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By Ulrich Maidl, Marc Comulada, Janosch Stascheit

"INTRODUCTION Cohesive soils are notorious for causing clogging of the cutter head and the excavation chamber of tunnel boring machines (TBMs). While clogging leads to a drastic reduction in excavation performance, it further induces higher wear of tools and other parts of the cutter head and may even prevent a controlled support of the tunnel face and, thus, lead to face collapse and excess settlements or sinkholes. Employing well-balanced soil conditioning techniques, the clogging tendency can be significantly reduced. The monitoring and control of soil conditioning as well as the timely detection of potential clogging tendencies require a close monitoring of all relevant machine parameters and measurements. To this end, a reliable and powerful Process Controlling software that gathers all machine and process-related information is a prerequisite for successful mitigation of clogging-induced problems. The remainder of this contribution is organized as follows: First, a brief introduction to the Process Controlling system PROCON is given. Afterwards, the mechanisms and mitigation techniques of clogging are discussed. Finally, an example is given how Process Controlling has been employed to soil conditioning in a tunneling project with highly clogging soils.PROCESS CONTROLLING Being both the active part and a huge measuring device, the shield machine represents the core component in mechanized tunneling. This machine comprises a manifold of complex components and devices that require constant supervision and control and, thus, is equipped with a manifold of different sensors that provide a continuous monitoring of the state and condition of the machine (Maidl & Stascheit, 2014). If these data are put into the whole context of the tunneling process, they can provide insight to the assessment and optimization of the performance and to the prediction of potential risks and hazards such as, for example, the tendency of clogging of the cutter head."

Jan 1, 2016

By R. B. Krog

Airflow patterns in longwall bleeder systems are affected by gob permeability and porosity and the condition of the gateroad entries after mining. As longwall panels are mined, areas of the caved zone and portions of the remaining gateroad entries become inaccessible, making direct ventilation measurement impossible. Mine operators are left to estimate direction and amount of airflow in the gob and the surrounding gateroads. The most readily available locations are where air enters the worked-out area, approved measurement point locations (MPLs) and/or evaluation points such as bleeder evaluation points, intake evaluation points, and the outer bleeder entry. Ventilation models (network or Computational Fluid Dynamics, CFD) can model the gob and the surrounding bleeder system but calibrating these models is difficult without field data. NIOSH installed a tube sampling system ahead of a longwall face and, as the face retreated, released a slug of tracer gas (SF6) to determine transportation times and flow rates in the inaccessible gateroads. The data was used to calibrate both network and CFD ventilation models for a longwall panel. Both model types were used to predict the airflow patterns in the gob and to determine the airflow rate from the longwall tailgate corner back to the bleeders.

Jan 1, 2011

By Peikun Liu, Guangyu Sun, Raja V. Ramani, Shambhu Sharan, Raman Srikanth, Bharath K. Belle

The contribution of the various outby sources to the contamination of the panel intake air has been the subject of a relatively small number of studies. In this paper, after a brief review of past studies, results from recent experiments on rates of contamination of intake air by outby dust sources are presented. Present study indicates that each outby source by itself may not be a major contributor. The loading point in the continuous miner section did not appear to be of major concern from contamination point of view. Belt entry including transfer point contributes significantly to the intake air dust level, though reentrainment was not a major source of dust. In longwall panels, the stageloader-crusher was the most dominant source. The panel-to-main belt transfer point was not a major source. Taken collectively, the contribution of all outby sources can be significant. In one longwall section, at the beginning of the longwall face, the contribution of all the outby sources and the headgate cut-out operation was observed to be about 80% of the permissible exposure limit (2 mg/m3). In modem high production longwalls, the application of effective dust control measures to reduce the dust generated from the outby sources is essential to achieve compliance with the dust standards.

Jan 1, 1997

By Remo Grandori

"INTRODUCTIONDouble Shield TBMs were introduced in the market in the early seventies with three main targets:• Increase the TBM performances in term of advance per day thanks to the ability to erect a segmental lining simultaneously with the excavation phase.• Be able to advance through unstable and disturbed rocks under the protection of the shields• Provide a finished tunnel by installing a precast lining as the TBM advance.In 2003 SELI developed the design of the Double Shield Universal (DSU) TBM as an evolution of the original Double Shield TBM design.This new TBM design was targeted to improve: the TBM capability to advance through squeezing/converging rock formations under high cover, the telescopic joint design (allowing by such to operate the machine in double shield mode in very weak rock), the capability of the TBM to investigate and treat the ground around and ahead of the tunnel face.In the same lapse of time Single Shield TBMs, originally utilized for soft ground tunnelling, extended progressively their range of application to mix rocks and finally to hard rock tunnelling with increasing performances.This also thanks to the substantial reduction in the installation time of the segmental lining ring that contributed to minimize the TBM stand by time between two consecutive boring strokes.Today the choice between the two types of TBMs needs to be carefully evaluated project by project since one type of TBM may “prevail” in certain geologies and diameters and vice versa.THE VISHNUGAD PIPALKOTI TUNNELThe Vishnugad Pipalkoti Tunnel is part of the 444 MW Vishnugad Pipalkoti Hydro Electric Project (VPHEP) on Alaknanda river in Uttarakhand (India).The Owner is the Indian electric company “Tehry Hydro Development Corporation” (THDC) and the World Bank finances the project.The Headrace Tunnel total length is 13.4 Km and a section of about 12,3km will be excavated by TBM by SELI Overseas (Italy) in subcontract to HCC (India) the General Contractor for the project. The TBM will be delivered ex workshop in March 2016 and it is foreseen to start boring in the second half of 2016.Figure 1 below shows the location of the project and the following Table 1 summarizes the geometrical characteristics of the TBM tunnel."

Jan 1, 2016

By S. Chander

The results of an investigation to characterize the chalcopyrite/solution interface are presented. Several techniques including galvanostatic and steady state polarization, cyclic voltammetry and impedance spectroscopy were used. The results show that the dissolution of chalcopyrite is incongruent. Initially, at low potentials(<O.34V), iron species are released which give rise to the growth of an iron-deficient sulfide (IDS) layer. The dissolved iron might reprecipitate as a hydroxide layer depending on solution composition. Continued oxidation involves diffusion of species through the product layer. At higher potentials (>O.48V) further oxidation leads to dissolution of copper and sulfur species with a resultant breakdown of the IDS layer. The changes in properties of surface coatings resulting from various electrochemical treatments are discussed.

Jan 1, 1991

By Ted H. Eyde

Nearly 17 years ago a major producer of synthetic zeolites started an extensive exploration program for natural zeolite deposits which resulted in the discovery of over 170 occurrences in the western United States. A few years later several of the other producers and consumers of synthetic zeolites also started similar exploration programs. Since then, small quantities of natural zeolite minerals have been produced from at least 12 deposits in the United States. Of these the Bowie deposit, about 13 miles north of Bowie, Arizona, is the most important,having produced over 5,000 tons of vitric tuff zeolitically altered to the mineral chabazite and minor amounts of the minerals erionite and clinoptilolite. Mining Districts and Mineral Deposits of Arizona compiled by Charles A. Mardirosian, Consulting Geologist, estimates the value of the total production from the Bowie deposit at a very conservative $2,000,000. Unfortunately, none of the companies responsible for the discovery and the initial production of natural zeolites made any effort to develop the high volume, low cost applications of this unique mineral raw material. Instead, they developed only the high unit value uses to supplement their existing synthetic molecular sieve product lines. With the producers of synthetic zeolites thinking in pounds and not in tons, further development of natural zeolite deposits stagnated for over a decade.

Jan 1, 1974

By R. Vance, C. Cho, N. Mardi, Z. Qian, K. Prisbrey

One problem with the application of neural networks to the multivariable control of mineral and extractive processes is determining whether and how to use them. The objective of this investigation was to compare neural network control to more conventional strategies and to determine if there are any advantages in using neural network control in terms of set-point tracking, rise time, settling time, disturbance rejection and other criteria. The procedure involved developing neural network controllers using both historical plant data and simulation models. Various control patterns were tried, including both inverse and direct neural network plant models. These were compared to state space controllers that are, by nature, linear. For grinding and leaching circuits, a nonlinear neural network-based model predictive control strategy was superior to a state space-based linear quadratic gaussian controller. The investigation pointed out the importance of incorporating state space into neural networks by making them recurrent, i.e., feeding certain output state variables into input nodes in the neural network. It was concluded that neural network controllers can have better disturbance rejection, set-point tracking, rise time, settling time and lower set-point overshoot, and it was also concluded that neural network controllers can be more reliable and easy to implement in complex, multivariable plants.

Jan 1, 1998

By C. J. Im

As market conditions become more competitive, U.S. coal producers are faced with the increasing need to find methods of lowering production costs in their operations. One area worthy of investigation is the additional recovery of fine coal that is normally discarded in the preparation plant waste stream. United Coal Company is currently assessing the capability of the Deister Flotaire, a new application of a column flotation cell, to recover additional, saleable coal from preparation plant waste. This paper presents the technical data obtained to date. Work with a 0.76 m (30 inch) diameter cell installed in a plant shows considerable coal recovery is possible from a nominal 0.595 run (28 mesh) X 0 refuse stream.

Jan 1, 1986

By T. Skodack

This presentation will compare actual work site results for the loading and transport of shot rock for two major tunneling projects in North America. "SCARMAR" (the Canadian subsidiary of S & M Construction) is operating a rail bound Hagglund continuous gathering arm loader in combination with a Hagglund nine car shuttletrain system at the West End of Table Mountain on the B.C. Railway project near Tumbler Ridge, Canada. Al Johnson Construction is operating a Hagglund rubber tired continuous gathering arm loader in combination with haul trucks at the Rocky Mountain Pump Storage Project near Rome, GA. This paper will compare: 1) tunnel and ground conditions, 2) the total work cycle as it relates to mucking and haulage 3) efficiencies and related problems with the two systems 4) mucking and haulage rates 5) operating costs, and 6) recommendations for future large tunnel excavations. Manuscript not received in time for publication.

Jan 1, 1983

The properties of interfacial water at hydrophilic surfaces are of great importance in many technological areas including flotation, solid-liquid separation, dispersion and emulsions, flocculation, adsorption, corrosion, and soil contamination. This paper examines the use of FTIR/internal reflection spectroscopy (FTIR/IRS) to study the spectral characteristics of interfacial water at silica surfaces. FTIR spectra were characterized by consideration of the OH stretching region (3000-3800 cm-1) associated with the vibrational spectra of interfacial water. The broad peak in this region was deconvoluted in order to isolate overlapping spectral features that describe the nature of hydrogen bonding in interfacial water. Three distinct bands were found; -3600 cm-1 (free OH), -3400 cm-1 (incomplete tetrahedral coordination), and -3240 cm-1 (complete tetrahedral coordination) and the variation of their intensities with pH was found to be significant. This spectral information helps to explain orientation and bond ordering of interfacial water molecules at hydrophilic surfaces.

Jan 1, 1998

By Barbery G., A. Maachar, M. Bourassa

Laboratory testing for flotation circuit design is carried out on a routine basis in a large number of lab- oratories throughout the world. Usually a sample of ore, assumed to be characteristic of the material to be processed in a future plant, having a mass of the order of a few kilograms, is ground in a batch ball or rod mill, in the presence of water and some re- agents (for pH control, etc. .. ); after dilution to the adequate solid concentration, the resulting slurry is transferred into a laboratory batch flotation machine, having a volume which can vary from 0.5 to 8 10 -3m3. Various types of machines are in common use, manufactured by the same companies that market industrial size flotation machines. The operation of flotation in the laboratory is carried out by an experienced technician, who uses parameters such as impeller rotation speed, air flowrate addition, froth height, froth removal rate, in conjonction with reagent addition sequence, to "test" the ore. After flotation, the froth products ("concentrates"), and the solids remaining in the cell are filtered, dried, and analyzed for the various elements of interest. For flotation circuit design, a kinetic test is usually carried out, in which the froth products obtained at various times are collected to assess the time response of the ore in the laboratory machine with the combination of reagents used. Although this description is rather sketchy, it enables to outline some of the major difficulties in using laboratory data for flotation circuit design: 1. ore sample representatively 2. feed preparation procedure (laboratory compared to industrial scale) 3. laboratory procedures (type of ma- chine, type of operation, experimental errors. . . ) 4. flotation machine scale-up 5. flotation kinetic scale-up 6. flotation circuit design using laboratory data These various points will be discussed in the present paper, in order to stress the problem areas as well as possible solutions. ORE SAMPLE REPRESENTATIVITY It has been stated many times that one of the major problem in designing a flotation circuit is the representatively of the sample to be taken. Sampling of an ore body during prospection and evaluation is a specialized field, which has been progress in with the introduction of geostatistics. The application

Jan 1, 1986

By J. E. Miller

The development of a new means of measuring the relative abrasivity of a slurry came about by necessity in 1967 during a full scale loop test of a 560 H.P. reciprocating pump handling magnetite slurry. In order to evaluate the life of expendable fluid end parts, the question of the amount of attrition in a re-circulated slurry had to be considered. An expected reduction in abrasivity as a result of this attrition would certainly give erroneous data on a parts life test. There- fore, some means of measuring such change in abrasivity became imperative. Several test methods were investigated1 but it was felt that these did not fully represent the wear due to back and forth rubbing action associated with a reciprocating pump. A "rubbing block" device used some years ago to determine the quality of hard facing materials was recalled, along with its shortcomings, in that an attempt was made to suspend a small percentage of abrasive particles in a colloidal viscous "mud". Erratic results were attributed to the fact that it was difficult to maintain a consistent slurry concentration under the metal wear block and the reciprocating speed was not great enough to maintain good agitation.

Jan 1, 1973

By Wen-Long Cai, A. Frederick Banfield

This paper investigates, through case studies on a porphyry copper and a coal deposit, the differences and relevances between an approximate production schedule approach, i.e., the best case and the worst case schedules and a practical production schedule approach. The comparisons were with regards to: 1) choosing an optimum ultimate pit size, 2) determining processing capacities, 3) selecting &apos;optimum&apos; cutoff grades, and 4) blending. The comparison criteria was to maximize the project net present value. Conclusions were drawn based on the study results.

Jan 1, 1996

By X. P. Zheng, H. K. Lin

Barium fluorophlogopites were synthesized in the laboratory to investigate the effects of composition and crystal parameters on surface properties and floatability. The negative surface charge of mica is determined by the barium content, the crystal cell volume, the distance between the layer structure and the Ba-O bond length. The higher the barium content, the larger the cell volume and distance between the layer structure, and the longer the Ba-0 bond, the more negatively charged the surface is, and, hence, the more easily adsorbed are cationic collectors. When an anionic collector (sodium oleate) is used, barium oleate forms on the mica surface and hence chemical adsorption occurs.

Jan 1, 1995

By Ilmar J. Martens

The statistical information and cost data used in this report has been made available by NICKDATA INC. Since 1982, NICKDATA INC. of Toronto, Canada, has produced an annual comprehensive nickel industry cost study. Up to date information on 22 mines, 21 smelters, and 16 nickel refineries representing 30 nickel production operations in 17 countries are included in the computerized cost analysis. The report is compiled from information obtained through regular annual visits to major nickel operations and continuous monitoring of information on all nickel producers. The 1984 report which was completed this summer, reveals drastic changes in the nickel industry cost structures.

Jan 1, 1984

By Seokwon Jeon, Ho-Young Jeong

"Various numerical methods have been tried to estimate the cutting forces of a TBM disc cutter. In this study, SPH/FEM coupled method was newly employed to improve the traditional FEM analysis. The disc cutter and rock were modeled by Lagrange and SPH codes, respectively. The numerical cutting test was carried out for representative Korean rocks with different cutting conditions. The results show that the cutting forces obtained from numerical simulation had a good agreement with those from LCM tests, and that applying SPH method to rock cutting model has advantages and improvement compared to traditional FEM method. Erosion criterion and erosion limit were not required to simulate the rock fragmentation process, and the cutting forces from the numerical simulation was more stable and accurate. The results indicate that the numerical simulation can be successfully used to estimate cutting performance of a TBM. 1. INTRODUCTION Various numerical studies have been carried out to accurately simulate the limitations of linear cutting machine (LCM) tests. Numerical modelling methods have advantages comparing with full scale tests in terms of cost and time involved. Many numerical methods have been used to simulate rock cutting process by different cutting tools and the studies are summarized in Table 1.In 2D simulations listed in Table 1, because they do not take account of rolling force and horizontal rolling mechanism of a disc cutter, indenter was selected as cutting tool in their modelling. For these reason, 2D modelling is not suitable for rock cutting modelling using a disc cutter. In contrast, 3D numerical models can take account of the indentation process by thrust force and penetration processes controlled by rolling force."

Jan 1, 2016

By A. S. Hall

Significant pyrite often does not dissolve in the Sobek (1978) nitric acid extraction; therefore, the standard conservative approach is to estimate pyrite using sulfur present in the sum of the nitric acid and residual sulfur fractions. Alunite, when present, appears as residual sulfur. Because alunite does not generate acidic effluents, overestimation of AGP can occur if all residual sulfur is assumed to be undigested pyrite. Evaluation of 16 samples from the Florida Canyon Mine revealed that petrographic examination coupled with a modification of the Sobek method to include a 6 hour hot (250°F) &apos;nitric acid extraction resulted in a more accurate estimation of AGP.

Jan 1, 1999

By A. K. Sheik

A small underground mine in northern Idaho was used as an experimental facility for studying the role of water in the analysis of mine opening stability. Laboratory test data, borehole measurements and geological mapping assisted in constructing a coupled finite element model of the rock mass. The model was used to make quantitative estimates of: 1) rock stress, strain and displacement changes, and 2) water pressure and flow velocity changes that occurred during historical mining. Stope cuts and wet fills were included in the analysis. Stability of crown pillars between stopes was of particular interest. The relatively low effective stress and high rock mass strength showed that water pressure changes were of no great consequence in agreement with experience. The computational tools used in the analysis may be applied to other wet mines with appropriate changes to site-specific input data.

Jan 1, 1999

By J. Kemeny, R. Fuentealba, C. Rodriguez, F. Fernandez, M. Rocha, T. BoBo

"Mathematical modeling in conjunction with mineral characterization is widely used as a method for design and optimization of comminution circuits, to simulate the processes of crushing, grinding and classification. An important input parameter to the simulation models is the Run-of-Mine Particle Size Distribution (ROM PSD). The run-of-mine size distributions due to blasting have a great influence on the performance of a semi-autogenous grinding (SAG) mill. In this paper, a mine case study was conducted where there are four primary geologic units and the material properties between the four units vary considerably. Also, the mixture of the four unit that will be mined at any given time also vary considerably. This presents a challenge in terms of optimizing the blasting for mill production throughout the mine life. As part of the case study, field rock mass characterization, laboratory rock mechanics tests, and laboratory breakage tests were conducted. The field characterization and rock mechanics tests provide material properties used to simulate the effect of different blast designs on run of mine particle size distributions (ROM PSD). The JKSimBlast software was used for these simulations. The rock breakage tests provide material properties used to simulate crushing and grinding performance. The JKSimMet software was used for these simulations. The goal of the mine is a mill throughput of 95,000 tonnes (104,720 tons) per day (TPD). Based on this goal, run-of-mine fragmentation analysis was conducted for four blasting designs resulting in powder factors of 0.44, 0.54, 0.64, and 0.94 kg/t. The powder factor of 0.44 represents a standard blasting design, while the 0.54 and 0.64 kg/t designs are high-energy blasts specifically to assist with mill production. The 0.94 kg/t design was investigated for the one geologic unit with very high strength. The results of the run-of-mine fragmentation analysis was then input into a crushing and grinding simulation model to predict the mill throughput for the time periods of 1-5 years and 6-10 years. The results indicate that certain blast designs are able to achieve the 95,000 tonnes TPD (104,720 tons TPD) goal, while other blast designs were not. A standard blast design with a 0.44 kg/t powder factor, for example, was not able to achieve the throughput goal, while a design with a 0.64 kg/t powder factor was able to achieve the goal in both the 1-5 and 5-10 year time periods. INTRODUCTION In recent years, mathematical modeling in conjunction with mineral characterization has been widely used as a method for the design and optimization of comminution circuits. The Run-of-Mine Particle Size Distribution (ROM PSD) is a function of rock properties and design parameters of the blast and has a significant impact on the crushing and grinding treatment circuit. Traditionally, design of the grinding treatment is estimated using only the F80 value instead of the full distribution of sizes in the feed, but the finer sizes have great influence on the treatment of a grinder, particularly in the SAG mill."

Jan 1, 2015

By Lennart Bergstedt

Boliden Aktiebolag, the prime base metal mining company of Sweden, annually treats some 11-12 million tons of sulphide ore in nine concentrators. Its first flotation plant was established in the early thirties for the complex Boliden ore. Since then, the number of mines and plants has gradually increased. Considerable effort has been devoted to the development of all phases of the technology of ore prospecting, mining, milling, smelting and refining. This has been necessary due to the complex and low-grade ores. The development of concentration has mainly been directed toward the arts of grinding and flotation. During the forties and fifties, open-stage fine crushing followed by two-stage grinding in rod and ball mills with cyclone classification was successfully introduced and used throughout the plants. The increasing cost of grinding media led to studies of an autogenous grinding technique as early as 1945. Basic test work commenced during the early fifties, with a. number of ores tested for pebble grinding. In 1956 a new pilot plant was built, with equipment installed for the continuous testing of pebble grinding and, later, for primary autogenous grinding of run-of-mine ore. The intensive test work showed that pebble grinding was feasible in almost all of the plants. At this early stage of testing, however, the merits of autogenous grinding could not be fully evaluated. As a. consequence the rod mill/ball mill grinding systems were converted to rod mill/pebble mill systems whereever possible. In parallel with the converting of grinding systems the development work concerning the merits of autogenous grinding went on. The major result

Jan 1, 1977