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By R. Pandey, G. Elie, E. Sarver

Respirable crystalline silica (RCS) is generally considered the most hazardous constituent of coal mine dust, and a new federal rule is expected to further limit exposures in U.S. mines. For regulatory purposes, RCS is monitored by collecting filter samples, which are analyzed for quartz (the predominant form of RCS in coal mines). The analysis is done using Fourier transform infrared spectroscopy (FTIR) in a centralized laboratory. To enable more timely results, National Institute for Occupational Safety and Health (NIOSH) mining researchers developed a directon- filter (DOF) FTIR analysis method and free FAST software that can be used in the field. For samples collected under specific conditions, FAST processes the FTIR spectral data to determine quartz mass. While the DOF FTIR method is not approved for regulatory RCS monitoring, it could be useful for engineering purposes, such as to evaluate mining parameters or new dust controls. This field study demonstrates how the method, including FAST, can be applied using low-cost, widely available sampling components. It further demonstrates how quartz percentage can be estimated in the field, by pairing a continuous personal dust monitor with a filter sampler.

Jun 1, 2025

By Carrie Smith

The 2025 Women in Mining USA National Conference, held April 15-18 at the Grand Hyatt Riverwalk in San Antonio, TX, brought together hundreds of professionals for a fourday event focused on empowering women and creating space for all individuals in the industry. Under the theme “Empowering the Future of Mining,” the conference served as a dynamic platform for professional development, knowledge-sharing and cross-sector collaboration. Organized by Women in Mining USA (WIM USA), whose mission is to foster equity, sustainability and leadership in mining, the event featured an extensive agenda including workshops, keynote speeches, panel discussions and networking opportunities. Attendees ranged from industry veterans to emerging professionals and students, united by a shared commitment to progress within one of the world’s most essential and traditionally maledominated sectors.

Jun 1, 2025

By Keith Olson

In the heart of Appalachia, where coal mining has shaped communities and economies for generations, Bluefield State University (BSU) has made a landmark decision to reestablish its mining engineering technology program. This move comes at a critical juncture for both the university and the mining industry, which faces significant workforce challenges amid evolving technological demands and an aging professional demographic. The program’s revival represents an educational initiative and a strategic response to industry needs and regional economic development. Nestled in the mountains of southern West Virginia, BSU has a storied history intertwined with the region’s mining heritage. The institution’s decision to bring back this specialized program after a hiatus of several years signals a renewed commitment to serving both regional industry demands and providing career pathways for students in an area where the cyclical nature of resource extraction economies has often limited economic opportunities. “This program’s return reflects our deep understanding of this region’s needs and our commitment to preparing graduates for meaningful careers that support our local industries,” said Darrin Martin, president of Bluefield State University. “We’re bridging the gap between education and industry with a modernized curriculum that addresses today’s mining challenges while preparing for tomorrow’s innovations.”

Jun 1, 2025

By Rennie B. Kaunda, Robert J. Sterrett

Some people in the mining-engineering field mistakenly believe that mine-water management primarily revolves around the treatment of mine waters that fail to meet applicable water-quality standards. While water-quality control is undoubtedly important, it represents only a fraction of what constitutes comprehensive site-wide, minewater management. A more holistic perspective recognizes that it also involves mine dewatering to maintain safe and workable conditions, securing sufficient water supply for operations, strategically handling surface water within and surrounding the openpit to prevent issues like flooding, developing robust post-closure plans to mitigate long-term environmental effects, and proactively minimizing any adverse impacts on local communities and ecosystems. This article provides a brief overview of topics that fall within the concepts of mine-water management. The focus is on openpit mines, as they are generally larger than underground mines. The management of mine water is highly dependent on local and regional climate such as tropical, desert or temperate climate. Each climatic setting has its own unique challenges, but there are also commonalities.

Jun 1, 2025

By Joel Lööw, Johan Larsson, Stig Vinberg, Malin Mattson Molnar, Mats Jakobsson, Jan Johansson

The mining industry is undergoing rapid transformation, driven by technological advancements, sustainability concerns and demographic shifts. This transformation will put more younger people in management positions. This study provides valuable insights into the leadership behaviors of younger and older managers within a large Swedish mining company, highlighting the importance of managerial experience and targeted training programs to foster effective leadership, particularly in the context of change management. The findings emphasize the need to create work environments that support managers to develop their leadership, contributing to improved employee well-being, operational efficiency, and adaptation to the changing demands of the modern mining sector.

May 1, 2025

By Ashma Singh, Nichole Maistry

Due to declining iron ore grades, low-grade ores with complex mineralogy — namely, banded iron formation (BIF) — are being explored to maximize iron ore resources and increase the life of mine. Flotation is the standard global process used for the beneficiation of BIF ores, as it is a complex ore reserve, and liberation is typically achieved below 1 mm. This study focuses on the flotation of a South African BIF, evaluating its response to different collectors, as well as effect of grind. As flotation is an expensive process and South Africa ranks high on the production cost curve, preconcentration by gravity or magnetic separation is performed prior to flotation. Thus, flotation was also performed on a gravity concentrate to determine if a grade suitable for steelmaking (approximately 63 percent) is achievable. The results indicate that the use of an alkyl ether amine-based collector partially neutralized with acetic acid is suitable for separation of hematite from illite and quartz at high pH values. Further optimization tests are being pursued to improve overall recovery and grade.

May 1, 2025

By Katherine Hynard, Colin Eustace

Suboptimal decisions introduced during the mine planning process are generally a consequence of both a myopic view of planning objectives as well as time and resources available to convert longer-term plans into execution plans. Erosion of strategic mine plan value in conversion to execution plans is likely to amount to billions of dollars each year. When integrated with operations data feeds, simulation and optimization tools can be used to preserve the value in the strategic mine plan. Optimization models are capable of both automating production of execution plans and improving performance. This reduces the manual burden of revising plans while improving alignment with long-term production objectives. Simulation models can also support the process of developing effective execution plans by providing forward visibility of mine operations performance. They can also be used to test the robustness of optimized execution plans and response to operational variability and disturbances.

May 1, 2025

By Jonathan K. Hrica, CASSANDRA L. HOEBBEL, Jennica L. Bellanca

Accidents involving powered haulage and mobile equipment like haul trucks are a major safety concern in the U.S. mining industry. They account for more than 50 percent of surface mine fatalities each year [1]. A recent National Institute for Occupational Safety and Health (NIOSH) analysis of 91 fatal incidents identified loss of vehicle control and situational awareness as key contributors [2]. However, the first-hand perspectives of operators are often missing, emphasizing the need for deeper insights into operators’ decisionmaking, lessons learned, sensory cues and mental strategies used during near-miss events. The findings in this analysis will help inform the development of training and safety solutions to prevent or reduce haul truck accidents.

May 1, 2025

By Carter Brown, Kate Brown Requist, Eric Lutz, Moe Momayez, Athira Satheesh

New mining health and safety training modalities are becoming increasingly prevalent in the underground mining industry. Various digital training tools have been developed over the past several years, but the extent of their use remains unclear. Advances in gamified training by way of computerbased video games and virtual reality (VR) have opened a new avenue for mine rescue and self-escape training, but these methods have not been widely adopted across the mining industry. Mine rescue and self-escape situations require a mix of in-classroom training as well as live drills, but it is important to assess the extent of and effectiveness of new training modalities. The Mine Rescue and Self-Escape Survey (MRSES) was distributed to underground mining operations to collect perceptions of current training effectiveness as well as willingness to adopt new training methods as a complement to live rescue drills. Responses from the MRSES indicate that adoption of digital training technologies has been slow-going despite an interest in their use. Further, there appears to be no meaningful connection between more frequent escape and rescue training and feelings of emergency preparedness. With relatively little use of already developed digital training tools but an interest in their adoption, it may be time to reassess current emergency preparedness training philosophies.

May 1, 2025

By Yi-Hsuan Chen, Jürgen Brune, Candace S. J. Tsai, Alejandro Munoz, Connor Krause

This study highlights the significant presence of submicrometer- sized airborne particles in underground coal mines, especially around the belt conveyor drift areas. Using realtime instruments and gravimetric samplers, the assessment revealed that particle concentrations were notably higher in the belt entry compared to other locations, with a strong presence of submicrometer- and nanoparticle-sized dust. The study’s findings emphasize the importance of addressing small particle exposure, as these particles, composed of harmful substances like calcium, copper and iron, can pose serious health risks to miners. This research emphasizes the importance of improving air exposure estimation through more effective monitoring and characterization techniques to better understand and reduce workers’ exposure to hazardous airborne particles in the mining environments.

Apr 1, 2025

By Adrianus Halim, Jenni Hooli, Bartłomiej Skawina, Fredrik Sundqvist

Transitioning from diesel-powered loading and hauling machinery to battery-electric vehicles (BEVs) responds to the need for deepening underground mines as regulations become tighter. When using BEVs, exhaust gases and diesel particulate matter (DPM) emissions can be eliminated, and the energy required for the machines is used more effectively. Unlike their diesel counterparts, which are refueled, BEV loading and hauling machines — specifically, load haul dump (LHD) machines — can use battery swapping. This brings additional aspects to the operation that need to be considered, which have not yet been studied extensively. This study used discrete event simulation (DES) to analyze how the different numbers of BEV LHDs affect queueing and productivity when using different numbers of batteries and different swapping times in an underground block cave mine. The results identified the formation of working groups, where the machines swapped their batteries concurrently within each group, and their relation to the queueing time. Additionally, the minimum number of batteries per machine was identified to maximize productivity while minimizing queueing time. This study demonstrates DES as a powerful tool to assess and analyze conceptual systems and identify their underlying structures, which can enhance the deployment of BEV LHDs in underground block cave mine operations.

Apr 1, 2025

By Georgios Bartzas, Vasiliki Karmali, Konstantinos Komnitsas, Anna Kritikaki, Dimitra Vathi, Stylianos Tampouris, Arne Peys

Large volumes of slags, with varying mineralogical and geochemical characteristics, are produced annually by the ferrous and nonferrous metallurgical industry. Most of them are considered as potential secondary resources and may be valorized, following the principles of circular economy, for the recovery of critical elements, including energy transition metals. Apart from the economic benefits, valorization of slags may contribute to the competitiveness of the metal industry and the conservation of natural resources. Valorization also results in minimization of environmental impacts on soils and waters in slag disposal areas, due to the prevention of solubilization and subsequent migration of potentially hazardous elements. The present study utilizes ferronickel (FeNi) slag for the production of alkali-activated materials. The effects of the main experimental parameters, including sodium hydroxide (NaOH) molarity, silica/sodium oxide (SiO2 /Na2O) molar ratio in the activating solution, precuring and curing time, curing temperature and aging period on several properties of the final products, are assessed.

Apr 1, 2025

By G. Akdogan, S. M. Bradshaw, A. P. Van Wyk, T. Punt

This study investigated the performance of citric acid as lixiviant for cathode material from end-of-life lithium-ion batteries (LIBs). Black mass containing 84.2 weight percent MNC (LiNi0.45Mn0.4Co0.15O2) and 15.8 weight percent LCO (LiCoO2) material was leached at solid-to-liquid ratios of 20, 50 and 100 g/L. Leaching with 1.5 M citric acid, 2 volume percent H2O2 and a solid-to-liquid ratio of 20 g/L at 95 °C extracted 90 percent Co, 95 percent Li, 94 percent Mn and 94 percent Ni within 20 min. At the highest solid-to-liquid ratio of 100 g/L with 1.5 M citric acid, 10 volume percent H2O2 and 95 °C, 84 percent Al, 84 percent Co, 87 percent Li, 86 percent Mn and 96 percent Ni were leached after 40 min, producing a leach solution containing 0.68 g/L Al, 20.0 g/L Co, 6.0 g/L Li, 13.6 g/L Mn and 19.3 g/L Ni. Using stepwise addition of H2O2, instead of initial bulk addition, did not significantly improve the leaching efficiency but did reduce the required leaching time. Temperature control of the reactor was also more manageable with stepwise addition of H2O2, and evolution of gas was less vigorous. It was observed that the leaching efficiencies of Co, Li and Mn decreased slightly at solid-to-liquid ratios of 50 and 100 g/L, while the leaching of Ni increased slightly. The solution leached at 20 g/L could be stored for six weeks without any spontaneous precipitation. However, solutions leached at 50 and 100 g/L showed changes in concentration after one month of storage, suggesting that processes that have a large material throughput and use high solid-to-liquid ratios around 100 g/L must ensure that the solutions are not stored for extended periods of time.

Apr 1, 2025

By Kadri Dagdelen, Lee J. Zamalloa

Truck-shovel dispatch systems based on linear or nonlinear programming algorithms have been in operation since the mid-1980s, with different levels of success depending on the correct arrangement of operational resources and the complexity of the mine. These systems are known for shortcomings related to the logic behind the decision-making of the operational objectives. This makes it necessary to have a human agent (dispatcher) to guide the system when the operational parameters change, creating the possibility of suboptimal decisions due to the human factor. To address this issue, the present work discusses the implementation of a methodology based on artificial intelligence (AI) techniques to assist in the decision-making of the best optimization goals arrangement when operating a fleet management system. The focus of the analysis is on the evaluation of variable goal weights in a nonpreemptive, multigoal optimization model for multiple uncertain scenarios based on regions of optimal feasibility.

Apr 1, 2025

By Mir Ahmad Mohammadi

Land uplift due to mine flooding has become a significant challenge with extensive historical mining activities, particularly in Germany’s Ruhr district. The cessation of coal mining operations has led to a gradual rise in groundwater levels, altering geotechnical and hydrological conditions and causing surface uplift. This study develops a system dynamics (SD) model to investigate the dynamic interactions of influential variables such as groundwater levels, total stress, porosity and permeability with land uplift over time. The model integrates causal loop diagrams (CLD) and stock flow diagrams (SFD) to comprehensively understand the system’s behavior. SFD illustrated that for a 10 percent increase in groundwater level, the land uplift increased by about +6 percent, and a rise of 200 percent in total stress caused an 18 percent increase in effective stress, which decreased the land uplift by about 20 percent. This study highlights the importance of dynamic modeling in informing land-use planning and mitigating the long-term impacts of land uplift after mine closures.

Mar 1, 2025

By Alessandro Navarra, Aldo Quelopana

Sophisticated models have progressively been developed to address the challenges related to long-term, openpit mine planning under conditions of geological uncertainty. Prior research has acknowledged that strategies for mine planning and the design of mineral concentrators are interdependent; thus, it is highly desirable to optimize them together. However, achieving detailed holistic optimization of the mineral value chain remains unresolved because of the inherent limitations associated with mathematical formulations and computational processing capacity. This paper details a method that contributes to bridging these limitations by employing a novel parallelized variable neighborhood descent approach combined with an embedded mass–balance component using linear programming techniques refined through Dantzig– Wolfe decomposition. This approach is exemplified through a case study of a gold deposit, which illustrates the enhanced performance capabilities of the new algorithm. The findings demonstrate significant improvements in the optimization process for mine planning, providing a stronger link between the mine’s output and processing plant’s capabilities.

Mar 1, 2025

By Mehmet Mesutoglu, Ihsan Ozkan

This study investigates the feasibility of rock bolting support in an underground coal mine gallery with a thick coal seam. The Ömerler underground coal mine working area, owned by West Lignite Enterprise of Turkish Coal Enterprises, was selected for this purpose. Longwall top coal caving is implemented as the production method in the Ömerler underground coal mine. Field and laboratory studies were conducted to determine rock mass and rock material properties, followed by experimental, empirical and numerical analyses based on the acquired data. The obtained design results were evaluated using a resin-grouted rebar rock bolting (RBR) system and steel arch support (SAS) pilot application areas. The numerical modeling results conducted using the fast Lagrangian analysis of the Continua 3D (FLAC 3D v6.0) program indicated less displacement and secondary stress change in the RBR-supported zone compared to the SAS-supported zone. In situ measurements also demonstrated that RBR provided more successful support to the roof during coal production activities. The findings suggest that RBR is a more effective solution when evaluating the feasibility of rock bolting support systems in underground galleries with thick coal seams at the Ömerler Mine. This study emphasizes the importance of more sustainable and safe support systems to enhance operational efficiency in the coal mining industry.

Mar 1, 2025

By Jon Kellar, Samuel Kessinger, Prasoon Diwakar

Tantalum (Ta) and niobium (Nb) are extracted from many different ore types. The major economic orebody mined for tantalum and niobium consists of tantalite ((FeMn)Ta2O5) and columbite ((FeMnNb2O5)) in a solid-solution mineral commonly referred to as “coltan.” The largest supplying region, The Democratic Republic of the Congo (DRC), is unfortunately also the most ethically compromised source for this critical mineral. Officially, the U.S. government has deemed coltan ore from the DRC a “conflict mineral” [1]. The lack of pragmatic and effective local mining regulation in Central Africa, when coupled with high levels of violence and corruption, has spawned a widespread, illegal, unethical and, most importantly, unsafe economy. This illicit economy is centered around first, illegally mining these valuable conflict minerals and second, smuggling these minerals into the global supply chain. Handheld spectroscopy devices could provide further transparency to these opaque supply chains, giving miners, traders and refiners the ability to authenticate the provenance of the minerals they encounter, and allowing companies to prove compliance with the regulatory agencies attempting to curtail illicit mining.

Mar 1, 2025

By Peter Amelunxen, Brandon Akerstrom

Since its introduction 40 years ago, the compartmental model of flotation has been used to predict the performance of mechanical flotation cells. However, it has found limited success for modeling dual-chamber machines and, as a result, engineers have adopted empirical correction factors usually derived from field audits of industrial cells to predict the performance of dual-chamber flotation cells. This paper introduces an extension of the compartmental model that applies to both single- and dual-chamber cells. The model is tested against pilot test work performed at Capstone’s Pinto Valley concentrator, and then used to evaluate the key operating and design parameters of dual chamber flotation cells. The results suggest that the design of the mixing chamber — for example, whether it is pneumatic or mechanically agitated — is not a significant contributor to overall machine performance. The work also suggests that the highest recoveries are achieved when the froth recovery is high, and longer separation chamber residence times and/or higher internal circulating loads are only beneficial when the froth recovery is low. Lastly, the results show that the single most important driver of the machine performance is the froth recovery of the separation chamber.

Mar 1, 2025

By Claudia Castillo, Katja Freitag, Jan Cilliers, Diana Drinkwater, Robert Seitz

The talent gap in mining is not a new challenge. Mining companies continue to seek innovative ways to attract, develop and retain talent, and younger workers are looking for opportunities to develop their professional careers. Training provides a key value proposition for both employees and employers as it helps build a talent pipeline while offering opportunities for learning and growth and value creation. In 2020, Metcelerate launched its 20-month program for early career mineral processing engineers. The program helps develop critical technical skills in the workplace and is a tool to identify motivated engineers and change culture within teams. Learners cap their skills development by executing a technical investigation. This generates immediate value—a win-win outcome for learner and company.

Feb 1, 2025