiple regression analyses, producing a series of equations to predict the secant and tangent moduli from the given stress level, bulking factor, rock strength, and thickness-to-width shape ratio of the particles.

Jan 1, 1993

By Chris D. Shewmaker

So you want to install 2,600 augered cast-in-place piles, about 155,000 lineal feet, in 33 working days? It can be done. The Public Service Enterprise Group (PSEG) decided to build a combined cycle power plant in Lawrenceburg, Indiana. PSEG selected Fluor Constructors Indiana, L.P. to design and build the plant. Fluor Constructors, in turn, selected Richard Goettle, Inc. to install the piles. The initial plan was to install the 2,600 piles in 33 days, working six (6) ten hour days per week. After successfully installing and performing four pile load tests - up to 300 ton capacity - we set out to complete the work and meet the aggressive schedule. After three weeks of installing an average of 75 piles a day with three drill rigs, Fluor relaxed the schedule because we were so far ahead of their projected construction sequence. We elected to continue drilling on a ten-hour day, five days a week schedule. In all, we installed nearly 2,800 piles, totaling 175,000 lineal feet, in about 47 days.

Jan 1, 2004

By D Syme

In the middle of 2000, BHP Billiton implemented a Six Sigma Plus business improvement program known as Operating Excellence. It was developed based on a business bottom line initiative to deliver 35 - 40c/share and was one of the BHP Billiton strategies to deliver $2 earnings per share and a longer term $40 share price (BHP share price). Cannington is a silver, lead and zinc mine owned and operated by BHP Billiton. Through implementing Six Sigma Plus Cannington wanted to:have in-house capabilities to change and improve; tailor for the needs of each business unit and department; have æSharing of its KnowledgeÆ as a tool for improvement and have a competitive edge across Cannington û to be better than our competitors; learn from and leverage off the successes of improved safety and prior business improvement efforts; and ensure networking and sharing of information have common measurement systems across all assets. As with most business improvement programs û Six Sigma Plus was met with some degree of skepticism, especially given the amount of resources involved. After 18 months, much of this skepticism has been replaced with enthusiasm as peopleÆs understanding and acceptance of its fundamental concepts are being realised. The idea behind Six Sigma Plus is that it combines sound technical solutions with high acceptance by those who need to work with or implement the change. The future vision for Six Sigma Plus is that it become part of what we do at Cannington û just like safety and environment û so that Six Sigma tools and methodologies are used in our every day work.

Jan 1, 2002

By W Taylor, S Chen, R Haywood, M White, R West, J Ranasinghe

In March 2012 a combined BHP Billiton and Hatch team embarked on a program to improve the concentrate burner efficiency of BHP Billiton’s Olympic Dam copper flash smelting furnace. A multi-faceted approach including an analysis of the furnace using operational knowledge and first principles engineering led to the design and supply of a new central-lance (disperser). A new, patented, swirl method of introducing the copper concentrate into the furnace was developed to integrate with the existing concentrate burner. Plant trials in 2014 demonstrated an increase of nearly 10 percent in the oxygen efficiency of the furnace. The improved efficiency is expected to provide savings in operating costs and asset life extension of downstream gas and dust handling equipment.CITATION:White, M, Haywood, R, Taylor, W, Chen, S, Ranasinghe, J and West, R, 2015. Improved copper flash smelting at Olympic Dam, in Proceedings MetPlant 2015, pp 382–395 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

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. Hooman, W. M. Marx, R. C. W. Webber-Youngman

This paper discusses a study that investigated different underground bulk air heat exchanger (>100 m3/s) design criteria. A literature review found that no single document exists covering all design criteria for different heat exchangers, and therefore the need was identified to generate a guideline with decision analyser steps to arrive at a technical specification. The study investigated the factors influencing heat exchanger designs (spray chambers, towers, and indirect-contact heat exchangers) and the technical requirements for each. The decision analysers can be used to generate optimized, user-friendly fit-for-purpose designs for bulk air heat exchangers (air cooler and heat rejection). The study was tested against a constructed air cooler and heat rejection unit at a copper mine1. It was concluded that the decision analysers were used successfully. This tool (decision analysers) can be used by engineers for the efficient and cost-effectively design of heat exchangers.

Jan 1, 2015

By A. W. Diedericks

Rosh Pinah Zinc Corporation (RPZC) identified implementing a Mineral Resource Management (MRM) programme at the mine as a strategic incentive. The purpose of the programme is to optimize the economic value of the RPZC mineral resource, over the total value chain of the mine, taking expected macro economic conditions into consideration as well. With Mineral Resource Management still being a relatively young drive in the mining industry, information on the concept is relatively scarce. RPZC had several successes and problems with implementing such a concept and also still has a way to go before a complete Minerals Resource Management approach is implemented at the mine and entrenched as a working culture. The purpose of this paper is to: ?define a systems approach to implementing a Mineral Resource Management programme at a base metal mine ?indicate the specific MRM approaches taken at RPZC ?indicate the expected advantages of implementing a MRM approach ?measure the actions already taken against the systematic MRM approach, and indicate the advantages already captured ?indicate the way forward taking lessons learned into consideration ?indicate proposals to implement the MRM approach in the macro mining environment in South Africa.

Jan 1, 2003

By R. L. Grayson, G. Mishra

Introduction Many old underground mines have been developed extensively into reserves requiring large numbers of workers to maintain and rehabilitate lengthy track haulages and/or belt conveyor systems. Often, large numbers of fans are required to maintain minimal airflows in areas where poor conditions and huge leakages prevail. Problems that beset one such coal mine and projects undertaken to restore it to potential profitability are presented. Brief history The Vesta No. 5 mine was opened in 1908. Drift development began near the Monongahela River, which was the primary avenue for shipping metallurgical coal to coke ovens in Pittsburgh. Over the ensuing 75 years, the main haulage entries were developed a distance of 16.1 km (10 miles) to the present mining area. Track haulage was used to transport coal from working sections to the river loading facility. As haulage distance and areas of high water influx increased, management decided, in 1973, to construct an underground conveyor belt system. The project spanned 36 months and culminated in a system of 22 flights, ranging from 205.7 to 1767.8 m (675 to 5800 ft) long. Six intake and eight return entries were developed as the mains were advanced. These entries provided adequate ventilating capacity over the years, but as extensive gob areas progressed and roof conditions deteriorated, the entries became inaccessible and more resistant to airflow. By 1981, five fans were being used to circulate 943.9 m3/s (555.5 cfm) of air through the mine. An average of 6440 t (7100 st) were produced from 20.8 continuous miner unit shifts and 2.7 longwall unit shifts each day in 1981. The ratio of support to production personnel was 1.94. To maintain the outby 16.1 km (10 miles) of haulage, 110 personnel were used. The average cost per ton was $43.54 ($39.58 per st), resulting in excessive bottom-line losses. The mine possessed a rather promising reserve, mostly in lease, of good quality, medium-sulfur metallurgical coal, but it also had a number of formidable operating problems. Operating problems Contributing factors toward relatively low productivity and high costs were the conditions of the track haulage, conveyor, and ventilation systems. Productivity was affected greatly by downtime associated with the conveyor system, which lacked adequate access for making splices or other repairs. Many areas within the conveyor belt entry itself required more

Jan 3, 1987

By R. G. Gürtunca, J. A. Breslin

This paper briefly describes the progress in mine safety in the United States, with emphasis on recent events that have followed since the explosion at the Sago Mine in January 2006. Legislation following the mine accidents last year and areas of work carried out by the National Institute for Occupational Safety and Health (NIOSH) related to the accidents are discussed. American coal production in 2006 was 1,150 million short tons. Most of this coal is consumed domestically, with annual exports of coal about 50 million tons. One third of annual production is produced at surface mines and the rest from underground. This coal is produced by about 82,000 miners working at 1,400 coal mines. Major improvements in coal mine safety have been made in the US since the Federal Mine Safety and Health Act of 1977. The fatal injury rate in underground coal mines between 1977 and 2004 was reduced by 47.8% to 0.036. The annual number of fatalities dropped from 112 to 14 during that period. Likewise, the non-fatal days-lost injury rate was reduced by 42.6% from 10.87 to 6.24. The improvements in mine safety during this period can be seen in the graph of underground coal mine explosion fatalities and injuries from 1980 to present, which is shown in Figure 1. Between 1984 and 1993 (9 year period) there were 5 explosions and one major mine fire, for a total of 55 fatalities. Over the seven year period from 1993 to 1999 there were no fatalities from coal mine fires and explosions. However, in the six years since 2000 there have been 5 explosions and one fire, which have caused 37 fatalities. [ ]