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By George J. Karabin

The Roof Control Division of the Pittsburgh Safety and Health Technology Center, MS HA, is routinely involved in the evaluation of ground conditions in underground coal mines. Assessing the stability of mined areas and the compatibility of mining plans with existing conditions are essential elements in assuring a safe working environment at a given site. Since 1985, the Roof Control Division has successfully used the Boundary Element Method of Numerical Modeling as a tool to aid in the resolution of complex ground control problems. This paper will present an overview of the modeling methodology established and details of techniques currently used to generate coal seam, rock mass, and gob backfill input data. A summary of coal and rock properties used in numerous successful evaluations throughout the country will be included and a set of Deterioration Indices that can aid in the quantification of in-mine ground conditions and verification of model accuracy will be introduced. Finally, a case study will be detailed that typifies the complexity of mining situations analyzed and illustrates various techniques that can be used to evaluate prospective design alternatives.

Jan 1, 1994

By Michael A. Evanto, George J. Karabin

The Mine Safety and Health Administration, Pittsburgh Safety and Health Technology Center, Roof Control Division, is routinely involved in the evaluation of ground conditions in underground coal mines. Assessing the stability of mined areas and the compatibility of mining plans with existing conditions is essential to ensuring a safe working environment for mine workers at a given site. Since 1985, the Roof Control Division has successfully used the boundary-element method of numerical modeling to aid in the resolution of complex ground control problems. This paper presents an overview of the modeling methodology and details of techniques currently used to generate coal seam, rock mass, and gob backfill input data. A summary of coal and rock properties used in numerous successful evaluations throughout the United States is included, and a set of deterioration indices that can aid in the quantification of in-mine ground conditions and verification of model accuracy is introduced. Finally, a case study is detailed that typifies the complexity of mining situations analyzed and illustrates various techniques that can be used to evaluate prospective design alternatives.

Jan 5, 1999

By Peter Moser, G. Reihholf

Holcim, one of the world's leading suppliers of cement, aggregates and concrete, has set up a few years ago a working group “Quarry” in order to optimize the performance of its central European quarry operations in terms of work safety, environmental standards and economic performance. One of the activities of this working group "Quarry" addresses the subject of blast fragmentation in the quarries. A benchmark study of the blast work in all quarries has shown substantial differences for the various operations in terms of drill& blast costs. Especially big differences were found with respect to the drilling patterns as a function of the borehole diameters and with respect to the utilization of the borehole volume for charging the explosives.

Jan 1, 2006

By Hans W. Brodbeck

The main problem in tunneling without the use of explosives lies in the development of tools capable of continuous mechanical destruction of rock, resulting in a fragmentation which lends itself to a smooth, uninterrupted transportation of the broken rock away from the tunnel face. While all moles of U.S. design mainly achieve this by crushing the rock by means of "disk cutters" or "roller bits," a boring system based on the principle of cutting the rock came into being in Europe, whereby the rock is worked in a manner very similar to the milling of metals. For tunneling purposes, this principle was first developed by the late Austrian engineer Wohlmeyer. Between late 1962 and the spring of 1965, the first experimental machine was tested in a German coal mine, working in coal and shale over a distance of some 3000 ft, divided over two runs separated by a period of time to allow for equipment modifications. In 1964, a collaboration was started between Wohlmeyer and the Habegger engineering firm of Thun in Switzerland. The normal Habegger range of equipment consists of aerial ropeways, ski lifts, and certain tool machines, to which in later years have been added monorail passenger-transport systems. One of these was installed as the main mode of transport at the 1967 World Fair in Montreal. After taking over the Wohlmeyer patents, Habegger further developed the original cutting principle, aiming at more robust machines in order to be able to tackle harder rock. A first machine was built and tested at a site near Thun in sandstone averaging 17,000 psi compressive strength and limestone of 25,000 psi. In May 1966 this machine was delivered to Japan for the boring of a pilot tunnel for the Honshu-Hokkaido railway connection under the sea. A second machine, incorporating many improvements based on experience gained with this first mole, was built during 1966 and tested in the same limestone as mentioned previously (25,000 psi), before being installed to bore the head race tunnel of the Julia hydroelectric power scheme near St. Moritz, Switzerland, in the early summer of 1967 (Fig. 1 ) .

Jan 1, 1970

By Abdulazeez Rotimi, Barry Sheppard, Abid Adekunte

Good engineering practice is a function of sound theoretical knowledge, first-hand experience on previous projects of similar scope and scale, good acquaintance with case histories of similar projects completed by others in similar environmental conditions, as well as satisfactory degree of exposure to state-of-the-art methodologies. The four factors itemised above are typically interdependent. They amalgamatively influence the judgement of the Engineer and they ultimately result in the delivery of safe and cost-effective solutions by Professional Engineers. This technical paper presents detailed information on the ground engineering aspects of a large-scale housing development project located on a sloping site that had been presumed to be unstable in West Sussex, England. The ground engineering design package for the scheme comprised of temporary working platform designs & stability assessment for piling rigs and other construction machinery, geostructural designs for approximately 1km total run of permanent bored pile retaining walls to support the split-level construction on the sloping site and geostructural designs for the permanent foundation piles to support the housing units. The paper details how the four factors outlined above were amalgamated by the project’s foundation specialist consultants & piling contractors to deliver safe and practical solutions for the development, with significant savings in materials, cost and project completion time.

Sep 8, 2021

By Franz-Werner Gerressen

As alternative energy industries pick up speed internationally, and as government regulation and restriction limit the use of impact hammers due to environmental limitation from construction induced noise during pile driving operations, unconventional solutions for more complex offshore foundation installations have become a necessity. Manufacturers and equipment suppliers race to develop alternative techniques to accommodate for offshore foundation construction in various soil conditions and at greater water depth. The FLYDRILL, and the Seabed-Drill BSD are two innovative systems for the installation of offshore monopiles with reduced environmental impact

By Leonhard Weixler, Jean Wehbe, Gordian Ulrich, Franz-Werner Gerressen

"As alternative energy industries pick up speed internationally, and as government regulation and restriction limit the use of impact hammers due to environmental limitation from construction induced noise during pile driving operations, unconventional solutions for more complex offshore foundation installations have become a necessity. Manufacturers and equipment suppliers race to develop alternative techniques to accommodate for offshore foundation construction in various soil conditions and at greater water depth. The FLYDRILL, and the Seabed-Drill BSD are two innovative systems for the installation of offshore monopiles with reduced environmental impact.INTRODUCTIONThe FLYDRILL and the Seabed-Drill were born from techniques in the design and construction experiences gained from land based foundation drilling systems over the past 25 years. As the alternative energy industry ventures into uncharted territory of deeper water for offshore wind farms, fast current regions for tidal energy, and increasingly challenging soil conditions and project complexity, the advancement and development of new innovative equipment system and drilling techniques have become a necessity.The systems described herein show the development of the so called “FLY-Drill” system, and the all new “Seabed-Drilling” equipment applied at the first ever made job using a seabed drilling rig.FLY DRILLThe FLY DRILL method is a completely new concept for bored piling. The drilling unit with rotary head, Kelly bar, and drilling tool is suspended by the hoist rope of the base carrier crane. The hydraulic power for the drill unit is provided from the base crane.The drill head is fixed on the casing with a hydraulically operated clamping system during the drilling operation. When emptying the drilling tool, the clamp cylinders are opened and the complete unit is swung sideways."

Jan 1, 2017

By Rajesh A. Vaidya

A large scale piling work is undertaken in India for an important fast track industrial project. Thousands of solid square precast concrete piles are driven to depths of around 50m. Soils encountered are of alluvial origin with very soft clays varying in thickness from 10 to 18m at the top followed by medium dense to dense and occasionally very dense sand, stiff clay and finally dense to very dense sand layer as the founding layer. Recent site grading with around 4 metres thick hydraulically filled river sand necessitated driving the piles to the bottom sand layer to avoid problems on account of negative skin friction and to achieve optimum pile capacity. A process approach suggested by Bell et al (2002) to promote better understanding of the pile behaviour, pile capacity, and parameters assumed at design stage for static capacity and for wave equation analysis is followed with an aim to bring in effective economy in terms of pile length and pile installation speed. Soil investigation work is also undertaken in stages to cut down pile wastage. A judicious combination of PDA and static pile load tests is followed. Pile Driving Analyser (PDA) tests at end of driving and also at various stages of recovery of pile capacity are carried out to understand the pore pressure dissipation phenomenon. The paper attempts to present some of the valuable experiences that would go to establish precast pile as a very effective alternative to driven cast-in-situ piles and bored piles which are very common in this part of the world despite their limitations in terms of economy, speed and certain geotechnical aspects.

Jan 1, 2007

By Mikael Ramström

The IREDES Special Interest Group (SIG) for Drill rigs has been active since its inception at MineExpo 2000, in Las Vegas USA. The SIG for drill rigs is responsible for the development of a IREDES Drill rig profile. This includes the exchange of production planning, performance and quality reporting data between various kinds of drill rigs and the databases used by the operating mine. During year 2001 a first draft of the drill rigs profile was jointly prepared by drill rig suppliers, mining companies and third party suppliers and reviewed during several SIG meetings. In mid 2002 the profile was released for prototyping projects and since then, feed back received from these projects has been used as input to the first official IREDES release. LKAB and Atlas Copco decided in 2002 to start an IREDES prototyping project using the Simba L6C production drill rig as target equipment. The goal was to verify the drill rig profile and identify possible problems prior to the official release. This was done by implementing the IREDES prototype version in the LKAB?s production planning system and Simba rig control system. The Simba rig control system was designed to handle drill plan and logging information coming from the mine planning system. In parallel to this the mine production system was adapted for drill plan export and logging data import on IREDES format. This paper presents the most recent results of this prototyping project. Result from late 2002 show that the basic architecture of the drill rig profile works and that a common language for data exchange, IREDES will be a central issue for future mine automation. As a result from this and other IREDES prototyping projects the official IREDES release will be available in 2003. Soon after that release IREDES compliant products can be expected. This will include drill rigs and mine production planning systems.

May 1, 2003

By L Abrahamsson

The aim with this paper is to discuss experiences from the ongoing research project ‘Attract: A roadmap to attractive, inclusive, and safe mining workplaces’. The project’s aim is to analyse possibilities, effects, and consequences of the green and digital transformation in the Swedish mining industry from workplace, socio-technical and gender equality perspectives. The research project (2022–2025) at Human Work Science at Luleå University of Technology is financed by the strategic innovation program Swedish Mining Innovation (a joint venture by the national research funds Vinnova, Formas and the Swedish Energy Agency). The project includes a multidisciplinary research group of five senior researchers and five PhDstudents and a broad repertoire of methods, eg literature reviews, qualitative interviews with both managers and workers, workplace observations, workshops, surveys, and project seminars where the researchers and the company representatives together analyse the results. One important part of the project is the applied approach where the researchers work together with two mining companies and one subcontractor company. The project has two parallel main subprojects.

Sep 1, 2024

By A. Zangooi, J. A. Finch

"A frother analysis technique based on the formation of a colored solution with UV-VIS absorbance proportional to frother concentration over a certain range has been developed. The calculation of concentration requires the comparison of the sample absorbance at a selected wavelength with a linear calibration (frother concentration vs. absorbance) constructed with values collected from solutions of known concentration (standards) at the same wavelength. It has been found that concentration ranges for preparation of standards can vary widely. An integration of our experiences into a databank can offer some guidance on the selection of standard concentrations. The databank includes results from the analysis of 37 chemical reagents, commercial frothers, and natural oils used in research work or at industrial sites. Grouping frothers by similar chemical structure or origin provides a good basis for selecting the standards to approach the maximum absorbance range for the spectrophotometer in use.INTRODUCTIONA technique to determine frother concentration on samples of industrial milling streams based on formation of a colored solution with UV-VIS absorbance proportional to frother concentration has been developed. The concentration is determined by comparison of its absorbance, at some selected wavelength, with those obtained by processing a series of solutions of known concentration (standards), at the same wavelength. It is desirable to have linear calibration (frother concentration vs. absorbance) over the widest concentration range. The upper concentration can be restricted by the instrument, as there is a maximum detectable absorbance (minimum transmittance), which can be reliably sensed by the UV-VIS detector (in most cases maximum absorbance is 3)."

Jan 1, 2016

By T. A. Venugopalan

The 'Hall-Heroult' Process of reduction of Alumina to Aluminium has remainded basically the same for over 100 years, but the technology has been undergoing drastic changes with respect to selection of materials for Cathode and Anode, and also energy consumption. The latest generation pots have a working life of about 1800-2000 days normally. After the failure of the pots, the Cathode Lining is dug out and disposed of on land. Since the lining contains objectional materials causing pollution, various processes have been tried for re-processing of this waste. However, most of the processes have been unsuccessful from the techno-economic point of view. At Hindalco a new chemical process for converting the fluorine values of the dug out material to Cryolite was developed in 1988 and a" one ton per day Cryolite production plant has been operating since 1989. This process is especially applicable where the integrated Alumina and Smelter Plants exist side by side. The experience in operating this Plant is discussed in detail in the paper.

Jan 1, 1992

By Guan Jichang

An abandened breakwater, located at the rear of No. 2 berth in Dongdu Port area of Xiamen City, was not cleaned thoroughly when the backfilling of sand started. The uncleaned stone layer was about 2 to 3 meters deep, with the average piece of stone weighing about 1 to 3 kN. A large grain storing house, 220X 60m2 in area, was designed and built at the above mentioned complicated site. The foundation of the grain house are made up of the cast-in-situ piles. It is well known that it is difficult for the submarine engineering drill to go down through such large-sized stones. Having com-pared the various plans, a final decision has been made which involves explosions with small amounts of charge plus cone bit in the enlarging of the size of the pores. Such a method has successfully prevented the pores from slumping and made it possible to fulfill the project without any difficulties. This paper also introduces the ways in effectively dealing with each individual stone.

Jan 1, 1991

By Guozhu Ye, Mikael Lindvall

"Swedish iron ore contains about 0.1 %V. The vanadium is reduced to the hot metal in a blast furnace and oxidised to the slag in a converter. The high V-content, up to 5 % V, leads to a very limited external application of the steel slag in Sweden. Since 2004, MISTRA - the Swedish Foundation for Strategic Environmental Research has together with the steel and mining industry in Sweden and Finland initiated and supported a long term project aiming at efficient recovery of vanadium in the slag, and at the same time a useful slag product with low V-content. The proposed concept consists of a reduction step and a phosphorus removal step. This paper will highlight some of the results with focus on the various metallurgical reactors used for slag reduction, including results from recently performed pilot trials using a DC furnace for cotreatment of metallurgical slags and other wastes.IntroductionToday, less than half of the produced LD-slag in Sweden is recycled to the blast furnace as a lime source and the rest is temporarily stored inside the steel plant. The steel slags cannot be used externally due to its content of vanadium and free lime. As the slag storage area is limited, this has become a problem for Swedish steel producers. The disposition of the slag is also a great waste of a valuable vanadium resource. The current potential value of vanadium in the discharged steel slag annually amounts to roughly US$ 100 million. Currently, Swerea MEFOS is conducting an 8-year vanadium recovery project called VILD (Vanadium in LD-slag) aiming at efficient recovery of vanadium and at the same time producing a useful slag product with low V-content. The project is financed by MISTRA - the Swedish Foundation for Strategic Environmental Research and the steel and mining industry in Sweden and Finland. Various reactors and process options have been tested in the past 7 years, from 3 kg laboratory scale, 150 kg induction furnace, 3 MVA pilot DC furnace, 5 MVA pilot AC furnace, 5 tons Kaldo furnace, to full scale direct hot slag reduction in the industrial site (12 tons of slag). This paper will introduce the VILD-concept and review the experiences gained from these trials. The advantages and disadvantages of the different options will be discussed and concluded."

Jan 1, 2012

Mining Equipment Challenges Equipment Availability Unplanned downtime Maintenance Costs Secondary damage and catastrophic failures (T282 $750k) Emergency work is 4x the cost of planned work Inspections Troubleshooting time Incorrect repairs (parts, labor, lost production) Equipment Life Mis-operation of equipment

May 1, 2013

By Karl Gunnar Holter, Frank Clement

"INTRODUCTION Typically waterproofing of conventionally excavated tunnels has been done by installing pre-fabricated sheet membranes between the primary temporary support lining and the secondary permanent inner lining. The membrane acts as a separation or sliding layer between the linings, which is often desirable. The geotextile installed behind the sheet membrane provides the required drainage and protection of the system. The design of the tunnel lining is strongly influenced and limited by the use of waterproofing sheet membranes. Since primary and secondary linings are separated from each other, forming a double-shell lining system. In that case the secondary lining must be designed for all permanent loads, although the sprayed concrete primary lining continues resists ground and water loads for a long time after construction. Significant progress has been made in sprayed concrete technology over the last two decades, with advanced admixtures, as well as the improved application technology using spraying robots. The development of new admixtures like superplasticizers based on poly-carboxylates, alkali free accelerators and silica fume, enables designers to use permanent sprayed concrete linings (SCL) increasingly for long-term service life. When designed and applied correctly, sprayed concrete can be considered as permanent. The use of spray applied membranes has seen increased use over the last decade in some countries, and demonstrated functionality and cost-effectiveness in several situations. This paper describes the use of the sprayed waterproofing membrane MasterSeal 345, an EVA polymer based product, and the practical experiences from several projects. SPRAY APPLIED WATERPROOFING MEMBRANES The sprayed waterproofing membrane is polymer based and has been especially developed for underground structures. The membrane is applied between primary and secondary concrete linings and develops high bond strength on both sides to the concrete (doubled-bonded)."

Jan 1, 2016

Most laboratory sealant studies were carried out in 2.0 inch I.D. Plexiglas tubes of 9.0 inches height containing 4.0 to 4.5 inches reconstructed soil from an 0-8 or 8-16 inch soil horizon at the Lanse site. (When soil was used from the Kato site, the top soil horizon was approximately 0-4 inches. The 4-8 inch horizon was somewhat comparable to the Lanse 8-16 inch horizon.) A 20 mesh Saran or steel screen was placed over the rubber stopper with a bottom drain to a 100 ml measuring cylinder. In some earlier experiments a 1/2 inch bed of 1/4 inch pea-gravel was then added, but in later experiments this was eliminated as it showed no particular utility. Field soil samples collected by a shovel were stored in sealed containers and sieved through a 4 mesh screen just before use. (Moisture content was typically about 25% for A horizon soil and about 20% for B horizon soil.) The sieved soil minus roots was then added in increments of about 1 1/4 inches. Compaction was effected by dropping a weighted ramrod (1-7/8 inches O.D,) five times from a height of two inches. If about twenty tamps were used or if the soil columns were rapped vigorously while water-logged, compaction was high with no detectable percolation. Freezing such samples would then usually cause very slow percolation, e.g. 1-2 ml/day. Using this as a standard procedure, percolation flows were usually stablized after two to three days to rates of about 100 to 200 ml/hour. Percolate was recycled carefully to minimize disturbance of the soil surface. When percolation flows were about 100 to 200 ml/hour, various additives (sealants) were introduced to the moist column in two to three increments to maintain a slight head. Additive concentrations were usually 2-1/2% with some at 5% in earlier experiments. Typical use of 40 ml of 2-1/2% additive corresponds to 4400 lbs/acre. When no more additive was present as supernatent liquid, water washes of about 15 ml were then used several times followed by special additives as needed. More water washes were then used to maintain a head of about 1/2 inch. Percolate was collected in 100 ml cylinders to measure percolation rates in ml/hr. Turbid percolate was evaporated to determine amount of eluted latex. Percolate was sometimes checked for pH by Pan-pH Indicator Paper9,10 reading in 0.5 units. Surface tension measurements were sometimes made by a DuNouy tensiometer10 in experiments using a surfactant for pretreatment.

Jan 1, 1972

By E. Hasanbas

Vibrating screens and crushers are the workhorses of material sizing. Unfortunately their natural frequency is often in the range of typical supporting structures, thereby making installations prone to vibration problems. Much of the available literature regarding the support of vibrating screens is fairly confusing and outdated. This paper presents the results of utilizing accelerometers and finite element software in the analysis and design of supports for vibrating equipment. It contains data from field studies of vibrating screen and crusher installations, design of new and repair of existing supporting structures, and the correlation between field data and finite element time history analyses. Finally, the paper summarizes a method for analyzing and designing structures subjected to vibratory loads and predicting their behavior.

Feb 23, 2014

By Santosh Kumar Ray, DEBASHISH MISHRA, Niroj Kumar Mohalik, SOMU MANDAL, Jai Krishna Pandey, Asfar Mobin Khan

Coal is a low-cost and high-calorific-value fuel. The coal mining industry worldwide has been suffering from severe accidents due to coal dust explosion hazards since its inception. Statistically, it was observed that 12,489 fatalities had occurred in 104 reported mining accidents from coal dust explosions during 1900–2020. There are numerous methods for detection, prevention, and control of coal dust explosions in mines. The underground mining environment is unpredictable and has an array of variables. These undulating factors make it difficult to prevent or control the coal dust explosion hazard. However, coal mining is done aggressively throughout the world, especially in developing countries as coal is a major source of thermal energy used in power plants contributing to about 38% (IEA, (2019), World Energy Outlook, IEA, Paris https:// www. iea. org/ repor ts/ world- energy- outlo ok- 2019.) of world electricity. Worldwide, coal dust explosibility studies are carried out in experimental mines, laboratories, and simulations. The complexity, lack of proper infrastructure, and unavailability of laboratory equipment sometimes make it difficult to study coal dust explosibility. The authors have discussed in detail and proposed that the CFD modelling can be a viable option for studying and evaluating coal dust explosibility.

Jun 29, 2022

By Chenyang Zhang, Zhigang Yin, Wei Sun, Jingxiang Zou, Jianyong He, Yuehua Hu, Zhijie Xu

"In this work, a novel compound 4-Amino-5-mercapto-1,2,4-triazole was first synthesized and its selective adsorption mechanism on the surface of chalcopyrite was comprehensively investigated using UV-vis spectra, zeta potential, Fourier Transform Infrared Spectroscopy(FTIR), X-ray Photoelectron Spectrscpy Measurements(XPS), and Time of Flight Secondary Ion Mass Spectrometry (ToF-SIMS) and first principle calculations. The experimental and computational results consistently demonstrated that AMT would chemisorb onto the chalcopyrite surface by the formation of a five-membered chelate ring. The first principle periodic calculations further indicated that AMT would prefer to adsorb onto Cu rather than Fe due to the more negative adsorption energy of AMT on Cu on the chalcopyrite (001) surface, which was further confirmed by the coordination bonding energies of AMT-Cu and AMT-Fe based on the simplified cluster models at a higher accuracy level (UB3LYP/Def2TZVP). The bench scale results indicated that the selective index improved significantly when using AMT as a potential chalcopyrite depressant in Cu-Mo flotation separation.INTRODUCTIONFroth flotation is one of the most important processes to separate valuable minerals from gangue by taking advantage of differences in the physical chemistry of their surface properties(Laitinen et al., 2014), particularly in their surface hydrophobicity. Hydrophobicity differences between valuable and gangue minerals could be regulated by adding different chemical additives (surfactants)(Kor, Korczyk, Addai-Mensah, Krasowska, & Beattie, 2014), such as collector and depressant. It could be conducted economically to selectively separate and enrich the complicated and/or poor ores, by adopting appropriate surfactants. For example, the beneficiation of molybdenite usually relies on a two-stage process to realize flotation separation of molybdenite from other unwanted sulphide ores(Wie & Fuerstenau, 1974). In the first step, a bulk molybdenite concentrate is produced by utilizing kerosene/ diesel oil and pine oil/alcohols as collector and frother, respectively. Second, sodium hydrosulphide, sodium cyanide, ammonium sulphide, or Nokes reagent are adopted as depressants in the separation stage. However, these depressants are usually toxicant and cannot meet the requirements of environmental protection. A large number of efforts have been taken to develop alternative environmentally-friendly depressants (Ansari & Pawlik, 2007; J. H. Chen, Lan, & Liao, 2013; Li et al., 2015; Yin, Sun, Hu, Zhai, & Guan, 2017; Yin, Sun, Hu, Zhang, Guan, Liu, et al., 2017; Yin et al., 2016). Although some novel and environmental-friendly depressants have been reported to achieve good performance in Cu-Mo flotation separation at a laboratory scale, there are still some challenging problems, including toxicity, high price or poor performance in practice, which severely limit their practical applications in Cu-Mo flotation separation on a commercial scale."

Jan 1, 2018