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By Randy Vranes

Sophisticated information technology, quality management systems and a commitment to the environment has allowed Solutia’s Soda Springs phosphate mine and elemental phosphorus plant to reduce operating costs, improve product quality and contribute to the sustainable development of Idaho’s industrial minerals. Soda Springs background The Soda Springs phosphate mine and plant is a joint venture between Monsanto and its operating partner, Solutia Inc. The operation is based in southeastern Idaho in the Western Phosphate Field. The plant is located about 275 km (170 miles) northeast of Salt Lake City, UT and about 4 km (2.5 miles) north of the town of Soda Springs.

Jan 1, 1999

By James F. Reynolds

Introduction There are 1.4 Gt (1.5 billion st) of recoverable coal under less than 914 m (3,000 ft) of cover in Colorado in pitching seams. Snowmass Coal Co., in cooperation with the US Department of Energy, introduced the longwall mining method in pitching seams to North America. This venture is a coal mining research program directed toward the profitable production of coal under difficult mining conditions as found in pitching seams of the western US. Snowmass Coal classifies pitching seams into the following categories for longwall on the strike in seams 3 m (10 ft) or less thick: • Flat = 0 to 10°: Normal continuous mines and shuttle cars work efficiently. • Slight = 10° to 22°: The maximum pitch that rubber tired equipment will function. • Moderate = 22° to 40°: The angle of repose of mined coal. • Steep = 40° to 60°: The limit of safe use of this roof support. • Vertical = over 60°. The longwall roof support covered here will work in all pitches except vertical. The shearer and conveyor will work in flat through moderate conditions. Longwalling across strike with this equipment in seam pitch over 60° could be accomplished with an inclined face. Development of the first longwall panel began in 1979 and was completed in 1981. The longwall equipment was installed and mining began on Aug. 11, 1981. Mine Planning and Development The original mine plan took advantage of old works abandoned in the 1960s. The gates were developed on a two-entry system with the entries rising 2° to the strike, allowing water to drain from the face. The mining method was by Alpine F6A road header continuous miners with bridge conveyor type coal transport into 5.4-t (6-st) bottom dump coal cars hauled on 1.1-m (42-in.) gauge track by 7.2-t (8-st) battery locomotives. The initial concept was to haul coal from the longwall by battery locomotive. Lack of discipline, however, was shown in the irregular direction of the gate entries, and local rolls in the coal seams severely limited the capacity of battery locomotives. Current mining law prohibits using an intake escapeway for belts or trolley locomotives. A two-entry system is the simplest method of panel development in a pitching seam. A continuous miner cannot be trammed from one entry to another because of steep "X" cuts. Thus, the development requires a continuous miner in each entry. The configuration of the old mine works resulted in a first panel longwall block of three 108 m x 1.6 km (355 ft x 5,400 ft). In panel development, the use of battery locomotives for coal hauling became evermore costly. When the panels were completed and the setup room finished, the lower gate entry was changed to a belt entry and battery locomotives were abandoned. A new slope was driven and the mine supply system was converted to rubber tire diesel supply. The latest generation of roadheader and standard high powered shuttle car-to-belt system is now used for development. Selection of Longwall Equipment Longwall mining across the strike on pitching seams is currently practiced in many nations. Equipment similar to that used by flat seam longwalls is available for pitching seam use in Great Britian and Germany. Face equipment includes a twin outboard armored face conveyor. It was selected to give maximum retention of coal on the conveyor due to flight rigidity and to prevent coal from sliding down the face and jamming the lower belt gate. Also selected was a 22-mm (0.9-in.) Dowty twin-outboard face conveyor for a 106-m (350-ft) face with a single 112-kw (150-hp) drive

Jan 12, 1983

By J. R. Heberger, B. H. Ngo

The Safety Pays in Mining v2.0 web application, developed by the National Institute for Occupational Safety and Health (NIOSH) Mining Program, helps mines determine the potential costs associated with mining injuries. This web app categorizes injury cost by part of body injured, by the cause of the injury, or by the nature of the injury. When the user selects one of over 150 common types of mining injuries, the app provides information on the distribution of costs of workers’ compensation claims for that type of injury. Based on other user inputs, Safety Pays in Mining v2.0 will estimate the total costs of the selected injuries and the estimated impact of total injury costs on mining company profits and will provide some examples of services and personal protective equipment on which companies could spend the savings that result from the prevention of injuries. This paper reviews the Safety Pays in Mining version 2.0 web application by discussing the development and updates to the app, how it is used to show the true costs of mining injuries, and how mines can benefit from using this app.

Feb 1, 2024

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 SANDEEP KUMAR JENA

This paper reviews the recovery of potassium from different rocks and mineral sources. Global demand for potassium is rising steadily due to the growth of agricultural production. Fertilizer manufacture consumes the majority of the world’s potassium production, with other uses including those in the pharmaceutical, glass, ceramic, food and detergent industries. The availability of soluble potash (K2O) minerals, such as sylvite, kainite and carnalite, in countries like Canada, the United States, Israel and Russia makes them major potash producers, whereas agriculture-based countries like Liberia, Somalia, Central African Republic, Thailand, Indonesia, Malaysia and India meet their potassium requirements through imports only. In these countries, the huge availability of potassium-bearing rocks/minerals like nepheline syenite, feldspar, mica and glauconitic sandstone, containing around 4 to 17 percent K2O, brings up the prospect of commercial production of potassium. Potassium recovery from minerals/rocks is complicated due to the uniform distribution of potassium throughout the crystal structure. Different physico-chemical separation methods like bioleaching, chemical leaching, flotation and roast-leaching have been discussed for the successful recovery of potash values from these rocks/minerals. Although seawater is vastly available, the recovery of potassium from seawater using chemical precipitation, solvent extraction, membrane separation and ion-exchange methods is not cost-effective due to low concentration of potassium.

By J. F. Brune, A. Verma

"Face ignitions in underground coal mines are a major risk for underground mining operations, as they can lead to methane or coal dust explosions. The 2010 disaster at the Upper Big Branch Mine resulted in 29 fatalities due to a methane and coal dust explosion initiated from a face ignition. Much research has been conducted to mitigate face ignition hazards, from water sprays to installing passive and active explosion barriers. Despite the increased use of water sprays in U.S. coal mines, there have been more than 50 documented face ignitions in the U.S. underground coal mines since 2010, indicating that this hazard still prevails. This paper will examine the statistics of face ignitions and gas explosion in U.S. coal mines based on MSHA data. It will study factors contributing to these face ignitions and outline best practices for their prevention based on experience and practices worldwide. INTRODUCTION Methane and coal dust explosions are one of the major causes of coal mine disasters in the U.S. and around the world. Such disasters have resulted in the large number of fatalities and loss of mine infrastructure. The recent explosion at the Soma coal mine in Turkey has caused the death of 301 miners (Mining Turkey, 2014). As documented by U.S. Mine Safety and Health Administration (MSHA, 2015a), the U.S. coal mining industry has also experienced several catastrophic mine explosions with accidents at Upper Big Branch mine, Darby mine, Sago mine and Jim Walter Resources No. 5 mine in the last decade, causing the deaths of almost 60 miners. Every explosion requires a source of ignition, the right amount of fuel and oxygen. In underground coal mines, methane acts as a fuel while ventilation air acts as a source of oxygen. The source of ignition may vary from spontaneous combustion, electrical equipment and switchgear, mechanical heat sources, face ignitions due to friction rock-on-rock or from cutter bits and lightning strikes. Under the right conditions, energy of less than 0.3 mJ is sufficient to ignite methane-air mixtures (James, 2007) that can result in a catastrophic explosion. Much research has been done to mitigate the methane explosion hazard by proper dilution, continuous monitoring of methane and elimination of ignition sources. Historical studies indicate that face ignitions are the major cause of explosion in underground coal mining operations worldwide (Belle, Carey, and Robertson, 2012). Statistics shows that most mine disasters were started from a small face ignition, which turned into a major explosion fueled by additional methane and coal dust (Belle et al., 2012). To investigate face ignition hazards, researchers must study potential ignition sources as well as potential explosive atmospheres near mechanical coal cutting operations. Statistical analysis of U.S. coal mine face ignitions reported by the U.S. Mine Safety and Health Administration (MSHA, 2015b) shows that several factors are responsible for face ignitions."

Jan 1, 2016

By Russell Barr

Strategic alignment throughout a mining organization is critical to effective strategic execution and good business performance. The alignment of strategic goals and objectives in the different operations and functions in a large global operation is a challenge facing executive management in light of legacy organizational structure and processes. An additional confounding factor in strategic alignment of acquisition and new project expansion is that mining projects and operations are frequently multi-cultural in terms of country origin as well as organizational culture. This brings together many cultures to accomplish the project or complete an acquisition (Financial Times, 2006). The mining industry presents numerous challenges to executives and mine management by the nature of the operation and organizational processes used in running it. For example, there seems to be an inherent conflict between the individual goals of the components that constitute a mineral processing operation (the mine, the mill, the smelter and the refinery), and lowest cost production of the final product. Managers of these component operations have specific objectives passed down from the corporate executives. Those site managers tend to be compensated based on throughput and perform to this main metric. This tendency to maximize throughput for an individual operation can contradict the general process flow of a best-fit solution to producing the final product at the lowest cost. In an effort to become more aligned, firms are increasingly using balanced scorecard derivatives at great cost and effort (whether internally or externally sourced) in an attempt to help with strategic alignment. Balanced score-cards have been effective in providing a good strategic scorecard to companies with some measure of strategic alignment. Many firms make this effort of using balanced scorecards. However, most firms are not strategically aligned or, at best, are sub-optimized, in terms of strategic alignment (Kaplan and Norton, 2006). The tendency in mining operations is to focus on operating individual components as optimally as possible and stretching existing assets to the best possible production rates. ?Making tons? is the common operational focus. Numerous factors underpin this focus and can affect the ability of the operation?s ability to align properly with the corporate strategy and strategic goals. Critical factors are legacy organizational structure, culture, processes and performance measurement systems. Changing anyone of these factors to affect better strategic alignment requires significant attention to managing change.

Jan 1, 2008

By Andrew B. Cecala, Emily J. Haas, Jay F. Colinet

A sociotechnical system (STS) creates a framework that allows an examination of how social and technical factors affect organizational outcomes within a specific environmental context. STS has been rigorously studied with a primary research focus addressing worker-technology interactions. Although these interactions are important, the social processes and interactions that occur whenever any technical or environmental change is introduced into the system have been undervalued. If social processes are better understood, mining organizations could efficiently prepare and stabilize for such changes. With this goal in mind, we sought to extend STS theory through applying principles of meta-design to analyze the results of two case study interventions. Specifically, we studied the impact of an unregulated dust control technology (the Helmet-CAM) and a regulated dust control technology (the Continuous Personal Dust Monitor) on factors within an STS including employees’ knowledge of, communication about, and use of technology to mitigate respirable dust sources. The results are presented in a way that first, addresses the overarching principles of meta-design STS including organizational participation, flexibility, and communication and second, examines how technology implementation processes differ when the organization is complying with a formal, higher-level requirement. Results show that a prominent focus on the social factors within an STS framework could help reduce unpredictability on the technical side and may improve communication within the system to help reduce adoption time, especially if and when accompanying a new, formal work process.

By Andrew B. Cecala, Emily J. Haas, Jay F. Colinet

A sociotechnical system (STS) creates a framework that allows an examination of how social and technical factors affect organizational outcomes within a specific environmental context. STS has been rigorously studied with a primary research focus addressing worker-technology interactions. Although these interactions are important, the social processes and interactions that occur whenever any technical or environmental change is introduced into the system have been undervalued. If social processes are better understood, mining organizations could efficiently prepare and stabilize for such changes. With this goal in mind, we sought to extend STS theory through applying principles of meta-design to analyze the results of two case study interventions. Specifically, we studied the impact of an unregulated dust control technology (the Helmet-CAM) and a regulated dust control technology (the Continuous Personal Dust Monitor) on factors within an STS including employees’ knowledge of, communication about, and use of technology to mitigate respirable dust sources. The results are presented in a way that first, addresses the overarching principles of meta-design STS including organizational participation, flexibility, and communication and second, examines how technology implementation processes differ when the organization is complying with a formal, higher-level requirement. Results show that a prominent focus on the social factors within an STS framework could help reduce unpredictability on the technical side and may improve communication within the system to help reduce adoption time, especially if and when accompanying a new, formal work process.

By Trevor R. Ellis

Minerals appraisers/valuers often find great difficulty in attempting to employ the sales comparison approach to the market value appraisal of development and operating stage mineral properties. An important factor generally overlooked is a comparison of net operating income (NOI) margins on a per-unit-of-production basis between mineral properties, whether these be demonstrated or forecast margins. NOI margins can vary greatly between mines or quarries that are producing similar products. Ultimately, the expected NOI margin determines what a buyer is willing to pay for an income-producing property. Here, common criticisms of the sales comparison approach by mineral appraisers are introduced. These are counterbalanced by raising some issues in the way the inputs for the income approach are usually derived by minerals appraisers and by review of some conspicuous examples of the much-too-common misuse or abuse of the income approach in market value mineral appraisals. Example transaction analyses and sales comparison analyses are used to demonstrate the author?s methodology for adjusting units of resource in his transaction adjustment tables. The examples are used as the basis for a discussion of ways to employ adjustments for operating economics and many other factors, while warning against the potential for double counting. The conclusions include a recommendation that minerals appraisers attempt to apply at least two of the three valuation approaches when appraising the market or fair value of development and operating stage mineral properties, the two being the sales comparison and income approaches.

Jan 1, 2011

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 Paweł Stefaniak, Natalia Duda-Mróz, Sergii Anufriiev, Wioletta Koperska

Due to the high environmental risks and negative impact of a failure, tailings storage facilities (TSFs) need constant monitoring. Advanced mathematical models have been developed in the past to predict the behavior of TSFs and raise alerts if needed. To be precise and reliable, such models need a spatial distribution of soil types within the dam as an input. Getting this data from laboratory measurements is time and costconsuming. In this article, we propose an ANN-powered algorithm, which allows us to accurately estimate the soil distribution based on a cone penetration test (CPT).

Jun 25, 2023

By William G. Pariseau

Solvay Chemicals Company mines trona in south-central Wyoming and has done so for many years. The mine is one of several in a mid-continent sedimentary basin that hosts the largest trona resource in the world. Trona is an evaporite, a sesquicarbonate that occurs in several seams of varying thicknesses and depths. Trona is processed into soda ash which has a number of industrial uses in the manufacture of glass, detergent, paper and chemicals. Figure 1 shows the location of the Solvay Mine. A ventilation shaft was recently excavated at Solvay Chemical Company’s mine in the trona patch. In fact, a 22 ft (6.7 m) diameter shaft (inside diameter) was bored upwards from the 1500 ft (457 m) level to the surface. The first bored section was 26 ft (7.9 m) in diameter that allowed for a 2 ft (0.6 m) thick concrete liner. This section began at a depth of approximately 1500 ft (457 m). A second bored section was 24 ft, (7.3 m) in diameter that allowed for a 1 ft (0.3 m) thick concrete liner. This section began at a depth of approximately 750 ft (229 m). This shaft is the #5 Shaft. Figure 2 shows the cutter head used to excavate the shaft.

Feb 1, 2025

By Scott Thayer, Michael Murphy, Natalie Cope, Gabriel Esterhuizen, Anthony Iannacchione, Tim Miller, Brent Slaker

"The Subtropolis room-and-pillar mine extracts the Vanport Limestone (Allegheny Formation, Pennsylvanian System) near Petersburg, Ohio. Strata instability problems associated with excessive concentrations of lateral stress caused the mine operator to implement a change in layout design. This mining method has been identified as a stress control layout, which has been used by other underground stone mines in the past with varying degrees of success. Practical experience has shown that entry headings advance in the direction of the principal lateral stress, producing lower stress concentrations with better mining conditions. It is important to minimize stress concentrations along the mining front, so an arrow-shaped advance is recommended. This technique advances more developments (headings) in a “good” direction and reduces developments (crosscuts) in a “bad” direction. As is expected, the stress control layout enhances the potential for shear failures in crosscuts. It is, therefore, important to focus crosscut engineering interventions that either: (a) lower stress concentrations (for example, an arched roof) or (b) enhance strength of the strata containing the shears (for example, rock reinforcement). This study focuses on observing strata conditions on a regular basis and monitoring the response of this strata to changing geologic and mining conditions through 3D Dynamic LiDAR scans.INTRODUCTIONProject AimsThe Subtropolis Mine is extracting the Vanport Limestone in northeastern Ohio. Since the start of mining in 2006, ground conditions have been significantly affected by excessive lateral stress condition. In some other mining districts with this hazard, certain mine layouts have been shown to lessen the potential for unstable ground conditions. The term “lessen” is used to state the realization that stress concentrations are not eliminated but instead occur in less frequency and intensity, and their locations can be projected.The stress-control mine layout, specifically for large-opening room-and-pillar stone mines, naturally evolved at mines suffering from excessive lateral stress problems. These mines will typically experiment with methods to mitigate adverse impacts, thus developing best practices for their conditions. These practices have evolved into a basic framework for the stress control mine layout. For example, Jack Parker was able to write about personal experiences at the White Pine Mine in Michigan (Parker, 1966, 1973). Various researchers at the U.S. Bureau of Mines (USBM), the Mine Safety and Health Administration (MSHA), and the National Institute for Occupational Safety and Health (NIOSH) have studied the effectiveness of stress-control mine layouts over a wide range of geologic conditions (Emery, 1964; Mark and Mucho, 1994; Iannacchione et al., 2003). While the stress control layout design approach has proven successful in many categories, it can be difficult to implement. For example, excessive stress conditions in crosscuts can put the ground control focused intervention at odds with ventilation and haulage constraints, thus limiting optimal crosscut size, shape, and location. Therefore, more information on the effectiveness of this approach is needed."

Jan 1, 2019

By Eduardo Pimenta de Melo, Rambabu Pothina, Rajive Ganguli

Sensors are everywhere in the mining industry, with sensor information being used to monitor and operate processes. Therefore, when sensor information is wrong, economic losses can occur. Unfortunately, sensor errors are usually not detected till they become large. This is problematic as most calibrate their sensors no more than once a year (Beamex, n.d.). Using principles of data mining, where all relevant information is tapped to glean hidden information, Pothina [8] designed an algorithm to detect errors in temperature sensors in gold stripping circuit in Pogo mine, Alaska. This paper continued his work by analyzing the behavior of the algorithm on baseline data and testing the algorithm in new data and under more rigorous conditions. It also made a change to the algorithm. The modified algorithm performed very well in the new data. It also worked well under the new error conditions. Three types of errors were seeded, a fixed additive error (+ 2%), a fixed subtractive error (− 2%), and a noisy, normally distributed error, with a mean value of + 2%. Artificially seeded errors were detected within about 20 gold stripping cycles. Inherent bias in operation impacted algorithm performance by increasing the number of cycles needed to detect errors. This paper reinforced Pothina’s [8] conclusion that when data mining approach is used, sensor errors can be detected even when they are pretty low. Significant economic losses can thus be minimized.

By Dennis Ofiara, Michael Lewis

An experimental 1.75 meter Shaft Boring Machine was designed and manufactured by The Robbins Company. The drill was used by contractor Drillcon Raise AB to drill test shafts at an SKB underground test facility. SKB is the Swedish authority responsible for safe management of nuclear waste materials. This “SBM1.8” Shaft Boring Machine was used to drill shallow test shafts ingranitic rock at SKB’s Aspo underground laboratory. The drill used a unique vacuum mucking system. The bored shafts were held to very strict tolerances for bore diameter, straightness, and verticality. This drill was launched and operated from a mobile launcher. Headroom and working space were limited. The SBM1.8 drill produced acceptable test holes. SKB will carry out several studies to determine the suitability of this geology, and of this technique, for safe nuclear disposal. In addition to future use at SKB, many applications are foreseen, particularly in the civil construction industry.

Jan 1, 2005

Smart defense: that?s what the industry needs to play for the next four years, according to panelists at the 118th Annual Meeting of the Northwest Mining Association (NWMA), which met December 2-7 in Spokane, WA. The conference was well attended, with approximately 2,200 attendees, 244 booths in the two packed exhibition halls, and a rich offering of short courses, field trips, social events and technical sessions. Speakers at the packed legislative session articulated many of the frustrations felt by members of the mining community after the U.S. elections in November, and offered words of advice. Matthew Ellsworth, the new Government Affairs hire at NWMA, stated it best: ?Elections are like Christmas: you find out who?s naughty and nice ? and it?s always going to come again.?

Jan 1, 2013

When it comes to safety in the mining and extractive industries, success is literally a matter of life and death. Anything short of perfection is not acceptable. In recent years, the mining industry in the United States has made tremendous strides in terms of health and safety for its workers. Part of that success has come with an increased focus on the issues of safety, an intense examination of procedures, liberal sharing of best practices and a focus on the synergy between safety, reliability and environment. During his closing keynote address of the Safety Management & System Reliability Conference in Minneapolis, MN on Nov. 15, Joe Driscoll, vice president of Great Basin Gold, showed a calendar from the coal fields in Pennsylvania from the early 1900s. The calendar marked the number of mine-related deaths each month. Some months, the number was as high as 50. It was an illustration of how far things have come, but there is still much more work to be done.

Jan 1, 2013

The 28th annual American Mining Hall of Fame Awards Banquet and fundraiser sponsored by the Mining Foundation of the Southwest will be held at the Marriott University Park Hotel, Tucson, AZ on Saturday, Dec. 4, 2010. The Mining Foundation of the Southwest is a nonprofit organization whose objectives are public education about the mineral industries, and recognition of outstanding accomplishments in and contributions to the fields of mineral and fuel resources. Funds are being raised to the support the foundation?s educational programs. Among these is the Educational Outreach Program operated jointly by the foundation and the Arizona Department of Mines and Mineral Resources.

Jan 1, 2010

By A. Broussaud, J. D. McKay

Benefits analysis of adaptive Expert control systems operating at plants in Africa and the United States are presented. Proper statistical tools and techniques are discussed. Technical and practical pitfalls of strategy comparison are also presented and illustrated with from published data. Advantages and disadvantages of a “Pay for Performance” approach to a project are reviewed.

Jan 1, 2001