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By Bruce Watzman

"Few issues are more important to the National Mining Association (NMA), the U.S. mining industry and NMA’s MINExpo International 2016 exhibitors than safety.Global mining safety and health is a journey necessitating continuous improvement, collaboration and innovation on the part of both mining operators and their suppliers.MINExpo 2016, which takes place Sept. 26- 28, 2016, in Las Vegas, provides attendees with the opportunity to view technologies to help refine management of mining safety and health, utilizing NMA’s CORESafety system. CORESafety ‘One of the best’Launched by NMA in 2011 and moving forward ever since, CORESafety is driving continuous improvement in safety and health performance among participating industry companies by shifting from a command-andcontrol regulatory approach to a risk-based systems approach built on the Plan-Do-Check-Act model (Fig. 1).Considered an exemplary safety and health management system, NMA’s CORESafety system helps mining operators change their approach to safety and health management by enhancing the safety and health culture throughout their organizations. Although it is challenging to consistently and completely control all the factors and variables occurring in daily mining operations, experience has shown that applying systematic controls to as many variables as possible is the most successful approach for improvement in mining safety and health.When embarking upon the development of the CORESafety framework, NMA’s leadership set an ambitious goal to eliminate fatalities and reduce the injury rate 50 percent in five years, or the “0-50-5” goal. While the goal has not been met yet, the steady progress has been extraordinary with fatalities among participating companies dropping 45 percent during the period 2011-2015 (Fig. 2). Data also demonstrate that, as participating companies increase their level of implementation, total injury rates have also declined (Fig. 3).In a September 2015 interview with NMA, Penn State University mining engineering Professor Jeffrey Kohler praised CORESafety as “an inspired and timely program that brings together key elements to achieve safety and health goals.”"

Sep 1, 2016

By Brian Heer, David Young, Randall Essex

The Manapouri Power Station is New Zealand’s largest hydroelectric facility located on the South Island of New Zealand. Constructed in the 1960’s, it includes a 700 MW under-ground power station and a 9.8 km (6.1 mile), 9.2 m (30 ft) diameter tailrace tunnel. The output of the power station is currently limited due to excessive head losses in the tailrace tunnel. To remedy this situation, the Electricity Corporation of New Zealand (ECNZ) retained Woodward-Clyde to design a second tailrace tunnel and appurtenant facilities and prepare Contract Documents for construction. The Project will involve the construction of a 9.8 km(6.1 miles), 10 m (33 ft) diameter, TBM-mined tunnel, hydraulic control structures at the upstream and downstream ends of the tunnel, an underground dewatering shaft and station, and tailrace channel improvements. This paper summarizes the key design and construction issues addressed during the planning and design phases, outlines the risk management provisions incorporated in the Contract, and overviews the Interactive Tender Process (ITP)that was implemented during the pre-tendering and tendering periods.

Jan 1, 1997

By L. B. Hales

Expert control of grinding and flotation plants has been successfully used in the minerals industry since the 1970?s. The earliest of these systems were written in a hard-coded fashion in FORTRAN, BASIC or Pascal. Second generation systems were built using the first experimental expert system shells that were being developed in the artificial intelligence community. Later systems were deployed in expert system shells designed for real-time processing plants that also included the ability to model the process with neural network models and optimize setpoint selection through the use of genetic algorithms. Significant performance increases have been achieved using these systems, but in general, they suffer from the static nature of their rules and to a degree the process models also. Typical improvements quoted in the literature suggest throughput rate increases of 4 to 8 percent and recovery increases of 1 to 4 percentage points. In over 30 years of designing and installing expert systems we have never seen performance numbers less that these but have often seen numbers in excess of the high values. However, once the system has been installed and tuned up the performance usually does not improve much thereafter. Granted, the initial increases in throughput rate and recovery are significant but a question always lingers, that is, can the expert strategies be modified further to squeeze a little more improvement out of the system. The answer to this question is a resounding yes, however a complete understanding of what we do well as designers and operators of expert control systems is required as well as how we can improve upon our best practices is required to move us from the performance plateau we have been on for a number of years to a new higher level of performance.

Jan 1, 2009

By Jim Owens

The methodology of quarrying changed significantly in the Indiana limestone industry in the 60 years between Sept. 11, 1941 and Sept. 11, 2001. The former was the date of the Pentagon groundbreaking ceremony, while the latter was when the building was damaged by American Airlines Flight 77. So too, though to a lesser degree, did the machinery and methods used to fabricate the stone. The rededication ceremony on Sept. 11, 2002 marked the end of the Phoenix Project, as the rebuilding effort was named. The story of this remarkable project illustrates what the American construction(and Indiana limestone) industry can accomplish when working toward a common goal.

Jan 1, 2005

By John Marsden

Despite the recent pullback in metal and mineral prices, and the associated market adjustments, the mining industry is still facing a serious issue with the declining availability of graduate expertise. This is due to a combination of an aging workforce, retirements and retrenchments, coupled with a lack of suitably qualified graduates entering the workforce. The issue has certainly improved since 2004 when the industry picked up the rates of hiring graduate engineers and mining/mineral school enrollments picked up in response. This hiring effort has helped to cover the ?gap? years from about 1985-2000, when industry demand for graduates was particularly poor. However, the recent market pullback is likely to set back this progress, as recruitment and hiring wavers as a result of cost cutting measures and economic uncertainty. A key issue for the mining industry is how to ensure the survival and growth of relevant ?core? degree programs. Such programs include mining, metallurgical, mineral processing and geological engineering. The mining industry needs a healthy, high-level education program to ensure an adequate supply of appropriately qualified graduates for the mining industry. Two-thirds of the professionals entering the minerals industry who graduated within the past 40 years graduated prior to 1985. Since 1985, we have been living off the legacy of graduation classes from the mid-1970s and early 1980s. It is estimated that we have been producing graduates at approximately 40 to 50 percent of the sustaining rate since about 1985. Further growth in the domestic industry would increase graduate requirements significantly, and the export of U.S.-graduates to other parts of the world (as is currently occurring) also impacts the total graduate requirements.

By P. L. Crouse, S. J. Lubbe, M. J. Kabangu

A selective extraction and separation of zirconium by solvent extraction with 1-octanol is proposed. The process is based on the dissolution of the metal basic carbonates in hydrochloric acid in the presence of potassium fluoride, using 1-octanol as extractant. The effect of several process parameters, including hydrochloric acid and potassium fluoride concentrations, reaction time, and phase ratio between the aqueous and the organic phase was investigated. Zirconium is enriched in the organic phase. The best extraction and separation results were obtained with the basic carbonate dissolved in 10% hydrochloric acid and 1.5 M potassium fluoride. The optimum reaction time was 15 min with an organic to aqueous phase ratio of 2:1. Based on the selectivity of zirconium over hafnium in the organic phase, a McCabe-Thiele diagram was constructed. A near complete stripping of zirconium from the organic phase was achieved using a 3 M sulphuric acid solution. Additional studies are required in order to determine the reaction mechanism and the chemical speciation of the current investigation.

By R. R. Oder, R. E. Jamison, E. D. Brandner

This paper presents preliminary test results obtained with a 0.38 kg/s (3000 lb-hr) beta prototype MagMill™. In processing Upper Freeport coal the beta prototype recovered 82% of the weight of the feed and 91% of the heat content while reducing the potential emissions of sulfur, kgSO2/GJ(lbSO2/MBtu), by 61%. Pyritic sulfur in the MagMill™ product was reduced by 78% compared to that in the feed. For all runs, the mill product was controlled between 70 to 80% finer than 74 µ particle size. Recoveries of mercury, arsenic, and selenium ranged from 35 to 45% of that in the feed. Power draw was reduced by 26% and mill throughput was increased by 9% compared to the pulverizer operating with no magnetic separator attached.

Jan 1, 2000

By S. D. Hill, G. E. McClelland

To maximize productivity and improve minerals processing technology, the U. S. Department of the Interior, Bureau of Mines, is investigating a particle agglomeration technique as a means of increasing the percolation rate of leaching solutions through heaps of clayey or finely crushed, low- grade, gold-silver ores. Bench-scale and pilot-scale experiments conducted on different ores indicated that the percolation rate of cyanide leaching solution was enhanced markedly by mixing the ore with a binder, such as lime or portland cement, moistening the mixture, then mechanically agglomerating and aging the feed prior to heap building and leaching. In addition, the rate of silver and gold extraction markedly increased without sacrificing total recovery of values. The use of concentrated cyanide solution instead of water during the agglomeration procedure substantially decreased the leaching time required to obtain maximum recovery. Results from bench-scale and pilot-scale experiments using the particle agglomeration technique are discussed.

Jan 1, 1981

By Shuangchun Yang, Le Tong, Ronggui Fan, Cunlei Li

Acid mine drainage (AMD) is difficult to treat due to its physicochemical characteristics, such as high pH and high heavy metal concentrations, so it causes great harm to the environment and human health. If acid mine drainage is discharged arbitrarily without treatment, it will lead to a series of environmental problems and cause long-term environmental pollution. In this paper, the source and hazards of acid mine drainage are introduced in detail. And the principle, the mechanism, the application, and basic information of the current primary technology of the treatment for acid mine drainage are comprehensively introduced and summarized. The summarized treatment technologies for acid mine drainage mainly include neutralization, sulfidization, constructed wetland method, adsorption method, microbiological method, ion exchange method, membrane technology, and microbial fuel cell technology. Also, the primary technology of treatment for acid mine drainage is systematically compared and evaluated. Moreover, some suggestions on the development direction of water treatment technology in the future are put forward. This paper provides a scientific reference for scientific and technical works to treat acid mine drainage.

Sep 4, 2020

By James Warner, Peggy Ganse, Glen Smoak, Raymond Henn, Sam Bandimere

Over the past several decades, cement-based grouts using ultrafine cement as are placement for portland cement have begun to gain acceptance as an alternative to chemical solution grouts, however the amount of information currently available on these grouts is limited. For this reason, the authors developed a field testing program to evaluate the penetration capabilities of various ultrafine cement grout mixes. The tests were conducted by injecting sand columns using different portland and ultrafine based grouts, the measuring penetration distances after applying equal injection pressure for the same time period. Results of tests performed in 1999 and 2000 are discussed herein.

Jan 1, 2001

By W. K. Hitchcock

Anecdotal evidence suggests that re-entering a sealed heating poses a significant hazard, whereby the original heating is rejuvenated at an accelerated rate forcing withdrawal and re-sealing of the area. Bulk-scale laboratory experiments using a two-metre column confirm these mine site observations. A high volatile bituminous coal from New South Wales, Australia was allowed to develop a significant hot spot before being inerted with nitrogen and allowed to cool. Air was then allowed back into the coal after the nitrogen was turned off and a hot spot developed almost immediately at the same location as the original hot spot before it quickly migrated towards the air source within a day. Two more re-entries were simulated. Each successive re-entry developed a broader hot spot and took longer to reach thermal runaway. These results clearly show the behaviour that can be expected when trying to recover a section of an underground coal mine that has been sealed due to a spontaneous combustion event.

Jan 1, 2009

By H. H. Murray

The largest reserves of palygorskite in the world are located in Anhui and Jiangsu Provinces in East Central China. The deposits are Middle Miocene in age and range from 3 to 6 m in thickness. The deposits are the alteration product of basaltic volcanic ash. The Chinese Geological Survey estimates the palygorskite reserves are in excess of 200 million tons. The elongate particle shape results in unique colloidal properties. Large quantities are exported to Japan, Taiwan, Southeast Asia, New Zealand, Australia, and West and Gulf Coasts of the United States. The markets include agricultural carriers, paint, joint tape compounds, animal feed binders, catalyst support, drilling muds, and suspending agents for chemicals, pharmaceuticals, and medicines. The viscosity is high and the quartz content is generally 5% or less.

Jan 1, 2009

By D. Blackwell, W. R. Reed, G. Ross, S. Peters, M. Shahan

Dust collectors for roof bolting machines generally use a dry box to collect the roof bolting material. Recently, an underground mining operation converted a dry box dust collector to a wet box dust collector with a unique exception from MSHA for testing purposes.Water is routed to the roof bolter fromthe main water line of the continuous miner. The wet box utilizes a water spray to wet the incoming material. Testing was conducted comparing the two different collector types. Respirable dust concentrations surrounding the roof bolter with the different collection boxes were similar. The main difference in respirable dust concentrations occurred when cleaning the dust boxes. The average respirable dust concentration during cleaning of the wet box was 0.475 mg/ m3, and during the cleaning of the dry box, the average respirable dust concentration was 1.188 mg/m3, a 60% reduction in respirable dust concentration. The quartz content of the roofmaterialwas high, ranging from 28.9 to 52.7%during this study. The results from this study indicate that using the wet box as a collector reduced exposure to respirable dust up to 60% when cleaning the collector boxes.

Aug 26, 2020

By William Gleason

During the 116th National Western Mining Conference and Exhibition in Denver, CO, the host city was often referred to as world?s mining capital, so it was fitting that the conference looked at the mining industry through a global lens. In the current world economy, the mining industry must keep a sharp focus on such things as commodity prices and global supply and demand as well as local issues that can have a dramatic impact on a mine?s social license to operate. In short, companies should mine locally but think globally. During the three-day conference at the Colorado Convention Center, a range of global and local issues that effect the industry were discussed. A record 1,144 people attended the conference.

By A. A. El-Midany, R. M. Farag, A. M. Salem, S. E. El-Mofty

Bentonite represents one of the main players in the stability of the drilling mud. Its particle size and particle size distribution affect the physical properties of the drilling mud especially the rheological properties. Therefore, a specific particle size distribution was recommended by American Petroleum Institute (API) for use in drilling mud. To clarify the effect of individual size and size distribution, in this study, the bentonite sample was classified into different size fractions. Each size fraction was tested separately in terms of controlling properties such as filtration loss, plastic viscosity, gel strength, cake thickness, and packing density. The effect of each size fraction on the rheological properties of the suspension was correlated to the behavior of the whole particle size distribution in the bentonite sample. The results indicate that the coarser the particles, the higher the rheological properties; in this case, the API mixture is the highest. The filtration loss and cake thickness for the API mixture are lower than that of the individual size fractions due to its wider size distribution due to the filling of voids between larger particles with smaller ones, which lead to bed compaction and consequently lower fluid loss and cake thickness.

By B. Salopek, D. Rajkovic, D. Rumenjak

In decision making support system, that are used in various fields of environmental protection (environmental impact assessment, environmental management systems, setting environmental standards and regulation, etc.), it is often important to apply various mathematical environmental engineering models. The question of linking environmetal engineering modeling to decision making support system used in environmental protection is not yet methodically solved. The reasons for that could be manifold. Decison making support systems, used in environmental protection, because they are simply taken from bussines decision making, are not often adequate for specific problems raised in environmental protection. On the other hand, there are great number of types of models in environmental engineering, what urges the problem of finding the way of their proper linking with decision making support systems. The application of fuzzy logic in that field is estimated as one of possible solution of the problem.

Jan 1, 2005

By R. Heiser, J. Vendetti, B. P. Connor, E. J. Haas

Health and safety indicators help mine sites predict the likelihood of an event, advance initiatives to control risks, and track progress. Although useful to encourage individuals within the mining companies to work together to identify such indicators, executing risk assessments comes with challenges. Specifically, varying or inaccurate perceptions of risk, in addition to trust and buy-in of a risk management system, contribute to inconsistent levels of participation in risk programs. This paper focuses on one trona mine’s experience in the development and implementation of a field-level risk assessment program to help its organization understand and manage risk to an acceptable level. Through a transformational process of ongoing leadership development, support and communication, Solvay Green River fostered a culture grounded in risk assessment, safety interactions and hazard correction. The application of consistent risk assessment tools was critical to create a participatory workforce that not only talks about safety but actively identifies factors that contribute to hazards and potential incidents. In this paper, reflecting on the mine’s previous process of risk-assessment implementation provides examples of likely barriers that sites may encounter when trying to document and manage risks, as well as a variety of mini case examples that showcase how the organization worked through these barriers to facilitate the identification of leading indicators to ultimately reduce incidents.

Jan 1, 2018

By R. Heiser, J. Vendetti, B. P. Connor, E. J. Haas

Health and safety indicators help mine sites predict the likelihood of an event, advance initiatives to control risks, and track progress. Although useful to encourage individuals within the mining companies to work together to identify such indicators, executing risk assessments comes with challenges. Specifically, varying or inaccurate perceptions of risk, in addition to trust and buy-in of a risk management system, contribute to inconsistent levels of participation in risk programs. This paper focuses on one trona mine’s experience in the development and implementation of a field-level risk assessment program to help its organization understand and manage risk to an acceptable level. Through a transformational process of ongoing leadership development, support and communication, Solvay Green River fostered a culture grounded in risk assessment, safety interactions and hazard correction. The application of consistent risk assessment tools was critical to create a participatory workforce that not only talks about safety but actively identifies factors that contribute to hazards and potential incidents. In this paper, reflecting on the mine’s previous process of risk-assessment implementation provides examples of likely barriers that sites may encounter when trying to document and manage risks, as well as a variety of mini case examples that showcase how the organization worked through these barriers to facilitate the identification of leading indicators to ultimately reduce incidents.

Jan 1, 2017

By J. Yianatos

The collection zone residence time distribution (RTD) of mechanical self-aerated flotation cells was characterized for liquid and solid per size class (-45 mm, +45-150 mm and +150 mm). It was found that a single large industrial cell with a volume of 130 to 250 m3, now used in plant operations, can be well represented by an LTST (large and small tank-in-series) model plus dead time. From a scale-up point of view, results showed a similar mixing behavior for industrial cells ranging from 130 to 250 m3. Also, single mechanical cells showed a similar mixing pattern (RTD) when compared to large pneumatic flotation columns. It was confirmed that for practical purposes, the mixing condition in a flotation bank of three or more cells in series can be well described by the classical N tanks-in-series model.

Jan 1, 2008

By G. S. Hansford, C. J. N. Dempers, G. E. Searby, A. W. Breed, M. A. Jaffer

The bioleaching of sulfide minerals involves a ferric attack of the mineral with the role of the micro-organisms being the oxidation of the ferrous-iron back to the ferric form, and the oxidation of sulfur, either via thiosulfate or polysulfides, to sulfate. The kinetics of bacterial ferrous-iron oxidation and the chemical ferric leach kinetics of sulfide minerals can both be described as functions of the ferric/ferrous-iron ratio. The independently determined bacterial ferrous-iron oxidation and chemical ferric-iron leaching kinetics have been successfully used to predict continuous bioleaching operations.

Jan 1, 2000