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By Farhang Hedjazi

Anglo Asian Mining have recently installed an industrial-scale UF/RO plant to treat process liquors from the integrated heap leach/agitation leach/ resin-in-pulp gold ore treatment facilities at their Gedabek gold-copper mine in Azerbaijan. The UF/RO plant is designed to treat 60 m3/h of leach solution to produce discharge quality water. The RO concentrate, which contains elevated concentrations of copper, silver and cyanide, is sent to the company’s SART plant for the recovery of the metal values as a precipitated sulphide concentrate and the cyanide, which is recycled to leaching. The new water treatment plant improves the sustainability of the operations at Gedabek by enabling replacement of fresh water input with RO permeate and safe discharge of permeate to the environment, during periods of excess water balance. The paper includes pilot plant data and early results from the full-scale plant.

By Will Roberts, M. E. Williamson

After verification of methodology and testing of prototype systems during 2005/06, Nautilus Minerals expanded their Papua New Guinea (PNG) operations to a full commercial exploration program in 2007. Included was the deployment of sensors and survey systems to locate, characterize and verify massive sulfide deposits with potential as mine sites within the tenements held by Nautilus in PNG. This presentation discusses some of the gear developed and operated during the 2007 PNG investigation.

By John Owens, Marc Endicott, Hamid Maleki

This study presents a historic overview of the role of mobile roof support (MRS) technologies in improving stability and worker safety and presents the results of recent field evaluations of the MRS load rate monitoring device and other remote deformation-monitoring techniques. Field studies were implemented at two sites in cooperation among researchers from the National Institute for Occupational Safety and Health (NIOSH), Maleki Technologies, Inc., and J. H. Fletcher & Co. The objective of the field programs were to (1) study the interaction between MRS’s and coal mine strata and (2) develop and test suitable monitoring systems for assessing roof and pillar stability. An MRS consists of a roof canopy, four hydraulic cylinders, a caving shield canopy, and associated electromechanical systems mounted on crawler tracks. The machines are controlled by radio from a remote location and operate on self-contained power units. Typically, MRS’s have capacities of 5,340 and 7,120 kN (600 and800 tons). In comparison to posts, an MRS is capable of maintaining the yield load after significant amounts of roof-floor deformation. Because the mining cycle is accelerated, MRS’s help reduce the potential for time-dependent roof falls. MRS performance has been monitored in the laboratory under controlled static loading conditions and in the field under deep, two-seam mining conditions. Laboratory studies have quantified support capacity and system stiffness as a function of machine height. Field investigations have focused on determination of optimum operating conditions and development of warning systems that indicate excessive load on the machine and/or impending roof-pillar stability problems. Analyses of field data show that roof instabilities are influenced by (1) pillar failure, (2) pillar yielding, (3) mine seismicity, (4)geologic structures, and (5) panel layout designs and mining practice.Pillar yielding and failure (unloading) and seismicity can be conveniently monitored by the load rate monitoring device, but for consistent detection of roof falls, additional deformation measurements directly within the cuts are needed.

By Jürgen Kretschmann

According to the model of product life cycles, the global coal mining industry is in the stagnation phase. The coal demand of the main consumer, China, has peaked in 2013 and is slowly declining. The Norwegian sovereign wealth fund, the world’s largest, has excluded coal-related companies for ethical reasons. Important players like the UN or the EU have already begun to describe pathways towards decarbonization. Increasing competition between coal mining companies and the mining regions can be expected worldwide if companies want to keep their positions on the global and national coal markets. Companies will focus on the best deposits. European countries like France, Spain, or Germany are only forerunners of this development—their centuries of coal production have been finished. The concept of sustainable development (SD) is fundamentally based on a model of progress where ecological, economic, and social dimensions should be developed equally and positively. But without the idea of competition, the concept of SD is incomplete. Questions arise, such as how can SD be realized on stagnating or declining markets without guarantees for companies “to live forever”? How can SD be a corporate goal in a phase of decline? How can declining mining regions sustainably progress into a better future? The German hard coal mining industry’s lifecycle has ended in 2018 after 60 years of stagnation and decline. As of 2019, all hard coal consumed in Germany will be imported, especially from Colombia, Russia, and South Africa. What has been done in Germany to handle the coal decline in a sustainable way and the lessons learned from this process is described in this paper. It may be useful for mining regions who will face a similar future sooner or later.

With respect to liability damages, claims and costs thereof relating to or ansmg out of contamination, special or non-special wastes, hazardous wastes or pollution in connection with the performance of this subcontract: It is understood that the subcontractor's work and responsibility wholly exclude any requirement to handle such contaminants or to otherwise be responsible for such contaminants, and Subcontractor shall not be nor be considered to be a generator of such contaminants. Contractor shall indemnify, defend and save harmless Subcontractor and its sureties, from and against all liability, damages, claims and costs relating to or arising out of contamination, special or non-special wastes, hazardous wastes

By S. J. Schatzel, W. P. Diamond, F. Garcia

Methane explosions have historically been one of the major causes of fatalities and injuries in underground coal mining operations. Advanced numerical models and predictive modeling approaches have the potential to offer optimized methane control solutions for general mine planning purposes and to address specific methane-related operational problems. This paper describes the development of reservoir models for the longwall mining environment and their application for investigating the influence of various completion design parameters on the methane drainage effectiveness of gob gas ventholes. The influence of increasing longwall panel width on the effectiveness of current gob gas venthole completion and placement strategies in the Pittsburgh Coalbed were evaluated and optimized designs developed to capture the expected increase in methane emissions on the larger panel.

By David C. Oyler, Winton J. Gale, Jinsheng Chen, Christopher Mark

A collaborative project between RAG Emerald Mine, NIOSH, and SCT Operations was conducted to investigate ground behaviour, reinforcement performance, and stress redistribution in a coal mine entry subjected to a severe horizontal stress concentration. Field measurements indicated that the stresses applied to the study site nearly doubled during longwall mining, resulting in roof deformations extending to a height of 4.8 m (16 ft) above the entry. This paper focuses on the computer simulation that was undertaken to provide more insight into the roof behaviour and rock bolt interaction during mining. The model’s input rock properties were derived from extensive laboratory testing, and the model itself simulated a broad range of failure mechanisms. The effects of different bolt patterns on roadway behaviour were evaluated. Comparison between the model results and the field measurements indicated that that the model effectively simulated the critical elements of the actual roadway’s behaviour. With the confidence gained, the model was used as a baseline for additional simulations that evaluated the expected performance of alternative roof support systems. The study will also provide a benchmark data set for future applications of numerical modelling to U.S. coal underground mining.

By D. Majuste

This paper describes an experimental approach to evaluate the effect of organic impurities or even additives on metal electrowinning and product quality. In addition to electrowinning tests and electrochemical measurements, the approach includes organic analysis by Fourier Transform Infrared spectroscopy and gas chromatography; video monitoring of the reaction interface; and product characterization by using scanning electron microscopy, crystallographic texture and bending tests. The mechanical behavior of metal cathodes was assessed with a customized bending device that is able to bend the cathodes up to angles similar to that of the stripping machine. In this work, the effect of a potential organic impurity, lubricating oil, on the production of electrolytic zinc is taken as a case study. The findings of the investigation allowed a better understanding on the role of this organic on energy consumption and product quality and a qualitative prediction for the behavior of Zn cathodes during the stripping operation. Simple control and optimization procedures resulted in significant energy savings.

By William H. Schiffbauer, Ph. D. Mowrey

Proximity warning devices can improve workplace safety by alerting workers when they are in a hazardous area near moving equipment. Industrial work sites often present extreme challenges to safety-based proximity warning devices. Many commercially available types of proximity warning sensors and systems can be rendered useless when covered with mud, ice, snow, ore, rock, and other material. The list includes radar, ultrasonic, capacitive, and visual types of sensors and systems. Addressing these shortcomings, NIOSH personnel have developed a patented active proximity warning system called HASARD (Hazardous Area Signaling and Ranging Device) which employs lowfrequency, low-power magnetic fields which are quite impervious to severe environmental conditions. A shapeable wire loop antenna which provides the marker of dangerous work areas, has been mounted on a continuous mining machine and was mounted inside 1.3-cm thick angle iron. This loop antenna was exposed to more than six months of active underground coal production, which included being covered by and scraped over with tons of rock, sprayed by a continuous stream of water, and immersed in thick mud. After six months the loop antenna showed signs of wear, but was still capable of performing its intended function. The HASARD system is now being applied to other industrial applications and is showing much promise, especially in harsh environments. This paper details the system, describes the tests that have been done, and mentions other areas where it can benefit the safety of industrial workers.

By Peter L. Swanson

NIOSH has developed an automated PC-based seismic monitoring system for use in mine ground control studies. The distribution and coordination of data acquisition and processing functions across a local area network (LAN) is a central feature of the system. Design requirements include (1) the use of lowcost, off-the-shelf, data acquisition and computer hardware, (2) the capability of automatically merging waveform data sets from different types of monitoring systems, (3) delivery of raw and processed data underground and on the surface, as well as to remote sites, and (4) automated data collection and processing over long periods of time without the need for human intervention. Current mine-wide installations utilize multiple, autonomous seismic networks located both underground and on the surface and provide 20 to 40 stations within a radius of several kilometers. Event locations, magnitude estimates, and other processed data are distributed for display and analysis on network nodes both underground and in the offices of mine engineers and managers. This paper describes the system's hardware and software components, examples of installations in hard-rock and coal mines, and a few observations from western U.S. longwall coal mines.

By Takashi Ohya, George V. Keller, Richard G. Geyer

One aspect of a program to improve the chances of survival following coal mine disasters is the development of a communications system which will allow surviving miners to make their circumstances known to rescue teams. At present, it appears that an electromagnetic system may be most practical. The development and design of an effective electromagnetic communications link for signalling between mine workings and the surface requires knowledge of pertinent physical properties of the rocks overlying the mine workings and the characteristics of the ambient noise against which a communications signal must be recognized. Knowledge of the overburden electrical transmission properties is useful not only for determining a practical operating transmitter frequency at a given mine, but also for ensuring the best possible electromagnetic coupling for routine or emergency communication purposes. Field studies of the electrical transmission properties of the overburden of coal mines in Colorado, Illinois, and Pennsylvania generally show that a rela- tively uniform and unimodal electrical conductivity distribution exists provided that the region has not been subject to considerable structural or metamorphic deformation such as that observed in the Gary District of West Virginia. Measurements of ambient surface electromagnetic noise levels at several mines in Colorado, Illinois, and West Virginia were taken and analyzed and are presented in the form of amplitude histogram plots both as a function of frequency and time of day. These amplitude histograms may be used in conjunction with overburden resistivity data in implementing an uplink communications beacon system which will yield a specified signal-to-noise ratio at the surface. Numerous C.W. field transmission tests were made in various coal mining environments with use made of either a buried vertical-axis transmitting loop or a short insulated grounded current line. These transmission tests were made from 20 Hz to 20,000 Hz in frequency and at several geographic surface receiving sites. The results of these field measurements show, in general, good agreement with theoretically calculated results. Since the produced surface magnetic field from a buried vertical-axis loop source or the produced surface horizontal electric field from a buried horizontal current line show better agreement with theoretical results, they could be used for beacon location system. One criterion would be in detecting the equatorial and polar null lines of the horizontal electric field component which is normal to the direction of emplacement of a buried transmitting line current source. A second criterion would be in the surface mapping of the maximum in the vertical magnetic field directly over a vertical-axis loop transmitter and the associated null in the vertical magnetic field at a horizontal offset distance which is about 1.4 times the depth of burial of the transmitter. Finally, a third criterion would lie in the surface mapping of the null in the horizontal magnetic field directly over the vertical-axis beacon and the associated maximum in the horizontal magnetic field at an offset distance from the transmitter axis of half the depth of burial of the loop transmitter. In mapping the vertical magnetic field over a buried vertical-axis loop transmitter, the size effect of the transmitter loop must be taken into account when the separation distances between the transmitter and receiving sensor are less than ten times the effective radius of the source loop; increasing the size of the transmitting source relative to the source-receiver separation distance shifts the null in the vertical magnetic field to greater offsets. In mapping either the vertical or horizontal magnetic field over a buried vertical-axis loop transmitter, care should be exercised in ascertaining that measured nulls and maxima are along radials through the axis of the buried source loop. For the main part, coupling experiments show that ambient electromagnetic noise in coal mining districts is less of a problem above 1000 Hertz. But secondary and perhaps undesirable maxima and null phenomena (as well as penetration problems) would occur in many coal mine provinces in the behavior of the surface horizontal magnetic field (over a buried vertical-axis loop transmitter) if transmission frequencies as high as 10 kHertz were used.

By James C. Cawley

A summary is presented of existing leaky feeder communications systems currently in operation in North America. Background information pertaining to previous use of leaky feeder technology is discussed along with the survey methodology. A review of some pertinent facts concerning propagation in tunnels and specific reference to mine tunnel propagation is presented. A summary of the characteristics of each mine visited is presented in tabular form, and methods of procurement and maintenance are discussed. The role of user training in efficient system use is presented. Seven sites representing eight mines are included in the survey. Economic and technical topics are considered.

By C. Laughton

The Deep Underground Science and Engineering Laboratory (DUSEL) is to be constructed at the defunct Homestake Mine, in South Dakota. As a cornerstone of DUSEL?s research program, it is intended to conduct experiments into the fundamental nature of neutrino and proton particles. The experimental apparatus required to con-duct these experiments will be housed in large rock cavern(s) sited at depths of over a kilometer. As conceived, these cavern(s) are planned to have mined volumes of up to half a million cubic meters, and spans of approximately 50 meters. The paper will describe key end-user requirements, and outline the in situ rock conditions and mine site constraints that are likely to play determinant roles in identifying candidate sites and developing cost-effective design options(s).

By Emad Farouz

This paper presents a case history of a successful construction-phase pile load test program that optimized the pile design in challenging ground conditions at the Great Neck Wastewater Treatment Plant in the Town of North Hempstead in Nassau County, New York. The improvements and expansion of the wastewater treatment plant included the construction of several new structures to comply with new stringent nitrogen discharge requirements and new design flow. The challenging ground conditions included up to 20-ft thick organic deposits with weight of hammer blow counts and up to 14 percent organic content and tidal ground water that was near the ground surface. The foundation design evaluated various deep foundation alternatives and selected driven closed-ended pipe piles then filled with concrete as the most suitable foundation. The selection process included considerations of cost, risk, vibrations, noise, and schedule. The contract documents utilized an innovative approach of performing an optimization load test program that was implemented during construction to optimize pile lengths and reduce potential vibration and construction schedule. This paper discusses the details of the successful load test program including static testing, dynamic testing, and the innovative contracting approach utilized to implement the construction phase load test program. It also discusses the successful development and implementation of driving criteria for production piles and construction challenges. The successful load test program resulted in savings of several hundred thousand dollars, optimized schedule, and lower environmental impacts.

By B. M. Eiter

The impact of fatigue is seen not only in its effect on the job performance of haul truck operators but also on the health of the operator and the productivity at the mine site. Its impact can even extend outside of the mine site to the health and well-being of the surrounding community (Fourie et al., 2010). In this paper, a case study of a small, surface mining organization is presented. The goal is to highlight the fatigue risk management system implemented at the studied mine site. Mine safety personnel who were interviewed discuss the changes made to the infrastructure of the mine, to administrative areas such as the number of shifts and the use of vacation time, as well as the implementation of new technology into haulage vehicles. This paper reviews how these changes are supported in the research literature.

By Brain E. Ladd

A load test program was performed on two auger cast piles constructed in the Inner Coastal Plain geology of North Carolina. Both test piles were installed through Coastal Plain deposits and into underlying Piedmont residual soils; one test pile was embedded into partially weathered rock (PWR). The recommended 100-ton design load was confirmed by a test program that included instrumenting the piles with strain gages. The two piles performed differently during the load tests due to the effect of embedment into PWR. Loading Test Pile No. 1, which was not embedded into PWR, to failure at about 230% of the design compressive load allowed for evaluation of the mobilization of the ultimate shaft and end bearing resistances. Mobilization pile resistance was evaluated by comparing shaft and end bearing resistances to top of pile deflection (?) normalized by the pile diameter (D). For Test Pile No. 1, the ultimate average shaft resistance was achieved at ?/D of about 7.5% and ultimate end bearing resistance at ?/D of about 9.5%. Test Pile No. 2, embedded into PWR, achieved a ?/D of only about 4% at 200% of the design load and was not loaded to failure. Shaft resistance was mobilized at a different rate within each individual geologic layer, i.e. ultimate shaft resistance did not occur simultaneously for all geologic layers. As the available total shaft resistance was exceeded and end bearing mobilized, the unit shaft resistances reduced from the peak values. A modified Davisson offset using ?/D of about 6.5% appears applicable for evaluating the ultimate capacity of auger cast piles in the Inner Coastal Plain.

By Matthias Rheinlander

The paper will describe Virtual Design and Construction (VDC) as a tool which will enable us to build a project ?virtually? on a computer before constructing and operating it in the real world. VDC computer models are built, using information from various sources including survey, 3D laser scanning, CAD and GIS to represent the project and its components in a coordinated and consolidated infrastructure model. This model is reviewed and evaluated by, and shared among project teams including owners, con-tractors, designers, engineers, construction managers, stakeholders and operators. It allows teams to fix costly design and construction issues before construction on site. Benefits and lessons learned from global projects will be discussed

By John J. Sammarco

The functional safety of programmable electronic (PE) mining systems is an international issue and concern. From 1995 to 2001, 11 PE-related mining incidents in the U.S. were reported by the Mine Safety and Health Administration (MSHA); 71 PE-related mining incidents were reported in Australia. MSHA does not have regulations for formal evaluations of the functional safety of PE mining systems. Hence, the National Institute for Occupational Safety and Health (NIOSH), in partnership with MSHA and the industry, generated the NIOSH safety framework for functional safety of PE mining systems. An overview of the NIOSH framework is given; the key framework elements, the safety life cycle and safety integrity levels are detailed. The safety framework approach has impacted the national and Australian mining industries by enabling the industries to advance from an ad-hoc approach to a formalized and systematic functional safety process. In retrospect, valuable lessons were learned for addressing functional safety and for changing industry perspectives and practices. These lessons continue to benefit mining and are applicable to other industries as well.

By William Adamson

Precise and data driven methods of predicting and modelling blast induced vibration intensity are created and applied under field conditions on a routine basis today. These models are fed with controlled field measurements of vibration pulses generated by controlled charges under known geometric conditions. With such models blasting and geomechanical engineers can estimate vibration intensity at established critical points in mine bench geometry (surface mining) as well as within semi-permanent crown and rib pillars (in underground mining).Damage to bench walls and destabilization of large-scale geomechanical structures can be partially attributed to high intensity blast induced stresses on the rock mass and structures that define important features such as safety catch berms and haul roads. In the underground environment, weakening of critical pillars in block caving or Long Hole Open Stoping(LHOS) operations may lead to ore sterilisation. Blast vibration intensity can be linked with physical alteration in critical rock mass volumes within themine. Often the potential for vibration damage is estimated by the calculation of a critical value of vibration intensity, derived from a consideration of laboratory measured rock matrix properties. Efforts to confirm the accuracy of these estimates of critical vibration level include post blast excavation photography as well as the visual examination of rock mass, pre-and post-blast, using video camera observation of the walls of purpose drilled observation holes. These methods clearly indicate a change in fracture state due to the blast induced vibration, however further modelling of geomechanical stability will benefit if seismic measurement data can be interpreted in terms of geomechanically relevant strength parameters. This paper describes some of the results of previously unpublished research studies conducted in underground operations in Chile and Australia, where cross-hole seismic measurement profiles were interpreted in terms of dynamic modulus. This work dates from a period between 1987 and 1990 and the Author suggests that 30 years on, applying modern day technology, instrumentation and modelling methods, more meaningful, practical and applicable results may be obtained.

By J. P. Proulx, Richard O’Meara, Ruilin Yang

A blast optimization project was carried out at an Open Pit Metal Mine using the Multiple Blasthole Fragmentation (MBF) Model and the Multiple Seed Waveform (MSW) blast vibration model. The aim of the project was to optimize rock fragmentation of the ore blasts to significantly increase metal recoveries while keeping the blast vibration levels at the highwall under control. The project also examined the blasts in the waste rock using the Fragmentation model to expand the blast pattern and select economical explosives for drill and blast cost savings while minimizing any adverse effect on the dig rates. Two sets of near field signature blasthole tests were conducted in both hard ore and relatively soft waste rock. The information from the near-field signature blasthole vibration was used as input to both the MBF and MSW models, as site specific geological information interacting with blasting. The implementation of the full blast design is also input to the MBF and MSW models. A production blast for each rock type was monitored for blast vibration and rock fragmentation. The full blast information and the blast results are used to calibrate and validate the models. The Fragmentation and Vibration model were established for the two rock types at the mine. At each site the Fragmentation modeling was conducted in parallel to the Vibration modeling to ensure blast vibrations were under control while the rock fragmentation was improved. The Fragmentation MBF and MSW are each an integral part of the blast optimization tool. Various scenarios using different explosives, hole delays and blast patterns were modeled for rock fragmentation and blast vibration. The recommendations from the modeling project were to be field trialed at the mine. The implementation of the recommendations was expected to help the mine significantly in terms of the mining economics, and high wall stability and safety.