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By Trevor Riters

Advancements in Emerson’s instrumentation technology have brought value and efficiencies to the mining industry. Some think of instrumentation as basic sensors and valves, but with our solutions, we equip operators with real time, accurate, and reliable data that they can use to operate more effectively. Working with Caltrol, an Emerson Impact Partner, we successfully engineered wireless skids for a leach pad to provide precise measurement and control of raffinate solution to many of the large mine sites in Arizona.

Feb 1, 2025

By B. Stewart

Recent ore pass failures have underlined the need for improved designs, standards, structural monitoring methods, and better hang up prevention and removal techniques. Researchers at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) are investigating methods to improve safety during transport of ore in ore passes. Design criteria and hang-up prevention and remediation strategies involve studies of the effects of static and dynamic ore and waste rock loads on chutes, walls, gates, and support structures. Particle flow analysis methods were used to simulate the response of various ore pass designs to a wide range of ore loading conditions. A full-scale mock-up of actual ore pass and chute assemblies was duplicated and tested for load response. Data from a particle flow code and the mock-ups were com-pared. Loads on an active ore pass chute were measured.

Jan 1, 1998

By G. S. S. Raman, M. S. Klima

Coal refuse slurries stored in tailings impoundments can potentially lead to environmental concerns such as effluent seepage, property devaluation, and in extreme cases, dam failures. Pressure filtration offers an opportunity to reduce the impoundment requirements by providing significantly drier solids. A full-factorial design was used to study the effects of temperature and pH on dewatering a refuse slurry obtained from a coal preparation facility in Pennsylvania, USA. The experimental results indicated a strong effect of temperature on cake moisture as the cake moisture after about 2800 s was 22% at 43 °C and only 36% at 10 °C for tests conducted at pH 3. ANOVA results confirmed the statistical significance of pH, temperature, and their interaction effect. Also, the results showed no significant differences between the tests conducted near neutral and alkaline pH values at low and ambient temperatures. On the other hand, Tukey’s test indicated higher reductions in cake moisture at higher temperatures for lower pH values. This study affirms the need to monitor and control the pressure filtration process as throughput could significantly vary with changes in temperature and slurry conditions.

By C. A. F. Pinto

In the present work compared flotation kinetics of apatite with four different collectors was established. Sodium oleate and rice bra~ oil were used to represent conventional collectors. The new collectors included a sulfosuccinate and a sulfosuccinamate. It was observed that the collection ability of each reagent was very dependent upon the mineral size ranges. The results-were analyzed in terms of size-by-size recovery curves. Flotation rates were also very dependent on size ranges of the mineral particles. One of the new collectors displayed higher flotation rates for coarser particles than the other reagents tested. Synergetic effects were also apparent when a conventional collector was mixed to a new collector.

Jan 1, 1991

By R. L. Bullock

The New Lead Belt of Missouri, situated in the heart of the Clark National Forest, stands as a dynamic example of how mining activities can successfully coexist in a restricted wilderness area. After 16 years of intensive drilling activity, mine development and surface plant construction, many would agree that the mine-plant design philosophy of St. Joe has minimized the imbalancing effects to the ecology and the wilderness appearance of the Ozark area. In a recent dedication speech of St. Joe's newest operation, it was stated: 1 "this Brushy Creek Mine, as well as nearly all of the mines in this district, lies within the boundaries of the Clark National Forest. Here the Forest Service has an outstanding and realistic program for multi-use of Federal lands. Mining, lumbering, recreation and conservation coexist in, what I consider, a delightful wilderness environment. I believe that this same type of usage could be permitted on all government land without seriously detracting from its natural beauty." Each and every activity in the process of discovery, exploration, development and finally operating a mine and process mill could have drastically degraded some phase of nature's environment were it not for the well developed and executed plans of the mining people involved. This is not to say that everything has been kept in perfect balance; but most certainly the industrial impact on what was once a wilderness area has been held to a minimum. What follows is the story of how each phase of this gigantic development was handed by industry people. Through their interaction and cooperation with government agencies, educators and researchers, allowed not only the ecology of the area to be protected, but the aesthetic beauty of the Ozarks to remain intact.

Jan 1, 1973

By Michael Roach

"There’s a bit of confusion and misinformation in the tunneling and underground construction industry regarding contractor joint ventures. If it was all so clear I would not have been "asked" to write this article. For those of us on the contractors’ side of the fence, joint venture business relationships have been a part of life for a long time. But even for contractors, there can be a bit of confusion, and it normally begins on bid day.How often have you received bid results and wondered (out loud, usually), "Who the hell are the Lake Mead Intake Constructors"? or the "Regional Connector Constructors"? Once you get past the name, you see that there is nothing behind Oz’s curtain other than a couple of contractors bidding and building work in an attempt to make a profit. So take a few minutes to read the rest of this, and I’ll do my best to dispel a few mythWhat is a joint venture?In some form or fashion, joint ventures are as old as industry itself. In the United States, some of the earliest (and largest) joint ventures involved the railroads and oil companies in the late 1800s. In the United States’ underground construction industry, joint venture names such as, Healy-Greenfield, Green and Winston, Gates & Fox and Walsh, Shea-Ball, Kenny-Paschen and S&M-Traylor bring back memories of successful joint ventures that operated over many projects.There are nearly as many definitions for joint ventures (JVs) as there are attorneys. A short and simple definition is, "an association of two or more companies engaged in a singular, for-profit business enterprise without actual partnership or incorporation." That’s it. Two or more contractors decide to partner up for one or more projects. One benefit of the JV relationship is that the partners typically do not need to file incorporation documents, or articles of organization within the state where they intend to operate. So it is a relatively easy business arrangement to pull together. Other benefits of the JV arrangement include: • Oportunities to gain new expertise and capacity.• The ability for firms to move into new geographic markets.• JV agreements are not long-term commitments.• Sharing of financial support for a project.• Sharing of financial risks within a project. between the partners.• Can complicate dispute resolutions with the owner and between partners"

Jan 1, 2014

By Girish Roy, Robert Goodfellow, Angel Del Amo, Bingzhi Yang

Designing and constructing tunnels in seismic prone areas present unique challenges to both designers and contractors. The Westside Purple Line Extension Project– Section 3 in Los Angeles requires crossing an active fault that may subject the tunnels to extreme structural demands. In order to ensure that the linings will safely accommodate the fault movement, a revolutionary composite section—steel plate embedded in the intrados of the precast concrete segmental tunnel lining was finally selected. Additionally, continuous expansion steel plates over the circumferential joints will be installed to mitigate the potential opening of the circumferential joints.

Jun 13, 2021

By S. A. Saki, J. F. Brune

"INTRODUCTION Longwall coal mining leaves large areas where the coal has been made removed and the roof rock strata collapse, forming a zone of broken rock rubble called the gob. Figure 1 shows a typical longwall gob area along with the gate roads. The ventilation pattern for progressively sealed longwall panels follows a simple “U” pattern where fresh air is coursed inby to the headgate, flows along the face and exhausts through the outby tailgate as shown in figure 1(a). An important variation of this pattern is the back return (BR) arrangement where the exhaust air from the face is drawn inby and around the nearest open cross cut before it turns in the outby direction towards the exhaust fan. Figure 1(b) illustrates the use of back return. This arrangement moves the point of low pressure from the tailgate corner up to 60 m inby and thus maintains fresh air in the tailgate region that could otherwise be contaminated with gob air.The gob area may contain remnants of unmined coal or parts of overlying coal beds that continue to release methane, eventually filling the gob area with methane in concentrations far above the explosive range of about 4.5 to 15%. Many gob areas must be equipped with gob ventilation boreholes (GVBs) to extract methane, and GVBs often exhaust methane at concentrations from 50% to 90% (Saki, 2016). Due to oxidation processes occurring in the gob, the oxygen content is reduced to a low level, with nitrogen and CO2 making up the major remaining components of the gob atmosphere. FORMATION OF EXPLOSIVE GAS ZONES IN GOBS Since the longwall face area is ventilated with fresh air below 1% methane and the face and gob areas are not separated, an explosive fringe will form where the methane content lies within the explosive range and oxygen content remains above 12%. Figure 2 shows a typical development of such an EGZ. This figure is based on a computational fluid dynamics (CFD) model developed by CSM researchers to analyze gas concentrations and flow patterns in longwall mining. Figure 2(a) shows the formation of EGZ in the gob with a U type ventilation scheme, where EGZ lies right behind the shields in the tailgate corner. Figure 2(b) shows the formation of EGZ in the gob combining U type ventilation scheme with BR, where EGZ is pushed away from the face deep into the gob. The CFD modeling parameters and boundary conditions have been verified with field data from two cooperating, active longwall mines (see Worrall 2012, Marts 2015, Gilmore 2015 and Saki 2016). Other mine geometries, methane inflow rates and gob permeability distributions can be modeled to establish representative gob atmospheric conditions. Two GVBs were operating in the model, extracting 0.165 m3/sec each. The methane in the working areas and returns was kept below 1%. Methane flowing into the model from a rider coal bed above the mined seam was at the rate of 0.55 m3/sec."

Jan 1, 2017

By James R. Jones

The tempo of air pollution control regulations has increased dramatically in the past few years. Because coal mining operations are frequently located in remote areas away from urban developments, specific regulations applying to coal mines have received lower priority and are thus only now being promulgated and/or enforced. Therefore, many mine operators are not yet familiar with the regulations and the impact upon their method of operations. Few have been faced with an inspector on the property sighting them for specific violations. Several of the Mid-western states are just now requiring permit applications to be submitted.

Jan 1, 1973

By Kanchan Mondal, Gopi Bylapudi, Anand Bhagwat, A. J. S. (Sam) Spearing

Corrosion of steel roof support systems can cause potential premature failure of the support, thus adversely affecting the excavation stability and rock-related safety. An in-house corrosion test system was designed and developed to test full-length roof bolts for material performance based on tensile load capacity and strength under different corrosive conditions found underground. Initially, ASTM A615 grade 60 steel roof bolts, which are the most commonly used bolt material in the United States, were tested with and without stresses in a simulated underground coal-mining environment for approximately six months. This paper mainly discusses the test system, protocol and system shortcomings, and makes recommendations based on the observations and results.

By Thomas B. Borak, Keith J. Schiager, Janet A. Johnson

OBJECTIVES OF RADIATION MONITORING Monitoring is a tool used in the practice of radiation protection. The primary reasons for monitoring are to reduce radiation exposures to levels that are as low as reasonably achievable and to assure that no individual receives a dose exceeding the maximum individual dose limit. The documentation of radiation doses for legal, medical, or epidemiological reasons is a subordinate function of any monitoring program. The investment in radiation monitoring programs should be guided by four criteria: (1) the detection and avoidance of unnecessary exposures, (2) the magnitude of potential health risks, (3) the determination of combined doses and risks with adequate confidence, and (4) the verification of compliance with established limits. FIRST CRITERION: DOSE REDUCTION - DETECT AND CORRECT UNNECESSARY EXPOSURES The system of dose limitation advocated by the International Commission on Radiological Protection (ICRP, 1977), and subscribed to in a broad sense by various regulatory agencies, is comprised of three essential ingredients: (1) [justification] of any practice that produces radiation doses by some commensurate net benefit, (2) [optimization] of radiation control measures by reducing doses to levels that are as low as reasonably achievable, and (3) [limitation] of individual doses to preclude inequities and [moldistribution] of risks. All too often, only the third criterion - the limitation of individual doses to prescribed regulatory limits - is explicitly addressed in everyday radiation protection programs. The emphasis of most exposure control and monitoring efforts appears to be directed toward limiting and documenting individual doses that might approach the legal limit. The first two criteria, i.e. justification and optimization, should contribute to a rationale for allocating monitoring efforts. When applied to individuals, these criteria mean the detection and elimination of unnecessary exposures. This should be a high priority of any monitoring program. Measurements should be directed toward detecting inoperative or ineffective control measures, whether or not there is a risk of exceeding the individual dose limits. The ICRP recommends a procedure that can be used effectively to reduce unnecessary exposures. A n investigation level should be established at an exposure rate substantially lower than the regulatory limit, e.g. 30% of the limit (ICRP 26, 1977, p.33). Measurements obtained during routine monitoring that exceed the investigation level are evaluated with respect to cause and potential reduction. To be effective, the evaluation results should be formally recorded and conveyed both to management and to the workers involved. Although the investigation level recommended by the ICRP is based on a fixed exposure rate or derived air concentration, an equally effective evaluation program may be based on the investigation of a percentage of all measurements. For example, one might investigate the highest 5% or a random selection of all measurements. In any case, the objective is to detect and correct situations that are producing unnecessary exposures. SECOND CRITERION: MONITOR IN PROPORTION TO THE MAGNITUDE OF RISK The ICRP criteria apply generally to all radiation exposures. However, a second priority for monitoring programs should be established on the basis of the nature of the exposures and the magnitude of the health risks involved. Current practices in radiation protection are based on dose limits to specific organs and assessment of individual exposure pathways, with little consideration of the combined doses from various pathways. Although the intent of the ICRP recommendations was to limit the total dose to each critical organ, combined doses from external and internal sources are rarely determined. The recent recommendations of the ICRP (Publ. 26, 1977) are based on the limitation of total health risk from occupational radiation exposures. Implementation of this concept would necessarily require the measurement, calculation and summation of doses and concomitant risks to all organs of the body from all exposure pathways. The U.S. Environmental Protection Agency has taken the first step toward translating the ICRP recommendations into regulations. The proposed recommendations for Federal Radiation Protection Guidance for Occupational Exposures (USEPA, 1981) include provisions for summing the risk-weighted organ doses to determine compliance with an effective whole-body dose equivalent limit. Whether or not the proposed guidance is modified before final adoption, it seems clear that some version of dose summation and combined risk limitation will be included in future regulations. With this

Jan 1, 1981

By J. D. McKay

Flotation columns have been readily accepted for use in most sulfide flotation plants; however, recently columns are being used in many other areas. Recent improvements in design methodologies have overcome many operating problems and led to improvements in metallurgy. In addition, physical improvements in column design have simplified their operation while leading to better control. The Turbo-Air External Bubble Generator has provided a method for bubble size control and variation in air holdup and carrying capacity. These have enabled commercial operations to improve grades and recoveries by optimizing performance.

Jan 1, 1990

By Robert R. Dorfler

AMPS[. has completed a rationed grinding ball test in a 2.93 m x 2.93 m ball mill at Climax Molybdenum Company. The test consisted of purging the ball distribution formed by charging 100%, 76 mm carbon steel balls with a distribution formed by charging 50% 76 mm and 20% 51 mm alloy steel balls. The resulting change in ball surface area yielded improvements in both tons ground and fineness of grind with a significant reduction in total ball consumption. This paper summarizes preliminary studies leading to the plant test, grinding efficiency results, and future plans to optimize the ball charge.

Jan 1, 1981

By F. H. Nehl

The U.S. Bureau of Mines investigated the selective electrowinning of Ag and Au from cyanide solutions contaminated with Cu with the goal of decreasing the amount of Cu co-deposited. Decreasing Cu co-deposited will reduce refinery costs. Direct current was applied to the cell in pulsed and square wave voltages at 0.7 A?h per 150 mL of solution. Times tested for each cycle ranged from 1 to 10,000 ms. Graphite, lead, and stainless steel were evaluated as electrode materials. Square wave e1ectrowinning at 70? C gave the best separation of Ag and Au from Cu. Applying 2.5 V during the duty cycle, 0.0 V the rest of the period, a duty cycle of 10 to 30 pct, and a period of 100 ms to 1,000 ms gave the following results: Ag concentrations decreased from 34 µ g/mL to 0.1 µ g/mL, Au concentrations decreased from 54 µ g/mL to 0.2 µ g/mL, and Cu concentrations remained almost constant at 560 µ g/mL.

Jan 1, 1993

By Sushil Bhandari

A computer model is developed for the problem of dispersal of dust (suspended particulate matter) resulting from blasting operations in surface mines. Undulated surface (lower boundary) simulation was carried through sixth order polynomial by least square approximation. Segmentwise terrain simulation was linearly added to build ground feature extending either side of the blast location. Assuming the initial dust concentration in the vertical column to. be uniform and treating the finite vertical line sources as a series of point sources to height, H varying from zero to top of the dust mushroom, integration was done of the concentration effects from H = 0 toL tan[0] (L = horizontal distance of the blast location and [0] is the angle of the top of dust cloud from the point of observation). Using frame of reference moving with the mean wind, the ground level 'concentration (GLC) has been computed over the undulated terrain. Standard deviation (s) of concentration has been parameterized based on mixed layer similarity theory in convective boundary layer.

Jan 1, 2002

By S. D. Rosenthal

"This article will share my ‘shift in career direction’ journey from corporate mine engineer, with 31 years of mining various commodities with a wide range of responsibilities in a variety of countries, to the world of academia. There are times in one’s career that a change is required, albeit perhaps not as drastic of a change as moving to teaching. This paper will share how the transition arose, the decision to make the change, the challenges of the first year in academia and the journey within academia going into the second year.As a graduate of the Montana College of Mineral Science and Technology (Montana Tech) with a B.S. mining engineering degree in May of 1982, my first job with Utah International in the Farmington, NM area took me back to my home state of New Mexico. Some of you will remember that the early 1980s was not a period of prolific opportunities for mining engineers, given low commodity prices, especially for copper (for example, Anaconda Co. had been taken over by Arco and was in the midst of closing down its Butte operations). Coal was good and the learning opportunities abounded with Utah (which became BHP and then BHP Billiton).Gold was taking off in the mid to late 1980s thanks to use of cyanide and heap leaching technology improvements, coupled with deregulation of the gold price, so I ventured off to work in the gold industry with a (then) junior Canadian company called Barrick at a new acquisition of theirs known as Goldstrike. That same gold surge was causing a shortage of iron ore mining engineers in Australia. So after a few years in Nevada, I uprooted the family and left for a little town in the Pilbara of West Australia, known as Newman, to work in the iron ore industry with BHP Iron Ore. An initial short overseas posting turned into six plus years before transferring to BHP’s Indonesian steam coal mines in Kalimantan on the island of Borneo. BHP was going through a rough period following some ill-fated projects (Magma Copper purchase, Beanup and HBI) and was reviewing assets and staffing, so internal opportunities became scarce. Employees were encouraged to “leave the company and find work elsewhere.” So, off I went to Argentina to try copper mining in the Andes with Minera Alumbrera. This short stint in South America was followed by a move to another mining town, Morenci, AZ, and a posting with Phelps Dodge (now Freeport- McMoRan). After 12-plus years without living close to snow, we moved to the Denver, CO area in a new position with Newmont Mining Corp. Along the way I became a professional engineer (Nevada) and completed a masters in project engineering and management. After 11 years with Newmont, I moved to Butte, MT where I accepted a position as assistant professor of mining engineering."

Jan 1, 2015

By John Murray, Daniel Ebin, Robert Gould, Yiming Sun, Lizan Gilbert

The Atlanta Plane Train Tunnel West Extension is being constructed at Hartsfield-Jackson Atlanta International Airport using the Sequential Excavation Method (SEM). The tunnel has shallow ground cover and mixed-face conditions and passes underneath the SkyTrain and MARTA stations and airport terminal buildings. It includes a twin tube Bifurcation with a span of over 45 feet and ground cover of 12 feet. A flat roof is being constructed at the Bifurcation to maximize rock cover and minimize surface settlements. This paper focuses on design and construction challenges for the Bifurcation and tunneling beneath the world’s busiest airport, while minimizing impacts to operations.

Dec 1, 2022

Because the Environmental Protection Agency has identified methane as a greenhouse gas, the importance of de gasification through gob wells has become more critical. It has been observed that the degree of methane emission is closely related to the geomechanical characteristics of coal bearing strata, roof, floor, and surrounding coal seams. Monthly production data from 250 gob wells were collected from the Warrior Basin in Alabama, and many interesting correlations were observed between methane production with longwall face width, face advancement rate, number of gob wells in a panel, and geologic columns. Extensive finite element analyses were performed to estimate the characteristics of the emission zone in an attempt to corroborate these findings. This paper describes an investigation for developing correlations between the geomechanical behavior of the methane emission zone with methane production.

Jan 1, 1996

By C. Garcia, A. Potulska, J. J. Opazo, T. Comi

"The Sierra Gorda SCM sulfide ore processing plant began commissioning in the third quarter of 2014. Located in the Atacama Desert in northern Chile, the project is an open pit mine and Copper-Molybdenum processing plant is one of the most highly-instrumented operations in the world. It is the first hard rock operation in Chile and the second in South America to utilize HPGR technology. It is a significant Molybdenum resource especially in the first five years and the Molybdenum separation plant is complex. Designed to process up to 60 million lbs. of fine Molybdenum per year, it uses the latest technology and equipment to ensure superior recovery and product quality. It also has gas handling and alarm systems to fulfil the Company’s vision of “Zero Harm”. This paper discusses the overall operation and issues relating to the concentrator start-up. These include a review of the mineral processing design, the unified process control center and management information systems, and the correlation of geological and metallurgical performance data (mine-to-mill) for use in anticipating and preparing for treatment of diverse ore deliveries. INTRODUCTION Sierra Gorda SCM is a joint venture partnership with KGHM International (owned by KGHM SA, Poland), Sumitomo Metal Mining, and Sumitomo Corporation (Japan) operating in northern Chile. The Sierra Gorda open pit mine and Copper-Molybdenum processing plant will become one of the largest mines in the world. The need for optimum production efficiency and sustainability has driven the creation of the most modern, well-instrumented mine in Chile. This paper contains a general review of the project including geology and history. This was a very fast-track project going from greenfield site acquisition to mill start-up in 10 years. Highly-experienced and motivated engineers and technical staff have overcome many significant challenges resulting in a rapid ramp-up of production capacity. A potential expansion to double the production rate in the fourth year of operation has also been intensely studied. The Sierra Gorda property is located in the Atacama Desert of northern Chile, in the District of Sierra Gorda, Region II of Antofagasta, Chile (see Figure 1). There is almost no precipitation in this area. The mine site is generally flat with some rolling hills. The project is located about 5 km from the village of Sierra Gorda at an elevation of approximately 1,700 m above mean sea level. The village is near a highway and railway line. The city of Calama, home of the famous Chuquicamata Mine, is located about 60 km northeast of Sierra Gorda. In addition, the SG mine is in the midst of numerous other mines including Spence, Esperanza, Mantos Blancos, El Tesoro, Lomas Bayas, Gabriela Mistral, El Abra, Radomiro Tomic, and Escondida, to name a few."

Jan 1, 2015

By Robert C. Maxton

The foundry industry is a basic source of structural component for all industry. Millions of tons of castings are produced annually in both ferrous and nonferrous alloys. These castings are subjected to a wide variety of heat treatments, finishing techniques, mechanical tests and machining operations. Through all of these steps the quality of the casting is of paramount importance to the end use of the product. The Quality Assurance Program at Minneapolis Electric Steel Castings Company is designed and established to provide a superior product for both original equipment manufacturers and the mining industry.

Jan 1, 1982