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By A. Adu-Acheampong

The Mid-Tennessee Zinc (MTZ) mines, comprised of the Gordonsville, Elmwood, and Cumberland sites, last operated 4 years ago and are undergoing rehabilitation to begin production in 2008. The mines utilize a random room-and-pillar mining method that results in complex ventilation networks. Upon decommissioning, the mechanical ventilation units were removed and disposed of and several shafts sealed. In an effort to re-open the mines and operate in compliance with imminent Mine Safety Health and Administration (MSHA) diesel particulate matter (DPM) regulatory limits of 160TC µg/m3, a new ventilation system was required. The new ventilation system was developed primarily based on the diesel equipment required to meet production. Particular emphasis was placed on the DPM, diesel equipment utilization, main fan sizing, and fan locations to enable the mines to meet MSHA?s ventilation requirements in a cost efficient manner.

Jan 1, 2009

By Kotaro Ogura

"Ethylene has been produced in aqueous solution from CO2 by the electrochemical reduction driven by a natural energy. This process is useful for storing a large amount of the natural energy. In the closed system, the conversion efficiency of CO2 is almost 100%, and the maximum selectivity for the formation of ethylene is more than 70%. On the other hand, the current efficiency for the competitive reduction of water is less than 10%. The electrolysis is practicable under such special conditions as three-phase interface consisting of gas, solution and metal, concentrated solution of potassium halide, low pH and copper or copper halide-confined metal electrode. These requirements are thoroughly examined, and the grounds to reply upon are revealed. A series of chemical apparatuses including an electrolytic cell in a large scale are designed for the ethylene production, which allow us continuously to supply raw CO2 and to extract the product.IntroductionIn connection with the depletion of the petroleum reserve, much attention has been paid to the utilization of natural energies such as sunlight, wind force and waves. However, these energies are always changeable, and some means of storing them are necessary for the common use. In general, natural energies are transformed to the electric energy at the time of utilization, but the electricity is not very storable. This is one of the reasons why the application of natural energy is not so expanded. On the other hand, the storing of natural energy by plants is very skilful. In the photosynthesis, solar energy is transformed to chemical energy by fixing carbon dioxide."

Jan 1, 2009

This paper is a collection of thoughts and frameworks. It addresses a simple question: æIf we are to believe the large number of people and institutions indicating that humans are destroying the Earth and that the end is nigh, why do we bother trying to be sustainable?Æ The paper lays out evidence for the existence of multiple hazards to global society. The existence of a hazard alone is insufficient to make an assessment of risk. Risk estimates are required to support decision-making. An approach to assessing risk is provided and some limited data are presented. A new ædefinitionÆ or statement of what sustainability (in a broad sense) might have become is then given. A decision framework for guiding decision- making about the risks is developed. This framework includes a definition of leadership with inherent implications for what determines whether a leadership position by title is actually leading. The paper concludes by offering a view of minerals industry sustainability and considerations around maturity in the current economic situation. It is hoped that by placing this collection of frameworks around sustainability, a supporting structure emerges that will facilitate action. It is proposed that action taken in this way will be more effective than reaction to regulation or even social license to operate imperatives because it is driven by a more holistic view of the challenges and the potential roles of individuals û all of whom are potential leaders at some scale of action.

Jan 1, 2009

By Elaine T. Cullen

Underground mining, like many high-risk industries, is facing a crisis in the near future. This industry has traditionally relied on a master-apprentice relationship to train new workers, but experienced miners are retiring in large numbers, leaving few "masters" to properly train their replacements. With a recent resurgence in mining, many new miners are entering the workforce each day. The rise in the number of inexperienced workers has implications for worker safety in an industry in which one mistake can blow up the entire workplace. The explosion in the Darby Mine in May 2006 that killed five miners illustrates what can happen in hazardous environments such as underground mines. The Health Communications Team at the National Institute for Occupational Safety and Health Spokane Research Laboratory was asked to address this problem by developing new training and safety awareness materials to promote safe flame cutting and welding practices. This article describes how occupational ethnographic techniques provided insights needed for "new product development." The result of this work was a national initiative to raise awareness and to protect underground coal miners from the dangers of flame cutting and welding in an environment filled with solid fuel and methane (natural gas). Although this project was initially designed for the mining industry, the approach and lessons learned are applicable to any high-risk industry and should be of interest to other social marketing or occupational safety and health professionals.

Jan 1, 2009

By C. Özgen Karacan

Methane emissions from the active face areas and from the fractured formations overlying the mined coalbed can affect safety and productivity in longwall mines. Since ventilation alone may not be sufficient to control the methane levels on a longwall operation, gob vent boreholes (GVB), horizontal and vertical drainage boreholes, and their combinations are drilled and used as supplementary methane control measures in many mines. However, in most cases, the types of degasification wellbores chosen are decided based on previous experiences without analyzing the different factors that may affect this decision. This study describes the development of an expert classification system used as a decision tool. It was built using a multilayer perceptron (MLP) type artificial neural network (ANN) structure. The ANN was trained using different geographical locations, longwall operation parameters, and coalbed characteristics as input and was tested to classify the output into four different selections, which are actual degasification designs that US longwall mines utilize. The ANN network selected no degasification, GVB, horizontal and GVB, and horizontal, vertical and GVB options with high accuracy. The results suggest that the model can be used as a decision tool for degasification system selection using site- and mine-specific conditions. Such a model can also be used as a screening tool to decide which degasification design should be investigated in detail with more complex numerical techniques.

Jan 1, 2009

The pyroclastic-filled Voorspoed kimberlite pipe has a low grade due to significant internal dilution which translates to a marginal business case. The site, with excavations, tailings dumps and buildings remnant of mining from 1906 to 1912 is to become De BeersÆ benchmark mine in South Africa. In a climate of skills shortages and lean structures, a geological service to optimise exploitation of this complex resource was established. As historical mining removed the higher-grade centre of the pipe, initial production was in the weathered upper benches along brecciated pipe margins. Trenching and blasthole logging before blasts helped to mitigate the effects of the drastic contact deviations that occur when working with an inferred geological model. However, identification of unfamiliar weathered kimberlite and delineation of unmodelled internal waste posed challenges. Efficient grade control by demarcation and allocation of individual truck loads will be vital to continue profitable mining at Voorspoed. Further challenges arose across disciplines. The first yearÆs planned production of mostly weathered kimberlite was processed through a plant designed for VoorspoedÆs unusually competent ore. The high clay content of the weathered material led to clogged chutes and overloaded fines disposal, hampering efforts to commission the plant. Resolving this problem involved mining æout of planÆ to provide a blend of fresh and weathered kimberlite. The calculation of an accurate mine call factor was hindered by a lack of haul truck monitoring, process stoppages and stockpiling in the plant during commissioning. Updating of the geological model to incorporate the contact changes observed in the pit was slowed by the need to first understand how 40 years of exploration data was integrated to create the model. A plan, involving focused mine geology practices, is in place to upgrade a portion of the resource from Inferred to Indicated level of confidence. These challenges are not limited to new mines but will be ongoing as new information is constantly gained at Voorspoed and many mining operations.

Jan 1, 2009

By M. E. Coleman, G. Money

"Clyde Materials Handling is an established customer-driven solutions provider, which utilizes its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries.With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets.Clyde Materials Handling has supported operators within the metals market by developing and deploying pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustainable solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes.Clyde Materials Handling has worked closely with their customers, such as Codelco in Chile, where their pneumatic solutions have been used to inject a consistent, pulseless and accurate flow of copper concentrate into a bath smelter, which has helped to fuel the operational capacity, availability and productivity.This paper will discuss and highlight the ways in which pneumatic injection technologies, created by Clyde Materials Handling, and applied in partnership with their customers, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Peirce Smith Converter.Clyde Materials Handling has applications injecting Electronic Scraps, Dusts, Reverts, and other additives to the Peirce Smith Converter. They also have experience of modified PS Units used for Slag Cleaning. There experience with the Codelco Teniente Converter is also directly related to this area of operation."

Jan 1, 2009

By Gordon Chen

The Block 37 Chicago Transit Authority (CTA) Tunnel Construction Project was originally designed by STV to connect Blue Line subway in North Dearborn Street and Red Line subway in State Street in the downtown Chicago Area. The project was proposed using tunnel mining techniques combined with steel pipe jacking and fiber glass rebar soil reinforcement. Weidlinger Associates, Inc. (WAI) and Kiewit Construction Company proposed an alternate design using open cut construction technology. WAI designed a complex temporary excavation support system using Soldier Pile Tremie Concrete (SPTC) walls and Soldier Pile Lagging walls supported by cross lot/corner bracing elements. Below the top of the existing tunnel, a top-down construction technique was utilized. A steel temporary traffic decking system at top of the excavation site served as the daily street traffic function as well as the first level of bracing for the support of excavation. The project encountered great challenges of soft clay conditions in downtown Chicago, numerous existing utilities in the excavation site and the requirements of protection for a number of historical buildings nearby as well as the protection of the city streets. The construction was successfully completed at both State Street/Washington Street and Dearborn Street/Randolph Street. The monitoring system showed that ground movement and adjacent building settlement was kept to a minimum during construction.

Jan 1, 2009

By C. Lara-Valenzuela, R. Perez-Garibay, F. López-Saucedo, A. Uribe-Salas, L. Magallanes-Hernandez

A relationship between gas dispersion parameters, namely gas rate (Jg), gas holdup (Eg), average bubble size (db) and bubble surface area flux (Sb), with the metallurgical performance (e.g., grade and recovery) has been established.. Results of eleven columns operating at five concentrators of Grupo Pefioles (Mexico), ranging between 1.52 to 3.35 min diameter and performing in the cleaning stages of lead and zinc circuits, are presented and discussed. The results showed that the effect of gas dispersion parameters was consistent and that both, Sb and Eg, correlate well with recovery particularly when the influence of feed pulp density is also considered.

Jan 1, 2009

By Jeffrey Loeb

Recent trends in blasting engineering and its related fields, at the level of professional academia, have tended to exclude detailed discussion and examination of the formative experiences of the engineering student. In particular, the extra-curricular aspects of the undergraduate program in engineering—focused, in this case, on the summer job—will be shown to contain a wealth of heretofore underappreciated knowledge in the field. In Surveying the Damage: Post Traumatic Stress and Pre-Blast Surveys, I intend to outline and examine some of the more unusual experiences afforded me by my work as a preblast surveyor in the summer of 2007. In this capacity, I was required to make a visual note of existing conditions of surrounding residential and commercial structures within 100 m (328 ft) of two separate blasting sites in central-east Ontario. In the interest of both convenience and specificity, I have attempted to organize the paper as a crossdiscipline survey of the field according to the conference’s list of suggested topics. In the paper’s first section, I will discuss the topic of Environmental Improvement and Remediation by using a case study in which not one, but two dead cats were found during the course of a routine pre-blast survey. The second section will undertake a discussion of on-site blaster gossip as an entry point into a wider discussion of Workplace Communications Management. In the paper’s final section, I will detail an early morning encounter with a 300 lb, stark-naked trailer park inhabitant as a cross-sectional analysis of the topics of Drilling in Hostile Environments, Vibration and Seismology (Sizemology?), Ethics in Blasting, Crisis Management, Risk Assessment and Public Relations. It is my hope that this paper will begin to open up a critical space for discussion of the formative experiences of engineering students during the undergraduate university program in terms of their far-reaching effects on later performance within the industry.

Jan 1, 2009

By Dennis Dolinar

Improperly designed support systems have led to unplanned roof falls in longwall tailgates. To prevent such falls requires appropriate support and adequately designed support systems. The National Institute for Occupational Safety and Health (NIOSH) is currently developing a standing support design methodology based on the ground reaction curve. To design the support system with this methodology requires a quantitative assessment of the ground and support interaction, which is developed from instrumented test sites installed in longwall tailgates. To compliment and expand the field data results and to optimize the support design, numerical modeling is also conducted. The models are calibrated from the test site data. In the present study, data was obtained from a longwall tailgate in the Illinois basin. The test site was located in the Herrin No. 6 coal seam at a depth of 500 ft. At the site, the immediate roof was a weak shale overlain by a competent limestone. Above the limestone, sandstone formed the intermediate roof. The floor consisted of a weak underclay. In the study, the performance and interaction with the surrounding rock mass of two different standing supports, an engineered crib and a conventional 4-point wood crib were monitored. The two cribs have similar load-displacement characteristics at least through 6 in of displacement. Beyond 6 in, the engineered crib becomes unstable and begins to strain soften and shed load. The measurements and developed ground reaction curves indicated that the tailgate at the mine was a low convergence environment until well inby the face. Because the convergence was well below their capacity, both supports provide more than adequate levels of support to the tailgate. Significant convergence and support loading did not occur until 90 to 100 ft inby the face. The results of this study were also compared with results from similar studies conducted in the Pittsburgh seam to further advance the development of the ?ground reaction curve? based support system design.

Jan 1, 2009

By E. Amini

"While methods exist to allow the simulation and optimization of existing flotation operations, there is a deficit in the ability to predict the performance of a new ore type pre-processing. A laboratory scale batch flotation testing methodology has been developed to assess the flotation potential of ores (known as the JK Floatability Index or JKFI). Previous work conducted by Alexander and Collins (2008) showed that the test could be used to predict full scale results in base metal ores. In this work, JKFI tests were applied to three different types of ore and one blend from a greenfields gold deposit to show the test applicability to flotation of precious metals. The results from the JKFI test on one ore type were then used to predict the response of all ore types (including the blend). To validate the predicted kinetic parameters, a comprehensive survey was performed on a pilot plant where each of ore types was processed in the circuit. An acceptable agreement was found between the experimental recoveries and predicted recoveries which indicate the potential of this method for use in predicting the flotation response of an ore.INTRODUCTIONOver 100 years, flotation has been considered an efficient method to concentrate different types of sulphide and oxide minerals and coal. Thus, numerous research studies have been undertaken to find an appropriate model to predict the behaviour of particles in flotation circuits (Barnwal et. al., 2006; Bascur and Herbst, 1983; Cecile and Villeneuve, 1991; Deng et. al., 1996; Zheng et. al., 2006). Most methods are based on the ore flotation response in an industrial plant which is expensive and time consuming to characterise. It is difficult to reliably predict flotation response for new types of ores in industrial scale plants.The floatability component modelling (FCM) approach, developed within the Australian Minerals Industry Research Association (AMIRA) P9 project, has been used to derive models of operating flotation plants for the purpose of simulation and optimisation (Alexander and Morrison, 1998; Alexander et. al., 2000; Varadi, 2006). This approach has been applied at a large number of operating sites treating a wide variety of ores. The approach requires metallurgical surveys to be undertaken in conjunction with batch flotation tests and cell characterisation. This allows ore and machine parameters to be derived, which are then used in the P9 Flotation Model. The development of a FCM generally requires a large commitment of resources and time. While there has been significant support of this approach in industry, the FCM approach is limited to ores already being processed (Runge, 2004; Wightman, 2006)."

Jan 1, 2009

A dedicated tunnel construction version of the Caterpillar 328D LCR compact radius excavator is proving highly productive on the A9 Autoroute construction project near Visp, in Switzerland. It is the first machine of its kind to operate on a Swiss contract and uses a special dedicated front attachment designed and constructed by German Caterpillar dealer Zeppelin. The machine offers a powerful, stable and compact solution for tunneling contractors. A rear overhang of just 305 mm (12 in.) provides a tail swing radius of just 1.9 m (6.2 ft). The 328D LCR is ideal for the restricted working areas within a tunnel construction site. The machine is equipped with the wide tracks from the 330D L conventional crawler excavator, ensuring maximum stability when operating. In addition, the boom mounting has been moved further toward the center of the machine for the tunnel model, creating an increased lift capacity over the front end compared with a standard 325D L. The boom itself features a robust box section construction, with high-strength steels, additional supporting struts and reinforced bearings for maximum durability. All pins have hard-chromium plating for optimum protection against wear. Stick digging force is a powerful 134 kN, with up to 212 kN of bucket digging force available, for maximum penetration in blasted material. The 328D LCR is also equipped with a heavy-duty dozer blade as standard. This ensures outstanding stability when working and providing a useful secondary tool for clearing and leveling within the jobsite. Two 45° tilting mechanisms in the boom construction, allow the boom to be swung to 45° on either side of the machine. So the specially designed attachment linkage provides increased rollback for access to the roof of the tunnel. A Caterpillar CW45S mechanical quick-coupler allows rapid changes between specialist tunneling attachments, standard Caterpillar buckets and a range of Caterpillar work tools. The machine is powered by a Caterpillar C7 diesel engine. This six-cylinder EU Stage IIIA diesel motor [ ] offers 8 percent more power than its predecessor, with 140 kW (190 hp) available at just 1,800 rpm. Caterpillar?s ACERT combustion technology results in lower fuel consumption and reduced exhaust emissions. However, the tunnel machine is also equipped with a diesel particulate filter as standard, to further cut exhaust gases within the tunnel working. The 328D LCR is designed for use in transport tunnels of 6.8 m (22.3 ft) in height. With the tunneling boom in place, the machine has an operating weight of 42,540 kg (93,783 lbs), yet retains a transport height with the tunnel boom of just 3.9 m (12.8 ft). Transport width with 600 mm (23.6 in.) track shoes, is just 3.2 m (10.5 ft). On the A9 tunnel contract, the machine is being used by a consortium of Swiss and Austrian companies working for the canton of Valais? Routes Nationals Construction (RNC) department. The 31.8-km (19.7-mile) A9 Autoroute construction project will connect Sierre in the west and the town of Brig to the east. The tunnel that is bypassing the town of Visp is just one of a number along the mountainous route.

Jan 1, 2009

By Sheryl D. Gallagher

The project consisted of filling an abandoned underground limestone mine to facilitate construction of a new entrance ramp to I-470 in Lee?s Summit, Missouri. Due to collapse of mined areas near the project site, design included determination of the limits of remediation for the project and minimum construction requirements for mine infilling. The Judy Company, contractor selected for the mine infilling, experimented in the laboratory with several grout mixes to determine the appropriate mix for the project. Infilling was accomplished from the ground surface, and camera observation was used to monitor the barrier wall construction and infilling process. It was discovered that some of the mapped rooms were larger and some were smaller than indicated on the construction plan.

Jan 1, 2009

Safety is the No. 1 concern of any drill contractor or mine operator. Everyone in the industry knows a safe site helps stabilize operational costs and enables higher productivity. When it comes to exploration drilling, research has proven a majority of injuries are caused by the mishandling of coring rods. A driller helper will typically handle up to 50 rods per shift or up to 15,000 rods per year. With an annual 340 t (750,000 lb) in rods managed by hand, the risk of serious injury is extremely high. Because of this, the top request from the exploration industry is diamond rod handling. The Boart Longyear 4200 surface exploration drill, slated for release in 2009, will give the industry a hand-free, operationally safe rig.. Developed through the collaboration of its global drilling services and products divisions and targeted at the 1,200-m (3,900-ft) NQ market, the upcoming Boart Longyear 4200 surface exploration drill features the safest and most flexible rod management sys-tem in its class. The rig includes the industry?s first, truly hands-free rod handling system. This increases operator safety on the jobsite. In addition to the rod handler, the rig also features many new innovations that boost productivity and rig efficiency while minimizing the risk of downtime due to component failure or operator error. Boart Longyear has also included an intelligent PC-based operating system designed to allow complete drilling control as well as diagnostics reporting for the rig.

Jan 1, 2009

Surfaces forces have been measured between gold sphere and gold-coated glass plate in xanthate solutions using an atomic force microscope (AFM). The measurements conducted in potassium amyl xanthate (PAX) and potassium ethyl xanthate (KEX) solutions showed long-range hydrophobic forces, with the force curves showing no evidence for nanonubbles on the surface. The strongest hydrophobic force was measured at contact angle of 94° with a decay length of 23 nm. The hydrophobic force became weaker at higher concentrations and after a long immersion time, which may be attributed to the xanthate species adsorbed on top of the first mono layer. The hydrophobic force became stronger when the residual xanthate solution is displaced by pure water, indicating that hydrophobic force becomes the strongest in pure water.

Jan 1, 2009

By John G. Kovac

A computer simulation has been developed to estimate the chances of a miner making a successful escape while wearing a SCSR. The model takes into account: (1) training in the use of SCSRs, (2) apparatus integrity, and (3) the oxygen cost of a mine escape. This Bureau of Mines report examines survival odds for a prototypical escape, and illustrates how these odds change when SCSR training is improved.

Jan 1, 2009

By Tony Suckling

"As we head toward the United Nations Climate Change Conference in Copenhagen in December, the environment and sustainability will become headline news for a while. Governments are expected to agree to a set of binding targets to reduce carbon emissions probably before 2020, and certainly before 2050. This will, in effect, initiate a low carbon economy in many parts of the world. Sustainability has mainly been rhetoric so far, the exceptions being projects for those looking to the long-term future and not for short-term financial gains.The probabilities and consequences of negative impacts on the environment and on society over the short term and in the long term can be assessed and mitigated, but mitigation often adds cost. Also, we cannot know what technologies will be available, say 1,000 years into the future, which is about 40 generations of our society. It is easier to have a connection with 100 years into the future, which is only about 4 generations. Individuals may have a different sense of sustainability, and place a different value on mitigation, its cost, its importance and its potential impacts.Sustainability means different things to different parties on a construction project. For example, a land developer is likely to have a different view on the design in terms of sustainability than that of the designer. The developer may also likely to be more interested in sustainabiliy if there are tangible economic benefits that might accrue. Achieving sustainability on any project, leads to conflict between competing interests or demands cooperation between the economic and technical sectors involved. The foundations for a building or bridge, by definition, need to interact with the ground whose behaviour cannot be dictated by man. The aims of sustainability are the same as for the building or bridge, both of which are constructed of manmade materials, but it is less clear how they should be achieved. An example is the driven pile that does not produce spoil waste, but is likely to be too noisy to be acceptable in an urban environment. This then begs the question, should the public accept the nuisance of short-term pile driving to achieve a more sustainable foundation? Additionally, the question has to be asked, can the deep foundations industry develop its techniques and products to help make them more acceptable and appropriate more often than is possible now?"

Jan 1, 2009

By C. Özgen Karacan

Degasification and methane control in underground coal mining is an important area augmenting conventional ventilation in order to prevent possible fires and explosions due to excessive methane emissions. Coal bed reservoir engineering has been applied for many years to coalbed methane production. In recent years, modeling the flow and draining methane, not only from coal bed itself but also from the overlying strata, have been recognized as important areas of expertise for supplementing underground ventilation. This paper demonstrates the applications of coal bed reservoir engineering and modeling techniques for optimizing and controlling methane emissions in longwall and continuous miner sections. Practical applications and some considerations are presented for reservoir modeling, borehole performances, and face emission predictions for various coal bed and borehole configurations. A section on field reservoir studies and well bore log analyses for methane control are also presented as a complementary way of controlling methane and optimizing ventilation.

Jan 1, 2009

By Joël P. T. Kapusta, Romeo U. Pagador, Noparut Wachgama, Chumnoom Khuankla

"Thai Copper Industries (TCI) is a custom copper smelter and refinery in Rayong, Thailand, with an annual capacity of 165,000 tons of cathodes. It employs the El Teniente Technology as the primary smelting reactor to produce white metal from copper concentrates. The white metal is further treated in Hoboken Siphon Converters to produce blister copper then refined in anode furnaces before being cast into anodes for electro-refining in the on-site tankhouse.Thai Copper Industries is the first copper smelter to install and successfully operate on a commercial scale with the Air Liquide Shrouded Injection (ALSI™) Technology in the Hokoben converters with sonic injection of oxygen enriched air and nitrogen for cooling of the injector tip areas. Following commissioning and the establishment of operating practices, the performance of the Hoboken converters with ALSI™ Technology produced outstanding results. The unique combination of an El Teniente and Hoboken siphon converters, both of which are bath smelting operations, offers very high blowing and oxygen efficiencies. As a consequence, reverts recycling was accelerated with minimal build up on the mouth, end-plates or even below the siphon that is typical in Hoboken converters.These outstanding results in the Hoboken Siphon Converters with ALSI™ Technology helped the TCI Plant reach a production of about 75% of its capacity within four months despite the fact that the TCI staff is quite young and its converter know-how and experience are not yet fully developed."

Jan 1, 2009