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By Jianbo Hu, Gang Han, Tao Zheng, Junfeng Jiang, Rui Su, Qihua Zhao

The rock quality designation (RQD) is a commonly used index for the classification and evaluation of rock mass quality and is widely adopted in mining and geological engineering. The traditional method of obtaining RQD still requires manual measurement of core length and calculation of RQD, which is inefficient. To address this problem, we propose a framework for drilling core image segmentation and RQD estimation from digital images of cores in core boxes based on the deep learning algorithm. The proposed framework is generated by combining the Mask Region-Based Convolutional Neural Networks (Mask R-CNN) instance segmentation algorithm, the U-Shaped Convolutional Neural Networks (U-Net) semantic segmentation algorithm, and the image processing functions of the Open Source Computer Vision Library (OpenCV). To demonstrate the accuracy of the proposed method, seven boreholes in the Xiushuihe vanadium-titanium magnetite mine, located in the Sichuan Province, China, were used as the case study. According to the comparison of the manual measurements and calculations of the cores taken from seven boreholes used to conduct this study, the framework can record the length of the drill cores and calculate RQD within an average error rate of 3.42%, while it saves about 85% of the working time. The results illustrate that the proposed framework enhances the efficiency of RQD calculation while satisfying the engineering requirements.

Jul 31, 2023

By Shenghui Chu, Zhibiao Guo, Dongshan Yang, Yuanxin Zhao, Xiaohui Kuai, Jingwei Gao

The technology of automatically formed roadway without pillars (AFRP) via roof cutting and pressure releasing (RCPR) is a reformatory method for gob-side entry retaining, which automatically creates a roadway by utilizing the fragmenting and expanding properties of rock strata and the mining pressure, to realize a novel technique for coal mining without coal pillars. The Anju Coal Mine is the first kilometer-deep mine where this technology is applied. To conduct a geomechanical model experiment, this research uses the 5307 working face in this mine as its backdrop. The experimental results show that this technology can efficiently decrease the pressure of the AFRP surrounding rock. The roof maximum stress of the AFRP is 21% lower than that of the belt roadway, while the side abutment pressure of the former is 13.4% lower than that of the latter. The comparison of model experiment data and field monitoring data shows that the roof and floor approaching deformations on the roof-cutting side and solid coal side of AFRP differ by 8.8% and 9.6%, respectively. The model experiment results and field monitoring data show good agreement, and the deformation of the AFRP surrounding rock can be successfully managed by this technique. The study’s findings can serve as a guide for using this technology in kilometer-deep coal mines.

Jul 31, 2023

By Gregory M. Rumbaugh, Todd R. Kostecki, Christopher Mark

From 2015 to 2021, five massive pillar collapses occurred at four underground stone mines in the eastern USA. These events resulted in powerful airblasts that damaged mine infrastructure and mobile equipment, seriously injured miners, and disrupted underground travelways. Each of these pillar collapses propagated through the overlying strata, causing a subsidence sinkhole on the surface. Pillar collapses are particularly hazardous for miners because they can occur with little warning and can affect miners that are far from the pillar collapse area. The following case studies show that certain factors may increase the likelihood of a pillar collapse. For instance, each of the 5 events involved at least 12 benched pillars with width-to-height ratios (w/h) of 0.8 or less. This study elaborates on these factors and proposes a framework to assist mine operators where they identify similar hazards.

Jul 24, 2023

By Erik Sundström, Magnus Nygren

Having seen significant improvements to accident rates in the last 40 years, companies in the Swedish mining industry now show a greater focus on the development of safety cultures throughout their organisations and workplaces. However, there is a lack of research examining the different safety initiatives and strategies practiced in the industry today. This study explores the potential influence and consequences such initiatives may have on the development of safety cultures in the Swedish mining industry. Twelve interviews with experts on safety initiatives from four different Swedish mining organisations were conducted and analysed in a process based on qualitative thematic analysis to identify notable connections to safety culture development. The results of these interviews highlight proclivities in the implementation and use of safety initiatives such as subjects of focus, methods and desired effects. This enables the interpretation of the conceptualisation and methods for the development of safety culture in these organisations based on their approaches to safety development. We believe the results of this study can serve as support for discussions on safety culture development in the Swedish mining industry, and be of interest for international mining industries, in addition to approaches to research in this field. However, we also believe it is important to emphasise the opportunities to approach safety culture in mining from different perspectives than those common today.

Jul 19, 2023

By Maral Malekian, Pat Bellett, Eranda Tennakoon, Fernanda Carrea, Moe Momayez

Slope instabilities in open-pit mines pose a safety risk to workers and a financial burden on production. The direct impact of slope stability on safety and production makes slope failure predictions one of the important challenges in the mining industry. Predicting the precise time of slope failure has been the subject of much research in conjunction with the development of innovative monitoring technology designed to prevent sudden failures. This paper investigates the use of AutoRegressive Integrated Moving Average (ARIMA) model to predict the time of slope failure. Input data such as inverse velocity (IV) and dimensionless inverse velocity (DIV) from 20 slope failures were used to train the model predict the failure time. For comparison purposes, the time of slope failure using the traditional inverse velocity method is also provided. We show that ARIMA provides 90% more accurate predictions than the TIV approach.

Jul 12, 2023

By Haitao Wang, Shen Wang, Dongyin Li, Yongjia Xu, Jinzhao Liu, Xiangjun Chen

The safe and efficient driving of the roadway along the gob is becoming an increasing challenge due to the influence of the integrity and bearing capacity of the side coal and rock mass in the gob under the roof cutting mining mode. The mechanism of protection of the gob-side roadway is shown by modeling the influence of roof cutting and the application of a destress technique on the lateral coal and rock mass zones. The distribution characteristics of stress, displacement, and fracture in the overburden are analyzed by numerical simulation method under the three working conditions. The results indicate (1) construction of row holes and blasting can form artificial structure’s fracture plane above the roadway, which can effectively cut the connection of overburden. The artificial structure’s fracture plane decreases the peak value of the lateral coal body’s support pressure. The peak point and the critical location of the stress reduction area are both transferred to the deep part at the same time, providing adequate space for the gob-side roadway. (2) The stress arch foot in the lateral rock mass rises to the rock layer at the bottom of the roof cutting plane after top cutting, as does the high-pressure area of deviator stress. The fracture plane prevents lateral coal and rock mass instability and limits the negative effects of roof deformation above the gob-side roadway. (3) The triangle slip fracture zone moves to over the roof cutting drilling zone due to the fracture plane, showing a high position compared to its original zone.

Jul 11, 2023

By Amy McBrayer, Andrea Brickey

Area mining is a surface mining method that allows for efficient mining and contemporaneous reclamation of tabular or bedded deposits, e.g., coal. Mine planning methods for area mines differ from those of open pit metal mines. Area mines in the Powder River Basin (PRB) use various processes for mine planning at both the strategic and tactical stages. With the ever changing commodity markets, it is becoming increasingly important for mine operators to be able to react quickly to the changing business environment. Tools that allow for the development and rapid comparison of production schedule scenarios are key to ensuring agile mine operations. A survey of mine engineers responsible for mine design and production scheduling at coal operations provides clarity on the current mine design and production scheduling processes in the PRB, as well as a discussion on potential solutions to upcoming challenges. In this article, we describe various mine planning processes used by the coal producers in the Powder River Basin. The survey identifies a clear gap in the ability to create comprehensive schedules associated with limited tools and lack of engineering labor needed to frequently conduct the mine design and scheduling process.

Jul 8, 2023

By J. Guerrero, O. Pavez, N. Toro, A. Nazer

In the 19th century, mining in northern Chile was of great economic importance. Today, the ruinsof the copper smelters and abundant fragments of refractory bricks from their furnaces remain. Therefractory materials have not been previously studied. the origin, physical and chemical properties, and compressive strength of 10 different samples of historical refractory bricks collected on-site were investigated. The characterization results showed that the bricks are silico-aluminous, unlike the magnesium-chromium bricks used by current foundries. It was determined that 90% of them were produced in the UK and 10% were manufactured in Chile. The phases present are mullite, quartz, cristobalite, and tridymite, and the chemical composition corresponds mainly to SiO2. The compressive strength of the historical bricks is similart to those currently used,. These results may contribute to the knowledge of the 19th century mining and metallurgical historical heritage of Chile and the UK.

Jul 5, 2023

By V. Quezada, Á. Astudillo, L. Valásquez, M. Garcia

Seawater has become a viable alternative for different uses in copper hydrometallurgy. In this paper we review the main physical and chemical characteristics of seawater and how these influence copper production. Reliable data on the use of continental water are reported, and the current use and consumption of seawater in the Chilean mining industry is analysed, indicating the main areas of use and the main problems encountered. Additionally, the influence of the elements in seawaterthat have the most influence on the extractive metallurgy of copper are considered. The Chilean copper mining industry currently consumes approximately 4.1 m3/s of seawater, which corresponds to 25% of the total water used. The use of seawater for the leaching of copper sulphide minerals, such as chalcopyrite, is beneficial because it provides 20 g/L of chloride, thereby improving copper dissolution kinetics.

Jul 5, 2023

By J. Hadjigeorgiou, Y. Potvin

In a benchmarking paper published in the SAIMM Journal, Potvin and Hadjigeorgiou (2008) reviewed ground control strategies to manage large deformations in underground hard rock mines. Significant differences were identified in the design and acceptable tolerance between civil and mining engineering practice for squeezing ground conditions. Variations were also noted in ground support strategies between Australian and Canadian mines. In this paper we review progress in design methodology and ground support practice since 2008, including the availability of more effective deformation monitoring, new design tools, greater access to yielding ground support elements, and better installation practices. An improved understanding of technical and practical issues associated with squeezing conditions has led to the development of ground support guidelines for a range of squeezing ground conditions in hard rock mines.

Jul 5, 2023

By O. S. Tinkler, K. C. Sole

Approximately 20% of current world copper cathode output is produced using a hydrometallurgical process route, generally referred to as the leach–solvent extraction–electrowinning flowsheet. Since its commercialization in the late 1960s, steady improvements in the performance and efficiency of the solvent-extraction reagents and equipment, combined with significant developments in leaching and electrowinning, have made an ever-widening range of ore types amenable to this technology. Following successful implementation on all major continents, a large proportion of growth in recent years derives from the re-emergence of copper solvent extraction in the Central African Copperbelt. This review provides a brief history of the development and evolution of copper solvent extractants and mixer-settler contactors, and the significance of the Copperbelt region in achieving commercialization and acceptance of the technology. The opportunities and challenges presented by the abundant high-grade oxide ores of the Copperbelt are contrasted with the processing of solutions derived from the low-grade mixed oxide–sulfide ore bodies that are prevalent in other geological regions. The current status of hydrometallurgical copper production in the African Copperbelt, within a global context, and a medium-term outlook for the technology are discussed.

Jul 5, 2023

By Hamid Maleki

This paper reviews a study conducted for Australian Coal Research Limited (ACARP) to assist Anglo-American operations with better understanding of coal burst mechanics and control based on U.S. practical experience, investigations, and inspections in three major U.S. coalfields over the past 45 years. The study examined both nonviolent and burst-prone case studies to identify contributing risk factors and addressed failure mechanisms for major U.S. coalfields in Utah, Colorado, and Kentucky, which have diverse characteristics. To investigate the mechanics of coal burst, a multipronged approach is used. First, field measurements in three mines from East Mountain, Utah, are complemented with finite-difference stress analyses to address the importance of horizontal stress in coal pillar mechanics of violent failure. Second, the computational procedures for estimating seismicity resulting from slip along geological discontinuities are reviewed, as these measurements point to seismicity being the trigger mechanism for violent failure of marginally stable structures. This joint-slip seismicity mechanism is in agreement with the more recentimproved re-examination of mining-induced seismicity (MIS) data from the Crandall Canyon Mine, Utah by University of Utah (UOU). Third, a hybrid statistical-analytical methodology is applied for identifying significant factors affecting coal burst. It utilizes data from 30 case studies including those from Utah, Colorado, Kentucky, and other eastern U.S. mines. The statistical approach reinforces field measurements and points to strata rigidity, joint spacings, and horizontal stress field as significant factors affecting damage resulting from coal bursts. This provides practical capabilities for identifying operations of higher risk using a rigidity-cavability variable. Overall, the study provides valuable insights into the mechanics and risk factors associated with coal bursts in major U.S. coalfields. By utilizing a multipronged approach that incorporates both field measurements and statistical-analytical calculations, the study offers practical capabilities for identifying operations of higher risk and improving coal burst control.

Jul 1, 2023

By Todd Minoski, Matthew McElhinney, Mark Morris, Mark Mazzella, Joseph Bright, Morgan Sears, Craig Compton

To promote the safety and health of U.S. mineworkers, researchers with the National Institute for Occupational Safety and Health (NIOSH) are currently involved in gathering additional field data from the nation’s underground coal mines. The purpose of this field study was to monitor ground movement and changes in pressure during mining where conditions include a thick parting in the coal seam. To accomplish this, three arrays of field instrumentation were installed in the wraparound bleeder of a room-and-pillar panel at the Maple Eagle mine located in southern West Virginia. Borehole pressure cells (BPCs) were used to monitor the change in pressure in pillars located adjacent to the gob. Roof extensometers were installed to measure roof sag at various horizons in the immediate roof, while rib extensometers were installed to measure displacement of the in-seam parting as mining progressed. Additionally, visual observations and manual measurements were taken during subsequent site visits. The repeatability of results, important from a scientific perspective, was accomplished by successfully obtaining field measurements from two nearly identical instrumentation sites. The data collected indicated that the front abutment extent at the edge of the panel was approximately 200 ft, corresponding to a distance of 9– 10 times the square root of the depth. Yielding of the slabbed pillar began when the pillar line was approximately 290 ft outby the instrumentation sites. This was followed by load shedding onto the abutments and the measurement of small amounts of roof sag in the No. 1 entry. Instrumentation data, as presented in this paper, can be used to better understand stress redistribution, pillar performance, and roof/rib displacements. Additionally, this data is suitable for assisting in the calibration of numerical models. Insight gained from applying these models can be used to make better engineering-based judgments for conditions that could potentially be encountered in the future.

Jul 1, 2023

By Peter Zhang, Daniel Su, Bo Hyun Kim

Shale gas wells drilled in longwall chain pillars are influenced by longwall mining. Longwall mining on each side of the chain pillars can create overburden movements and induce deformations in gas well casings. If the deformations result in a casing breach, intrusive shale gas could leak into the longwall mine with serious safety consequences. This study concerns five shale gas wells in the chain pillars between two adjacent longwall panels in the Pittsburgh coal seam under a cover depth of 670 ft and a mining height of 7 ft. The gas wells were constructed with typical casing design, but a casing cementing alternative with uncemented production casings was practiced. Four production casings were uncemented, and one production casing was unintentionally cemented with good quality cement to a 535-ft depth and low-quality cement stringers from a 444- to 535-ft depth. The longwall faces passed by the shale gas wells as each adjacent longwall panel retreated. Production casings were surveyed by a multi-finger caliper after each panel was mined. No deformation was detected in the four uncemented production casings, but small deformations were detected in the partially cemented production casing. The maximum measured deformation in the cemented production casing was 0.05 in. after first panel mining and 0.06 in. after second panel mining. The casing deformations were also predicted by the FLAC3D model set up on site-specific overburden geology. The predicted deformations were in good agreement with the measurements in terms of deformation locations and magnitudes. All five shale gas wells resumed normal production after being temporarily plugged during the period of mine-by. This study provides a successful demonstration of the effectiveness of a casing cementing alternative for decoupling production and intermediate casing, and thus minimizing the influence of longwall mining in the shale gas wells drilled through longwall chain pillars.

Jul 1, 2023

By Christopher Newman, David Newman

The ability to assess, address, and predict mining-induced stress distribution is paramount in maintaining a safe and efficient underground operation as coal mines continue to develop at deeper depths and in more geologically complex reserves. This is especially true for longwall mining operations given their limited flexibility in panel layout and orientation. This paper focuses on ground behaviors and conditions observed at two deep-cover, steeply dipping longwall mining operations in Utah’s Unita coal basin. This region is susceptible to coal pillar bump/bounce events as a result of high depth of cover, high-extraction mining, and the close proximity of a thick massive stiff sandstone stratum to active mineworks. The successful prediction of mining-induced coal bump events for Mine A and Mine B operating in the Unita basin has prompted mine management to develop a rock mechanics testing database for reserve calculations. The database is applicable to mine planning as well as the development of multiple numerical models to proactively identify and address adverse ground conditions using input parameters calibrated to site-specific behaviors and conditions. For both Mine A and Mine B, the most critical question relates to longwall development and recovery for “extreme” deep-cover longwall panels at overburden depths greater than 600 m. This paper highlights the impact of high-stress concentrations associated with deep-cover longwall mining as well as the methods applied to mitigate stress impacts on miner safety and longwall production.

Jul 1, 2023

By Vincent A. Scovazzo

During the winter months of late 1985 and early 1986, residents along Dry Fork near Grundy, Virginia (United States) experienced seismic events that they attributed to longwall mining at Island Creek Corporation’s (Island Creek) Virginia Pocahontas Mine No. 3 (VP-3 mine). Island Creek contacted STS D’Appolonia Ltd. (STSDL) on March 7, 1986, to investigate these events. An STSDL representative, Vincent Scovazzo, interviewed residents of Dry Fork on March 10, 1986. It was noted that only people within a residential structure felt the events they described as house shaking, vibrating walls, and ceramics falling from shelves. STSDL representative installed a blast monitor at a residence. Within 2 days, various events were recorded. Some could be attributed to truck and heavy equipment movement. Eight events had no obvious cause but appeared on resident’s written logs as earthquakes caused by mining. STSDL contacted Utah Geophysical, Inc. who had developed a technique to determine the mode of rock failure using the seismic record. Utah Geophysical was engaged to install and monitor a microseismic network, locate the epicenter of the events, and work with STSDL in determining modes of failure. The network was comprised of six geophones located at five stations. Data was recorded for 24 days from May 20 through June 13, 1986. The data was filtered to eliminate events determined to have an origin other than the longwall panels’ overburden and under-burden. The larger events from this filtered data set were selected and analyzed to determine their hypocenter locations, time of occurrence, magnitudes, and failure mode. Processed data was interpreted, tabulated, and plotted by STSDL to provide information relative to the sources of the seismic vibrations and their possible relationship to the mining operation.

Jul 1, 2023

By Malte J. M. Gurgel, Axel Preusse

The planning, construction, and monitoring of underground storage facilities is a key factor in meeting upcoming challenges as part of the energy transition from fossil fuels to renewables. Therefore, the many years of knowledge and expertise in ground control gained from coal mining are highly valuable for new mining and storage operations. For such applications, our previous work examined cavity registration, combining structure from motion and LiDAR through a case study in a former lead ore mine. Building on this, the results of this recent case study are discussed regarding the possible application in sites for nuclear waste disposal in Germany including a view on the situation in the United States. Photogrammetric methods are particularly suitable as part of long-term monitoring, which relies on both precise survey results and a large variety of detailed visualization. In order to gain a better understanding of the resulting application potential for holistic monitoring, both existing repositories sites in Germany and ones yet to be found are examined. This search and selection process for high-level nuclear waste disposal is studied in detail together with rules resulting from the (German) mining law, regulations, and other guidelines. Hereby, key requirements of photogrammetric products like oriented images, point clouds, and three-dimensional (3- D) models are identified for different case studies. The findings on accuracy and integrity of the generated models are not only of interest for future repository sites or underground pumped storage power plants, but also offers various possibilities for underground mining of coal and other commodities.

Jul 1, 2023

By Arash Nikvar-Hassani, Lianyang Zhang

To address the drawbacks of the conventional portland cement/fly ash (PC/FA)–based cementitious material currently used in practice to construct pumpable roof supports (PRSs), a novel cementitious material has been developed based on geopolymerization technology. The novel cementitious material is comprised of two pumpable grout streams: Stream 1 is a slurry composed of pozzolanic material and high-calcium additive and stream 2 is an alkaline solution comprised of a gelling agent. Biopolymer has been added to the second stream to provide ductility to the geopolymer cementitious material. In the laboratory scale, systematic experiments have been carried out to investigate the viscosity, setting time, and uniaxial compressive strength (UCS) of the new cementitious material and develop the right recipe for field applications. By collaborating with industry and the National Institute for Occupational Safety and Health (NIOSH), full-scale PRSs have been constructed and tested. The results show that (1) the novel cementitious material based PRSs has much higher peak UCS and similar or higher residual strength than the conventional PC/FA-based PRSs; and (2) unlike the PC/FAbased cementitious material, the novel cementitious material shows good long-term durability with nocracking/disintegration when exposed to air.

Jul 1, 2023

By Christopher Mark

Sixty years ago, underground coal mining was the most hazardous job in the United States. Roof falls were a big part of the problem. They killed about 100 miners every year, more than all other causes put together. Fast forward half a century to 2016, which is the first year ever with zero roof fall fatalities. Just three miners were killed by roof falls during the following 6 years. How was this historic goal achieved? This paper starts with a modern analysis of the causes of the roof fall fatalities in 1968. Then it follows the reductions over time by category, using snapshots of the fatalities occurring in subsequent decades. Along the way, it evaluates the influence of the regulatory environment, changing mining methods, and better ground control technology. The paper shows that in 1968, more than half of roof fall fatalities at large mines were attributable to an inadequate safety culture. The immediate effect of the 1969 Coal Mine Health and Safety Act was to reduce the riskiest activities, like needlessly going under unsupported roof. Other hazards, like large roof falls, required technological developments before they were brought under control. Roof control plans, which the U.S. Bureau of Mines had been advocating since the 1920s, played a significant role throughout the process.

Jul 1, 2023

By Alper Kirmaci, Taghi Sherizadeh, Dogukan Guner, Samuel Nowak, Khaled Mohamed, Morgan Sears

Coal ribs present a major safety hazard in underground mines, and there is currently no unified approach for their design in the United States. To tackle this issue, this study investigated the stability of underground coal pillar ribs under development load. Utilizing over a thousand 3DEC models, a framework for calculating coal pillar rib rating (CPRR) was developed. A detailed step-by-step method was outlined for computing the CPRR based on a 3DEC analysis, which was then validated with various 3DEC models, demonstrating a strong correlation between the two models. The results demonstrated that the rib factor of safety (RibFOS) under development load is directly proportional to CPRR, coal mine roof rating (CMRR), and floor strength, and inversely proportional to the overburden depth and rib height. Moreover, a regression equation was formulated to predict the RibFOS based on the aforementioned parameters. Furthermore, empirical relationships were developed between the RibFOS and the applied primary rib support density (PRSD) in U.S. coal mines. To ease the calculations, a stand-alone application, Design of Rib Support (DORS), was developed. This application can be used to assess rib stability and easily calculate CPRR, RibFOS, and PRSD.

Jul 1, 2023