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By David Smith

Construction of a new transportation link frequently requires crossing under an existing highway or railroad. Although traffic diversions may permit a cut and cover structure to be built, ‘zero impact’ tunnel solutions are becoming increasingly popular. The vertical clearance between the new tunnel structure and the existing highway or tracks may be very low; sometimes less than two meters. This leaves little room for error since any ground loss can rapidly translate into surface settlement. Problems can be avoided by maintaining the stability of the tunnel face and by minimizing ground movement around the tunnel lining. This paper examines construction methods that have been used to construct short tunnels with shallow cover, and highlights factors to be considered for future projects.

Jan 1, 2005

By Baha Abulnaga

Slurry pipelines are used in a number of countries to convey processed ore mixed with water over long distances from remote mine sites to ports or plants for further processing. In Egypt and Sudan, numerous mineral resources are scattered in remote areas. Through the years, Egyptian geologists have identified 268 sites for metallic ores and 386 sites for industrial nonmetallic minerals. A large portion of these sites are in the Eastern Desert in an area called the Nubian Shield. Similar sites are found in the Sudan where mining contributes to less than 1 percent of the gross domestic product (GDP). There are three important components of infrastructure needed to develop these resources ? power, water and transportation. While Egypt is able to satisfy 70 percent of its needs in iron ore from the Gadideh Mine in the Western Desert, it needs to expand its other resources to reduce imports heavily sedimented. Dredging of these sediments and transporting them by slurry pipelines would enhance an industry of bricks or agricultural development based on tailings technology often used in mining. This article explores the potential for slurry technology for opening new mines in the desert or recuperating the sediments of the Nile. The technology by itself would be new to both countries and would benefit from collaboration, particularly to de-silt the Nasser-Nubia Lake.

Jan 3, 2010

By Constance F. Acton

Based on laboratory structure analyses, a pilot plant investigation was undertaken to evaluate a Michigan conglomerate native copper ore. Comminution or sized feed was accomplished using wet, closed circuit autogenous grinding with and without crushing of the recirculating load. Coarse metallics were concentrated in two stages of jigging with fine metallic copper being recovered in a three-stage xanthate flotation circuit. With a feed averaging 2.09 % Cu, copper recovery ranged from 86-93 % Cu with an average grade of 55.5 % Ca. An evaluation of the processing flowsheet is made in terms of pertinent independent, dependent, and external variables and design factors. Rate equations are developed to describe the grinding and flotation circuits separately as well as the entire circuit as a whole. Performance equations for the overall operation and for the unit operation of autogenous grinding alone are developed in terms of suitable capacity, efficiency and energy consumption terms. Thus, the effects of feed rate, recirculating load and flowsheet design can be rationally evaluated. Energy consumption for various conditions in the pilot plant is compared to the laboratory value. Additionally, size and scale up factors are discussed. Recommendations are made for further studies to be undertaken to further quantify the ore characteristics and the nature of the autogenous grinding operation. However, the feasibilty of beneficiation of this type of native copper ore by means of an autogenous grinding/jigging/flotation circuit is clearly established.

Jan 1, 1977

By Brian Garrod

Increasing use of pressurized-face tunnel boring machines in North America has produced a similar increase in the application of precast concrete tunnel linings. Where a pressurized TBM is needed, immediate ground support and ground water pressure resistance is also required. A segmental lining installed within the TBM tail shield provides the only available means of providing such a sealed lining. This paper addresses new developments in North America in lining applications and design. For the purposes of this paper, a precast concrete tunnel lining is defined as a tunnel lining constructed using precast concrete segments that are assembled into a lining ring. The lining rings are connected adjacent to each other to form a tunnel lining. Each segment has a sealing gasket around it so that when the lining is completed, it provides a fully waterproof lining system. The ring is erected within the tail shield of the TBM and the annular gap around the ring is filled with grout as the machine moves forward. The ring is not expanded and normally provides the finished lining of the tunnel with no requirement for a second pass lining. The TBM has a series of hydraulic rams that push on the leading edge of the segmental lining to provide the sole system of forward propulsion for the machine. The rings are tapered, being longer on one side than the other. This allows the rings to be installed either on a curve or in a straight line depending on the rotational position of the rings.

Jan 1, 2008

By Dirk van Zyl, S. Chander

Minerals have been critical to human society from the earliest and their use has been intertwined with the development of civilization. In the Western World, the mining, processing and extractive metallurgy associated with ores was first described in detail by Agricola in the 16th century. He considered these collective activities to be the most necessary and the most profitable of professions, and wrote, "without doubt, none of the arts is older than agriculture, but that of the metals is not less ancient; in fact they are at least equal and coeval, for no mortal man ever tilled a field without implements. In truth, in all works of agriculture, as in the other arts, implements are used which are made from metals, or which could not be made without the use of metals; for this reason the metals are of the greatest necessity to man." Ours is still a materials-dependent society that relies heavily on minerals for raw materials. Today our dependence on minerals is exceptionally great. To meet the need for fuel and non-fuel minerals in a representative year, in the United States alone, about one billion tons of coal and 2.7 billion tons of ore are mined. These mineral products are essential for fertilizers, for construction materials, metals and alloys, for manufacturing household and industrial items, for transportation, and for the generation of electric power. It is instructive to consider the diversity of uses found in our society for a single mineral product - silver, for example. Experts believe that in the past 5000 years we have mined about a million tons, or 31.9 billion troy ounces of silver. In 1988, 133 million troy ounces of silver were used in the Unites States. Most of the silver used was for techno- logical, medicinal and industrial purposes, Table 1. X-ray films, for example, carry comparatively large amounts of silver to lessen patient's radiation exposure. Silver does not prevent tooth decay, but each year about two million troy ounces of silver is used for dental work in the United States. In small quantities it is used in medicine. No metal - not even copper conducts heat and electricity so efficiently as silver. Silver wires lace solar cells, and silver oxide batteries power hearing aids, calculators, submarines and satellites. Hardened with tungsten or molybdenum, miniature discs of silver pass current from wire to wire in cars, telephones and computers. A dish- washer timer alone may have 50 such electrical contacts, which open and close without excessive heat or friction. Silver is an important component of solar reflectors, since no other material reflects light so well or uniformly. In our personal lives, silver remains in high esteem to adorn our tables, provide precious objects and jewelry. In many parts of the world, silver in the form of coins, jewelry and bullion is used for financial independence and security against the vagaries of paper currency. In India, silver is used in its purest form as thin foils to decorate sweets and other edibles. It is obvious that this mineral product, silver, is of great value and utility in our society. Minerals and Environment The benefits of minerals do not come without problems. Much of the silver, for example, lies locked up in copper, lead-zinc or precious metal ores; to extract it creates vast quantities of waste material. On the average, in order to recover one ounce of silver about a quarter ton of ore must be mined. To meet the world's annual demand for silver, approximately 100 million tons of waste is generated every Year. The problem with silver is repeated with all minerals. Conversion of mineral ores into usable materials necessitates the generation of large quantities of waste products that create tremendous disposal problems. In addition to waste material discarded during mining, wastes may be generated during processing as gases, liquids or solids that must be subsequently converted into forms more acceptable for disposal. Associated with the handling, treatment and management of waste products are a number of environmental problems. Environmental problems are not new to the minerals industry. In his Geographia, Strabo (63 B.C. - 20 A.D.), gives an account of the conditions of labor under which men

Jan 1, 1992

By Jon Y. Kaneshiro, Sean A. Menge, M. Luis Piek, Brian Barker

The Lake Hodges to Olivenhain Pipeline project is part of a 40-megawatt pumped storage project linking two reservoirs as part of the San Diego County Water Authority’s $939 million Emergency Storage Project. Seeking to expedite project completion, the project was advertised as Design-Build, a first for the owner. Awarded to Kiewit Pacific with Parsons as designer, the 1,750m (5,700ft) long, 4.25-m (14 ft) horseshoe tunnel was excavated with conventional drill-and-shoot technique. The mining method was well suited to deal with the shear zones, the very abrasive rock, and 13.3% and19.6% grades. At the apex of the alignment, a 60m (200ft) by 3.6m (12ft) diameter raisebore shaft with surge chamber to protect against pump malfunction was constructed. Upon completion of mining, the tunnel was lined with a 3m (10 ft) diameter high strength steel pipe. Scheduled to come on-line by January 1, 2008, the Lake Hodges to Olivenhain pumped storage project is valued at $108 million, delivering a reliable source of water in emergency situations and electricity-generating capability to meet the growing demands of the San Diego region.

Jan 1, 2007

By Bill Cain, David F. Tsztoo, R. John Caulfield, D. Scott Kieffer

In 1994, the East Bay Municipal Utility District (EBMUD) commenced a system-wide Seismic Improvement Program to protect their facilities from catastrophic damage. A primary focus of this program has been on retrofitting the 75-year old Claremont Tunnel, which crosses the active Hayward Fault zone. A large earthquake on the Hayward Fault could generate enough right-lateral fault slip to effectively sever this important lifeline. The retrofit project involves construction of a new bypass tunnel through the Hayward Fault zone, together with systematic contact grouting and localized structural repair of the existing concrete liner. Several innovative design measures have been incorporated into the seismic retrofit design, including an oversized tunnel cross section, backfill concrete side drifts, seismic isolation of an internal structural pipe, and shear fuses in the final lining.

Jan 1, 2005

By Clement K. Chase

Since the dawn of cyanidation leaching techniques for precious metals, certain manganese-bearing silver ores have been a problem due to low silver extraction. Since simultaneous occurrence of silver and manganese is common in nature, this situation has made many otherwise attractive silver deposits uneconomic in the past. Several older techniques have been useful but at $1.29 per ounce of silver, the economics were unfavorable. With the new look in silver prices and some improvements in processing technology, neglected silver districts offer new promise.

Jan 1, 1981

By Wojciech Klecan

Cobb County, located on the northwest side of Atlanta, GA, is continually growing and, like many other metropolitan areas, it needs to increase the capacity of its waste water system to meet future demand. The Cobb County Water System (CCWS) is the responsible agency for water distribution, waste water collection and treatment in most areas of the county. CCWS, one of the most progressive agencies in the metro-Atlanta area, is addressing its future waste water capacity needs in the southern part of the county with the construction of the South Cobb Tunnel and Pump Station. This project consists of an 8.8-km- (5.5-mile-) long, 8.2-m- (27-ft-) diameter, tunnel boring machine (TBM) excavated waste water storage and conveyance tunnel; six tangential vortex-flow intakes ranging from 1,533 to 5,700 L/s (35 to 130 mgd) peak flow capacity, two construction shafts, six 1.8-m (6-ft) finished diameter connecting tunnels ranging in length from 6 to 975 m (20 to 3,200 ft) and a 5,700-L/s (130-mgd) wet/dry pit pump station. The pump station will have a semi-circular wet well with a dividing wall that extends almost to the top of the shaft and a spilt dry well for reliable operation. Roller gates will control the flow to the wet well from the tunnel. The pump station will have six 1,420 L/s (32.5 mgd) pumps and two sets of stair wells and elevators. With a finished diameter of 32 m (104 ft) and a depth of 62 m (204 ft), this is the largest pump station shaft constructed so far in Georgia for the dewatering of a waste water tunnel. The pump station shaft was also the highlight of the well attended and successful 2009 Shaft Design and Construction Short Course held in Atlanta, Sept. 10-11. The two-day course was sponsored by the Underground Construction Association of SME and Pennsylvania State University and concluded with a field trip to the pump station shaft. The tunnel starts south of the city of Austell and finishes at the South Cobb Water Reclamation Facility (WRF), located on the banks of the [ ] Chattahoochee River just north of Interstate 20 (Fig. 1). The South Cobb Tunnel will run 30 to 137 m (100 to 450 ft) below the surface, with an average depth of about 91 m (300 ft), through metamorphic rocks (Fig 2). The construction contract was awarded to Shea-Traylor JV with the lowest bid price of $305 million and notice-to-proceed was given on July 14, 2008. Jordan Jones & Goulding, Inc. (JJG) is the project designer and performed the geotechnical investigations. Parsons/Jacobs Associates is the construction manager. The South Cobb Tunnel is CCWS?s second deep hard rock tunnel. The 15.3-km- (9.5-mile-) long, 5.5-m- (18-ft-) diameter TBM excavated the Chattahoochee Tunnel was the first deep tunnel to be construced in Cobb County. Construction began in 2000 and the project was completed four years later. It is located about 16 km (10 miles) northeast of the South Cobb Tunnel in similar geology. It was designed by JJG to meet east Cobb?s long-term waste water capacity needs and provide flow equalization to the R.L. Sutton WRF. The Chattahoochee Tunnel was named ?Outstanding Civil Engineering Project of the Year? by the Georgia Sec-tion of the American Society of Civil Engineers in 2006.

Jan 1, 2009

By Nural Kuyucak

Several thousand years ago, metallurgists discovered that by combining two relatively soft metals, copper and tin, they could make a new material, bronze, that was stronger than either metal separately. Bronze and other alloys show how different materials can be integrated to create something new and better. Today?s mining industry can likewise find benefit in an integrated approach to managing the external impacts it has through its waste materials and its use of water. Just as using bronze gave ancient nations an economic and military advantage, mining companies can gain competitive advantage through finding better ways to manage water and waste. Trends pushing this include: ? Environmental ? Regulations on water-taking and the quality of discharged water are becoming more stringent. Net zero discharge requirements are often imposed by regulators. Mining companies also come under pressure to manage environmental impacts of mine waste, including minimizing the area occupied by waste and seepage amount resulting from infiltration of water from a smaller surface area. ? Social ? Particularly in arid parts of the world, there are multiple possible uses for each gallon of water. Local residents do not want to see a reduction in supplies of water for agricultural, domestic, manufacturing and other purposes. They get suspicious about any potential impact of water being mixed with their water reservoirs if it comes from a mining site, even if it would be treated. Such suspicions may cause conflicts among the stake-holders and delays in project approval processes.

Jan 1, 2009

By H. Sarvamangala

Biomineralization of manganese on titanium condenser material exposed to seawater has been illustrated. Biom-ineralization occurs when the fouling components, namely, the microbes, are able to oxidize minerals present in water and deposit them as insoluble oxides on biofilm surfaces. Extensive biofilm characterization studies showed that an alarmingly large number of bacteria in these biofilms are capable of oxidizing manganese and are, thereby, capable of causing biomineralization on the condenser material exposed to seawater. This paper addresses studies on understanding the exact role of the microbes in bringing about oxidation of manganese. The kinetics of manganese oxidation by marine Gram-positive manganese oxidizing bacterium Bacillus spp. that was isolated from the titanium surface was studied in detail. Manganese oxidation in the presence of Bacil-lus cells, by cell free extract (CFE) and heat-treated cell free extract was also studied. The study confirmed that bacteria mediate manganese oxidation and lead to the formation of biogenic oxides of MnO2, eventually leading to biomineralization on titanium surface exposed to seawater.

Jan 1, 2008

By L. K. Marshall

Last month's engineering fundamentals article discussed some general considerations of underground mine ventilation. This month's article takes a look at auxiliary ventilation-brattice, fans, and ducting-in underground mines. The need for good, efficient auxiliary ventilation increases as mines get deeper and move farther from ventilation shafts. New mining methods and equipment resulted in faster work area advances, liberating more dust, gas, and heat. As a result, worker health and safety requirements in the face area have become more stringent. For all these reasons the safety and efficiency of any underground mine depends heavily on its auxiliary ventilation. The purpose of such ventilation is to supply sufficient quantities of clean air to the face of the drift and to maintain air quality within desired limits until expelled from the mine.

Jan 2, 1982

By Antonio Nieto

According to the analysis of surface powered haulage accidents involving off-highway haul trucks in openpit mining, the U.S. Mine Safety and Health Administration (MSHA), reported 1,300 fatal accidents from 1990 to 2005. Of these, 163 were considered off-highway truck haulage accidents, and at least 23 involved collisions of an off-highway truck with a neighboring vehicle or a worker on foot (Nieto and Dagdelen, 2006). In general, an average of 18 nonfatal accidents and three fatal accidents occurred in openpit mining per year when equipment backed over the edge of an embankment, stockpile or dump point (Fessak, et al., 2003). The specific problems that need to be solved can be determined by carefully studying the accidents involving haulage trucks (Marrara, et al., 2004). Solutions to haulage truck safety must consider the human factors affecting each task even when engineering solutions seem most appropriate. In surface haulage, human performance becomes a critical issue because of the unusual demand the vehicle?s places on their human operators: ? Roadways and working areas change frequently in mining operations. ? The sheer mass of mining equipment such as trucks requires control inputs (e.g., braking) far in advance of the desired action. ? Rough roads, loading and unloading impacts can subject the driver to dangerous shocks and vibration. ? Visibility is sharply curtailed by the bulk of the vehicle generating large blind spots. All of the above issues can be attributed partially to the lack of visibility (Pyles et al., 2003). Driver visibility and communications are key issues to reduce mining truck accidents. Analysis of fatalities and injuries involving mining equipment demonstrates the need to develop new intervention and control strategies to mitigate the risks associated with mining equipment operation. Ongoing development of these and other new strategies is required to achieve a reduction of injury in the mining industry

Jan 2, 2010

By R. J. Latino

Because of the lack of a universally accepted definition or standard for RCA, we are left to our own conventions in the marketplace as to what is most ?effective? or a ?Best Practice? for our own facilities or organization. This lack of uniformity in the application of RCA produces an equal lack of uniformity in the measureable outcomes of RCA on the bottom-line from site to site and industry to industry. What is the definition of success for an RCA? Is it regulatory compliance? Is it some quantifiable measure of bottom-line performance? Is compliance and bottom-line performance the same thing? Can we measure the ROI we receive by doing compliant RCA? These questions must be adequately addressed if any definition of RCA is to be effective on the bottom-line. Like our various Corporate Vision and Mission Statements, what would be our Vision and Mission for RCA? When pondering the answer to this question, we should consider: ? What Key Performance Indicators will the Success of RCA be Linked to? This provides a direct correlation to the corporate dashboard and therefore garners support for the RCA effort when implemented at the sharp end. Not until we know what KPI?s will effectively measure our maintenance and reliability objectives can we begin to establish which opportunities will afford the greatest returns1. ? What Bottom-Line Metrics will be Tracked to Measure the Effectiveness of Our RCA Effort? Will it be increased production, profitability, regulatory compliance, etc.? Will it be decreased injuries/fatalities, claims, customer complaints, risks, etc.? We should be specific about these metrics and their correlation to the metrics on our corporate dashboard. ? What Will Trigger an RCA Investigation? Normally companies will establish quantifiable thresholds to be surpassed before an RCA will be conducted. Examples may be an OSHA recordable injury, a failure event in which production losses exceed $250,000, an equipment failure in excess of $50,000 or a regulatory violation. This is the norm. However, we should realize this is using our RCA skills totally on a reactive basis. High Reliability Organizations (HRO) strive for proaction and they also use RCA proactively. Why can?t we use RCA to analyze why unacceptable risks from an FMEA are so high? It is perfectly applicable yet rarely implemented in this fashion.

Feb 27, 2013

By J. P. Ducarme

Numerous fatal/nonfatal accidents involving underground workers struck by powered machinery occur yearly, with continuous miners and roof bolters involved in the majority of these accidents. In an attempt to reduce these accidents, researchers at the the National Institute for Occupational Safety and Health (NIOSH) Pittsburgh Research Laboratory conducted studies of operator interactions with the motions of continuous mining machines and roof bolter boom arms. These operators generally perform their tasks in close proximity to the equipment in confined workspaces, often employing awkward postures. Since experiments with human subjects using the actual equipment were not feasible due to safety concerns, researchers opted to conduct controlled experiments in laboratory settings. Utilizing motion capture technologies and computer simulations, the studies collected data on equipment and operator movement in a range of seam heights and working postures. This article details the results of these studies to examine operating speeds based on usage and seam height.

Jan 3, 2010

By R. C. Warner, L. Mills, S. D. Botts, M. Marticorena

The Antamina Mine is located in the mountainous region of the Ancash Department of Peru at an elevation of approximately 4200m.The 120 km main access road crosses the headwaters of numerous high-value trout streams and is adjacent to pristine lakes, some of very high ecological and scenic value. In addition, the mine discharges mine water and tailings supernatant to the Antamina and Ayash watersheds. These streams provide the primary water supply for irrigation by local residents and provide excellent fishery habitat. The rock walls and earthen diversions constructed by historic and current indigenous residents of Peru are world-renowned and local residents continue this tradition, passed down from the Inca Civilization, for both agricultural purposes and water distribution. The key elements of sustainable development – economic, environmental and social development have been incorporated into Antamina’s sustainable development program through integration of indigenous knowledge and capabilities into enhanced storm water, erosion reduction and sediment control systems. Examples of incorporating indigenous technologies and knowledge into cost-effective and environmentally sound environmental controls are:(1) placement of rock walls on steep terrain to reduce slope length and erosion, (2) installation of rock walls (porous rock check dams) within elongated sediment ponds to increase detention time, (3) construction of rock-lined ditches to convey clean water (4)use of rock walls, with or without geotextile, to function as a seep berm, and (5) appropriate selection and usage of native Andean species for protection of canals and sediment ponds, and steep slopes.

Jan 1, 2004

By Paul H. Johnson

Resource Engineering and Development, Inc. is desigining and building a portable 150 to 225 tpd, flotation-cyanide leach plant with unitized, skid-mounted components. This plant design, with its portability, low capital investment, and high recovery of silver and gold from many partially oxidized ores, is well suited to treat many small, highgrade deposits, old waste dumps, and old mill tailing piles. A description is given of flotation and/or cyanide leach tests run on 18 partially oxidized, newly mined ores; waste dump materials; placer slimes; and old mill tailings.

Jan 1, 1981

Train services through the Channel Tunnel linking Britain and France where scheduled to be fully restored in February 2009 following several months of repairs after a major fire in the tunnel on Sept. 11, 2008. A lorry caught fire on a shuttle train carrying heavy goods vehicles bound for France through the 50-km- (31-mile-) long northern tunnel. The fire, that spread to other vehicles, raged for about 16 hours. The extreme temperatures of up to 1,000º C (1,832° F) caused extensive damage to about 600 m (2,000 ft) of the 7.6-m- (25-ft-) diameter tunnel?s concrete lining, approximately 11 km (7 miles) in from the French entrance. The Channel Tunnel operator, Eurotunnel, awarded the repair con-tract, estimated to be between ?50 to 60 million, to a consortium of Freyssinet, Eurovia Travaux Ferroviaires (ETF) and Vinci Energies. Freyssinet was appointed to look after the civil engineering works, while ETF would be responsible for track and overhead wire restoration and Vinci Energies responsible for other equipment. The technique of hydrodemolition, which uses high-pressure water jets to remove concrete from various structures, was specified as the method to remove the fire damaged concrete. Freyssinet subcontracted the concrete removal to the specialist hydrodemolition and industrial cleaning contractor Philip Lasserat.

Jan 1, 2009

Several of the larger copper projects recently built have included a molybdenum byproduct circuit as part of the overall project due to the favorable molybdenum market conditions and overall economic contribution to the project. This paper provides a summary of moly plant flotation practices across a number of both recent projects and historical ones. Modern Molybdenum flotation flowsheets predominantly incorporate self-aspirated cells and forced air cells with nitrogen addition. The paper provides insight into the process considerations, capital and operating costs associated with both of the cell types. It also reviews metallurgical aspects and important safety aspects. Other aspects including instrumentation and degree of automation are also discussed along with overall plant design.

Feb 27, 2013

By J. A. M. Cano

Since the beginning of operations at the pellet plant at Ponta Ubu ES, Samarco Mineração SA has produced pellets for direct reduction and blast furnace processes. Of the total amount of pellets produced from 1977 through 1993, 55% are used in the blast furnace, about 45 Mt (49.6 million st). The principal components of pellet gangue are calcium oxide, magnesium oxide, silica and alumina. They should be added in adequate quantities to guarantee the mechanical resistance of the fired pellets under blast furnace conditions. Over the years, the pellets produced by Samarco had a silica content between 2.5% and 2.8% and varying binary basicity preferably between 0.8 and 0.85. On the other hand, the increasing amount of industrial waste in siderurgical plants caused by the increase of steel production has caused some countries to put into practice methods to reduce the volume of slag produced in the blast furnace. This paper’s goal is to find an alternative for decreasing the amount of slag produced in the blast furnace. It is possible to decrease pellet gangue by decreasing the silica content to about 2%, leaving the metallurgical properties and quality of pellets unaltered. For this work, Samarco pellets were used with SiO2between 2.5% and 2.8%, pellets with high silica and pellets with SiO2 between 2.0% and 2.3% low silica. Both were partially fluxed by the range of varying basicity CaO/SiO2from 0.8 to 0.95 during production.

Jan 1, 1995