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By F. X. Spachtholz

"Raw materials industry is crucial for national economy. German mining companies are known for their high degree of resource efficiency based on modern technology and know how. K+S is one of the world’s leading suppliers of standard and specialty fertilizers. In the salt business, K+S, with sites in Europe as well as North and South America, is the world’s leading producer. The mine sites of K+S are distributed all over the world producing mainly potash and magnesium salts and rock salt. Focus is on the sustainable use of the natural deposits in order to stay competitive. For this reason a raw material policy, both national and international, is necessary to ensure access to new mineable deposits which are still available in Germany. Further on, knowing market conditions is a must for sustainable development. At least sustainability and resource efficiency in potash and rock salt mining are achieved by constantly developing new technologies as well as optimizing the organization and improving qualification of workers."

Jan 1, 2011

By António Fiúza, Anthony Danko, Patrícia Leitão, Aurora Futuro, Cristina Vila, Lurdes Dinis

The average global recovery rates for processing scheelite ores by physical methods are normally in the range 50 to 70%, and it is problematic to attain a minimum grade of 60% WO3 in the concentrates without penalizing further this yield. Direct hydrometallurgical processing of low-grade concentrates or medium- to high-grade ores may become an interesting global economic alternative as it allows increasing the recovery rate, avoiding major penalizations due to the grade of the concentrate and increasing the added value of the final product. Leaching of scheelite by sodium carbonate presents several advantages such as its selectivity regarding the dissolution of troubling metals like iron and aluminium, allowing for a simple and flexible process diagram. However, it has the disadvantage that it is performed at high temperature and pressure with a high consumption of reagents. The feasibility of leaching is appraised by the extraction yield and selectivity, but also by the operating cost. Considering these aspects, a relevant objective of the research was to transform alkaline pressure leaching into a feasible processing alternative directly applicable to both medium- and high-grade ores and simultaneously to low- and high-grade concentrates produced by physical methods. The research used ore samples and low-grade concentrates from a typical skarn orebody as well as high-grade concentrates from a chalcopyrite-scheelite orebody. Different operating conditions were tested. Temperature, pressure and reagent concentration showed to be fundamental, but not exclusive, in determining the leaching behaviour. The operating conditions are milder than the ones generally proposed in the literature or currently in use in industry, but with higher carbonate consumptions. The research was oriented towards potential industrial implementation allowing for the application of optimization methods and straight scale-up to pilot-plan design and project.

By Christopher J. Bise

INTRODUCTION A mine's power system represents the driving force behind all of the extraction and auxiliary operations, because the production and transportation of mined material and the operation of equipment, such as fans and pumps, are all dependent upon a power source. Once, compressed air was the primary power source in mining; today, however, electrical power dominates. This chapter reviews the basic theories of com- pressed-air and electrical power and provides several examples of applications in mine power systems. COMPRESSED-AIR POWER General Compressed air has been, and should continue to be, an important source of power in mining operations. It has been used as a means of blasting coal in conventional mining and is widely used to operate stopers, mucking machines, and other air tools in both coal and hard-rock mines. Such applications demonstrate the suitability of compressed air for applications requiring linear motion, but it is also utilized for its reliability and safety. A compressed-air system is composed of a compressor, a receiver, a distribution network, and the air-operated machines. A compressor takes in air at normal atmospheric pressure (free air) and compresses it to a higher discharge pressure. The discharge pressure must be high enough to overcome the friction in the distribution system of pipes and hoses and deliver the compressed air to the machines at the pressure recommended by the manufacturer. The most common type of compressor used in mines is the reciprocating compressor in which the air is compressed by a piston in a cylinder. An air receiver is a container or storage tank that is located in the distribution system between the compressor and the machines. It stores compressed air, when the full capacity of the compressor is not being used, and gives a more steady flow of air to the machines. The distribution network consists of pipes, Oalves, elbows, tees, and hoses that transmit the compressed air from the receiver to the machines in the mine. It is essential that the distribution system be designed with the proper sizes and lengths of pipe, hose, and other components to keep pressure losses well within allowable limits. The air-operated machines consist primarily of drifters, stopers, pluggers (sinkers), slushers, and several other pieces of equipment. Compressor Operation Every compressor is made up of one or more basic elements; a single element, or a group of elements in parallel, comprises a single-stage compressor. Many compression problems involve conditions beyond the practical capability of a single compression stage. Too great a compression ratio (absolute discharge pressure divided by absolute intake pressure) may cause excessive discharge temperatures or other design problems. It, therefore, may become necessary to combine elements or groups of elements in series to form a multi- stage unit, in which there will be two or more steps of compression. The number of stages commonly used in reciprocating compressors is as follows: Pressure Number of stages 0- 150 pig 1 80- 500 psig 2 500-2500 psig 3 2500-5000 psig 4 When pressure is referred to as pounds per square inch gage (psig), it means the pressure (in pounds per square inch) above barometric pressure as measured by a gage. The sum of barometric pressure and gage pressure is the absolute pressure (in pounds per square inch). The gas is frequently cooled between stages to reduce the temperature and volume entering the subsequent stages, thereby reducing the work required for compression. The basic reciprocating compression element is a single cylinder compressing on only one side of the piston (single-acting). A unit compressing on both sides of the piston (double-acting) consists of two basic single-acting elements operating in parallel in one casing. The reciprocating compressor uses automatic spring-loaded valves that open only when the proper differential pressure exists across the valves. Intake valves open when the pressure in the cylinder is slightly below the intake pressure. Discharge valves open when the pressure in the cylinder is slightly above the discharge pressure. In Fig. 1, Diagram A shows the basic element with the cylinder filled with air at atmospheric pressure. On the corresponding theoretical pressure-volume

Jan 1, 1986

By J. C. Stankus

Accurate evaluation of stress and geological conditions is critical to ground control design in underground openings. For a slope entry, the problem is more difficult because a slope will transverse through many different types of strata. Over the past three years, Keystone Mining Services, LLC, an affiliate company of Jennmar Corporation, has developed a new methodology designated the ?Stress, Geologic, and Support Design System (SGSsm)?. This patent pending method analyzes the stress, geology, and support design for a mine slope. It has been successfully applied in various new slopes across the United States. This paper will detail the main concepts of the methodology including: (1) Analysis of stress and geology and identification of strong, fair and weak zones along the slope; (2) Primary and supplemental support design; (3) Long term support design in the form of steel square sets or arches, and (4) Validation of the support design utilizing advanced finite element computer modeling.

Jan 1, 2011

By C. P. Mangelsdorf

Introduction The use of frequency of vibration measurements to determine tension has long been accepted by industries that use electrical or stranded cables of wire ropes in their operations. In contemplating how to determine the tension in chords of a roof truss, it seems almost inevitable that a similar approach should be investigated even though there are some important dissimilarities in physical behavior between a chord of a rod-type Birmingham truss and a stretched wire rope. While the dominant feature of both types of behavior is the existence of tension, the bending resistance of the vibrating truss chord cannot be ignored. And it is common to have attached to the chord, pieces of hardware (turnbuckles, extension sleeves, wedge boxes) that represent concentrations of mass not usually found in a vibrating wire rope. Analytical solutions to the problem of vibrating wires or beams can be found in the literature on vibrations (Timoshensko, 1955; Den Hartog, 1956). But in every case, at least one of the ingredients of the vibrating truss chord is missing. The presence of axial tension, or bending resistance, of concentrated masses and of end conditions peculiar to truss chords is a combination that appears not to have been dealt with before, although the techniques for dealing with it are commonly known. The purpose of this note is to report the results of a project to measure and calibrate such frequencies. The work was conducted by the University of Pittsburgh under the sponsorship of the US Bureau of Mines. Field observations Tests were conducted on 24 different truss installations. The first 18 trusses were installed in shale roofs above Kentucky No. 9 seam and Illinois No. 6 seam. The remaining six were placed against the competent sandstone over the Pocahontas No. 3 seam in West Virginia. Chord tension was determined by two electrical resistance strain gages, in series, applied diametrically opposite to one another on the rod before tensioning. Due to the combined effects of inexact gage placement, rod bending and residual torsion in the chord due to tightening, errors in tension as high as 1780 N (400 lb) were reasonably possible. Due to faulty soldering or damage, three of the first 18 trusses and one of the final six were rendered completely unreliable. In addition to strain, the first natural frequency of vibration was observed to the nearest 0.1 Hz. Dimensions recorded included the span between contact points at the bearing blocks (Fig. 1) and the locations and amount of excess rod and rod gap at the wedge box and turnbuckle, respectively.

Jan 9, 1985

Accurately estimating load distributions and ground responses around underground openings play a significant role in the safety of the operations in underground mines. Adequately designing pillars and other support measures relies highly on the accurate assessment of the loads that will be carried by them, as well as the load-bearing capacities of the supports. There are various methods that can be used to approximate mining-induced loads in stratified rock masses to be used in pillar design. The empirical methods are based on equations derived from large databases of various case studies. They are implemented in government-approved design tools and are widely used. There are also analytical and numerical techniques used for more detailed analysis of the induced loads. In this study, two different longwall mines with different panel width-to-depth ratios are analyzed using different methods. The empirical method used in the analysis is the square decay stress function that uses the abutment angle concept, implemented in pillar design software developed by the National Institute for Occupational Safety and Health (NIOSH). The first numerical method used in the analysis is a displacement-discontinuity (DD) variation of the boundaryelement method, LaModel, which utilizes the laminated overburden model (Heasley, 1998).

Jan 7, 2020

By George K. Schenck

INTRODUCTION Recent advances in high-pressure water jet technology can be effectively employed in mining and tunneling. The new equipment is based on available industrial hardware such as pumps, nozzles, and rotary swivels and seals, and is compatible with present mining and tunneling techniques. Principal advantages of water-jet assisted cutting relative to standard cutting are higher production rates, lower dust levels, and reduced fines. When used on rock and coal miners, water jets mean that relatively smaller and cheaper machines can be purchased. If properly applied, the combined effect is lower cost and significantly improved health and safety. While commercial use of high-pressure water blast cutting and extraction of rock (and concrete) already has a firm foothold in Europe, application of this new technique is just beginning in America. This paper begins with current American applications of high-pressure water jets for drills, for slotting and channeling machines, and then discusses the emerging technology for initiating rock failure in conjunction with drag bits on coal plows, continuous miners and boom-type miners (roadheaders). The focus of this paper is use of high-pressure water jets for cutting rock. High-pressure water jet cutting utilizes water above 70 MPa and currently reaches to 300 MPa and above. Some informatfon is included on low pressure "wethead" coal shearers and boom miners with water pressure to about 15 MPa.

Jan 1, 1983

Magnetic separation is an age-old technique for mineral beneficiation operations. The existing mathematical models for magnetic separators are quite complicated, and it is very difficult to measure the theoretical separation efficiency. The connectionist approach of modeling, to establish the relationships of the inputs and outputs, is preferred for this kind of problem. Experiments were carried out on a high-intensity roll magnetic separator to develop a database using four input variables (magnetic flux intensity, particle size, splitter position and roll speed) and two output variables (weight recovery and Fe recovery). The artificial neural network (ANN) and statistical methods (MLRG) were used to model the magnetic separation process. For the ANN, the regression coefficient (R2) values between the predicted and measured results were 0.89 and 0.94 for Fe recovery and weight recovery, respectively. Compared to ANN, the multivariable linear regression analysis showed inferior performance in predicting the weight recovery and the Fe recovery. The ANN models for the roll magnetic separator can predict the separation efficiency up to an acceptable limit. These models can be used to modify the operational parameters at mineral beneficiation plants to minimize the effects of variations in the raw material characteristics.

Jan 1, 2009

By C. Anim-Sackey, R. K. Amankwah

Some large-scale mining companies in Ghana have adopted proactive management strategies in dealing with small-scale (galamsey) miners who have encroached on their concessions. This has been mainly achieved by ceding portions of the concessions held by the companies to the Minerals Commission of Ghana for licensing to the small-scale miners. This development has created an amicable relationship between the mining companies concerned and the galamsey miners in their host community. Ghana’s small-scale gold and diamond industry The small-scale gold and diamond mining industry in Ghana has existed for many centuries as an informal sector. Since the regularization of the activities of small-scale mining in 1989, two types of small-scale miners have emerged — legal and illegal.

Jan 1, 2004

By A. D. S. Gillies

Diesel engine particulate matter pollution is a matter of concern currently in underground mines worldwide. A number of real-time Diesel Particulate Matter (DPM) monitors have been developed in recent years; two of these by the National Institute of Occupational Health and Safety (NIOSH) in the US. One, the D-PDM, is based on an adaption of the successful NIOSH?s Personal Dust Monitor (PDM) unit which is being taken up very successfully for mine respirable dust monitoring. The D-PDM measures all particulate matter within a sub-micron range as classified nominally at 0.8 micrometers by a purpose developed cyclone. The other, the FLIR Airtec, measures the Elemental Carbon (EC) component of DPM by a laser scattering approach. Both instruments have been evaluated underground in robustness and reliability testing in coal mines by the authors. Real time DPM monitors allow greater understanding of the sources and levels of DPM pollution in underground activities. They allow engineering evaluations to determine how conditions can be improved or mining personnel relocated to lower concentration levels. Studies are discussed that examine DPM concentrations from vehicles under varying ventilation conditions. Some of these concern tests undertaken during high activity longwall face moves. They focus on evaluating DPM during the various phases of the face Chock Shield moves. An initiative in some mines has been to limit the number of vehicles in the mining section or panel by the use of a Tag Board or Traffic Controller at the panel travel road entrance to manage exhaust DPM and gases. Diesel tags or tokens are used to control the number of vehicles entering a section or panel and so limit level of pollution. Summation of DPM levels from points monitored throughout a panel demonstrates increasing DPM levels from influence of additional equipment in series within the ventilation circuit. An alternative approach is to invest in underground continuous real-time monitoring of exhaust gases, DPM and section air quantity and integrate this information to determine whether an additional vehicle can enter without exceeding diesel target limit. This optimizes the access of diesel vehicles and replaces the existing manual tag board system. Real-time DPM monitoring allows the industry to pin-point high exposure zones such as those encountered where various vehicles work in areas of constrained or difficult ventilation. Identification of high DPM zones allows efficient modification of mine ventilation, operator positioning and other work practices to reduce underground miners? exposures.

Jan 1, 2012

By M. Schafer

The 6-m- (20-ft-) diameter cast-in-place tunnel lining for Phase 3 of the Mill Creek Tunnel (MCT3) has been completed. This article summarizes aspects of liner design and ad-dresses 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. The Mill Creek Phase 3 tunnel (MCT-3) is expected to be completed this year. It is one of the largest tunneling projects undertaken by the Northeast Ohio Regional Sewer District (NEORSD) to date. The tunnel horizon is situated within the Devonian Chagrin Shale rock formation at an average depth of 85 m (280 ft). The tunnel was excavated using a two-pass method. A full face, fully shielded, Robbins 7.2-m- (23.8-ft-) diameter tunnel boring machine (TBM) was used to excavate approximately 4,500 m (15,000 ft) of tunnel and facilitate installation of initial supports (first pass). The final lining (second pass) consists of 305-mm- (12-in.-) thick cast-in-place reinforced concrete and integral low flow channel. Seven shafts were constructed on the project. The excavation of the tunnel commenced at Shaft 14 and proceeded down grade to Shaft 9, the terminus shaft. Because of the presence of overbreak in the tunnel crown, measures were required to support the form and counteract the effects of buoyancy during concrete placement.

Jan 1, 2008

By Dr. Peter J. Conroy

The current study is part of the U.S. Department of Energy's (DOE) on-going subsidence research program. The long-term objective of the DOE program is to develop analytical methods of subsidence prediction applicable over a broad range of geologic and mining conditions encountered in the United States. The DOE currently has several contracts in progress to develop a sound data base that can be used in the development of predictive models. Dames & Moore is currently under contract to the DOE to collect and analyze detailed subsidence and hydrologic data from a coal mine employing longwall mining methods in the Eastern Coal Province. Work under Contract No. DE-AC22-80PC 30335 began in October of 1980 and will continue through September of 1984. This paper summarizes the work that has been completed through September of 1981 and presents the results that have been achieved during this period. Technical difficulties encountered during both the installation and monitoring phases are discussed, and recommendations for future work are presented.

Jan 1, 1982

By Dan Preston, Shane Yanagisawa, Robert Marshall, Don Deere

Geotechnical Baseline Reports often estimate the number of cobbles that will be encountered in terms of volume or weight. These estimates are practically impossible to verify in the field. ClaroVia Holdings in conjunction with Frontier Kemper Constructors Inc. developed Digital Geologist 2.0 to classify and count cobbles discharged from an EPB TBM at the RSC7 project in Burbank, CA. The system worked by using two stereoscopic laser sensors with a global shutter to scan and count cobbles at 12 frames per second. Results of the effort are revealed along with lessons learned and paths for improvement.

Jun 13, 2023

By N. Magdalinovic

Generally speaking, erosion, as a process which entails degradation of surface layers of earth under the influence of the mechanical energy of surface waters, and from the point of view of biosphere sustainability, is a harmful process. This is absolutely true when agricultural and forest areas are concerned. However, if erosion is viewed selectively, this general definition about its harm raises serious questions. In other words, the erosion which takes place in the terrains where there is no vegetation because of the geological composition of the soil, does no harm. On the contrary, if the mineralogical composition of such terrains is characterized by a presence of precious and rare metals, erosion can be very useful. It contributes to the creation of new alluvial deposits of these metals in the waters in the plain land. It is here that torrents from hills come down and cause erosion. And finally, if there were no erosion, there would be no renewable deposits of gravel and sand.

Jan 1, 2007

"Tell us how you got involved in mining and about your career path.My dad was a coal miner and my uncle was a metallurgist, so when I enrolled at Penn State’s New Kensington Campus, I chose the College of Earth and Mineral Sciences — exact majors didn’t get picked till the end of your sophomore year. Penn State New Ken had an associate degree in mining program and one of the guys in my carpool was going to take Mining 30 in the evening and the other guy (mechanical engineer) was also able to take an evening class. I didn’t want to break up the carpool, so I took Mining 30, complete with essay tests. I could write, so I did well, and the professor said I should go into mining engineering. Fast forward to the end of the next term at University Park, and I realized there wasn’t enough chemistry in mining. Switching to metallurgy would have meant another term at that point, so Dr. Lovell, my advisor, trotted me down the hall and to the next building and said I was a mineral processor. That stuck. I was a summer student at U.S. Steel Research between my junior and senior year and they paid for my master’s degree — all about clay and macerals in coal flotation. During that time, the steel industry tanked, and I thought a Ph.D. would be a good idea — I could always teach at the university level if I had those credentials. The Electric Power Research Institute had a Coal Cleaning Test Facility in Homer City, PA, and I conducted my Ph.D. research on rate and residence time in conventional coal froth flotation cells there and at a local cleaning plant. I went to work at the test facility in 1987 (later CQ Inc.) and stayed there until I started PrepTech Inc. in 1997. PrepTech offers some consulting services for coal cleaning plants and sells mineral processing equipment, mostly to coal companies. I can’t believe it’s been 21 years.And what about your SME career?Of course, I was a student SME member at Penn State. We used many of the SME books in class, so who wouldn’t want the student discount? While in Homer City, I became involved with the Appalachian Plateau Subsection of the Pittsburgh Section. We’d hold quarterly meetings with interesting speakers and had good attendance. I was the secretary. I’m still the secretary and also get the bank statements. We’ll need to close that out some time, but I guess I’ve been hoping for resurgence in the Indiana/Cambria/ Somerset area."

Jan 3, 2018

By Bruno Bussière, Guosheng Zhan, Michel Aubertin, Vincent Martin, Robert P. Chapuis

The study evaluates the hydrological behaviour of exposed and covered waste rock dumps. The objectives were to determine the major factors influencing unsaturated flow in waste rock dumps and covers, and to improve the in-situ, laboratory and numerical modeling characterization methods. Using material properties obtained from in-situ and laboratory tests, waste rock dumps of different configurations, with and without covers, were modeled. It was found that a properly designed “Store, divert and release” (SDR) cover allows most of the water to be diverted downslope and discharged outside of the waste rock dumps. The SDR cover seems to work efficiently even in extreme storm events. The numerical modeling results show that the unsaturated hydraulic properties (e.g. air entry value and water entry value) of the materials largely control the infiltration of water into waste rock dumps.

Jan 1, 2005

By T. R. Jr. McMillan

Introduction Examining the short- and long-term job prospects for engineers in the coal industry might include looking at coal tonnage projections, future export markets, federal regulations, and the decrease in overall graduates. But coal is the US most competitive basic industry. As such, why not go back to basics? That is, there are three basic challenges that need to be faced by students, faculty, and members of the coal industry. These challenges are counseling, career placement, and professionalism. Counseling Counseling can include elementary, high school, and college students, as well as individuals already employed. But what happens to students after they have selected a course of study at a particular university? As shown in Fig. 1, only 87,000, or 7.25% of our graduates have technical degrees. Generally, there is a strong market projected for these engineering graduates. However, many students who have majored in other nontechnical curriculums, have to scramble for jobs. This says something about our ability to make students aware of where the real job opportunities are. As a student spends four or five years pursuing a degree, he or she is looking for professional guidance. The student has the right to expect "real world" counseling - counseling that is not "the way it should be" but "the way it is." The influence of faculty members is significant. They should take this long opportunity to tell students not what they want to hear or what the problem's of academia or the industry are, but what the real job market is all about. If faculty do not use this opportunity, they in-advertently-through omission - mislead their students. Once a student graduates and is a working alumnus, faculty should take advantage of their relationship with the student and continue to stimulate conversation leading to a two-way exchange of ideas and information. Faculty should also encourage and solicit financial support for their mining departments from their alumni. These monies, in many cases, will be matched dollar for dollar or more, depending on the company the alumnus works for. In the private sector, the responsibility is to communicate with faculty and students. Alumni can be effective by participating in this two-way dialogue with their professors at meetings, technical seminars, and conventions. In many cases, alumni will employ summer or co-op students in their organizations. While getting to know these students, industry members should level with them on where the true opportunities are and what it takes to be successful. It is important to communicate with both faculty and students candidly on both the posi-

Jan 2, 1985

By D. Kwietnewski

With all of the unknowns associated with tunnel construction, how does a contractor choose a roadheader? This paper presents a review of several models of roadheaders being used in today?s tunnel projects. The features of different models of roadheaders are presented and compared. Roadheader size and cutter power generally determine which roadheader is best for a particular job. We will also present a model for matching features of the roadheader to the anticipated ground conditions such that the most efficient machine is selected for the project.

Jan 1, 2011

U.S. Borax’s mine in California’s Mojave Desert is the source of nearly half the world’s supply of refined borates. These minerals are used in hundreds of products, including essential plant nutrients that increase crop yield and quality, and safe building products that protect homes from insects and the elements. Borax’s workforce is also safe. In fact, it is among the safest in the nation. In 2003, the company was recognized by the U.S. Mine, Safety and Health Administration (MSHA) for achieving the best safety record among large U.S. mining operations. It was also recognized by its parent company, Rio Tinto, for achieving the best record among its nearly 80 worldwide mining operations. Borax’s safety performance is five times better than the national average. And its workforce recently achieved more than two million hours without a lost-time injury.

Jan 1, 2004

By S. Mukusha

Electronic spreadsheets are the most common and readily available software applications for analyzing and modeling quantitative problems. Spreadsheets can offer a vast array of opportunities for the analysis and modeling exercises encountered in the field of geomechanics. This study explores the potential for using spreadsheets of in the practice geomechanical engineering. The study also examines some of the barriers to widespread use of spreadsheets. Best practices and guidelines for overcoming potential pitfalls are discussed and highlighted through a case study.

Jan 1, 2000