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By Corry Goumans

Description of Project: Drilling, Blasting and Installation of Catenary Cables. Project Owner: Rio Tinto Alcan

Jan 1, 2010

By D. P. Bishop, G. J. Kipouros, R. L. Hexemer Jr., I. W. Donaldson, W. F. Caley

Aluminum powder metallurgy (APM) is an advanced metal forming technology frequently employed to fabricate complex structural components in a near-net-shape fashion. Exhibiting nearly 100% material utilization, APM continues to rise in popularity. Recent research initiatives in this field have emphasized the development and processing of advanced 2xxx and 7xxx series alloys. In particular, APM equivalents to wrought 7075 and 2024 have been sought. An overview of work completed in this area is presented. Included are data on the various production stages (powder compaction, sintering, forging, and heat treatment) as well as the microstructure and mechanical properties of the finished products.

Jan 1, 2010

By Tristan Worsey

This work was performed during the summer of 2008 during the junior year of a BS in Mining Engineering. It was observed that the mine was having a problem with back break during the blasting of development drifts. The unwanted back break was causing the mine extra costs in ventilation, ore dilution, ground support, back fill, explosives and man-hours. The blasting practices were observed for four weeks and the problems and their solutions were defined. In this paper the reasons and causes of the problem are explained with the proposed solutions to eliminate back break.

Jan 1, 2010

Well designed and maintained haul roads are the key to minimizing truck haulage on-road hazards and costs, as well as increasing productivity. However, practically designing and managing a haul road for optimal performance is often difficult to achieve. Poorly designed and built roads exhibit high rolling resistance - a 1% increase in road rolling resistance can typically reduce speed on ramp by as much as 10% - and on the flat by up to 26%. In the current economic climate, investment and operating decisions come under scrutiny. In the long run, this scrutiny returns improved efficiencies and leaner, healthier operations. The focus of this evolving evaluation process should and will certainly fall on haulage operations ? simply by virtue of their contribution to overall cost of operations ? often in excess of 50% of total costs for deep open-pit mines. Whilst the end result - improved efficiency and reduced cost per ton hauled ? is not in itself problematic, it is the route, or process followed to achieve these savings that needs to be carefully managed. We can be guided on this journey by our understanding of how a road design is developed, and, critically, the interplay between a good design and safe, cost efficient haulage. This paper briefly summarizes the evolution of mine haul road design, from the seminal USBM work of Kaufman and Ault in 1977, through to current geometric, structural, functional and maintenance management design components. These augmented design and management guidelines have been developed over the past decade, both in response to the requirements of mine operators for more safe and efficient haulage systems, and the truck manufacturers? requirements for a more predictable and controlled operating environment. These developments have been paralleled by the need to minimize haulage hazards, both from a health and safety perspective. Whilst improved mine haul road design does indeed reduce haulage accidents, recognition also needs to be given to human factors which are a significant contributor to haulage accidents. The human factor is the most problematic to address in a road design. It is often easier break the link between the interactive effects which may lead to accidents than trying to predict and reduce human error. These human factor interactive effects include the geometric, structural and functional design components and to prevent an accident or reduce the severity of its consequences, a road should be more accommodating to human error. The more that is known about human error, the better a road can be designed to accommodate those actions or non-standard practices that would, on a poorly designed road, invariably escalate an error into an accident.

Jan 1, 2010

By Michelle Crull, Susan Hamilton

Explosives safety requirements in the United States began in 1909 when the American Railroad Institute questioned explosives manufacturers regarding distances necessary to protect employees and property. In response to this inquiry, a group of explosives manufacturers collaborated to study over 200 explosive accidents. This study resulted in the 1914 American Table of Distance (ATD) published by the Institute of Makers of Explosives (IME). The 1914 ATD provided suggested separations between explosives and inhabited buildings, public highways, and public railways.

Jan 1, 2010

By Thomas M. Barczak

This US. Bureau of Mines report examines the roof and floor contact pressure provided by the interaction of a shield with the surrounding strata. Controlled forces were applied to an 800-ton two-leg shield in the Bureau's mine roof simulator; the distribution of forces acting on the canopy and base of the shield were measured with 24 hydraulic pressure cells. Several influential factors that affect the load distribution were investigated: (1) the magnitude of loading (leg pressure); (2) the profile of the canopy, principally the upward-sloping tip; (3) the base-lifting device; (4) horizontal load acting on the shield; and (5) compliancy of the immediate roof and floor. It was concluded that the shield does not develop full canopy or base contact without deformation of the strata. Maximum contact pressures are developed at the rear of the canopy and on the toes of the base. Less than 10 pct of the available shield capacity is developed at the canopy tip despite the design intention to ensure tip contact. Horizontal loading reduced the toe pressure acting on the base by as much as 75 pct. The base-lifting device exaggerated the inherently high toe loading, increasing the contact pressure by more than 200 pct.

Jan 1, 2010

By J. Drew Potts

In this U.S. Bureau of Mines study, four underground respirable dust surveys were conducted to determine factors affecting belt entry dust levels and how using belt air to ventilate work areas affected dust exposures. Belt entry dust levels on the surveyed longwall and continuous miner sections averaged 0.59 and 0.26 mg/m3, respectively. The stageloader-crusher contributed an additional 0.5 to 0.9 mg/m3 of dust to belt air, while the feeder-breaker contributed 0 to 0.2 mg/m3 of dust. A 1,000-ft increase in belt entry length or a 200-to 500-st-per-shift increase in production resulted in roughly a 0.1-mg/m3 increase in dust. Using the belt entry as an intake entry on the continuous miner section appeared to reduce dust levels by 0.1 to 0.3 mg/m3 during cutting. Belt air was not used to ventilate the face on the longwall section.

Jan 1, 2010

By Y. Miron

'This report presents a U.S. Bureau of Mines study to identify the causes of self-heating events beneath the floor of a deep underground coal mine. Mine samples from both heated and unheated areas were examined by various techniques, including visual, microscopic, thermal, chemical, and instrumental tests. The combined results led to the conclusion that pyrite (FeS2) oxidation was the prime cause of the beatings. However, adiabatic oven tests of selected samples did not indicate the effect of the pyrite on the self-heating process, probably because of the experimental conditions. A fast, simple procedure to assess the concentration of pyrite in the mine samples was developed, g the reactivity of the sample with an aqueous solution of hydrogen peroxide (H2O2).

Jan 1, 2010

By I. du Plessis

The metallurgical response of a difficult to treat coal and an easy to treat coal orebody were investigated in terms of the coal yield and the coal quality in a basic coal recovery flowsheet. The purpose of this paper is to show trends and derive principles for the treatment of different coal types. This investigation entailed using the LIMN simulator to simulate the metallurgical response by varying the plant operational parameters. The controllable plant variables investigated were: ?Cyclone size ?Screen and hydro-cyclone cut points ?Medium cut density ?Feed particle size distribution.

Jan 1, 2010

By Ronald S. Conti

This U.S. Bureau of Mines report discusses the results of research conducted in the Bureau's experimental mine at Lake Lynn Laboratory on the response of fire sensors to simulated mine fires, which included (1) a slowly developing coal-conveyor belt fire, (2) a rapidly burning liquid fuel-belt fire, and (3) a liquid fuel-belt fire in the presence of diesel exhaust. During these tests, several mine fire sensors were evaluated with respect to sensor placement, spacing, and type. The data indicate that smoke sensors alarm several minutes before CO sensors do; and that, in the presence of diesel exhaust, a prototype diesel-discriminating smoke sensor can successfully function without being sensitive to the diesel contaminants. The vertical placement of sensors in the entry near the fire was also shown to be critical in terms of alarm times. Additional data showed that variations exist in response time and level of response for two brands of electrochemical CO sensor. Results also indicate that early detection of fires will improve the probability of miners' escape, because of reduced smoke concentrations during the incipient stages of the fire.

Jan 1, 2010

By T. H. Dubaniewicz

Fiber-optic technology is progressing rapidly, including the development of fiber-optic sensors for many applications. These sensors have the advantages of high sensitivity, light weight, small size, high bandwidth, and freedom from electromagnetic influences. The U.S. Bureau of Mines is investigating the use of fiber-optic technology to monitor mine atmospheres. This report describes a methane monitor based on differential absorption of infrared light. The monitor can detect methane concentrations as low as 0.2 vol pct as far away as 2 km via fiber-optic cable. The upper range is 100 vol pct methane. Since the system requires no electrical power within the mine, it is intrinsically safe.

Jan 1, 2010

By M. J. Brnich

The purpose of this U.S. Bureau of Mines study was to assess the ability of trainees to don an unfamiliar self-contained self-rescuer (SCSR) after having become familiar with how to put on a different type of apparatus. Prepractice instruction was the same for all individuals learning to put on a device: a step-by-step, hands-on talk-through using the "3+3" method. Subjects were assigned to groups that had their initial donning instruction delivered on either the Draeger OXY-SR60B or the CSE SR-100. Trainees' performances were then evaluated using the other model. Donning trials were analyzed using a number of measures. It was found that SCSR design had a moderate influence upon how well the donning task transferred.

Jan 1, 2010

By A. C. Smith

The U.S. Bureau of Mines evaluated the effectiveness of automatic water sprinkler systems on the suppression of incipient and propagating conveyor belt fires under ventilated conditions. Large-scale experiments were performed at airflows ranging from 1.1 to 4.6 m/s. In incipient fire experiments with 100°C, standard-response sprinklers installed above and between the belts, the sprinklers activated later, the peak heat release rates were larger, and more belting was consumed at the higher airflow. In similar experiments with 74 °C, fast-response sprinklers, the sprinklers activated at the same heat release rate for both high and low airflows, but the peak heat release rate and amount of belting consumed was slightly higher at the lower airflow. In incipient fire experiments with sprinklers located only above the top belt, the heat release rate and amount of belting consumed was larger at the higher airflow. The propagating fire experiments showed that sprinklers located above and between the belts were effective in stopping flame propagation. Peak heat release rates and amount of belting consumed were larger at the higher airflows for both the 74 °C, fast-response and 100 °C, standard-response sprinklers. The sprinklers were equally effective at each airflow.

Jan 1, 2010

By A. Taylor, E. Thorn Corthay, J. Farrell, L. A. Westfall, S. Borchardt

Mining and metallurgical industries need to minimize their greenhouse gas (GHG) emissions; Hatch specializes in conducting mining and metallurgical energy management assessments and optimizing productivity. Projects executed have demonstrated that there is a wealth of energy management, waste reduction, and process efficiency improvements that require no or low capital investment. Typical energy cost savings are on the order of 5% to 12%, with similar reductions in GHG emissions. Hatch generates Marginal Abatement Cost Curves to optimize the implementation pathway, maximizing carbon abatement and minimizing cost. The findings of a practical case study from Cameco are presented.

Jan 1, 2010

By S. O. Bada

Coal is a complex mixture of organic and mineral constituents and is the most abundant resource of fossil energy in the world. In recent years, significant research into dry coal beneficiation has gained much attention, primarily due to the need to improve grades and reduce the environmental contaminants in coal without the use of water, and to achieve this in as cost-effective manner as possible, relative to wet beneficiation processes. This paper seeks to review the application of various electrostatic separators with their process principles, to draw comparisons between different dry beneficiation techniques with specific emphasis on the tribo-electrostatic separation method, and finally to report the results of tribo electrostatic separation conducted on various South African coals. Previous research conducted on Indian, European and American coals has indicated that this technique is likely to lead to significant economic benefit through the reduction of ash content, NOx and more specifically Sox by separating out the liberated Fe-S-bearing minerals prior to utilization. The removal of the latter suite of minerals is also likely to significantly reduce or eliminate the emissions of associated trace elements, including mercury and arsenic. The research results reported in this paper indicate that the rotary tribo-electrostatic process has the potential for significant upgrading of high ash pulverized South African coal. The impact of various operational parameters was investigated and key factors established for the optimum recovery of low ash and low sulphur fine coal.

Jan 1, 2010

By R. Michael

Among underground coal miners, hearing loss remains one of the most common occupational illnesses. In response, the National Institute for Occupational Safety and Health (NIOSH) conducts research to reduce the noise emission of underground coal-mining equipment, an example of which is a roof bolting machine. Field studies show that, on average, drilling noise is the loudest noise that a roof bolting machine operator would be exposed to and it contributes significantly to the operators? noise exposure. NIOSH has determined that the drill steel and chuck radiate a significant amount of noise during drilling. NIOSH and the Corry Rubber Corporation have developed a bit isolator that breaks the steel-to-steel link between the drill bit and drill steel and a chuck isolator that breaks the mechanical connection between the drill steel and the chuck. This effectively reduces the noise radiated by the drill steel and chuck and reduces the noise exposure of the roof bolter operator. The paper documents the evolution of the bit isolator and chuck isolator. Laboratory testing confirms that production bit and chuck isolators reduce the A-weighted sound level generated during drilling by 3.7 to 6.6 dB

Jan 1, 2010

By M. F. Chambers

The U.S. Bureau of Mines conducted experiments on electrowinning of neodymium metal by using a molten-metal cathode at 650° C and an electrolyte of 50 mol pct NdCl3 (neodymium chloride) and 50 mol pct KCI (potassium chloride). The molten-metal cathodes were alloys of magnesium and zinc or magnesium and cadmium. Current efficiencies were 90 pct with a Mg-Zn cathode and 80 pct with a Mg-Cd cathode; The Mg-Cd cathode was easily separated from the electrolyte. In contrast, the Mg-Zn cathode tended to mix with the electrolyte, making separation difficult. The cathode metals were separated from the neodymium by distillation at 1,100° C under a vacuum of 10-3 torr. Neodymium metal of 99.9+ purity was recovered from the Mg-Cd alloy cathode after 30 min distillation time. The neodymium recovered from the Mg-Zn system contained almost 2 pct Zn after vacuum distillation. Continuous operation using the Mg-Cd alloy cathode was demonstrated.

Jan 1, 2010

By D. M. C. Valbom

The introduction of new diamond sorting technologies as well as additional manufacturers I vendors, has increased the equipment selection and combinations available for recovery flowsheet design. This paper describes the methodology used and the benefits realized in the design of recovery plants by ensuring a fundamental understanding of the advantages and limitations of the technology embodied in the equipment, a comprehensive knowledge of the ore body characteristics, and the effective matching of this information in combination with operational commercial requirements.

Jan 1, 2010

By E. A. Domínguez

Kaolin deposits of Patagonia (Argentina) were formed by ?in situ? alteration of volcaniclastic rocks or by erosion, transportation, and deposition of residual clays in small basins. The mineralogy, geochemistry, grain size distribution, and specific surface area of natural and washed kaolins were studied in order to point out the relationships with the ceramic process. Primary kaolins are coarse-grained, kaolinite+quartz±halloysite, with a very low specific surface area. Sedimentary clays are either kaolinitic?smectitic and very fine-grained or kaolinitic with a coarser particle size distribution. An interdependence between mineralogy, chemistry, particle size distribution, texture, surface activity and ceramic behavior was found. Plasticity is strictly dependent on surface activity and expandable clay minerals. Slip rheology is affected by soluble salts, smectite, and tubular halloysite. Kaolinite-halloysite play an opposite role versus smectite-I/S in slip casting and tile pressing. Kaolinite and quartz are beneficial for drying behavior while expandable clay minerals increase drying sensitivity. Firing behaviour is mainly affected by minor components supplying fluxing oxides.

Jan 1, 2010

By G. F. Friel

A series of experiments in the U.S. Bureau of Mines Safety Research Coal Mine at the Pittsburgh Research Center evaluated the effects of crosscuts on the travel time of carbon monoxide (CO) along an entry to improve the accuracy of a mine-fire locator program. Three entries, ten single crosscuts, and three double crosscuts were instrumented with CO sensors. One-percent CO in nitrogen was released and monitored as it traveled the entries. In addition to dispersion of CO at the front of the CO wave, CO was entrained from the entry into the crosscuts. It was determined for an entry and single-crosscut configuration that the measured travel time for a concentration change of 5 ppm was 27% greater than the predicted time based upon entry volume only, but 13% less than the predicted time based upon entry and crosscut volumes. For an entry and double-crosscut configuration, the measured travel time for the same concentration change was 25% greater than the predicted time based upon entry volume only, but 10% less than the predicted time based upon entry and crosscut volumes. An effective dispersion coefficient for CO dispersion along one of the entries was estimated to be 1.5 m2/ s.

Jan 1, 2010