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By Michael Taylor, Thomas W. BoBo

Currently two of the most important characteristics of construction aggregates are (a) the particle size distribution (psd) and (b) the “shape” of the aggregate particles. The long established test methods and standards for these properties require substantial resources and most suppliers can take samples and conduct tests at intervals measured in days (psd) or even months (shape). Furthermore these tests require time: so the results are available only after material has been stockpiled or shipped. In the rare cases where problems are found the out-of-spec material has often been shipped to points unknown. There are substantial advantages to be obtained if the psd and other geometrical properties could be obtained from the material as it moves through the production processes and if the results could be reported back within seconds or minutes to Plant Control Managers. This paper describes a single on-line system used to evaluate production of crushed material in a production quarry. The system consists of an enclosure (containing the camera and lighting etc.) mounted over a production belt. Images are fed by fiber optic cable to a nearby control room where the data are analyzed; stored; displayed; and made available for integration into a process control system. Numerous forms of display can be created according to the needs of the producer. Once programmed by an automation engineer all functions of operation are fully automated. The system has permitted over 400 tests per hour with a feed back time less than 2 seconds. Sufficient geometrical measurements are made so that many different “shape” factors can be computed on a similar time scale. The paper summarizes the results from approximately 100 shifts of about 8 hours each and compares the imaging method with the current standard hand methods. Study of the data generated showed that, when combined with additional plant information, the system can be used to generate additional useful control information.

Jan 1, 2005

The technical parametrization of reserves is a technique which has made an important contribution to the definition and the calculation of optimal mining projects. Its applications to a new open-pit optimization program have already been presented in various papers (François-Bongarçon and Maréchal (1976); François-Bongarçon and Guibal (1981)). The present paper gives a brief description of the general problem of parametrizing reserves before going into the details of the practical algorithms used in two typical cases, i.e. open-pit mining and mining between hanging wall and foot wall.

Jan 1, 1982

By Luminita Calin

King County (Seattle, WA) is on a monumental task of building the new Brightwater System complete with a new treatment plant, three main conveyance tunnels, a new outfall into Puget Sound and other ancillary works. This paper will describe the first conveyance tunnel, Brightwater East currently under construction by the Joint Venture of Kenny (Sponsor) / Shea / Traylor that is scheduled for completion in early 2010. The project located in Bothell, WA (north of Seattle) is in both King and Snohomish Counties. It was the first of the major tunnel projects that was scheduled by King County for the Brightwater System. The East Contract consists of the following major elements: 14,000 ft of 19'-2' EPBTBM mined tunnel using 16'-8' ID bolted, gasketed precast concrete segments for a primary liner; installing and encasing 14,200 ft each of 48', 66', 27', 84' in diameter steel pipes inside the tunnel along with three runs of fiberoptic cable; 2,430 ft of 72' in diameter microtunnel including three caisson shafts and associated structures; one Intercepting Structure (IS) shell to mine from that is 74 ft deep and 74 ft finished in diameter with 130 ft deep slurry diaphragm walls, tremie slab and final concrete wall lining; one Influent Pump Station shell (IPS) 83 ft deep, twin 77 ft inside diameter cells, with 160 ft deep slurry diaphragm walls, tremie slab, and final lining; two short 12 ft in diameter inter-shaft connector tunnels; one extraction shaft 40 ft deep by 40 ft wide and 140 ft long for connection to the new treatment plant piping.

By R. K. Jade

Although several studies in combining and bifurcating flows in two-way junctions and splits are reported, deviations persist in the estimated shock loss coefficients (SLCs). Due to their complex nature, more work has to be done to be able to correctly predict flow losses at these locations. In two-way splits, the flow at bifurcation is known to be characterized mainly by two recirculating zones in the downstream branches, whereas, in a junction one recirculating zone is observed immediately downstream of the main branch. The relative flow rate in the branches (quantity ratios) is treated as the only parameter defining the losses at these locations. However, the effect of wall roughness, if any, on SLCs becomes important for mine ventilation. This paper presents the critical determinants of shock losses at splits and junctions at varying quantity ratios. The flow at 90º split and junction was examined both experimentally and numerically for Reynolds number in the range of 1.0×104 to 1.6×105. With a well designed laboratory setup, using precision instruments, velocity and pressure measurements were carried out, by using two scales of wall roughness. 3D numerical simulations for these experiments were conducted by using ANSYS CFX modeling tool. CFD simulations yielded results that are reasonably close to experiments, providing high degree of satisfaction in numerically predicting losses across the splits and junctions. However, comparisons of these numerical simulation results with existing literature standards showed significant under-estimation of shock losses by the standard literature by as much as 50%. A clear rise in the magnitude of shock losses was noted in both the approaches, with increased wall roughness. Based on the current studies, predictor equations incorporating quantity ratios are developed for accurate estimation of shock losses. Further investigations on roughness are needed, before one is able to incorporate wall roughness into the prediction of SLC.

Jan 1, 2009

By Wern-ping Chen

Technical and non-technical challenges exist in each mega infrastructure project. It?s no exception to the first US underground PPP Port of Miami Tunnel (POMT) project in Miami, FL. The POMT will connect two man-made islands, the Dodge and the Watson Islands, under the Biscayne Bay within highly porous limestone formation. Permeability as high as 0.1 cm/sec has been identified. Its 41-ft outside diameter, if constructed, is the largest precast segment lining in the US. Besides its geological and hydro geological challenges and risks, local community influence and impacts have controlled the fate of this project. This paper describes its tender design enhancements and the evolving of its slow advancement in resolving local community issues.

By J. Wyn Prior

The seismic refraction technique is probably the most popular geophysical method of bedrock profiling in geotechnical site investigations but is somewhat restricted by the inherent assumptions in the method. This paper describes how Hales' method of profile interpretation is modified to overcome the assumptions of increasing velocity and layer thickness with depth when only first arrival data is available. A further expansion of Hales method enables presentation of refraction data in a form whereby bedrock features, such as changes in velocity, relief and dip in particular, are more readily recognized. Characteristic curves of the more common bedrock features are presented as an aid to bedrock feature recognition.

Jan 1, 1976

By M. Valdebenito, J. Rajala

An OCS Expert control system was implemented by Svedala Cisa at the Minera Maricunga Refugio Crush-Leach Operation near Copiapo, Chile. The purpose of the Expert system was to maximize production through the primary and secondary crushing circuits and help balance crusher usage between each stage to maximize total plant production. Interesting aspects of the control strategies are discussed. Benefits of the control were verified through a randomized On/Off test program. Tonnage increases ranged from 5% to approximately 20% at good confidence intervals. Benefits analysis results are discussed. The crushing plant at Refugio is very remote and is located at approximately 15,500 ft. This poses many challenges. The effect of altitude and remote location on plant operation are discussed.

Jan 1, 2002

By Russell Miller, Fun-Den Wang

High Pressure Water Jet Assisted Tunneling The high pressure water jet assisted tunneling project was conducted in a granite quarry near Skykomish, Washington, approximately 90 miles east of Seattle. A 7-ft diam tunnel boring machine was modified and equipped with high pressure water jets. The concept that tunneling rates can be improved by using high pressure water jets was validated, with an average increased advance rate of 50% to 60%. For some tests, the advance rate was more than doubled. A comprehensive economic analysis has shown that very significant savings are possible. At a 50% increase in advance rate, cost savings of 14% and 24% were projected for 10-ft and 20-ft diam tunnels respectively. These benefits were seen to be relatively insensitive to water jet equipment costs.

Jan 1, 1976

By A. P. Grobbelaar

Andalusite is a member of the sillimanite group of minerals consisting of andalusite, kyanite, and sillimanite. These minerals are the structural polymorphs of Al,Si05 (the anhydrous silicate of aluminium) and although chemically similar, they differ in physical properties due to their different crystal structures. For further information on the sillimanite group, see the chapter on Kyanite and Related Minerals that follows. The minerals are generally the products of the metamorphism of alumina-rich sediments and are found in schists, gneisses, or hornfelses, which have undergone either regional or thermal metamorphism from their original form. Sedimentary deposits may also form since the minerals are chemically and physically resistant to breakdown. When heated to a sufficiently high temperature the sillimanite group minerals convert to mullite with a resultant volume expansion and the liberation of silica. Due to the stability of the mullite formed, its high hot strength and resistance to chemical and physical erosion, they are widely used in the manufacture of refractories and special ceramics (Table 1). The reaction can be represented as follows: [ ] The worldwide use of these minerals depends to a large degree on their availability (Fig. 1). Andalusite, with its lower conversion temperature and the lowest volume expansion on being heated is the natural choice as a raw material to produce energy-saving refractories without prior calcination. The Republic of South Africa holds by far the largest minable andalusite deposits of the world, estimated at some 70 Mt of known in situ reserves. The only other large commercial production of andalusite comes from France, with known reserves of about 5 Mt. Potential new deposits are known from China, Ireland, Australia, and South America. World consumption of andalusite in special performance refractories has risen from less than 10 ktpy in 1960 to nearly 300 ktpy in 1990, which is due to cost effectiveness in many industrial applications compared to other conventional refractory products. Andalusite-based refractories have traditionally been used in Europe, South Africa, and the Far East; usage in America was limited in the past due to relatively high delivery costs and availability of other local refractory minerals. However, there is a significant trend towards greater use of andalusite in North America, thus opening new markets and replacing other traditional refractory raw materials. GEOLOGY Andalusite occurs in metamorphosed rocks of clay-like com- position, as in the andalusite-hornfelses in thermal aureoles (contact metamorphism), formed under conditions of high temperatures and low stress, and in regional metamorphic rocks, such as the andalusite-schists. These schists are mostly unconnected with definite igneous intrusions but were presumably also formed at high temperatures and under low stress. Andalusite can also appear in alluvial deposits associated with the primary deposits. At depths of 10 to 20 km, temperatures of up to 450°C might be expected. Another result of increasing depth is an increase of pressure due to the load of the rock cover. The load stresses involved in metamorphism is generally believed to lie in the range 0 to 10 000 bars. During contact metamorphism the increase in temperature is brought about by the injection of magma. The temperature reached in the country rock at some distance from the igneous body will always be less than the initial temperature of the intrusion, which is presumably less than 1 200°C, and will vary with time and distance from the contact. A simple metamorphic reaction involving dehydration of an aluminous sediment can be: [ ] At higher temperatures sillimanite would form at the expense of andalusite, while kyanite would be the mineral formed at higher pressures, as can be seen in the phase diagram of A12Si05 (Fig. 2).

Jan 1, 1994

By William D. Leech

Lebanon used a TBM for the firsttime to excavate a tunnel in the country. A main beam TBM, built in 1979, bored the 3.8 m (12.5-ft) diameter by 4,020 m (2.5-miles) Madiq Tunnel. The TBM bored through karstic terrain of dolomitic limestone, limestone and marly-limestone rock having near horizontal beds with more than twelve faults crossing the axis of the tunnel. The TBM also encountered more than six major karst features, filled with various combinations of boulders, clay, void space and water. The excavation through these collapsed-breccia zones drastically slowed the TBM?s progress. When complete, which the Madiq Tunnel is a part, the Kesrouane Water Project along the coast will bring fresh and irrigation waters to the parched and heavily populated region north of Beirut. The paper will describe the tunnel geologic features, karst genius, TBM upgrades and performance, and TBM/karst difficult situations

By Steve Skelhorn

Over the recent years, major advances have been made in design of precast concrete segmental tunnel liner. Starting from basic, parallel sided rings, we now have state of the art, universal rings incorporating custom tapers to suit individual requirements. At planning stage, the ring diameter is normally fixed and the ring geometry is one of the first items to be assessed. Obvious factors such as TBM layout and curve radius can constrain geometry; however, there others factors that should be considered in order to optimize production. This paper takes a look at the history of the segmental rings and criteria for ring selection, including: general ring geometry;; individual segment geometry; ring taper, and ring width. This paper also explores optimization of ring with a focus on constructability.

By J. V. Thompson

The Powderhorn complex as a source of perovskite (calcium titanate) containing about 1.5% rare earths has been examined in several recent feasibility studies. Much promising exploration and process research has been done in recent years. This paper is presented with cautious optimism and with the acknowledgment that there may be some technical and economic areas yet to be explored. The Powderhorn carbonatite and alkalic stock in Gunnison County, Colorado, lies about 203 airlines km southwest of Denver at an elevation of 2450 to 2750 m (see Figures land 2). All of the mineable ore bodies are owned by Buttes Resources Company of Houston, Texas.

Jan 1, 1990

By K. Short

Over the past several years, the mining and minerals market was overloaded with discussions around reviving mature terminologies like distributed control systems (DCS), programmable logic controllers (PLC), and the ?new comers?: hybrid control systems (HCS) and programmable automation controllers (PAC) and, in parallel, which technologies would be more appropriate for mining and mineral processing applications. Ten years ago, a careful comparative analysis would make more sense. Control approaches had very distinctive differences where users needed to choose the right approach.

Jan 1, 2012

By Q. J. Browne, M. A. Miller

Silver Bell produces about 22,000T of fine copper annually from low-grade chalcocite and oxidized copper ore that is recovered by sulfuric acid leaching and SX-EW processing. The current mineable reserves are 146 million short tons averaging 0.39% Cu, at a 0.15% cutoff. Silver Bell utilizes two types of mining methods to develop the low-grade reserves: (1) a conventional blast, load and haul method for run-of-mine leach ore, and (2) rubblization of material on the margins of existing pits. Rubble leach ore is blasted, terraced with a bulldozer, and leached in place. Mining and/or rubble leaching is currently active in four separate pits. Laramide-age intrusive rocks host porphyry copper mineralization at Silver Bell. Quartz monzonite porphyry dikes and stocks, mafic-poor equigranular granite (alaskite), and sub-volcanic dacite porphyry are the predominant host rocks. Most of the ore currently mined comes from near-horizontal enrichment zones containing veinlets and disseminated grains of pyrite and chalcopyrite rimmed by chalcocite. Conversion from a milling operation to a leach only operation allowed for a much lower cutoff grade than was historically used at Silver Bell. Mine geologists were able to increase copper resources by drilling exploration targets that were previously interpreted to provide lower-grade mineralization below cutoff-grade for milling. Geologic parameters that effect the distribution of rubble and mineable leach ore include: ore grade and thickness, variable alteration styles in intrusive host rocks that affect fragmentation during blasting, acid consuming carbonate wallrocks (reactive skarn) which influence leach solution pH, solution flow paths and drainage, presence of leachable oxide mineralization in non-reactive skarn, and depth to hypogene mineralization which is currently uneconomic. Geologic parameters are used to predict rubble bench limits, vary blast hole spacing for consistent fragmentation, and correct errors in mineral zone classification based solely on blast hole assays. An expansion-drilling program has identified approximately 150 million tons of new leachable copper resources with an average grade of 0.35% Cu.

Jan 1, 2002

By J. Noll

Many underground metal/nonmetal mines are using enclosed cabs on mining equipment to reduce the exposure of miners to diesel particulate matter (DPM). However, some enclosed cab systems may not be meeting their expected efficiency in capturing DPM, which could be a result of inappropriate filter use, cab leaks, or insufficient pressurization. NIOSH investigated several types of filters for reducing DPM to determine which type had the best capture efficiency. The laboratory results indicated that a MERV 8 (Minimum Efficiency Reporting Value, as defined by the American Society of Heating, Refrigerating and Air- Conditioning Engineers) filter captured about 50 percent of the DPM, a MERV 16 filter collected 96-98 percent of the DPM, and two HEPA (high efficiency particulate air) grade filters captured over 99 percent of the DPM. NIOSH also performed a field study to measure the efficiency of two cabs at a limestone mine. The cab filtration systems of a loader and haul truck were found to be over 90 percent effective in removing DPM except under certain operating conditions when the efficiency was as low as 41 percent. Evidence seems to suggest that these conditions were when a window was open in the cab.

Jan 1, 2011

By M. Schafer

The 20 foot diameter cast-in-place tunnel lining for Phase 3 of the Mill Creek Tunnel (MCT-3) has been completed. This paper will summarize aspects of liner design and address the construction approach in placing the liner in areas of tunnel that experienced crown overbreak. Tunnel lining production rates, installation procedures and form buoyancies experienced during concrete placement will also be presented.

Jan 1, 2008

By J. Piper

Markets and Production Beryllium (Be), an extremely light metal, is used in many specialty applications. It the lightest element in Group 2A of the periodic table, with a specific gravity of 1.85 gm/cc, and a high melting point of 12850C (Calvert, 2004). The functional properties of beryllium are stiffness, strength, dimensional stability, resistance to corrosion from acids, and electrical and thermal conductivity. The ability to reflect neutrons and transmit x-rays, makes beryllium irreplaceable in uses such as precision optical components, inertial guidance systems, and in nuclear reactors (Anon, 1993). Beryllium is used in Cu alloys to strengthen and reduce corrosion in copper wire, and in lightweight oxide ceramics that are used as heat sinks, and as electrical insulators. The market revenue of beryllium can be broken down into the seven major groups below, and are plotted on the pie chart in Figure 1 (Anon, 2005). 1.) Telecommunications & Computer 2.) Magnetic & Optical Data Storage 3.) Aerospace and Defense 4.) Automotive Electronics 5.) Industrial Components 6.) Appliance, and 7.) Other.

Jan 1, 2007

The initiation of a panel cave is an extremely important and infrequent event in the life of a large underground caving operation. A new cave was initiated at the Henderson Mine in 1991, 15 years after its first cave had been developed in 1976. The original cave was started after a half billion dollars had been invested in the development of the mine, mill and 23 km haulage system. Many things had changed since 1976, the most significant of these being much lower realizations for molybdenum. In 1976 the high demand for molybdenum and uncertainty of caving characteristics, formed the basis for a very conservative cave initiation sequence with miles of boundary weakening and inspection drifting. In 1991 the highly competitive molybdenum market in conjunction with 15 years of caving experience made for a very different mining climate.

Jan 1, 1994

By T. F. Tomb

Although the number of operating longwalls (approximately 100) has remained relatively constant over the last five years, longwall production levels have significantly increased and have in some cases more than doubled. As a result of the increase in production, control of respirable dust continues to be a problem. Therefore, the Mine Safety and Health Administration (MSHA), Pittsburgh Health Technology Center, Dust Division, initiated a study to investigate the availability and adequacy of technology for controlling dust on longwall mining operations. The study involved 23 longwall mining operations in three different Coal Mine Safety and Health Districts. Each operation was visited for a full shift. Respirable dust samples were collected on face personnel and at fixed locations along the face. Parameters in place to control dust were noted with special emphasis being placed on obtaining quantitative data relative to ventilation, headgate dust controls, cutting drum sprays, external machine sprays and cutting sequence. Attempts were made to correlate dust control parameters in place at the time of the visit to dust concentrations measured at the tail, on the tail shearer operator and to the average concentration of dust determined from averaging all the measurements from the occupations sampled. The parameters in place to control dust were also compared to the gamut of technology known to be available to control dust. This paper presents a discussion on the effectiveness of the parameters in place to control dust and on the availability of technology for the control of dust on longwall mining operations.

Jan 1, 1990

By William Stewart, John Tinkler, Gary B. Hemphill

Of the 345 km long Taiwan High Speed Rail Project, connecting the cities of Taipeiand Kaohsiung, the 23 km alignment on Contract C230 required the construction of5755 m of shallow mined tunnels ranging from 137 m to 1285 m in length. All nine of these tunnels were mined using NATM methodology. On September 6, 2002, a collapse occurred in Tunnel T08 that affected approximately 50 m of tunnel. There was little warning. However, the crew was evacuated approximately 45 minutes prior to failure and thus, no injuries or loss of equipment. This paper will discuss the mining methods, jet grouting ground support, and the instrumentation selected for the rehabilitation and monitoring of the tunnel.

Jan 1, 2005