Search Documents

Editor?s note: Each year, the June issue of Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue. Thank you to the industrial minerals annual review editor, to the technical committees chair and vice-chair, and to the authors of the individual commodity profiles. Jim Norman, member SME, of GeoTrans, Inc., is the industrial minerals annual review editor. SA Ravishankar, member SME, of Cytec Industries, is chair of the industrial minerals technical committees. Technical committee vice chairs include: ? Abani Samal, member SME, of Pincock Allen & Holt, agricultural minerals. ? Aaron McMahon member SME, of Pincock, Allen & Holt, ceramics and refractories. ? Bradley S. Van Gosen, member SME, of the U.S. Geological Survey, chemical raw materials. ? Mark Zdunczyk, member SME, of Continental Placer, Inc., construction materials. ? Jerry Gauntt, member SME, of JEG Minerals Consultants, fillers and pigments. ? Michael Cheshire, member SME, of Indiana University, sorbents, filters and process aids. Their help makes possible this June industrial minerals issue. On behalf of ME readers, the editors thank them.

Jan 1, 2008

By Steve Chorley

Open-type, or main beam, tunnel boring machines (TBMs) can achieve impressive rates of production. This type of TBM typically outperforms other types of TBMs currently in use around the world. In good ground conditions, main beam machines have achieved production rates of more than 1 km/month (0.6 miles/month). However, installing effective ground support in poorer rock conditions on main beam machines can be a major cause of concern. The design of main beam machines is such that installation of ground support equipment, particularly at the front of the machine in what is commonly known as the L1 support zone, has traditionally been limited to rock drills and basic working platforms. Personnel working in the L1 zone have, until recently, been protected by roof supports and extended fingers, often with restricted access to working areas.

Jan 1, 2011

By None None

Use this month wisely — go online and take advantage of your new member benefit. As an SME member, you can read and download for free all of the full-text papers of the Mining, Metallurgy & Exploration (MME) journal, including the 22 papers in the launch Special Issue on Mineral and Metallurgical Processing in Honor of Professor Emeritus Douglas W. Fuerstenau as well as the archived articles of Minerals & Metallurgical Processing (MMP), all the way back to Vol. 1, No. 1. Just follow the instructions on this page.

By Malcolm Ross

Asbestos crystallizes within rock formations undergoing intense deformation characterized by folding, faulting, shearing, and dilation. Some of these conditions have prevailed during formation of the taconite iron ore deposits in the eastern Mesabi Iron Range of Minnesota. This range includes the Peter Mitchell Taconite Mine at Babbitt, Minnesota. The mine pit is over 8 miles long, up to 1 mile wide. Fifty three samples were collected from 30 sites within areas of the pit where faulting, shearing and folding occur and where fibrous minerals might occur. Eight samples from seven collecting sites contain significant amounts of ferroactinolite amphibole that is partially to completely altered to fibrous ferroactinolite. Two samples from two other sites contain ferroactinolite degraded to ropy masses of fibers consisting mostly of ferrian sepiolite as defined by X-ray diffraction and TEM and SEM X-ray spectral analysis. Samples from five other sites contain unaltered amphiboles, however some of these samples also contain a very small number of fiber bundles composed of mixtures of grunerite, ferroactinolite, and ferrian sepiolite. It is proposed that the alteration of the amphiboles was caused by reaction with water-rich acidic fluids that moved through the mine faults and shear zones. The fibrous amphiboles and ferrian sepiolite collected at the Peter Mitchell Mine composes a tiny fraction of one percent of the total rock mass of this taconite deposit; an even a smaller amount of these mineral fragments enter the ambient air during mining and milling. These fibrous minerals thus do not present a significant health hazard to the miners nor to those non-occupationally exposed. No asbestos of any type was found in the mine pit. © 2007 Elsevier Inc. All rights reserved. Keywords: Taconite; Asbestos; Amphibole; Reserve mining; Tailings; Mesabi iron range; Mineral fibers

Jan 1, 2007

By James Withers, Dongbo An, Jinhong Zhang

A micro-scale investigation was carried out by applying atomic force microscopy (AFM) to study in situ the adsorption of various collectors, i.e., oleic acid, octanohydroxamic acid (HA), and salicylhydroxamic acid (SHA), on bastnaesite in aqueous solutions. The obtained AFM images show that the surface morphology of bastnaesite changes greatly after it comes into contact with the solutions of the collectors, suggesting that all these collectors can effectively adsorb onto bastnaesite. Increasing temperature can facilitate the adsorption of oleic acid onto bastnaesite. Results from attenuated total reflectance–Fourier transform infrared spectrometry (ATR-FTIR) also show that all of these collectors adsorb strongly onto bastnaesite, with strong absorbance spectra being detected. The ATR-FTIR results confirm those obtained by AFM. In general, hydroxamic acid collectors (HA and SHA) adsorb onto bastnaesite mainly in the form of insoluble metal hydroxamate. This specific adsorption mechanism explains that a high selectivity with a moderate collectivity will be achieved with a hydroxamic acid collector for the flotation of bastnaesite.

By James Withers, Dongbo An, Jinhong Zhang

A micro-scale investigation was carried out by applying atomic force microscopy (AFM) to study in situ the adsorption of various collectors, i.e., oleic acid, octanohydroxamic acid (HA), and salicylhydroxamic acid (SHA), on bastnaesite in aqueous solutions. The obtained AFM images show that the surface morphology of bastnaesite changes greatly after it comes into contact with the solutions of the collectors, suggesting that all these collectors can effectively adsorb onto bastnaesite. Increasing temperature can facilitate the adsorption of oleic acid onto bastnaesite. Results from attenuated total reflectance–Fourier transform infrared spectrometry (ATR-FTIR) also show that all of these collectors adsorb strongly onto bastnaesite, with strong absorbance spectra being detected. The ATR-FTIR results confirm those obtained by AFM. In general, hydroxamic acid collectors (HA and SHA) adsorb onto bastnaesite mainly in the form of insoluble metal hydroxamate. This specific adsorption mechanism explains that a high selectivity with a moderate collectivity will be achieved with a hydroxamic acid collector for the flotation of bastnaesite.

By Aram Grigoryan

This paper addresses historical aspects and construction sequencing of the subway complex under Columbus Circle in Manhattan; the structural elements of the rehabilitation and new construction; and the challenges associated with design and construction. PB is providing engineering services to New York City Transit (NYCT) for the rehabilitation of the 59th Street/Columbus Circle Station Complex that services over 150,000 customers daily. The project involves structural repairs, modifications and new construction requiring underpinning and temporary supports, custom framing details, and construction staging procedures to meet stringent limitations within the operating transit station and around the Columbus Circle street intersections.

Jan 1, 2008

By W. James Marold

The New Croton Aqueduct (NCA) was the first major water supply tunnel for New York City. The 50-km (31-mi) long tunnel has 33 open shafts 6 m (20 ft) to 121 m (397 ft) deep. The tunnel and shafts are lined with brick and mortar, with cast iron lining and pressure covers in six pressurized shafts. Details of the 1895 construction are provided and compared to modern construction techniques. The paper provides rehabilitation techniques for the shafts and pressure covers, including grouting, epoxy lining, temporary bulkhead design and installation and placement of tremie concrete 98 m (320ft) below the water level in a 122 m (400ft)deep shaft using a Remote Operated Vehicle (ROV) to monitor the placement.

Jan 1, 2008

By Alex Naudts

Pre-excavation grouting is a predictable and reliable technique performed to prevent or minimize settlement in advance of, or during the tunneling operation. It safeguards the infrastructure above the tunnel alignment. Cement based suspension grouts and sodium silicate based grouts are frequently injected to consolidate and strengthen the formation and create a reinforced canopy above the tunnel trajectory. Grouting is typically performed through permeation and permeation in conjunction with hydrofracturing. Multiple injection passes through steel sleeve pipes are ideal, since they create an effective forespiling system to facilitate tunneling without causing unacceptable settlement, even with minimal overburden thickness. Ten pre-excavation grouting projects performed in the North America are discussed in this paper.

Jan 1, 2008

By Carlos Henrique Turolla Maia, Ulrich Maidl, Marc Comulada, Julio Claudio Di Dio Pierri

"Pure sands are typically the domain of slurry shields due to their high permeability and their granular characteristics. However, the Earth Pressure Balanced (EPB) shield machine technology has advanced in recent years with improved conditioning agents and shield machines that are equipped with slurry injection facilities and alternative mucking methods. These new so-called hybrid EPB machines have steadily increased the range of application of the EPB technology. The contribution discusses the capacities and operational features of hybrid EPB vs. slurry shield technology in pure sands. At the example of the Metro Line 4 in Rio de Janeiro (Brazil), the contribution shows that hybrid EPB tunneling in pure sands is possible and it is compared with a state-of-the-art slurry shield project as the KASIG project in Karlsruhe (Germany). Furthermore, the control of the support pressure by means of foam conditioning and slurry injection in conjunction with a close, real-time monitoring of machine parameters is discussed. INTRODUCTION Slurry shield and EPB technologies have both undergone significant developments in recent years, leading to the use of parts of one technology in the other and even to completely hybrid systems. Also the ranges of application (see recommendations by DAUB (DAUB 2010)) of both technologies have been shifted far beyond their original limits and are largely overlapping by now. Nevertheless, the basic principles of face support remain unchanged. Exploiting the possibilities of process data analysis (Maidl 2014), the interactions between the ground and the shield machine are a matter of research and have been intensely investigated. PRINCIPLES AND CALCULATION OF FACE SUPPORT PRESSURE Figure 1 shows the principles of two approaches for the determination of required support pressures: kinematic methods and numerical methods. Kinematic methods that are employed for the assessment of face stability only consider the situation in front of the TBM. The required face support force is determined by means of an assumed failure wedge that would form in ultimate limit state. Based on the ground properties, the vertical surcharge and the self-weight is transformed into a horizontal force along a virtual sliding surface. This horizontal force is to be balanced by the face support. The calculation results are amended by respective partial safety factors for water and earth pressure and the method-specific support pressure fluctuations are added."

Jan 1, 2016

By R. L. Guerguerian

Nowadays, most grinding mills driven by a wrap-around ring motor are operating successfully. Some of the earlier problems could be attributed to the lateral stiffness and stability of their bearings. As a result, modifications to the bearings included the rearrangement of the shoes, or the addition of more shoes, closer to the horizontal centerline. This technical paper reports a study of the effects of bearings on the lateral stiffness of grinding mills driven by a wrap-around ring motor. The discussions cover the design of the four shoe trunnion bearings and examine the effects of the angular location of the shoes.

Jan 1, 2000

By Steven W. Hunt

Appropriate seals, portal ground improvement, and compatible shaft construction techniques are vital elements for launching and receiving tunnels effectively in urban areas where adjacent property requires protection from excess ground movements. This paper focuses on seals and ground improvement along with shaft wall types, required to launch or receive tunnel boring machines within wet, permeable ground at the portal zone. The paper also discusses probing to verify suitability before the tunnel eye is cut. Methods addressed include: rubber gasket seals; soft eyes; double walls; top hats for reception; and, portal zone ground improvement (permeation grouting, jet grouting, un-reinforced slurry diaphragm wall panels, ground freezing, deep soil mixing, dewatering, and over-excavation and backfilling). This paper focuses on challenges with launch and reception of pressurized-face TBMs with precast concrete segment linings. Challenges related to pipe jacking are discussed in a separate paper titled ?Mitigating Microtunnel Launch and Reception Challenges? (Hunt and Finney 2008).

Jan 1, 2008

By John E. Newby

The Brightwater Conveyance System consists of four tunnel segments in three tunnel con-tracts, comprising over 21,760 m (71,400 ft) of pressurized face tunneling in complex glacial and non-glacial soft ground conditions with a large proportion 60 m (197 ft) or more below the ground surface with up to 7 bars groundwater head. This resulted in unique technical challenges for establishing geotechnical baseline values. The process used to develop these baseline values and specifications with regard to the level of risk that the owner, King County, was willing to accept is described in this paper.

Jan 1, 2008

The theme of the 2012 North American Tunneling conference (NAT) was ?Tunneling: Driving Value.? This theme best reflects where the tunneling and underground construction industry is to-day. Major advances that have been made in technologies have provided tremendous improvements in productivity, which, in turn, have allowed the industry to deliver more cost-effective and less disruptive solutions to the nation?s infrastructure needs. Despite a weak economy, domestically and globally, cities and states continue to spend billions on infrastructure improvements. For the underground construction industry, that means more transportation and water, wastewater, storm water projects and other underground structures. And, for each project completed, underground construction and tunneling technology grows. The NAT conference, put on by the Underground Construction Association (UCA) of SME, provides an outlet for technology transfers among professionals. This year?s conference, held in Indianapolis, IN June 24-27, attracted 918 attendees, up from 803 at the last NAT in 2010. The accompanying exhibit also featured 116 exhibitors occupying 140 booths. That was up from 108 booths in 2010. So, the meeting continues to grow as underground construction professionals throughout the world seek to learn from their peers.

Jan 1, 2012

By Kevin Andrews, Terry Hamric, Scott Nelson

"Mining conditions in underground coal mines are dictated by the environment in which the coal seams were geologically deposited. Depositional features can change rapidly, significantly affecting mining conditions. Mine geologists understand factors affecting mining conditions, predict future conditions, and provide guidance to mine management. A case study demonstrates how a mine in Appalachia merged an understanding of depositional environments with mining conditions and drilling data to make informed decisions as the mine encountered geologic anomalies. The assessment included drilling, mapping of geologic hazards and mine productivity, and creation of a conceptual depositional model. Metallurgical coal quality and clean tons per foot served as incentives for continued advance. Mining in the south was historically favorable, with good production and advance rates. As mining advanced north, changing geologic conditions caused the upper seam split to abruptly disappear. The mine ramped down into the lower seam split. Mining in the north area encountered unfavorable conditions, including transition roof, “horsebacks,” sandstone intrusions, roof rolls, and bony floor, resulting in low rates of mining advance. The mine geologist characterized the features and created a predictive model for future mining. Most of the adverse conditions were attributed to the coal in the north being part of an incised, transgressive valley fill environment, as compared to the favorable conditions in the south resulting from a floodplain depositional environment. Geologic conditions, low productivity, and unfavorable future predicted conditions in the north ultimately resulted in mine closure and reallocation of resources to a new mine with better forecasted conditions.INTRODUCTIONThe role of a geologist in assisting coal mining operations to understand and predict the impact of varying geological factors on mining productivity is a critical one, especially when management decisions must be made about the future prospects of a mine operating in difficult conditions. Chase, Newman, and Rusnak (2006) provide a very thorough discussion of the evolution of the role of the coal mine geologist and emphasizes the importance of understanding geology with regard to mine management decisions. Using actual mining performance data to determine which geologic factors are the most critical for mining is a powerful tool for making informed mine management decisions. For example, Nelson, Mullennex, and Miller (1988) provide a case study of analyzing the geologic factors impacting productivity of a Kentucky longwall mine to predict future mining conditions for the operation. In that case, the difficult geologic factors for longwall mining were prevalent across much of the remaining permit area and, in response, mine management converted the operation from a longwall operation to a continuous miner (CM) operation to better adapt to the geology. In another example, Keim and Miller (1999) evaluated geologic conditions impacting a West Virginia longwall mine. In both examples, significant geotechnical and geological information was available, including the opportunity to compare predicted mining conditions against actual conditions as mining progressed. Numerous examples of advanced Geologic Hazard Mapping (GHM) methodologies have come from government agencies and academia. For example, development of the Coal Mine Roof Rating (CMRR) system (Molinda and Mark, 1994) provided a standard means for geologists and engineers to communicate quantitatively with regard to mine roof conditions, and the introduction of the Stability Mapping System (SMS) provided an efficient means for analyzing numerous factors affecting coal mine stability (Wang and Heasley, 2005)."

Jan 1, 2019

By Kanchan Mondal, Gopi Bylapudi, Anand Bhagwat

Corrosion of steel roof support systems can cause potential premature failure of the support, thus adversely affecting the excavation stability and rock-related safety. An in-house corrosion test system was designed and developed to test full-length roof bolts for material performance based on tensile load capacity and strength under different corrosive conditions found underground. The roof bolts tested are also used to identify the possible corrosion mechanisms that influenced the bolts’ performance over time. Initially, the most commonly used bolt material in the USA, the ASTM A615 grade 60 steel roof bolts, was tested with and without stresses in a simulated underground coal mining environment for approximately 6 months, and the results are discussed. Localized corrosion forms such as crevice and pitting were mainly observed after testing. The stressed and unstressed roof bolts with and without threads that were tested in alkaline coal mine corrosive environment for 6 months passed their load-bearing capacity as per ASTM F432 test standards. From the results, it is concluded that this test protocol could be applicable to test the material performance of different roof bolt metallurgies and coatings with desired modifications to the proposed methodology for the specific underground mine environment. This paper mainly discusses the test system and protocol and shortcomings of the system and makes recommendations based on the observations and results.

By Kanchan Mondal, Gopi Bylapudi, Anand Bhagwat

Corrosion of steel roof support systems can cause potential premature failure of the support, thus adversely affecting the excavation stability and rock-related safety. An in-house corrosion test system was designed and developed to test full-length roof bolts for material performance based on tensile load capacity and strength under different corrosive conditions found underground. The roof bolts tested are also used to identify the possible corrosion mechanisms that influenced the bolts’ performance over time. Initially, the most commonly used bolt material in the USA, the ASTM A615 grade 60 steel roof bolts, was tested with and without stresses in a simulated underground coal mining environment for approximately 6 months, and the results are discussed. Localized corrosion forms such as crevice and pitting were mainly observed after testing. The stressed and unstressed roof bolts with and without threads that were tested in alkaline coal mine corrosive environment for 6 months passed their load-bearing capacity as per ASTM F432 test standards. From the results, it is concluded that this test protocol could be applicable to test the material performance of different roof bolt metallurgies and coatings with desired modifications to the proposed methodology for the specific underground mine environment. This paper mainly discusses the test system and protocol and shortcomings of the system and makes recommendations based on the observations and results.

By Edwin F. Shorey, Richard F. Coon, Steven B. Fradkin

Crosstown Interceptor Phase IA is the first deep tunnel element of the Milwaukee Inline Project. The tunnel contract includes 6,492 meters (m) of 9.1-m-diameter tunnel, two access shafts, and partial lining for structural purposes. The work also includes grouting to be performed as directed by the engineer to provide groundwater infiltration control in lined and unlined reaches of the tunnel. This paper summarizes infiltration observations, progress of the grouting work, and its potential application to the remainder of the Milwaukee project.

Jan 1, 1987

By Derek J. Penrice

A critical element of the Transbay Transit Center Program, the Caltrain Downtown Extension (DTX) will extend commuter rail service into downtown San Francisco and accommodate future statewide high-speed rail service. The DTX project includes 1.8 miles of underground construction, comprising significant sections of mined and cut-and-cover tunnel. At the request of stakeholders, an updated cost estimate was prepared early in the project?s preliminary engineering phase. Unsurprisingly, this yielded a cost substantially higher than the available budget. This paper provides a summary of the management processes and planning decisions taken to bring the project back to budget, resulting in a configuration which derives maximum value from available funding and retains maximum flexibility for future system expansion.

Jan 1, 2008

By P. Hickey, J. Spenceley, T. J. DeMull

Development of the Batu Hijau Project was successfully completed in the fourth quarter of 1999 with the final handover and start-up of ore processing facilities. The development project had started more than three years earlier, in August 1996, when the Owner, PT. Newmont Nusa Tenggara (PTNNT), awarded an EPC contract to Fluor Daniel (FD) for design and construction of the project including: copper concentrator, port, power plant, town site, and infrastructure. PTNNT managed the development of the mine and procurement of mine equipment with its own forces. Bringing the Batu Hijau copper deposit into production was the largest mining project ever undertaken. Development of Batu Hijau was a complex project involving the work of tens of thousands of people in all parts of the world to complete engineering, manufacture and deliver equipment, supply materials, and build the plant. The ore deposit is located on the tropical island of Sumbawa in a remote and undeveloped section of Indonesia. The location and environment presented challenges for all phases and aspects of the project. To meet the challenges, the project team combined good planning and teamwork to best utilize the resources available. This approach assured continuity of personnel through construction to operations and minimized cost, resulting in completion of the project ahead of schedule and under budget.

Jan 1, 2001