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By JOHN HOMER, Jacob L. Carr, Jonathan K. Hrica, Kathleen M. Stabryla, Iman Benbourenane, Jennica L. Bellanca

Given the recent focus on powered haulage incidents within the US mining sector, an appraisal of collision avoidance/warning systems (CXSs) through the lens of the available research literature is timely. This paper describes a rapid review that identifies, characterizes, and classifies the research literature to evaluate the maturity of CXS technology through the application of a Technology Readiness Assessment. Systematic search methods were applied to three electronic databases, and relevant articles were identified through the application of inclusion and exclusion criteria. Sixty-four articles from 2000 to 2020 met these criteria and were categorized into seven CXS technology categories. Review and assessment of the articles indicates that much of the literature-based evidence for CXS technology lies within lower levels of maturity (i.e., components and prototypes tested under laboratory conditions and in relevant environments). However, less evidence exists for CXS technology at higher levels of maturity (i.e., complete systems evaluated within operational environments) despite the existence of commercial products in the marketplace. This lack of evidence at higher maturity levels within the scientific literature highlights the need for systematic peer-reviewed research to evaluate the performance of CXS technologies and demonstrate the efficacy of prototypes or commercial products, which could be fostered by more collaboration between academia, research institutions, manufacturers, and mining companies. Additionally, results of the review reveal that most of the literature relevant to CXS technologies is focused on vehicle-to-vehicle interactions. However, this contrasts with haul truck fatal accident statistics that indicate that most haul truck fatal accidents are due to vehicle-to-environment interactions (e.g., traveling through a berm). Lastly, the relatively small amount of literature and segmented nature of the included studies suggests that there is a need for incremental progress or more stepwise research that would facilitate the improvement of CXS technologies over time. This progression over time could be achieved through continued long-term interest and support for CXS technology research.

Jun 17, 2022

By E. Watkins, S. J. Schatzel, V. Gangrade, K. M. Ajayi, Z. Khademian

Longwall-induced deformations could jeopardize the mechanical integrity of shale gas well casings positioned in the abutment pillar of a longwall mine. The in situ and induced fracture networks surrounding the gas well could provide pathways for gas flow into the mine creating safety concerns. Hence, this study by the National Institute for Occupational Safety and Health (NIOSH) develops a discrete fracture network (DFN) model to characterize the fractures in the overburden based on geomechanical analyses of mining-induced fracture apertures at a study site in southwestern Pennsylvania. The apertures from the geomechanical model are used to develop a stochastic DFN model of the site in fracture flow code (FFC). Multiple realizations of the stochastic DFN model that replicate potential fracture geometries are simulated, and the fracture permeability is compared with field measurements. A maximum field measurement of 5.03 × 10− 12 m2 (5080 mD) and 3.82 × 10− 13 m2 (386 mD) was estimated over the abutment pillar at the Sewickley and Uniontown horizon, respectively. The results show that the average permeabilities from the DFN model agree closely with the field measurements. In addition, the comparison of all the field measurements and 100 DFN realizations show the model is representative of field conditions. These findings provide critical information regarding fracture characteristics in the overburden, which will further be used to predict potential shale gas flow to the mine in the event of a casing breach for an unconventional gas well.

Jun 17, 2022

By Yuchen Wu, Jing Mei, GUOZHONG LIU, KE GAO, Songjie Tian, Jianwei Cheng, Yu Wang, Yuhang Wu, Hui Wang

The stability and integrity of protective coal pillars between the longwall working face and development roadways are greatly affected by the mining activities such as the development face advancing or retreat mining. Due to underground strata pressure, the coal pillar cracks could be further developed and then the air leakage passages (mainly cracks) could be produced greatly. The air circulation caused by the atmospheric pressure difference between the two sides of the coal pillar may also provide suitable conditions for the possible spontaneous combustion of the residual coal in the mine gob. In this paper, a typical the protective coal pillar in a Chinese coal mine is studied. The deformation and stress of coal pillars during the mining process of longwall working face are simulated by using FLAC3D. The displacement and strain of coal pillars are analyzed. Two indexes, the linear fracture rate (LFR) and area fracture rate (AFR), are introduced to characterize the development of internal cracks’ development within coal pillars. By using field measurement, the air leakage intensity distribution due to coal pillar cracks is obtained; the equation of air leakage resistance of coal pillar under the influence of mining is derived. Then, the possible location of large air leakage of coal pillar is determined, which can be used as guidelines to study the possibilities of coal spontaneous combustions happening in pillar or mine gob. The research results help to control such potential hazards in advance.

Jun 16, 2022

By Bülent Erdem, Zekeriya Duran, Tuğba Doğan

The objective of this study was to evaluate the potential health risk associated with exposure of dozer operators to whole-body vibration. Measurements were made on 31 dozers used in different surface mines in Turkey. Predictions of adverse health effects of vibration were based on the standards BS 6841:1987, ISO 2631–1:1997, ISO 2631–5:2004, and the EU Vibration Directive:2002. Operators experienced high and comparable levels of vibration acceleration and dose during all dozer tasks: pushing the material (DOZE), moving forward (FORWARD), moving backward (REVERSE), and ripping (RIP). Specifically, DOZE, FORWARD, REVERSE, and RIP showed high potential of adverse health effects in terms of vibration dose according to the worst-case axis and vector sum criteria and a moderate adverse health effect for acceleration according to the worst-case axis criterion. Operators of large dozers were exposed to lower levels of vibration. However, no statistically significant relationship between vibration exposure levels and the propelling mechanism and the service time of dozers, operator experience, operator age, and ground type was found.

Jun 16, 2022

By Jue Kou, Fazhao Sun, Jiang Liu, Cuili Gui, Baoqiang Yu, Chunbao Sun

A novel special magnetic separator was developed based on the special properties of precious metal-bearing alloy in highgrade nickel matte. The recovery of Au, Pt, and Pd was 77.79%, 84.79%, and 81.79% respectively at optimum operation conditions of magnetic separator feed of 2.5t/h, pulp density of 45%, and flush water of 1.5t/h, and the recovery significantly improved comparing with normal magnetic separator. Magnetic field simulation of the special magnetic separator indicates that magnetic intensity of 0.6 T can be generated on the surface of magnetic drum, which can strengthen the recovery of heavy alloy that contains precious metals. The alternate strong and weak magnetic field can also make magnetic particles rolling on the surface of drum, which will reduce the generation of magnetic agglomeration to a large extent and decrease the content of impurities in magnetic concentrate.

Jun 16, 2022

By Peter Zhang, Todd Minoski, Gabriel Esterhuizen, Jack Trackemas, Berk Tulu, Morgan Sears

Longwall mining is a highly productive and efficient coal mining method used in the USA. During longwall retreating, the belt entry must be maintained stable, and any roof fall in the belt entry would jeopardize mine safety and substantially interrupt the continuous production of coal in the longwall face. Past experience of longwall mining has shown that belt entry stability was the greatest challenge in longwall ground control, and the occurrence of roof falls in belt entries was largely associated with high horizontal stress. To properly support the roof in the belt entry, it is important to understand how longwall-induced horizontal stress changes affect roof stability in belt entries and to strategically install supplementary support to prevent any potential roof falls. Researchers from the National Institute for Occupational Safety and Health (NIOSH) performed horizontal stress measurements in the immediate roof of the belt entries for two Pittsburgh seam longwall panels oriented unfavorably to high horizontal stress. Hollow inclusion cells (HICells) were installed in the immediate roof at the intersection in each of the belt entries, and stress changes were monitored as the longwall face was approaching and passing the intersection. Numerical models were set up to calculate the longwall-induced horizontal stress changes in the roof at the monitoring sites. With the verified model, investigations were made of how horizontal stress is concentrated and relieved in the belt entry roof near the face under different panel orientations. Both measurements and modeling results showed that high horizontal stress is concentrated in the roof in the belt entry within about 15 m outby the face when a longwall panel is unfavorably oriented to the major horizontal stress. The study demonstrated that longwall-induced differential horizontal stress can be used as an indication of the degree of horizontal stress concentration. Roof support strategies are discussed on how to maintain the stability of belt entry under high horizontal stress concentration.

Jun 14, 2022

By Peter Zhang, Daniel Su, Mark Alexander Van Dyke, Heather Dougherty, Bo Hyun Kim

The National Institute for Occupational Safety and Health (NIOSH) has been evaluating longwall mining-induced strata fractures and their impacts on casing stability of Marcellus shale gas wells located in longwall pillars. To understand the extent of overburden fractures after longwall mining, NIOSH researchers drilled a post-mining corehole into the fractured strata above the Pittsburgh coal seam longwall gob. Knowing the extent of the fracture zone height will help gas operators minimize the hazards of drilling into longwall gobs. The core was retrieved from the surface down to the top of the gob void. Various fractures were encountered varying from 35 to 64°, depending on lithologic type and relative closeness to the gob. The longwall panel dimension was 457-m wide and 3657-m long, in which the total fracture zone height was found to be at 141 m and the hydraulic connected fracture zone at 87.7 m above the top of the Pittsburgh seam. In addition to core drilling through the gob, FLAC3D modeling was also used to simulate the formation of fracture zone and the orientations of longwall-induced fractures. This study provides much-needed evidence on the fracture zone of Pittsburgh seam longwall gobs to help gas operators avoid potential hazards associated with drilling through highly fractured zones in longwall gobs.

Jun 9, 2022

By Chuang Sun, Feng Luo, Guo‑dong Li, Xue‑qing Li, Tuan He

The mining-induced failure of the coal seam floor is essential for water inrush. The mining disturbance to the floor, especially in the thick coal seam, is severe, and the water inrush risk is also higher than that in regular thick coal seam excavation. The superposition of many stresses, including in situ stress, mining-induced stress, and confined water pressure, must be considered in the prediction of the floor failure depth. This study adopted the elasticity analysis, FLAC3D numerical simulation, and on-site acoustic wave test comprehensively. The thick coal seam working face of the Zhong-Yu coal mine affected by confined water was selected as the engineering background to study the characteristics of the floor failure. Based on elastic foundation theory and the superposition principle, the mechanical model and the failure depth criterion of the floor were established, respectively. The distribution and evolution of mining-induced stress and the plastic zone in surrounding rock during the mining process are obtained by FLAC3D. In addition, the changes in the P-wave wave velocity in the floor before and after mining were compared and studied by the acoustic wave test method. The range of floor damage depth is determined on the basis of the above research.

Jun 8, 2022

By Ch. R. V. S. Nagesh, Ramesh Naidu Mandapati, Venkata Swamy Nalajala, Tondepu Subbaiah, Naga Jyothi Kothamasu

Leaching studies of magnesite obtained from Tamilnadu Magnesite Limited, Salem, have been carried out using hydrochloric acid leaching and percentage of magnesium chloride recovered was estimated. The variables considered in this study were the following: duration of leaching, volume percentage of hydrochloric acid, temperature, and pulp density. Percentage recovery of magnesium chloride increased with duration of the leaching, volume % of concentrated hydrochloric acid, and temperature. Percentage recovery of magnesium chloride decreased with increase of pulp density. The optimum conditions found to be pulp density (10%), hydrochloric acid concentration (30%), duration of leaching (2 h), and temperature (348.15 K). Iron was removed by treating the leach liquor with hydrogen peroxide and by raising the pH to 3.5–4. The purified leach liquor was subjected to spray drying for producing high pure magnesium chloride.

Jun 7, 2022

By Surendra Kumar Biswal, Sachida Nanda Sahu, B. C. Meikap

The unutilized iron ore fines (IOF, − 10 mm, 45% to < 60% Fe(T)) left at various mine sites during blasting and processing are rich in goethetic-hematite associated with high clay and considered a potential iron ore resource. The variation of loss on ignition (LOI) from mines to mines is based on the goethite and clay mineral content. The clay containing below 45 μm is mostly brittle, causing beneficiation problems. The IOF has an LOI of 7.83%, with high silica (5.52%) and alumina (4.57%), and 57.17% of Fe(T) subjected to both conventional deep beneficiation (CDB) and magnetization roasting using high-ash non-coking coal to adopt the suitable upgradation process. The CDB and magnetization roasting concentrate has 62.61% and 67.58% Fe(T) with 64.69% and 85.19% yield, respectively. However, the presence of 6.40% LOI in CDB makes the ore challenging for pelletization. Characterization like X-ray diffraction(XRD), scanning electron microscope(SEM), and chemical analysis was used to assess the concentrate quality and potential industrial application.

Jun 4, 2022

By F. Hörtkorn, Y. Narainsamy

Rather quietly, a new generation of European norms dealing with earthworks has been developed over the past few years, in particular a part of EN 16907 pertaining to extractive waste. Whereas the majority of the parts deal with routine geotechnical aspects, one part deals specifically with tailings dams. The standard is currently in draft form but if this becomes a European Standard, members of the European Union are bound to comply with the regulations. As such, the standard has the capacity to influence mining in Europe and potentially in South Africa. In this paper we review the standard and compare it to the South African standard on mine residues and the recently published Global Industry Standard on Tailings Management (GISTM). We conclude found that although the European norm makes great strides towards increasing tailings dam safety, there is room for improvement. The current South African standard has served well since its inception, but can be improved by using concepts from the European and global tailings standards.

Jun 2, 2022

By S. W. Jacobsz, Y. Narainsamy

Several high-impact tailings dam failures around the world in recent years have placed a renewed focus on the stability of tailings dams and pointed to potential shortcomings in traditional drained design and safety evaluation procedures. A need to consider undrained shear strength in the design of tailings facilities has become apparent. However, there are specific requirements that need to be met before undrained shearing occurs. In South Africa, the last major failure was likely the Merriespruit disaster in 1994, which leads to the question of whether the conditions required for undrained shearing are readily applicable to South African tailings dams. This paper describes research at the University of Pretoria that has recently commenced to further investigate the conditions required for undrained failure to occur. The research includes laboratory and field testing to replicate these conditions in the laboratory and relate them to those found in an active tailings dam.

Jun 2, 2022

By G. Howell, J. Wates, A. Coetzee, C. J. MacRobert

The Global Industry Standard on Tailings Management (GISTM) requires mining companies to make four key appointments as part of their tailings management structure. These four positions are an Accountable Executive with policymaking responsibilities, a Responsible Tailings Facility Engineer with operational responsibility, an Engineer of Record to ensure facilities are designed, operated, and closed safely, and an Independent Tailings Review Board to assess safety drivers regularly. Little guidance on the traits of these individuals is available in a South African context. Consequently, the tailings community of practice was surveyed to develop a table of ideal competencies and establish the flexibility in meeting these traits.

Jun 2, 2022

By H. Karabulut, S. Gündüz, K. Karacif, M. A. Erden

The corrosion properties of iron-based composite materials containing graphite and silicon carbide (SiC) reinforcement were investigated. The effects of silicon carbide reinforcement were investigated by adding 0.5% graphite and 1%, 2%, and 4% SiC. A powder metallurgy method was used to produce the composite samples. Iron, graphite, and silicon carbide powders were blended for one hour with a threeaxis mixer and then unidirectionally pressed under a pressure of 750 MPa. After pressing, the composite materials were sintered at 1100°C for one hour. The corrosion properties and microstructure, density, and hardness properties of the composite materials that can affect the corrosion properties were also investigated. It was determined that the pore ratio and hardness of the composite material increased, and corrosion resistance decreased, with increasing silicon carbide content.

Jun 2, 2022

By J. K. Pandey, ebashish Mishra, D. P. Mishra, N. K. Mohalik, S. K. Ray

The increasing demand for coal and depletion of shallow depth reserves are pushing towards deeper mining. In deeper coal mines with multiseam workings, the problem of ventilation surges many folds primarily related to air quantity requirement, heat, humidity and spontaneous heating/fire in goaved (gobbed) out areas. The paper describes the design of a new approach to improve the ventilation system of a real-life deep underground coal mine with multiseam workings. For this, the ventilation problem of one deep underground coal mine 6&7 pits Bhutgoria Amalgamated Colliery of Tata Steel Ltd. with multiseam workings has been studied in detail to determine an appropriate solution. A ventilation survey of the mine and computer simulation of the ventilation network has been carried out to reach a practical solution. Ventilation survey results have been analysed to develop a representative ventilation network of the mine for both qualitative and quantitative analysis. Further, computer simulation of the ventilation network of the mine has been performed to virtually verify the application of a highcapacity booster fan in the present ventilation circuit without disturbing the vulnerable areas. Field validation is also carried out after the implementation of the solution in the mine to determine its efficacy. Thus, the findings of this paper can be directly applied for the installation of booster fans to achieve the required air quantity in deep underground coal mines with multiseam workings having spontaneous combustion liabilities of upper seam goaved out areas.

Jun 2, 2022

By S. D. Dladla, S. Ramsamy

The majority of the tailings dam operations in South Africa will be required to comply with the new Global Industry Standard on Tailings Management (GISTM) within the next one to three years, depending on the dam classification and the requirements of the respective investors and insurers. With up to 72 auditable requirements, the implementation of the Standard needs careful planning and prioritization. This paper focuses on the practical steps to GISTM compliance for tailings facilities in operation in South Africa. The discussions are based on current practices, South African regulations, and industry standards requirements. The possible changes in dam classifications and the associated requirements are presented.

Jun 2, 2022

By Rudrajit Mitra, Erik Hulthén, TOBIAS HARTMANN, ELISABETH CLAUSEN, Aarti Sörensen

There has been an ongoing debate on how to transform engineering education to better prepare students for today`s professional world that is characterized by increasingly complex problems and challenges that engineers are tasked with upon entering the industry. Within the conceive–design–implement–operate (CDIO) framework, entrepreneurship education presents a valuable pedagogical approach to foster the necessary skills of the students through integrated, hands-on, active learning experiences. While numerous publications have addressed possibilities of how experiential, problem-based, project-based and active learning can be integrated into engineering curriculum, there has been hardly any attention on mining engineering with respect to adopting this approach. This paper will address the possibilities of integrating entrepreneurship education into mining engineering programs in particular. This paper will enhance and foster discussion among academics from mining engineering on how to integrate elements of entrepreneurship education on a course, program and departmental level to infuse value creation experiences across the curriculum.

May 25, 2022

By Aijuan Zhang, Liang Zhao, Yutao Wang, Yu Bao

In the green backfilling mining of underground coal mines, gangue in a coal seam is used to replace and fill goafs. However, the gas drainage time changes in the amount of gangue output and order in the extraction sequence of stope blocks, thereby changing the production output. A multi-objective integer programming model was proposed to solve this based on an improved non-dominated sorting genetic algorithm. The results show a feasible gangue filling rate can be found and the extraction sequence for a long-term planning time is optimized. It increases the planned annual output by 26% and reduces equipment idle time.

May 23, 2022

By J. Rostami, J. Brune, S. Slouka

Respirable dust poses long-term health issues to personnel working in mining and civil projects where mechanized mining and tunneling machines are used for hard rock excavation. Machines, such as longwall shearers, roadheaders, or continuous miners, use consumable picks to cut rock. However, rock dust is generated in the work environment each time the pick tip contacts the rock surface. Additionally, the generated dust can be reintroduced into the air further down in production, such as at transfer points. The purpose of this study is to characterize respirable dust particles generated at the pick tip at two stages of pick wear: new and moderately worn. Understanding dust characteristics in terms of concentration, size distribution, and particle shape throughout the life-cycle of the pick will provide a basis to mine and tunnel operators for changing out picks to mitigate dust generation at the source. This paper discusses the dust characteristics generated from preliminary full-scale cutting tests in a laboratory of an igneous rock block cut with conical picks at new and moderately worn levels of wear. The moderately worn pick generated a size distribution that favored smaller particle sizes compared to the new pick. The moderately worn pick also generated more overall dust, as the concentration level in mg/m3 was over double the amount of the new pick. Lastly, both picks generated particles that had similar aspect ratios and roundness measures.

May 18, 2022

By Nikhil Dhawan, Shrey Agrawal

Feldspar, a low-alumina, and abundantly available aluminosilicate source, is explored in this study to extract aluminum and potassium values. The sample comprises lamellar layers of microcline and albite with quartz containing 17.4% Al2O3, 9.67% K2O, and 66.3% SiO2. Mechanical (milling) and thermal (alkali and acid baking) activation are investigated, followed by HCl leaching. The milling treatment up to 6 h is inefficient in phase dissociation and results in ~ 40% Al and K dissolution. The alkali thermal treatment yielded 80% Al and 71% K extraction. Direct precipitation of the dissolved Al and Si values yielded alumina purity of ~ 29%, and silica gelation separated SiO2 and improved alumina product (94% purity, 71% recovery). Acid baking yielded 98% pure alumina precipitate; however, Al and K extraction were limited to ~ 45% and 65%, respectively. The microwave-assisted alkali treatment was optimal with 800 W and 10 min processing conditions yielding 80% Al and 71% K recovery with 2.26 kWh/kg alumina of thermal energy consumption. The final product contains γ-alumina with a specific surface area of 87 m2/ g. Keywords Feldspar · Alumina · Potassium ·

May 18, 2022