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By Neil J. Dahmen, Howard J. Handewith

INTRODUCTION Tunneling machines were introduced into civil con¬struction in the 1800s, but their practical applications were not realized fully until the 1950s. As of 1977, tunneling machines were being used on most tunneling projects of substantial size. As in civil construction, the mining applications of tunneling machines have included long drives such as tunneling for long ore-body develop¬ment drifts, long haulage tunnels, longwall access drifts, and long crosscut developments. Tunneling machines ranging from 1.75-m (5.7-ft) to more than I1.0-m (36-ft) diam are available from several manufacturers; machines for mining applications generally have ranged between 1.75 and 6.0-m (5.7¬and 20.0-ft) diam. Tunneling machines usually operate at or near horizontal grades and are supported by a rail-haulage backup system. However, declines and inclines have been made using alternative backup equip¬ment. Either circular or shaped tunnels may be bored, depending upon the particular equipment used. Using tunneling machines to bore openings through rock offers several advantages over the use of the drilling and blasting technique. These advantages include a rapid advance, continuous operation, uniformity of the opening size, smooth walls, and safe working conditions. Compared to drilling and blasting, boring reduces the disturbance of adjacent rock, thereby reducing the ground-support requirements and the exposure to water inflows. The smooth walls provide natural arching and present minimum resistance to the flow of air. A tunneling machine should be considered a spe¬cialized mining tool that is well-suited to certain mining applications. Properly applied and sustained, a tunnel¬ing machine contributes to realizing substantial econo¬mies in the development of underground mines. All costs herein are expressed in 1977 US dollars, unless otherwise noted. The mention of trade names and manufacturers is not intended to imply an endorse¬ment of any specific equipment. TYPES OF TUNNELING MACHINES As listed in Table 1, five principal types of tunneling machines were being manufactured in 1977. Each type of machine offers a special solution to a specific mining problem. Although each of these types of machines is described herein, most of this chapter is devoted to the full-face rotary rock-tunneling machine that has demon¬strated the greatest production in both civil construction and mining applications. Full-Face Rotary Rock-Tunneling Machines As shown in Fig. 1, a full-face rotary rock-tunneling machine consists of a rotating head that is fitted with rock-cutting tools and is forced into the tunnel face. This head is supported by a bearing on a structural support member that, in turn, is held in place by a hydraulically positioned wall-gripping mechanism. Both torque and thrust are reacted from the cutterhead, through the structural support and gripper mechanism, and to the tunnel wall. The rock cuttings fall to the invert at the tunnel face, and they are removed by means of cutterhead buckets or scoops that transfer the cuttings to a conveyor belt. After advancing the cutter¬head through a preset boring stroke, the tunneling machine is advanced by hydraulically pulling the gripper mechanism in from the tunnel walls, stroking forward, and resetting the gripper to the new forward position on the wall; the machine then is set for the next advance stroke. Full-face machines cut only circular openings. Ma¬chines with diameters as small as 1.8 m (6 ft) and as large as 6.1 m (20 ft) have been used in mining applica¬tions, excavating rock with unconfined compressive strengths in excess of 276 000 kPa (40,000 psi). Although special machines have been designed to turn on a radius of 30 m (100 ft) in both horizontal and vertical directions, the conveyors and backup sup¬port equipment generally limit tunneling machines to turns with a radius of more than 60 m (200 ft). The full-face rotary rock-tunneling machines have provided the fastest and most reliable production of any mining method or machine. These machines can be equipped to place any of a variety of ground-support systems, and they can be provided as "open" machines, as shown in Fig. 1, or as "shielded" machines, as shown in Fig. 2. The open machines have the advantage of allowing the ground to be supported as near to the tunnel face as possible. The shielded machines have been designed principally to allow placing precast con¬crete segments. The shielded machines completely pro¬tect the equipment and personnel at the heading, but they are economically limited to permanent long-life haulageways where full lining is required. Partial-Face Rotary Rock-Tunneling Machines As shown in Fig. 3, the partial-face rotary tunneling machine is equipped with a cutterhead that rotates slowly at about 0.21 rad/s (2.0 rpm). The single-disk cutterhead produces the tunnel section shown in Fig. 4 by means of an oscillating motion. These machines work on the undercutting principle, and they are avail¬able in spring-line dimensional increments of 0.1 m (0.32 ft) from 1.5 to 2.1 m (5.0 to 7.0 ft); the vertical dimensions are 2.4 to 3.2 m (8.0 to 10.5 ft), respec¬tively. Depending upon the tunnel width, the cutterhead disk may be fitted with from 8 to 16 drag-bit cutters. Penetration is achieved by means of hydraulic rams that force the tungsten-carbide bits into the rock mass. The operation is cyclic, with cutting occurring only on the upstroke. On the downstroke, the rotating cutter¬head draws the fallen muck from the invert into the panzer-type conveyor for rearward transfer. This feature allows time to either reposition ore cars or to exit the tunnel with muck trains while the machine is cutting, as shown in Fig. 5. Boom-Type Rotary Excavators The boom-type rotary-excavator tunneling machines commonly are known as boom-type continuous miners

Jan 1, 1982

By W. L. Cornell, F. W. Benn

The U.S. Bureau of Mines investigated froth flotation techniques to remove heavy metals (Pb, Cu, and Zn) from southeast Missouri lead mill tailings. It has been estimated that southeast Missouri contains between 200 and 300 million st of Pb tailings stored above ground. The tailings were classified as two distinct types: (1) pre- 1968 tailings from the Old Lead Belt (some more than 100 years old) and (2) post-1968 tailings from the New Lead Belt. The objectives of the investigation were to reduce the Pb remaining in the tailings to (500 ppm (<0.05% Pb) and to attempt to recover a marketable concentrate to offset a portion of the remediation costs. The remaining dolomite-limestone would then be used as mining backfill or agricultural limestone. Bench- scale froth flotation removed, in percent, 95 Pb, 84 Cu, and 54 Zn, leaving 94% of the original weight containing, in parts per million, 400 Pb, 40 Cu, and 300 Zn from the Old Lead Belt tailings. Separate flotation tests also removed, in percent, 85 Pb, 84 Cu, and 80 Zn, leaving 75% of the original weight containing, in parts per million, 400 Pb, 200 Cu, and 500 Zn from the New Lead Belt tailings . Concentrates recovered from the Old Lead Belt were retreated to produce a final Pb concentrate containing 72% Pb with a cleaner flotation recovery of 79%. Froth flotation proved to be a viable method to remove the heavy metals.

Jan 1, 1992

By Robert D. Schmidt

The Bureau of Mines is conducting an investigation to develop remediation techniques for residential water wells whose yield has been affected in the long term, by underground mining. Initial work relating to this project was conducted in 1984-1987 at a room and pillar mine in Indiana County, Pennsylvania. Piezometer nest data from the room and pillar mine reveals that a downward gradient in piezometric head exists in shallow strata as a result of drainage into the underlying mine void. The vertical gradient in head in turn results in well bore leakage in open-hole water wells. The relative yield of valley wells is only slightly affected however because the high surficial recharge rate through fractures more than compensates for fracture leakage into the underlying mine. The relative affect of well bore leakage on well yield is greater in certain hillside and hilltop wells that have comparatively low inflow rates at shallow depths. The static water level of such wells is determined to a much greater extent by the chance interception of deep outflow fractures, than is the case for wells drilled in a more intensively fractured valley bottom. The lower static water level of wells that intercept deep fractures does not necessarily reflect the water table conditions outside of a small radius around the affected well. The results suggest that permanently isolating well bore outflow fractures may remediate certain open-hole residential wells that have been affected by high extraction underground mining.

Jan 1, 1986

By Louis J. Czel

Although lithium was first discovered by Arfwedson in Sweden in 1817, it did not reach any significant status in commercial application until 1908 when Thomas A. Edison received a patent covering the use of lithium hydroxide in alkaline&apos; storage batteries. Edison&apos;s achievement can be regarded as a major breakthrough in the development of the lithium industry. In the years prior to 1908 lithium salts had found only modest applications in the pharmaceutical and pyrotechnic fields. The next important milestone in the growth of this net industry occurred in Germany in 1918 when Metallgesellschaft at its metallurgical laboratory at Frankfort-on-Main discovered that the addition of a few hundredths percent of lithium metal to aluminum and its alloys increased-the hardness. This brought into being a new commercial use of lithium in the manufacture of bearing metals. The new material, called "Bahnmetall" (railroad, metal), was widely used for, many years in the manufacture of bearings for railroad and automotive purposes. Its use continued until the early 1930&apos;s and there was a short-lived renewal of its production during World War II. Subsequent use of-the alloy was soon outmoded.

Jan 1, 1961

By David J. Boron

The United States has the largest total (364 billion metric tons) and recoverable (182 billion metric tons) coal reserves in the world.1 However, progressive coal utilization in this country has been hampered by environmental constraints, such as restrictions on sulfur dioxide, nitrogen oxides, and particulate emissions. New technologies are being pursued both to appease these environmental concerns and improve economic performance and process efficiency. These technologies, however, have not reached the level of effectiveness required for optimum operation. If more stringent emission standards are imposed, it is likely that the coal industry, and the industrial and utility sectors will look increasingly toward the successful development of new and advanced coal cleaning technologies in order to continue and promote the use of coal in this country. The EPA New Source Performance Standards In 1979, the Environmental Protection Agency in response to the amendments to the Clean Air Act of 1977 issued new source performance standards (NSPS) for utility and industrial boilers. The NSPS set emission standards for sulfur dioxide, nitrogen oxides, and particulates affecting boilers of 250 MM Btu per hour heat input or &apos;greater that started construction after September 1978. Plants starting construction or in operation before September 1978 remained subject to the provisions of the regulations promulgated in 1971, i.e., SO2 emissions of 1.2 15/MM Btu. The NSPS for SO2 emissions provides a sliding scale for SO2 reduction depending on the sulfur content of the run-of-mine coal, with an upper limit of 1.2 lb of SO2 per million Btu and a minimum emission level based on 70% SO2 removal. Table 1 summarizes the EPA NSPS for SO2 emission standards.

Jan 1, 1983

By J. G. Pippenger

The Coteau Properties Company&apos;s Freedom Mine is a surface lignite mining operation located near Beulah, North Dakota. Coteau, a wholly owned subsidiary of The North American Coal Corporation, produces more than 13.5 million tonnes per year, ranking it among the largest mines in North America. In 1993, Coteau ranked seventh in terms of annual coal sales, becoming the largest mine outside the Powder River Basin of northeastern Wyoming. However, for the Freedom Mine to stand among these Powder River heavyweights, Coteau over-came several obstacles, including a coal seam with three quarters the heating value and overburden to coal ratios three times higher than the Powder River mines. Coteau&apos;s ability to compete has been built around a program of continuous productivity improvement, cost efficiency, and innovation. This report highlights a few of the major improvements implemented in recent years.

Jan 1, 1995

By Richard O. Rouse

Today, I want to challenge this audience by charging each of you to be a greater manager and superior engineer to manage and engineer our way through the 1980&apos;s and profitably overcome all the present and proposed government regulations. May of the present and proposed regulations will tax you and your company&apos;s management and engineering to the brink of physical and monetary exhaustion, but I believe we can succeed and coal can be America&apos;s answer to her hungry energy needs. To put our 1980&apos;s challenge into perspective, I want to give two great challenges we must overcome. First - We must improve on our process of compliance to new government regulations in the technical and equipment end of our industry. The Lord said, "Let There Be Light". MSHA said, "Let there be light in underground coal mines". Since that time, we have lived through an unmanageable and tremendously costly period of compliance.

Jan 1, 1980

By B. Cavender

Investments in new technology are often intended to improve the production or cost performance of existing operations. The economics used to justify these projects can be flawed, however, if they do not adequately consider the potential benefits of the alterative: the fully optimized use of the facility&apos;s present equipment and personnel. While new technology can be effective, dramatic improvements in production performance can also be achieved through the rigorous application of standard industrial engineering and operations management practices. An intermediate approach may also be effective: many basic improvements In the mine or plant necessary to support new technology will be equally effective when implemented for the facility&apos;s present operators. Firms who optimize their present operations are able to save the capital and avoid the risk associated with new technology. These firms will also be able to capitalize more quickly on new technology when it is implemented.

Jan 1, 1999

By Kim B. Shedd, Erin A. McCullough, Donald I. Bleiwas

"The earliest known use of cobalt was to make blue glass in Mesopotamia before 2000 B.C.E. Since then, innovations across many diverse industrial sectors transformed cobalt into an essential commodity for contemporary society. The physical and chemical properties of the element cobalt and its alloys and compounds make them indispensable for a variety of applications, including aircraft engines, hybrid electric vehicles, machine tools, missile guidance systems, petroleum refining and smartphones. As a major industrialized nation, the United States is a leading consumer of cobalt and cobalt-containing products. However, with few exceptions, U.S. cobaltcontaining ore deposits are of low cobalt grade. Historically, U.S. cobalt mine and refinery output have not met domestic cobalt demand. As a result, U.S. cobalt chemical and alloy producers need to procure most of their cobalt from the international market, which can become susceptible to supply risk.The 1978 Cobalt Crisis illustrates supply risk. At that time, the Democratic Republic of the Congo (DRC) (then known as Zaire) was the world’s leading producer of mined and refined cobalt. An insurgent invasion of the country’s copper-cobalt mining region during a period of high cobalt demand and low producer inventories caused a temporary supply shortage in the international market. The monthly average cobalt spot price increased from $18/ kg ($8/lb) before the crisis to $99/kg ($45/lb) seven months later. The high price and concern about potential disruptions in supply prompted manufacturers to reduce or substitute for cobalt where possible, and encouraged increased recovery of cobalt from scrap. The DRC has regained its position as the leading producer of mined cobalt globally and continues to be characterized by high governance risks (U.S. Central Intelligence Agency, 2015; World Bank, undated). This article will present current and historical world cobalt production trends, which can help inform discussion about the variety of international supply chain risks consequential to its trade."

Jan 12, 2017

By R. Robertson

Dense medium cyclones are the preferred means for cleaning 112 in. x 14 Mesh to 28 Mesh (12.7 mm x 1.0 mm to 0.6 mm) raw coal and are becoming a common choice for cleaning raw coal from a nominal top size of 2-1/2 in. to 3 in. (63.5 mm to 76.2 mm) down to 14 Mesh to 28 Mesh (1.0 mm to 0.6 mm). During the last ten years, dense medium cyclone circuitry design has undergone changes which have combined to improve process efficiency. This paper describes these improvements and compares present day design with the design used prior to the mid 1980&apos;s. Improvements in the following areas are described: Raw coal desliming, cyclone configuration, drain and rinse applications, dilute medium circuitry, and instrumentation and control.

Jan 1, 1997

By T. E. Scartaccini

A drill recorder is a permanent data collecting instrument. In open pit blast hole drilling the application of a drill recorder is that of data collection, drilling control, and drilling education. The various drilling parameters (weight, RPM, penetration, torque, and air) have a drilling correlation which can be demonstrated and documented by a recorder graph. When the correlation is physically put to use during the process of drilling, then the recorder has become a drilling tool and is no longer just a data collecting instrument, per se. By being able to maintain accurate records and drilling control, comprehensive studies of changes both operational and technological can be made. These are based on in-progress facts and not after-the-fact logs. To determine total drilling efficiency, drilling conditions must be documented and controlled. Field operations at American Smelting and Refining Company&apos;s Mission Mine have proved that by increasing drilling control, demonstration of parameter relationships, and drill monitoring, more economic efficiency can be obtained. In comparing results obtained with recorder control and conventional control a decrease of 14 percent to 36 percent of drill footage costs were obtained. The percentage of variance is dependent upon whether drilling is milled-tooth or carbide-insert bit drilling.

Jan 1, 1970

By C. Roos, K. Jetmore

Developing a strategic underground mine plan is challenging and investigating multiple scenarios may take weeks. This process can be sped up using the Theory of Constraints to isolate the bottleneck mining activity and simplify the mine schedule process. This paper presents a technique to apply the Theory of Constraints to test multiple cutoff grade scenarios in Mineable Shape Optimiser and quickly produce many high-level production-based schedules that can be easily interpreted using stope-by-stope graphs, the Hill of Value, and through incremental return analysis.

Mar 2, 2022

By Virginia T. McLemore

The Black Hawk district in New Mexico hosts an unusual type of deposit: arsenide five-element veins. These deposits are Ag-Co-Ni-Bi-As-bearing carbonate veins with local concentrations of U, Pb, Zn, Sb, and other elements. They are high-grade silver deposits (1000s g/t Ag), but low tonnage (<1 Mt) and difficult to find. By 1881, claims were staked and a town developed. It is estimated that >$1,500,000 was produced in 1883–1893, when Ag prices dropped due to the 1893 Ag panic. Solid Silver Mining Co. produced $600,000 from the Black Hawk mine; one car load contained $28,000 worth of silver! The town of Black Hawk grew to 125 population by November 1883. By the end of 1893, the town was vacant; nothing remains. The district was idle until 1916, and the mines operated sporadically since because of lack of available capital, water issues, and difficulty in finding ore shoots. The area is a favorite for mineral collectors. Tungsten was found in the district in 1935 in quartz veins associated with pegmatites. Metal production from 1881–1960 is estimated as 3,000 lbs Cu, 1,000 oz Au, 1,286,000 oz Ag, and 4,000 lbs Pb. In addition, 10,542 short tons of 2.7–71% WO ore and 615 short tons of fluorspar ore have been produced from the district.

Feb 1, 2025

By K. Hajmrle

The production of nickel coated mica composite powder by hydrogen reduction of a nickel ammine sulphate solution, followed by the production of molded plastic samples containing Ni/Mica is described. Sample preparation by injection or compression molding is outlined and the better results in compression molding are explained by the combination of better particle-to-particle contact, less particle breakage during processing, and more random particle distribution in the plastic. Three volume resistivity measurement techniques are described and compared. Two of them (conductive paint and silver-rubber electrodes) are found reliable and are used throughout the work. The influence of nickel content and particle size of Ni/Mica on volume resistivity is evaluated and the optimum product defined. One of the most important assets of Ni/Mica, its ease of injection molding, is demonstrated by the good electrical properties obtained with little optimization of the injection molding process. Surface roughness of molded plastics with and without Ni/Mica is briefly discussed. Shielding effectiveness of Ni/Mica in four plastics (PP, ABS, PBT and PC) is presented and correlated to volume resistivity data for the same materials. The addition of 15 to 50 weight % Ni/Mica (3 to 16 volume %) to plastics and subsequent injection or compression molding produces composite materials having low volume resistivities (0.03 to 1 ohm.cm) and high shielding effectiveness (40 to 70 dB).

Jan 1, 1988

By Todd Burchett

Mining engineers spend countless hours and resources when designing a new underground coal mine. Their primary objective is to design the safest and most efficient operating mine with regards to coal production. A key variable often overlooked in this design stage is the slope conveyor. Typically, a slope conveyor is expected to operate with a 98-percent or higher availability. However, too often little effort is put forth by the mining engineer to optimize its design. Coal companies will rely on engineering, procurement, construction and management (EPCM) companies for the preliminary design, because the slope conveyor will be considered part of the surface material handling processes. This preliminary design will be used when soliciting quotations for the slope conveyor. Unfortunately, EPCMs may not have enough expertise with conveyors to optimize the design. This expertise is available with an original equipment manufacture (OEM) of conveyors, which ultimately may be responsible for supplying the slope conveyor. Each OEM will provide a bid package that represents what it considers to be the optimal design.

Jan 1, 2013

By Werner Burger

After its first introduction in 2013, Variable Density TBMs have increased their application significantly in mechanized closed mode tunneling. Throughout a variety of successfully completed and ongoing projects since then, Variable Density TBM technology has demonstrated its advantages in a wide range of applications. This paper will present the developments and lessons learned from these projects as well as the future potential of Variable Density TBMs.

Jun 13, 2021

By David E. Lindorff

The impact of surface coal mining on the geologic materials and ground water in different geologic settings is being investigated by the Illinois State. Geological Survey at three abandoned surface mines in Illinois. At a site near Ottawa in La Salle County, the overburden prior to mining consisted largely of pyritic shale; sand was the major component of the overburden and spoil at a mine near Coal City, Grundy County. Clays, lacustrine silts, and some shale and limestone were the dominant premining overburden materials at a mine near Harrisburg, in Saline County. Ground-water elevations at Coal City and Harrisburg are approximately at premining levels, whereas at Ottawa they are near the base of the spoil. Ground-water quality has deteriorated at all three sites, especially at Ottawa and Harrisburg.

Jan 1, 1981

By Irving Hauser

The determination of new ways to cut costs in then times of economic uncertainty is essential in running a successful business. Arco Petroleum Products Company a Division of Atlantic Richfield Company recognized an opportunity for a substantial cast savings in transporting calcined petroleum coke to market by simply building an economical port facility at a location that would enable them to drastically cut their normal rail haulage distance.

Jan 1, 1982

By Nikhil Dhawan, Shrey Agrawal, SHAILA MIR

The current study investigates the effect of microwave processing on low-grade banded iron ore using charcoal, coking coal, and non-coking coal. Charcoal showed better microwave heating response at low temperatures, and the coals exhibit better heating response at higher temperatures. Low carbon dosage ~ 12% is sufficient to generate concentrate with 61.8% iron grade and ~6% for 94.8% iron recovery comprising of magnetite phase suitable for iron-making applications. The process separation efficiency of ~ 95% is achieved at 6% carbon dosage and decreases with an increase in carbon due to formation of the fayalite phase. The metallization degree showed a strong dependency on reductant dosage and achieved amaximumvalue of 22.7%at 18%charcoal. The comparison of ore with pure iron oxide and the synthetic mixture of iron oxide indicated that the underlying bonding due to banded structure enhances the Joule heating during microwave irradiation and thereby aids in attaining higher temperature and better separation.

Sep 21, 2020

By John F. Shea

When Dick Robbins asked me to give a keynote address, I felt it might be in order to review some of the practices and techniques used in tunneling and work up to some of the concepts now used to mine and construct tunnels. Needless to say, there have been many changes in tunneling technology and also many changes in the Safety Codes controling them. An example of this latter change was the fact that in 1931, my father excavated the Owyhee Tunnel No.5 with gas locomotives. He was able to do it because there was no natural gas in the rock and the ventilation system was designed to free the tunnel atmosphere from powder and exhaust fumes. Today OSHA rules would never permit gas locomotives underground, although there were no incidents on this particular project. One of my first tunnels, as Project Manager, was the Clear Creek Tunnel for the Bureau of Reclamation. Our method of handling muck was the Conway Muckers. This unit was a valuable improvement to the hand mucking of previous generations. The Conway was also used in our Navajo Project, in New Mexico. Unlike the Clear Creek project, where water was one of our main problems - up to 7,200 gallons per minute, at a pressure of 395 pounds per square inch - in the Navajo Tunnel, we had a mixed face which caused a major problem with our support system. In one of the Navajo Tunnels, there was a major cave-in, when the squeezing shale came in during an attempt to strengthen the support system. Although moving shale was not a constant problem, there were areas where the shale was five to six feet above the spring line.

Jan 1, 1976