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By David Morrison

"The history of the mining industry is littered with in-pit crushing and conveying (IPCC), which should not be confused with the International Protocol for Carbon Capture, projects that failed. The failure is not the technical one of “did it achieve the desired tonnage rate for a longish test period” but, rather, the far more important one of “did it provide return on the investment in the manner that was promised?” While quite a few can claim the former, very few system installations can claim the latter.The reasons for the many failures are numerous, but they are all characterized by a combination of an element of engineering optimism in any, or all of the production rates, the productivity, or the operating and maintenance costs and in predicting the continuity of operating conditions. In these days of big data, propagating such a situation is rapidly becoming unforgivable.In this article, the three most common scenarios put to the corporate board for approval, and the logic as to why they were selected, are examined (with the irony included intentionally).• Fully mobile crusher, fed by a shovel and conveyed out of the pit to a waste dump / process plant.• Semimobile crusher (much more expensive than a fixed crushing station but which apparently allows trucks to short haul inside the pit and improve productivity), which moves when the face moves.• Relocatable crusher (more expensive than a fixed crushing station but which gets relocated at great expense after all the fixed infrastructure impeding relocation is demolished) fed by trucks that don’t leave the pit mostly.This paper will also consider the truth about their operational performance and associate costs."

Dec 1, 2016

By Rohan Fernando, David P. Snyder, John F. Burr, Susan M. Moore

"The Mine Improvement and New Emergency Response Act of 2006 (MINER Act Public Law 109-236) was passed by Congress in response to three major underground coal mine accidents in the United States that claimed the lives of 19 miners. The Act resulted in substantial changes in the underground coal industry relative to the use of technology for mine escape, rescue, disaster response and other areas where the lack of these technologies contributed to the fatalities caused by these tragedies. This year marks the 10th anniversary of the MINER Act, which makes it an opportune time to reflect on the events that led to its passage, the changes that have been made since then, and the work that remains to be done.As discussed below, the last decade has demonstrated tremendous cooperative efforts among mining operators, technology innovators, labor, The National Institute for Occupational Safety and Health (NIOSH), the U.S. Mine Safety and Health Administration (MSHA) and state regulators, resulting in substantial improvement of the technologies used for escape and rescue and noteworthy progress toward meeting many of the goals of the MINER Act. While the MINER Act and this article pertain primarily to coal mining, many of the technologies are equally applicable to any underground mining and have already found some acceptance outside of coal.Technology gaps targeted by the MINER ActThe MINER Act addressed several technology challenges:• Problems with donning and switching between self-contained, self-rescuers (SCSRs).• Poor visibility in smoke.• No wayfinding assistance for escape from the mine.• Limited breathable air supply.• Inability to locate trapped miners.• Inability to communicate with trapped miners.• Failure of mine seals."

Dec 1, 2016

"With up to 2,300 m (7,545 ft) of rock on top of it, the Gotthard Base Tunnel, which is scheduled to go into regular operation in December 2016 in the Swiss Alps, is not only the world’s longest, but also the deepest railway tunnel ever built. Accordingly, the temperatures in the tunnel are very high, with the surrounding rock expected to reach 45° C (113° F) once the tunnel is fully operational. Since unrestricted rail operations are only permitted in temperatures of 40° C (104° F) or less, the heat has to be controlled with suitable equipment. Large fans developed and built especially for this application by TLT-Turbo GmbH provide fresh air for regular operations as well as during maintenance and repair work. Separate fans ensure that the emergency exits are properly ventilated in case of fire. In addition to coming up with a technical solution that could handle the special challenges of this project, the engineers and planners had to develop detailed preliminary plans as well as a sophisticated logistics and installation concept.The Gotthard Base Tunnel consists of two 57-km (35-mile) long tubes, one in each direction. Including all connecting and access tunnels, the entire underground system measures 152 km (95 miles). At Faido and Sedrun, at approximately 16 and 36 km (9 and 23 miles) respectively, two multifunction stations were built that cut each of the two tubes into three sections of roughly equal length. Here, trains can make emergency stops and change tracks, if necessary. This is also where eight large axial fans made by TLT were installed that exchange the air, i.e. they extract a certain amount of heated air and inject the same amount of cool fresh air a few hundred meters further down the train tracks. In addition to the four exhaust and four supply fans, 24 so-called jet fans were installed along with associated components like silencers, shut-off dampers, drives and lubrication systems from TLT.In addition to exchanging the air, these fans are used to enable maintenance and repair operations in the tunnel. Current plans call for blocking each tunnel tube for one night per week in order to perform preventive maintenance work, thus enhancing the tunnel’s overall functionality and availability. During these hours, many people will be in the tunnel who require fresh air. “One of the major criteria for winning this bid was the fans’ ability to quickly switch between a wide-range of modes. TLT fans are among the best in the world in this regard,” said Andreas Kuhn, TLT’s project manager for the Gotthard Base Tunnel, about the selection of his company’s fans for this project."

Dec 1, 2016

By Kenneth Deaton

"A packaged cooling system is being developed for refuge alternatives (RAs) that will meet U.S. Mine Safety and Health Administration (MSHA) qualification guidelines for deployment in coal mines. This system will allow full occupancy ratings of deployed refuge alternatives to be maintained by keeping the apparent temperature inside the RA from exceeding 35° C (95° F).Research investigations sponsored by the National Institute for Occupational Safety and Health (NIOSH) have shown that heat buildup caused by occupants in mobile RAs will result in apparent temperatures that exceed the 35° C (95°F) limit established in 30 CFR 7.504.Figure 1 shows the temperature rise in an inflatable RA having an occupancy rating of 23 people at an 27° C (81°F) mine air temperature. This plot shows the need for either heat mitigation or occupancy derating in warmer mines.The Refuge Alternative Environmental Control System (RAECS) will be designed to provide enough heat mitigation to eliminate occupancy derating due to heat buildup over the 96-hour refuge period.This article describes testing of a prototype cooling system that uses proven vapor compression technology powered by batteries to keep the RA interior below the 35° C (95° F) limit for a minimum of 96 hours. Testing of this prototype cooling system was conducted in December of 2015 and January of 2016 at the NIOSH test mine in Bruceton, PA. December testing was conducted at the prevailing mine ambient temperature — approximately 15.5° C (60° F). The January testing was done with the mine ambient temperature in the immediate vicinity of the RA artificially elevated to 29° C (85° F). Realistic heat gain from RA occupants was provided by human simulators developed by NIOSH. These simulators add sensible heat corresponding to human metabolic processes and latent heat generated by respiration and perspiration. Heat generated by CO2 scrubbers was also added. Results of cooling system performance using these simulated loads at the two ambient conditions are described. A comparison of the apparent temperature in the RA using two different control techniques is also presented. This work documents the ability of the cooling system to meet the established apparent temperature limit at the full occupancy rating of a six person RA. A new cooling system intended for use with existing RA deployments and having greater cooling capacity is currently in development and will be described.Expendable desiccant modules were also used to provide supplemental water vapor removal and their role in mitigating cooling load is addressed."

Dec 1, 2016

By E. McCullough, S. Gaillard

"Diesel particulate matter (DPM) has been regulated by the U.S. Mine Safety and Health Administration since 2002 in underground metal and nonmetal mines. To demonstrate regulatory compliance, DPM samples must be collected and later analyzed by the U.S. National Institute for Occupational Safety and Health (NIOSH) 5040 standard method, but the FLIR Airtec DPM monitor can serve as a complementary engineering tool. The monitor is a handheld instrument that offers near-real-time measurements of elemental carbon (EC), which is a primary constituent of DPM. As part of an ongoing field study, the monitor was used to survey EC in an underground stone mine. This effort was aimed at determining spatial and temporal DPM variations in several key locations. The results of prolonged area monitoring—that is, lasting several hours — revealed that DPM concentrations were diluted substantially as air moved away from the primary production zone, but that concentrations could vary quite a bit in a single location from day to day and between seasons. DPM concentrations were generally lower in winter than in summer, which is consistent with increased natural ventilation airflows during winter. Using a modified sampling cassette, an attempt was also made to sensitize the Airtec monitor to allow for “spot-checking” of EC concentrations — that is, measurements made in several minutes. Preliminary field data showed that the sensitive cassette performed well in terms of providing accurate data that could be useful for rapid assessment of DPM. IntroductionDiesel particulate matter (DPM) is the solid fraction of the exhaust emissions from a diesel engine. It largely consists of elemental carbon (EC) and organic carbon (OC) (Birch, 2003). The World Health Organization International Agency for Research on Cancer classified diesel exhaust, including DPM, as a carcinogen (World Health Organization, 2012). It is believed to cause and/or exacerbate respiratory illness upon inhalation, deposition and retention in lung tissue. Because DPM exists in both the micro- and nanoparticulate ranges, it can bypass typical autoimmune defense mechanisms that keep larger particles out of the respiratory system (Ristovski et al., 2012)."

Dec 1, 2016

"There is no fast way to add more than 6.4 km (4 miles) of track, most of it underground, to the Sound Transit Link Light Rail system in the Seattle, WA area. But increasingly busy traffic through a number of neighborhoods made it necessary. That’s the challenge a joint venture of several tunneling contractors faced when starting its portion of the $1.9-billion Northgate Link Extension in 2013, and the project is still keeping it busy three years later. Completion will mean just a 14-minute ride from Northgate to downtown for an extra 60,000 passengers by 2030. The transit lines will join 57 km (36 miles) of new and under-construction light rail lines running north, east and south from Seattle.Voters tired of long commute times approved the project, a key part of Seattle’s regional mass transit system, in 2008. The extension is part of a plan adopted by the Sound Transit board in 1996 to connect the region’s major activity centers. The Northgate project is meant to relieve one of the area’s most congested traffic areas by connecting the Northgate, Roosevelt and University District neighborhoods to existing routes including downtown Seattle and SeaTac airport.Sound Transit dedicated more than a quarter of the project’s estimated expense — $440 million -— to general contractor JCM Northlink LLC to handle the tunnel segment. JCM is a joint venture formed in 2013 between Jay Dee Contractors of Livonia, MI, Frank Coluccio Construction of Seattle, WA and Michels Corp. of Brownsville, WI. The contractors regularly collaborate on large-scale projects and brought experience working on a different section of the extension they completed in 2013.JCM project leaders knew immediately that the schedule would be demanding. They had to work around the clock six days a week to meet deadlines. The extension runs through highly populated areas, meaning contractors had to follow strict city noise restrictions between 10 p.m. and 7 a.m. Plus, supervisors needed to manage the scheduling of nearly 250 employees to keep work running smoothly.“We had eight different operations and four different subcontractors trying to work in one tunnel,” said Chris Wood, JCM site project superintendent. “It’s important that we keep work linear. That’s the biggest challenge: keeping a path in and out so you can pour concrete, keep electricians and carpenters going, and accomplish everything else.”"

Dec 1, 2016

By Michael Gobla

"Since 1994 the Bureau of Reclamation (BOR) has used risk analysis to evaluate dams. Risk considers both the likelihood of failure and the expected consequences should failure occur. Risk analysis relies on the detailed formulation and critical analysis of all possible potential failure modes. Potential failure modes are formulated by describing the sequence of events that must occur to result in failure, where failure is defined as the uncontrolled release of the impounded reservoir. Failure occurs in response to loadings such as water seepage through a dam (static forces), shaking from an earthquake (dynamic forces), sudden flood inflows (hydrologic forces), or accidental overfilling (operational errors). Reclamation has, to a limited extent, applied risk analysis to inactive and abandoned mines to evaluate tailings dams, pit lakes and flooded underground mines. Case histories of potential failure mode analysis, as applied to mine impounded water, illustrate what critical technical information is needed to determine if failure is likely, what the consequences of failure are likely to be, and what are the highest risks that should be addressed first.IntroductionImpounded water and high water content wastes at mining and industrial processing sites are potential threats to public safety and the environment. Recent failures such as the TVA Kingston flyash impoundment failure in Tennessee in 2008 (4.1 million m3 or 5.4 million cu yd) release, the Mt. Poly Tailings Dam failure in British Columbia in 2014 (4.4 million m3 or 5.8 million cu yd) release, and the Samarco Fundao Tailings Dam failure in Brazil in 2015 (59 millon m3 or 78 million cu yd) release have renewed attention to this issue. Potential risks from impounded water at mining and industrial sites originate not only from tailing dams, but also from water in process ponds and conveyance pipelines, sediment retention dams, water retention dams, mine pit lakes and flooded underground mine workings.Conventional water retaining dams also have a record of failure. Notable examples of failure include Vajont Dam in Italy in 1963 (2,600 lives lost), Banqiao and Shimantan Dams in China in 1975 (171,000 lives lost), and Machhu-II Dam in India (10,000 lives lost). After the 1976 Teton Dam failure in Idaho, the U.S. Bureau of Reclamation (BOR) established a Dam Safety Program. By 1984, the agency developed and began using risk analysis methods. BOR operates and maintains an inventory of hundreds of aging dams which were designed and constructed over a period of 100 years. Many of these facilities were designed and constructed prior to the development and adaptation of modern soil mechanics in dam engineering. Diligent observational monitoring, detailed site investigations and the application of risk evaluation to the BOR dam inventory has identified many deficiencies resulting in significant demands on available funding for remediation efforts. The application of risk analysis has allowed the agency to rank sites by risk. By giving priority of remedial efforts to high-risk sites, significant improvements to dam safety have been achieved."

Dec 1, 2016

By William Gleason

"Speakers and attendees of the 2016 Cutting Edge Conference could not be faulted for keeping one eye on the presentations taking place at the Hyatt Regency at LAX in Los Angeles, CA on Nov. 7 and 8 and another on the results of the historic election in the United States that took place on Nov 8. While there was certainly interest in the presidential campaign, there was also a great deal of interest in Measure M on the California ballot. Measure M, which passed easily, is a half-cent sales tax increase that will fund the most ambitious transit expansion in Los Angeles County history.In the coming years, the ballot measure will transform a traffic-choked region by funding the construction of nearly a dozen new rail lines with an estimated $120 billion raised in four decades. Among the projects that could come to fruition are a twin-rail tunnels project through the Sepulveda Pass and new connections in the city.During the update on West Coast projects, Bill Hansmire summed things up with a slide asking “How much work is there on the West Coast,” and his answer was “Billions.”From Seattle, WA south to Los Angeles, there is already a lot of work for tunneling and underground construction experts, and Measure M ensures that there will be plenty of work for decades to come.Currently, The Los Angeles County Metropolitan Transportation Authority (Metro) has three rail projects underway that were funded by Measure R in 2008 — the Regional Connector, the Purple Line subway extension and the Crenshaw/LAX Line that are designed to alleviate the traffic pressure with an eye to more solutions.Measure M is the fourth sales tax increase to fund transportation in L.A. County, bringing the base sales tax rate to 9.25 percent. In some cities, which already levy their own sales tax, the rate would be higher, The Los Angeles Times reported.About 35 percent of the revenue will fund major new transit projects, such as the subway under the Sepulveda Pass, extension of the Gold Line to Claremont, extension of the Crenshaw Line to West Hollywood and acceleration of the Purple Line Subway construction along Wilshire Boulevard to finish in 2024, 10 years earlier than scheduled.About 17 percent would fund a dozen highway improvement projects, such as widening parts of I-5 in the Antelope Valley and southeastern county, adding bus lanes to the Sepulveda Pass section of the 405 freeway and adding truck-only lanes to a section of the 710 freeway."

Dec 1, 2016

By William Gleason

"There are few people more qualified to speak of the tumultuous times in the global mining industry during the past four years than Newmont Mining Corp. president and chief executive officer Gary Goldberg.Goldberg stepped into his current position in 2012, just before MINExpo 2012. Gold prices had hit record highs not long before that ($54.15/g or $1,856.40/oz on Sept. 8, 2011), expansions were happening around the world and the gold mining sector was still living in the glow of one of its longest upswings in history.That all changed between April 8 and April 15, 2013 when the price of gold dropped by nearly $200/oz ($46.27/g or $1,586.20/oz on April 8 to $40.45/g or $1,386.80/oz on April 15), putting an end to the decade-long mining boom and forcing mining companies like Newmont to re-evaluateeverything.Three years later, with the gold sector recovering, Newmont Mining is not only surviving but is thriving with a pair of mines coming online, Long Canyon in Nevada and Merian in Suriname. On Oct. 1, the Merian Mine went into production on time and more than $150 million under the initial development capital budget.Goldberg, who was one of the featured speakers at the opening session of MINExpo International 2016 on Sept. 26, also spoke with Mining Engineering about the previous four years and the future of the industry.“Mining goes through cycles all the time and gold is no different,” Goldberg told Mining Engineering when asked about surviving the downturn since 2012. “I thought it was important that we take a good methodical and steady approach across the business to determine what was the right thing to do and to set the business up to improve performance. Anyone can cut costs for the short term, but we set out to do it in a sustainable and reliable way. We created a program we call Full Potential to look for sustainable ways to reduce costs and improve productivity. That program has taken more than a billion dollars out of our costs since we implemented it 2013 and that shows up in our results. Our all in sustaining costs are down 28 percent and our productivity is up 39 percent.”During the downturn, Newmont restructured its business model, sold off some assets and created a leaner, more nimble operation. It has paid off with the addition of two new mines and the acquisition of another, the Cripple Creek & Victor Mine in Cripple Creek, CO.“The gold industry had not seen a downturn in 12 years. We had half a generation that had not experienced a downturn, so helping them through that in an organized way and keeping a view toward the long term throughout the downturn was important. We were one of the few companies that continued to invest in assets,” he said."

Nov 1, 2016

By R. Adsero

"A high altitude review of the state of the mining industry provided by a study of multifactor productivity shows a continuation of lower output year on year for the capital and labor inputs applied. The story is sadly similar for both U.S. mining and the Australian mining sector. In fact, according to PwC analysts, the world’s mining equipment productivity has declined 20 percent during the past seven years (Lumley, 2014). Although the reasons for the continuing decline in mining productivity are varied, the need for improvement is clear.The world’s mining industry fleet of more than 400 large draglines moves billions of tons of overburden and ore (phosphate, limestone, etc.) annually. This discussion will review a few of the tools available for improved productivity in dragline operations.Benchmarking equipment performance exposes the possibilitiesIn the September 2013 Mining Engineering cover story Graham Lumley and R. Adsero suggested that analyzing best practice equipment performance from an industrywide database for specific equipment performance improvement goals would be beneficial (Adsero, 2013). Benchmarking equipment performance by normalizing differences and then comparing specific measures of performance will provide a road map to improvement for those following the leaders. For those already performing at best practice levels, a benchmark confirms and bolsters what has already been achieved. As described in the SME February 2014 paper by this author, best practice is the average of the top 10 percent in annual output. Filling performance gaps identified by a comparison to best practice by investigating the details of the why and taking action to change, makes all the difference. This is true for all major mining equipment. Given the large gap between average performance and best practice performance most mining operations can benefit. Best practice performance provides a view of what is possible to the 90 percent majority of mining operations that are performing below the top 10 percent.For dragline mining operations, identifying specific characteristics and practices of leading dragline performance will provide a reference for comparison."

Nov 1, 2016

By W. R. Reed, J. P. Rider

"The Pittsburgh Mining Research Division of the U.S. National Institute for Occupational Safety and Health (NIOSH) recently developed a series of models using computational fluid dynamics (CFD) to study airflows and respirable dust distribution associated with a mediumsized surface blasthole drill shroud with a dry dust collector system. Previously run experiments conducted in NIOSH’s full-scale drill shroud laboratory were used to validate the models. The setup values in the CFD models were calculated from experimental data obtained from the drill shroud laboratory and measurements of test material particle size. Subsequent simulation results were compared with the experimental data for several test scenarios, including 0.14 m3/s (300 cfm) and 0.24 m3/s (500 cfm) bailing airflow with 2:1, 3:1 and 4:1 dust collector-tobailing airflow ratios. For the 2:1 and 3:1 ratios, the calculated dust concentrations from the CFD models were within the 95 percent confidence intervals of the experimental data. This paper describes the methodology used to develop the CFD models, to calculate the model input and to validate the models based on the experimental data. Problem regions were identified and revealed by the study. The simulation results could be used for future development of dust control methods for a surface mine blasthole drill shroud. IntroductionIn surface mines, production drilling is an essential process in blasting to fracture the hard rock overburden for removal. During the process, considerable amounts of respirable dust are produced. Past sampling at the shroud area of blasthole drills had documented time-weighted-average respirable dust concentrations ranging from 8.68 to 95.15 mg/m3 (Organiscak and Page, 1995) and 1.04 to 52.30 mg/m3 (Listak and Reed, 2007). These high dust concentrations, which may contain silica, can lead to respirable dust overexposures for the miners working nearby. These overexposures can lead to silicosis, an occupational lung disease that has no cure and is ultimately fatal.Two basic methods are used to control drilling dust: a wet suppression system or a dry collection system (Cecala et al., 2012). Dry drilling techniques using a dust collection system are preferred in rural mining locations where a constant water supply is not available, and in the case of rotary drilling where water is associated with accelerated bit wear due to bearing degradation and hydrogen embrittlement. In addition, dry drilling eliminates freezing-related issues with water in colder climates. Dry dust collectors are highly effective at removing dust, especially the finer material, as long as they are properly operated and maintained (Listak and Reed, 2007; Organiscak and Page, 2005)."

Nov 1, 2016

By C. L. Kosmoski, B. M. Eiter, B. P. Connor

"In the recent past, the mining industry has witnessed a substantial increase in the numbers of fatalities occurring at metal and nonmetal mine sites, but it is unclear why this is occurring. One possible explanation is that workers struggle with identifying worksite hazards and accurately assessing the associated risk. The purpose of this research was to explore this possibility within the mining industry and to more fully understand stone, sand and gravel (SSG) mine workers’ thoughts, understandings and perceptions of worksite hazards and risks. Eight mine workers were interviewed and asked to identify common hazards they come across when doing their jobs and to then discuss their perceptions of the risks associated with those identified hazards. The results of this exploratory study indicate the importance of workers’ jobrelated experience as it applies to hazard identification and risk perception, particularly their knowledge of or familiarity with a task, whether or not they had personal control over that task, and the frequency with which they perform that task. IntroductionAccording to the U.S. Mine Safety and Health Administration (MSHA, 2015a), 37 mine workers were fatally injured in accidents at metal and nonmetal mine sites between October 2013 and January 2015, following a record low of 16 in 2012 and in 2011. In 2014 alone, 29 mine workers were fatally injured at a metal or nonmetal mine site, and 52 percent of these fatalities occurred at a surface stone, sand or gravel (SSG) mine. In January 2015, Joseph A. Main, Assistant Secretary of Labor for Mine Safety and Health wrote to stakeholders in the metal and nonmetal mining community and identified several areas where improvement was necessary to promote the health and safety of mine workers. One area identified was an increased focus on “daily and effective workplace exams to find and fix hazards” (MSHA, 2015b).Hazard detection is challenging in the mining industry, despite the existence of regulation. Mining is a major undertaking involving the use of complex heavy machinery, equipment and processes as well as numerous and diverse worker activities that take place in a dynamic, challenging environment (Scharf et al., 2001). In other industries that are similarly dynamic and unpredictable, such as the construction industry, a large proportion of hazards go undetected (Carter and Smith, 2006). It is critical that miners are able to both recognize worksite hazards and accurately assess the risk associated with the hazards, because their health and safety depend on their deciding whether and how to remove hazards and mitigate risks."

Nov 1, 2016

By S. G. Britton

"Strategies to improve performance in mining production, maintenance and mineral processing operations have evolved over time from straightforward time studies of individual machine performance in the 1960s-1970s to more sophisticated and better focused statistical and financial tools that have emerged in the 1980s-1990s. These newer strategies fall under the broad descriptive category of operational excellence.Operational excellence is the term that embodies a number of performance evaluating strategies, the most popular and relevant to mining include the following:• Six sigma for addressing errors within mining or milling process and work standards.• Lean manufacturing to optimize organizational and operational performance through continuous improvement.There are other strategies that can be applied as well and this paper is not focused on a review of the pros and cons of any one strategy. However, the common threads in these strategies embody the expectation that expected results from these efforts can be quantified and that value will positively benefit the targeted work process, organizational unit, equipment deployment or time schedule when applied to it as part of continuous improvement efforts.The priority for proceeding with any one or more of these efforts is based on the calculated net value of the required resources to make the change versus the estimated value gained. The practice is identified as the value mapping process.This discussion summarizes the value mapping process methodology used at a mature uranium mine and mill in northern Canada to work through the myriad of potential improvement efforts available through the operational excellence process for continuous improvement."

Nov 1, 2016

By P. T. Bissert, T. J. Lutz, J. A. Yonkey, G. T. Homce

"The U.S. National Institute for Occupational Safety and Health (NIOSH) has been researching refuge alternatives (RAs) since 2007. RAs typically have built-in pressure relief valves (PRVs) to prevent the unit from reaching unsafe pressures. The U.S. Mine Safety and Health Administration requires that these valves vent the chamber at a maximum pressure of 1.25 kPa (0.18 psi, 5.0 in. H2O), or as specified by the manufacturer, above mine atmospheric pressure in the RA. To facilitate PRV testing, an instrumented benchtop test fixture was developed using an off-the-shelf centrifugal blower and ductwork. Relief pressures and flow characteristics were measured for three units: (1) a modified polyvinyl chloride check valve, (2) an off-the-shelf brass/cast-iron butterfly check valve and (3) a commercially available valve that was designed specifically for one manufacturer’s steel prefabricated RAs and had been adapted for use in one mine operator’s built-in-place RA. PRVs used in tent-style RAs were not investigated. The units were tested with different modifications and configurations in order to check compliance with Title 30 Code of Federal Regulations, or 30 CFR, regulations. The commercially available relief valve did not meet the 30 CFR relief pressure specification but may meet the manufacturer’s specification. Alternative valve designs were modified to meet the 30 CFR relief pressure specification, but all valve designs will need further design research to examine survivability in the event of a 103 kPa (15.0 psi) impulse overpressure during a disaster. BackgroundThe Mine Improvement and New Emergency Response Act of 2006, known as the Miner Act (U.S. Department of Labor, 2006), was enacted in the wake of three mine accidents involving explosions or fire that claimed 19 lives that year. Intended to help improve underground coal mine accident preparedness, the Miner Act includes provisions that target mine safety issues in areas such as emergency response planning; adoption of new technology; training and education; and mine safety standards enforcement. Section 13 of the Miner Act specifically directed the U.S. National Institute for Occupational Safety and Health (NIOSH) to provide for research into the effectiveness and viability of refuge alternatives (RAs) for underground coal mines, and the U.S. Department of Labor to act on the results of such research, as appropriate. These mandates culminated in the 2009 adoption of changes to the Title 30 Code of Federal Regulations, or 30 CFR, mining health and safety regulations (U.S. Department of Labor, 2008), requiring underground coal mines to supply mine emergency RAs and associated components so as to provide a life-sustaining environment for persons trapped underground. Such RAs can be either selfcontained mobile units or built-in-place facilities. The regulatory changes also include provisions establishing requirements for the approval of RAs and their components by the U.S. Mine Safety and Health Administration (MSHA), among which are numerous criteria for providing a safe breathable atmosphere under positive pressure within the RAs. One criterion for maintaining a safe RA atmosphere is the inclusion of an air pressure relief valve that will activate at a maximum of 1.25 kPa (specified as 0.18 psi, or approximately 5.0 in. H2O), or as specified by the RA manufacturer, above mine atmospheric pressure in the RA (U.S. Department of Labor, 2008)."

Oct 1, 2016

By Bradley S. Van Gosen, Anjana K. Shah, George M. Bedinger, Donald I. Bleiwas, Karl J. Ellefsen

"Ancient and modern coastal deposits of heavy mineral sands (HMS) are the principal source of several heavy industrial minerals, with mining and processing operations on every continent except Antarctica. For example, HMS deposits are the main source of titanium feedstock for the titanium dioxide (TiO2) pigments industry, obtained from the minerals ilmenite (Fe2+TiO3), rutile (TiO2) and leucoxene (an alteration product of ilmenite). HMS deposits are also the principal source of zircon (ZrSiO4), from which zirconium dioxide (ZrO2) is obtained for uses mostly in refractory products. Sometimes monazite [(Ce,La,Nd,Th) PO4] is recovered as a byproduct mineral, sought for its rare earth elements, and thorium (Ault and others, 2016; Sengupta and Van Gosen, 2016; Van Gosen and Tulsidas, 2016).HMS are sediments containing dense (heavy) minerals that accumulate with sand, silt and clay in coastal environments, locally forming economic concentrations of the heavy minerals (Fig. 1). Economic (mined) HMS deposits include Holocene sediments on modern coasts, such as examples in India and Brazil, as well as coastal deposits formed by transgressions and regressions of the seas during intervals in the Quaternary, Tertiary and Cretaceous, such as in Australia and the southeastern United States. Economic deposits typically contain heavy-mineral concentrations of at least two percent. Individual heavy minerals are commonly defined as minerals with a specific gravity greater than approximately 2.9 g/cm3. These minerals are generally resistant to chemical weathering and physical degradation and thus survive well in fluvial and coastal environments. Heavy minerals in coastal HMS deposits may include, in order of general abundance, ilmenite, leucoxene, rutile, magnetite, zircon, staurolite, kyanite, sillimanite, tourmaline, garnet, epidote, hornblende, spinel, iron oxides, sulfides, anatase, monazite, cassiterite and xenotime. Of these, ilmenite, leucoxene, rutile and zircon are the primary economic minerals. Garnet, monazite, cassiterite and xenotime are occasionally recovered as byproducts. The heavy minerals as a suite typically make up no more than 15 weight percent of a deposit and usually much less. Quartz and clay minerals form the bulk of the sediment. The geology of HMS deposits and examples of significant districts are summarized in Van Gosen and others (2014) and Hou and Keeling (2016)."

Oct 1, 2016

By C. McAllister, D. Preece, J. Berendzen

"The Multiple Blasthole Fragmentation (MBF) model models multiple explosive charge contributions and the effect on fragmentation of delay timing with its associated scatter for each blasthole. The model uses near-field blast vibration attenuation parameters and the ground p-wave velocity as inputs for part of the in situ rock property to model rock fragmentation. It models most blast design parameters explicitly and simulates the effect of wave reinforcement due to the interaction of simultaneously arriving waves or diminishing cooperative contribution from long delay intervals between charges within a blasthole or among blastholes. The fragmentation size is calculated at three-dimensional grid points within a blast, and the fines and oversized blocks are treated explicitly. The model takes a surveyed irregular geometry of the free face of a blast as the calculation boundary.This paper presents a case study on applying the MBF model at an openpit mine. Near-field vibration measurements from signature hole blasts were conducted to obtain the stress-wave magnitude and attenuation parameters as well as ground sonic velocity. A production blast was then monitored with the corresponding fragmentation measured, serving as site-specific inputs to the MBF model. Various blast design scenarios were then simulated to develop ones that provide better fragmentation to improve mill throughput for the mine. IntroductionThe semiempirical fragmentation models currently found in the literature (Cunningham, 1987; Lownds, 1995) cannot explicitly model contributions from multiple blastholes with varying delay intervals. Most of these models are not three-dimensional. Furthermore, these models predict an average fragmentation size within a volume surrounding a blasthole and use the average size to generate a size distribution over the volume. The percentage of fines and oversize blocks is included in the distribution. Typically, such models are inadequate for predicting fines and oversize blocks (Cunningham, 1987)."

Oct 1, 2016

By Ewan Alexander

"As human beings, we have managed risk since the dawn of the ages and have been adept at doing so. In order to survive, we hunted or gathered. If we did not take enough risk, we died. If we took much risk, we died (Fig. 1). As individuals and tribes, risk had to be optimized to maximize our chances to thrive, as individuals and as tribes.In today’s world, the risks are vastly different, but in order to thrive, these must be managed. And no industry knows this as much as mining. In fact, the International Council of Mining & Metals (ICMM) has proposed the Critical Risk Model (Fig. 2) as a means of identifying critical risk, critical controls and associated performance standards. The ICMM focuses on sustainable development performance in the mining and metals industry. It has 23 members, representing some of the largest mining companies in the world.This approach is going to help the mining industry. But it must be applied effectively, with the acknowledgment that the system alone cannot be effective. We can say this confidently, as even companies known for the strength of their risk and safety management systems continue to experience significant incidents, and, in some cases, catastrophes. Why does that happen when all safety metrics, including injury rate, are pointing in the right direction? In the view of the author, it is only when leadership, culture and systems work in complete harmony that the resilience of an organization to manage its significant risk is at an optimal level. It remains an ongoing leadership challenge to maintain that balance and the optimal mindset in the organization. So how do you maintain that special balance?Let’s start with a basic premise. Leadership, supported by simple effective systems, creates culture which creates outcomes. Everyone going home safely is an outcome, as is cost effective operations, and to achieve those outcomes efficiently, the organization must focus on the inputs. And those inputs include effective leadership, effective systems (for the purposes of this article, risk and health, safety and environment (HSE) systems), good planning, stable operations and competent workers. This article will focus on gaining maximum performance from your risk management system."

Oct 1, 2016

By Joseph A. Dos Santos

"The subject of this writing was first published in 1998 with the emphasis on the hardware cost comparison. Other costs, such as the required land area and spatial volume, were mentioned but not emphasized, as these were not deemed as important for new projects where the space was appropriated as required. During the last decade, these other costs have proven to be more than equal in importance. These costs are emphasized here through specific accounts of actual highangle conveyor installations that demonstrate the importance and the high-angle advantage An update on the progress in sandwich belt highangleconveyor technology is also provided.Origin and progress in sandwich belt conveyorsCover belts of the 1950s. Large volume, highangle conveying by “conveyors with cover belt, dates back to the early 1950s, when such systems were employed at the bucket wheel excavator boom conveyor in German lignite mines to increase the depth of cut without increasing the boom length. Various systems were developed, patented and built. These systems were not a lasting success for various reasons, which are noted by Rasper[1]. In his 1958 “Review of Cover Belt Systems,” Rasper summarizes the characteristics which are worth pursing and those that should be abandoned. The former are akin to good conveyor engineering. The sandwich belt conveyor model. The first sandwich belt conveyor model allowed calculation of the required hugging pressure to develop the bulk material’s internal friction and preclude material slideback. A modern, accurate version of the sandwich belt conveyor model is presented in Fig. 1. This model depicts accurately a derating of the material cross-section allowing an ample belt edge distance that can tolerate normal belt misalignment without material spillage. The calculations must thus recognize that only part of the hugging pressure is imparted onto the material with the remainder transferred belt edge to belt edge affecting a material seal. Mathematical development of the sandwich belt model is covered by Dos Santos and Frizzell in their 1983 article, “Evolution of Sandwich Belt High Angle Conveyors.”"

Sep 1, 2016

By Shawn P. Coughlin, Michael A. Schimmenti, Juan Leonardo Tello del Pino

"The Sistema de Potabilización Área Norte project (Northern Area Purification System) was a major expansion of the potable water system in Buenos Aires Province, Argentina. The aim of the project was to transport and purify raw water from the Paraná River to provide potable water for five communities in the northern part of the province, benefitting up to two million people. The project was constructed by a joint venture (JV) of four South American contractors and consisted of the following key components:• Treatment plant: A 16-ha (39-acre) area was cleared for the construction of a treatment plant to purify 900,000 m3/day (1.2 million cu ft/d) of raw water from the Paraná River and distribute it to the surrounding communities.• Bored tunnel: Nearly 15 km (9 miles) of 3.6 m (12 ft) inner diameter tunnel, ranging from 18 to 22 m (59 ft to 72 ft) below grade, was bored with two earth pressure balance (EPB) tunnel boring machines (TBM) to draw the raw water from the river. The TBMs started from a central launch shaft and proceeded in opposite directions. Cristina advanced northbound to the Paraná River Intake System, and Liliana advanced southbound to the new treatment plant.• Access and ventilation shafts: Five access shafts and eight ventilation shafts were installed along the length of the tunnel. The access shafts were designed to provide entry points for inspection and maintenance of the final tunnel. The five shafts consisted of one central launch shaft in the middle of the tunnel alignment, one retrieval shaft at each end of the tunnel (intake and treatment plant, respectively) and two intermediate shafts. The intermediate shafts were installed before the TBM passed, with a final liner to be installedafterward."

Sep 1, 2016

By Faruk Oksuz, Dave Schiemann, Matt Trotter, Mike Padilla, Carmen Scalise, Miquel Sanchez

"The McCook Main Tunnel system consists of a 10-m (33-ft) finished diameter, 490-m (1,600-ft) long, hard rock tunnel constructed from a 27.5-m (90- ft) diameter and 92-m (300-ft) deep main gate and tunnel construction access shaft. The gate shaft houses six, high-head 4.4 m by 9 m (14.5 ft by 29.5 ft) wheel gates to be installed in the bifurcated and steellined section of the tunnel. The tunnel also includes portal and energy dissipation structures as it daylights into the reservoir.The construction of the tunnel system has been divided into two contracts. The gate and construction access shaft was completed in August 2011. The tunnel excavation and concrete and steel lining was completed in September 2014. The remaining and undergoing construction include the tunnel connections to the reservoir and the Mainstream Tunnel and installation of gates and hydraulic cylinders. This article focuses on the live connection of the McCook Main Tunnel to the Mainstream Tunnel that was initiated in November 2014 and will continue through the seasonal drier weather conditions in Chicago approximately from October through April. Chicago TARP systemThe MWRD has been addressing combined sewer overflows (CSO) and flooding in Chicagoland since the late 1960s and formally adopted the tunnel and reservoir plan in 1972 to protect the region’s most precious drinking water supply, Lake Michigan. Phase I of TARP, which included construction of 175 km (109 miles) of deep storage and conveyance tunnels with diameters up to 10 m (33 ft), was completed in 2006. In addition to protection of Lake Michigan from CSO discharges, Phase I resulted in substantial improvements in surface water quality as well as the quality of life for lake and riverfront communities in Chicago. Water quality improvements and flooding mitigation will be further enhanced as Phase II reservoirs are placed in service, including the three large reservoir systems, McCook, Thornton and Majewski (Fig. 1).The McCook Reservoir is the largest reservoir in the TARP system. Once completed, this $700-million reservoir facility will receive 38 billion L (10 billion gal) of CSO and flood water via the McCook Main Tunnel, which connects the TARP Mainstream Tunnel to the McCook Reservoir, and from distribution and Des Plaines inflow tunnels which will bring flow from the Des Plaines Tunnel of TARP."

Sep 1, 2016