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By Patrick B. Kenny

Generally speaking, it is safe to address this conference as a conclave of Engineers, Owners' Agents, Governmental Representatives, and Contractors. As a group, we have assembled here to learn of our compatriots engaged in similiar underground operations throughout the United States and the World. We are here to learn of improved methods, higher technology, and better management. Through the acquisition of this knowledge, we each hope we can improve our own particular services, products and projects. This session is dedicated to a discussion of "Costs". The most apparent reason for a discussion of costs at this level is to expose subjects affecting costs and propose methods to reduce them. From that premise a contractor can identify three areas of discussion: design considerations, contract considerations, and governmental considerations. A fourth area of consideration is an introspective view of the contractor's role in the design construct process. Unnecessary costs and risks attributable to these areas are contributing excessively to ever increasing project and system costs. DESIGN CONSIDERATIONS On April 20, 1977 the Metropolitan Sanitary District of Greater Chicago accepted proposals for the Tunnel and Reservoir Plan on Contract A and Contract B. This letting called for construction of over 33 km (21 miles) of the Mainstream Tunnel bored at 9.75 m (32 ft) to 10.67 m (35 ft.) in diameter. Also included were all the appurtenant collecting and regulating structures. The proposal allowed the

Jan 1, 1979

By A. Mei, F. Amadini, F. Cernera, D. Baliani, A. Flor, M. La Morgia, F. Sassi

The risk of TBM jamming because of squeezing rock mass or excessive caving (instability of the cavity) conditions is always a focal point while boring long and deep tunnels with shielded TBMs. Mechanized excavation provides a large amount of real-time data, for each machine’s parameters. Several analyses have been executed to assess the correlations between different sets of TBM parameters for the exploratory tunnel. Instead of analyzing the full dataset, a different approach is proposed, with data processed sequentially to simulate the real excavation situation. The probability distributions are recalculated together with their statistical parameters while advancing. This approach is extended also to the training of a Machine Learning model able to foresee the behavior at future rings based on past rings (using a Recurrent Neural Network). The predictions show a promising first step toward creating practical tools that can assist contractors and designers to correlate and predict TBM excavation data. These tools will assist to predict and quantify high risk situations that could arise during excavation.

Jun 13, 2023

By F. F. Aplan

Estimations have been made of the tonnage of raw ores and coal treated by various beneficiation processes. The amount treated by gravity concentration is substantially greater than that treated by flotation, with coal representing the bulk of the material treated by gravity means. A discussion is given of the trends and anticipated improvements in gravity methods. Except for the concentration of iron ores, magnetic and elec- trostatic separation processes find their greatest use in the beneficiation of non-sulfide ores. Exciting new developments in magnetic materials and separation process (and, to a lesser extent, in the electrostatic process) indicate a substantial increase in the application of such processes to ores and a broad variety of non-ore uses.

Jan 1, 1989

By V. K. Paruchuri, J. D. Miller, J. Nalaskowski

An understanding of forces responsible for the stability of dispersions of colloidal particles when interacting with each other in aqueous solutions is of great interest academically and industrially. When water-soluble polymers are adsorbed onto colloidal particles, various effects on the stability of their suspensions can be expected ranging from steric stabilization to bridging flocculation. The possibility of detailed characterization of such systems using direct measurements of interaction forces between particles can help in further improvement of existing technologies of solid-liquid separation. An atomic force microscope (AFM) colloidal probe was used to measure the interaction forces between a silica sphere and a silica substrate in the presence of water-soluble polymers. Poly(ethlene oxide) (PEO) with three different molecular weights (7,000, 43,000, and 63,000), each with a very narrow molecular weight distribution, were used in this study. The interaction forces measured with the AFM over an extended time scale are discussed in terms of the adsorption kinetics measured through in-situ FTIR/IRS measurements.

Jan 1, 2003

By K. S. Narasimhan, T. C. Rao, R. Bhima Rao

Investigations have been carried out to evolve a grinding aid useful in grinding a 40% iron-bearing magnetite containing quartz as the major gangue, based on studies conducted with pure magnetite, pure quartz and its synthetic mixture. These investigations established that an addition of 200 g of CaO per metric ton of ore was the most effective in grinding quartz preferentially over magnetite at 75% solids concentration by weight. The limited rheological studies conducted suggest that the effect could either be due to dispersion or the structural modification of quartz. More importantly, a new concept, that of Critical Solids Concentration, where two different minerals behave like one with respect to response to communication in a tumbling mill, has been introduced for the, first time. Above this concentration, one of the minerals is ground at a faster rate than the other, whereas the reverse is the case below this concentration.

Jan 1, 1992

By F. M. Swain

High-calcium limestones occur in the upper part of the New Market Formation, of Lower Middle Ordovician age, in Franklin and Cumberland Counties, Pennsylvania. The high-calcium facies of the New Market Formation is represented by sublithographic limestone or vaughanite, which probably formed in quiet water; low-energy environments such as intershoal lagoons, or in protected bays similar to the present-day Florida Bay environment. Rapid facies changes are characteristic of the strata. The better grade of stone lies in the upper 100 to 125 feet of the New Market Formation and averages 95-97% calcium carbonate. Silica and magnesia are about equal in amount as impurities. One high-calcium belt extends from the Maryland state line through Chambersburg and Newville to beyond Carlisle. The strata in this belt are structurally complex, which requires careful field study' and core-drilling prior to exploitation. Stone suitable for blast-furnace flux is present in relatively large amounts, but stone for open-hearth use or portland cement requires more selective quarrying.

Jan 1, 1966

By R. R. Jozefowicz, T. X. Ren, J. S. Edwards

The control of methane emission into underground mine workings is important both for the safety and productivity of the mine. As deeper and gasser coal seams are mined, ventilation methods involving increasing air pressures and quantities across mine workings may not be able to cope consistently with methane emission rates during the production cycle. An accurate prediction of methane emission into mine workings is of great significance in the design of ventilation systems and additional methane control methods if required. Research has been conducted to develop a numerical method for simulating methane flow through strata in which permeability is strongly influenced by mining-induced stress. To achieve this objective, both numerical modelling using Computational Fluid Dynamics (CFD) and laboratory tests on rock samples and granular materials under triaxial stress condition were carried out. Correlation has been established between stress and permeability characteristics of rock-measure rocks and laboratory results are being incorporated into the CFD models. This paper introduces the use of CFD techniques to model methane flow through permeable strata around longwall coal faces currently undertaken at the University of Nottingham.

Jan 1, 1997

By W. E. Horst

Raw materials and mineral products are crushed, ground, or pulverized for a variety of reasons. Some of the most important reasons for size reduction are: to liberate marketable mineral species from a matrix of commercial minerals and gangue, to promote rapid chemical reaction through exposure of large surface area, and to produce a material with desirable size characteristics for handling, utilization, and storage. Comminution processes are currently used on vast tonnages of raw material annually. In the mineral industries where mineral products and other solids are processed, the various size-reduction unit operations represent a major portion of the manufacturing costs. The comminution process is an expensive unit operation from the stand- point of both capital and operating costs. Power consumption is large, and the energy conversion to useful work is very small regardless of the size-reduction system. In energy terms, about 1% of the all electricity generated throughout the world is expended in crushing and grinding operations by the cement industry alone. Comminution is a general term for size reduction that may be applied without regard to the actual breakage mechanism involved. General type of size-reduction equipment include crushers, tumbling mills of various type, impact mills, fixed-path mills such as a roller mill, and fluid-energy mills. Some comminution machines accomplish

Jan 1, 1985

By Adolf J. Jonaitis

Outokumpu developed TankCell flotation cell technology beginning in 1990, following 35 years of successful flotation cell experience and application. In 1994, Outokumpu proved favorable operating success of 100-m3 (3,500-ft3) TankCells for porphyry copper and zinc flotation. In 1995, evaluation of a 150-m3 TankCell led to the successful application of these large cells in several operations. More than 350 TankCells of 100 m3 and larger in volume have been installed and are in operation. Key features of the Outokumpu TankCell design will be described. In addition, discussion of operating data from various metallic mineral flotation operations worldwide will be presented. Large flotation cell development continues today, with operating cell volumes of up to 160 m3 (5,500 ft3) in operation.

Jan 1, 1999

By Milton E. Wadsworth, M. Ken Han

The kinetics of leaching of galena in hydrochloric acid solutions with sulfur dioxide gas have been investigated experimentally. The leaching method is then applied to complex sulfide concentrates to evaluate its selective leaching capability and to develop a new hydrometallurgical lead extraction process based upon the method. The leaching reaction follows a linear rate with an activation energy of 61.9,KJ/mole. The rate Is of first order with respect to the product [H+] [Cl-] . Excel lent selective leaching capability f s demonstrated and an attractive hydrometallurgical process flow sheet is proposed.

Jan 1, 1989

By S. P. Banerjee

There has been a phenomenal increase in production of coal from opencast mines in India. At the same time environmental problems caused by mining are receiving greater atttention. Deterioration in ambient air quality due to increased concentration of suspended particulate matter (SPM) in and around an opencast project is a major problem. Some measured values of SPM level around opencast mines in diff coalfields show that in many cases the TLV of 500 ug/m^3 is exceeded. The impact of dust emission from a mining project on surrounding areas are estimated by using computer models for air pollution dispersal but such treatment suffers from errors in predicting the dust load and failure to take into account the terraced nature of the opencast mine site. The haul roads have been identified as the most prolific source of dust and some recent trials on haul road dust consolidation in Indian mines are mentioned in the paper. Statistics regarding pneumoconiosis cases in Indian coal mines for the last decade are presented to show an increase in reported cases and a gist of the recently amended regulations on the subject of precaution against dust is mentioned.

Jan 1, 1991

By Z. Sartowski, M. J. Pearse

The authors present laboratory and plant results illustrating the benefits to be gained by using chemical additives, namely flocculants and surfactant dewatering aids, in the Bayer process. Advantages of synthetic flocculants over starch are illustrated in terms of more efficient solid/liquid separation in both the initial settling of blow-down slurries and in the CCD wash train. In addition, it is shown that the use of synthetic flocculants considerably reduce the levels of organic contaminants present in the process liquor. Secondly, very significant improvements in moisture removal were obtained by the application of dewatering aids to hydrate filtration/ washing operations.

Jan 1, 1984

By F. M. Doyle, K. Osseo-Asare, E. Peters

With the aid of molecular orbital theory, a discussion is presented of the relationship between the electronic structures of ions and molecules, and the elementary steps involved in homogeneous electron transfer reactions. An electronic theory of the reactivity of oxidants and the mechanism of action of oxidation catalysts is then presented, with emphasis on the oxidative decomposition of metal sulfides. For model oxidants, two molecular reagents: O2 and Cl2, and two ionic reagents: Fe3+ and CU2+ were selected; silver (1) was chosen as the model catalyst. The reactivities of these reagents are rationalized in terms of constraints on orbital overlap, the availability of unoccupied d orbitals, and the rearrangement of electronic configurations.

Jan 1, 1993

By R. Y. Wan

Newmont Gold has advantageously used the capabilities of mineral oxidizing bacteria to develop a process for the pretreatment of low-grade sulfidic and carbonaceous-sulfidic refractory gold ores. The biooxidation process results in the oxidation of the sulfidic minerals with increased exposure of gold for subsequent gold recovery. The biooxidized carbonaceous-sulfidic ores cannot be heap leached with cyanide because of the preg-robbing characteristics of the carbonaceous matter in the ores. Therefore, an alternative heapleach process using ammonium thiosulfate was developed to extract gold from these preg-robbing bioaxidized ores. The ammonium thiosulfate leach process was successfully applied in both laboratory and pilot plant tests. Satisfactory test results were achieved, encouraging the continuation of process development.

Jan 1, 1997

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

INTRODUCTION Several major factors introduce uncertainties into the assessment of radon progeny exposure to miners using time-weighted average radon progeny concentrations: uncertainty in the measurement of radon progeny concentrations in specific areas, assignment of an individual miner's time to those areas, variation in radon progeny concentration between measurements and potential human errors involved in calculating concentrations and handling data. The currently available grab-sampling methods for determining working level were analyzed to determine the magnitude of the uncertainty due to each of these factors. For all measurement methods studied, the variation in the airborne concentration with time in operational areas of a mine is the dominant factor in the uncertainty in determining annual radon progeny exposures for individual miners. Uncertainties relating to accuracy of the method and precision of measurement were found to contribute a significantly greater portion of the total uncertainty than human errors. Under normal conditions, if the technicians performing the measurements are conscientious and well trained, human error contributes little to the total uncertainty of the radon progeny exposure determination. The primary goal of radiation monitoring is the reduction of radiation exposure to the lowest reasonably achievable level below regulatory limits. Monitoring personnel in mines should be trained not only to obtain accurate estimates of miner radiation exposures but also to recognize and, when possible, to implement correction of situations which result in unnecessarily high radon progeny exposures. ESTIMATION OF UNCERTAINTY DUE TO HUMAN ERRORS Human errors affecting the assignment of annual radon progeny exposure to individual miners can be placed in two categories: those related to the measurement of radon progeny concentration in specific mine areas and those related to estimation of occupancy time for individual miners and transcribing data to permanent records. The former are specific for the measurement method used; the latter are common to all methods. Errors in Determination of Working Level All systems for determining radon progeny concentration require measurement of several parameters, which include volume of air sampled, count rate and decay time. These quantities and appropriate constants are used in a basic equation, specific to the system, which estimates working level. An unintentional random mistake in measurement of any one of these parameters or in the selection of proper constants will contribute to the uncertainty in the determination of working level. In our analysis of human error we separated each measurement method into a sequence of independent operations, with each step subject to operator error. For each operation we estimated the probability of occurrence and the consequence of errors to obtain a resulting uncertainty. Certain types of errors result in specific consequences. For example, we assumed that an error of 5 seconds in timing of a 5-minute sample results in a fractional error of 1/60 (1.7%). Other types of errors can result in a range of uncertainty. Transposing digits read from a scaler can produce errors ranging from near zero to approximately 60%. In these cases we calculated the statistical variance for the distribution of errors. We assigned the square root of the variance divided by the mean as the consequence factor for that type of error. This is essentially the same as a coefficient of variation. The product of the probability of occurrence and the consequence factor is the fractional uncertainty in the measurement due to that particular error. The total uncertainty due to human errors is calculated by taking the square root of the sum of the squares of the uncertainties generated by all manual operations. Uncertainties Due to Human Error for the Kusnetz Method One of the techniques most commonly used to estimate working level in U.S. uranium mines is the Kusnetz method. A generalized way to express the equation used to compute WL by this method is: WL = (Net Alpha Counts)/(V)(ST)(CT)(E)(K) where: V = sample flow rate in liters/min ST = sampling time in min CT = counting time in minutes E = absolute counting efficiency K = Kusnetz conversion factor (dis/min-L per WL), as a function of decay time in minutes. The example of human error analysis presented here is based on the Kusnetz procedure having a timing sequence of 5 minutes sampling time, 40 minute decay time, 2 minute counting time. During the sampling procedure a stop watch is used to determine the timing interval. We assume that it is common to make small timing errors of a few seconds, but larger timing errors occur infrequently. Errors greater than 30 seconds are considered to be essentially non-existent since we assume that the

Jan 1, 1981

By Andrew B. Allen, Charles W. Robinson, Robert L. Schneider

In April, the US Synthetic Fuels Corp. broke a three-year silence and made its first financial award by approving a $820,750 loan for the First Colony peat-to-methanol project in North Carolina (ME, May, page 403). Peat Methanol Associates (PMA), a partnership between Koppers Co., ETCO Methanol Inc., Transco, Peat Methanol Co., and l. B. Sunderland, broke ground at First Colony last year and plans to begin production in Dec. 1985. Although the award is only a small part of Synthetic Fuels Corp.'s $15-billion budget, it does signal the corporation's intention to move aggressively ahead. It also is a positive indication that First Colony will be completed and operated successfully. This article describes the methods and equipment that will be used to harvest peat at First Colony, as well as how the peat will be converted to methanol. Introduction Peat deposits found along North Carolina's coastal plain contain high-quality fuel-grade peat with an average heating value of more than 23.3 MJ/kg (10,000 Btu/lb) (dry), with a low sulfur and ash content. The deposits differ from other US peats in that they contain large, sound Atlantic White Cedar and Cypress logs, stumps, and roots that may extend throughout the full depth of the deposit. A second difference is that these deposits are much more highly decomposed and, in the raw state, have the appearance and feel of a heavy, reddish-brown grease. These factors make it impractical to use standard production equipment so a new line was developed. Also, because of these conditions, techniques were modified to facilitate production. First Colony Farms, located near Creswell, NC, developed and evaluated a milled peat program. Equipment for this production method was designed and built, production rates were established from field operations, drying rates were established, weather data were analyzed, and total operating and capital costs were estimated. The method depends on the sun and wind for drying peat to the desired moisture content, in this case around 40%. Therefore, field preparation is actually the construction of a large solar collector to dry the peat so it can be harvested and stockpiled. It is essential that this collector be properly profiled initially and maintained during production to prevent precipitation from ponding. Initial Field Preparation Initial field preparation includes cleaning existing canals and constructing ditches and water control structures for proper drainage of rainwater run-off, building adequate roads for site access, removing surface vegetation, and profiling and sloping the fields. At First Colony, the 60.7-km2 (15,000-acre) harvesting area was divided into 129.5-hm2 (320-acre) blocks about 1.6 km (1 mile) long and 805 m (0.5 mile) wide. This was accomplished by cleaning main outfall canals with adjacent roads built from canal spoil at 1.6-km (1-mile) intervals. Existing intermediate canals that feed into main outfall canals at 805-m (0.5-mile) intervals also are cleaned. Headland roads are constructed from canal spoil along each side of each intermediate canal. This 129.5-hm2 (320-acre) block is then divided into 32 harvest strips by small V-ditches constructed at 50-m (165-ft) intervals. At the end of the field with the lowest elevation, corrugated steel pipe culverts are installed under the headland road in each V-ditch to control rainwater runoff into intermediate canals. Runoff water from the fields is diverted to a holding pond to prevent any increase in peak water runoff rates and to allow for more uniform drainage rate than experienced to date. After the drainage system is installed, harvest strips are ready for grinding and sloping operations. Surface vegetation, made up of small, waxy-leafed shrubs such as Gallberry, Bayberry, Magnolia, and scattered pond pine, can be effectively ground and incorporated into the upper surface of the peat layer. Here, it will rapidly decompose and have little effect on overall peat quality, thus eliminating the standard practice of pushing the vegetation and upper wood layer into long windrows with bulldozers and hauling this debris from the fields. Incorporating vegetation into the upper surface is known as the initial 102-mm (4-in.) surface vegetation grind and is accomplished by using a modified Bros Rota Mixer. Following this operation, and by using the same unit, a sec¬ond grind with a depth of 200-255 mm (8-10 in.) is made. This reduces the debris to a finer consistency, mixes it with the upper peat layer, and grinds any wood found in the upper 200-255 mm (8-10 in.). After initial grinding operations are completed, the augering or sloping operations can be accomplished with little or no hin-

Jan 7, 1983

By D. Lelinski, R. Bokotko, J. D. Miller, J. Hupka

Air-sparged hydrocyclone (ASH) flotation is a new, promising technology, and, since its conception, numerous applications have been successfully tested. Nevertheless, research and development efforts have continued to improve the technology with respect to operating conditions and design considerations. Results, from experimental studies on bubble generation in the ASH system are presented in this paper. Bubble size distributions generated during ASH operation were determined using a high-speed photographic technique. The influence of many factors, including surfactant concentration, water flow rate, and porous-tube pore size have been studied. Test results indicate that these process variables have a profound effect on the bubble size distribution. With an increase in surfactant concentration or water flow rate (shear field), the bubble size distributions become narrower and shift toward smaller average bubble diameters. However, the influence of pore size is more complicated. Depending on the experimental conditions, the average bubble size was found to range from about 100 to 300 µm in diameter.

Jan 1, 1997

By Steven H. Brown

Ore bodies which were once uneconomical to mine by conventional methods such as tunneling or open pits, have become attractive due to the development of nonconventional techniques, involving considerably less capital expenditure. Technologies such as uranium solution mining or in-situ leaching, have enabled commercial scale mining and milling of relatively small ore pockets of lower grade, and may make a significant contribution to overall U.S. uranium supplies during the next 20 years. Commercial size solution mining production facilities have operated since late 1975. Solution mining involves the pumping of ground water, fortified with oxidizing and complexing agents into an ore body, leaching and solubilizing the uranium in-situ, and then pumping the solutions to the surface where they are fed to a processing plant. Processing involves ion exchange, precipitation, calcining, and packaging operations. This paper presents an overview of the solution mining process and the health physics monitoring programs developed over the last four years at several production facilities as a result of the radiological character of these processes. Although many radiological aspects of the process are similar to that of conventional mills, conventional-type tailings as such are not generated. Some special monitoring considerations are presented which are required due to the manner in which radon gas is evolved in the process and the unique aspects of controlling solution flow patterns underground. An overview of the major aspects of the health physics compliance and monitoring programs that have been developed are discussed.

Jan 1, 1981

By Michael J. Martinson

A powerful methane explosion in the mid-shaft pump station of a main service and ventilation shaft killed several persons on the station; more workers were killed when a mancage travelling down the shaft fell to the shaft bottom under a pile of broken concrete slabs from a brattice wall destroyed by the explosion venting into the shaft and a tangled mass of twisted steelwork from the equipped compartment. The newly-commissioned shaft serves a recent extension of an established mine on the Orange Free State (OFS) goldfield in South Africa. After outlining the circumstances in which the paper was written, and reviewing the nature and extent of the methane hazard in OFS mines, the paper describes the physical layout of the shaft and summarises evidence given by witnesses at the official inquiry concerning events prior to the explosion. No attempt is made to apportion blame for the incident.

Jan 1, 1989

By R. J. Wesely, Corby G. Anderson, L. Ernest Krys, John B. Ackerman, A. D. Zunkel, Suzzann M. Nordwick

Processing of the refractory precious metal ore from the Sunshine Mine is done in a fully integrated hydrometallurgical facility. This operating philosophy began with the construction of an antimony plant during World War 11, and it continued with the construction of a silver-copper refinery in 1984. The antimony plant relies on an alkaline sulfide ambient pressure leach combined with antimony electrowinning and antimony compound production. This plant is the largest producer of antimony metal in the United States. The one-of-a-kind silver- copper refinery uses a nitrogen species catalyzed sulfuric acid pressure leach system. The plant contains innovative downstream silver recovery processes as well as copper solvent extraction and electrowinning. This paper presents the pertinent process chemistries and flow sheets for the two unique hydrometallurgical processing plants.

Jan 1, 1993