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By Mokhinabonu Mardonova, Yosoon Choi

Open-source technology for supporting the Industry 4.0 has become the target of academic research in many sectors. This study reviewed the trends of open-source technology, its forms, and some industrial applications. As a case study using open-source hardware and software for the mining industry, this study proposed a low-cost environmental monitoring system for non-metallic underground mines to support mine safety and occupational health issues. The system was developed using open-source hardware, Arduino and 3D printer, to design the monitoring device. An open-source software, MIT App Inventor, was used for developing an Android application for smartphones to enable remote communication with the system. Field experiments were conducted at an underground tunnel and a non-metallic underground mining site to assess the performance of the system in both mobile and static modes, respectively. Although a few limitations related to the precision of the low-cost dust and gas sensors still exist, the findings of the experiments show that the mining industry can benefit from open-source technology deployment when considering cost factors

By Nikhil Dhawan, Ashwini Kumar, Yogendra Pratap, Himanshu Tanvar

India does not possess any soluble potash reserves and depends completely on imports. In this study, an attempt has been made to recover potash (K) values from the mica sample employing thermal and mechanical routes followed by leaching. Direct leaching of mica in different lixiviants is found to be ineffective with very low K-dissolution (1–5%). Heat treatment with different fluxes, such as NaCl, NaOH, and CaCl2, is carried out and almost 85% K-values are recovered. Mechanical activation of mica and with different calcium additives is carried out to recover potash values. K is recovered in leach solution in the form of soluble salts, such as K2CO3, K2SO4, and KOH, and leach residue consists mainly of calcium-alumino-silicates. Using mechanical activation with flux, it is possible to recover >95% K-values from mica sample. Mechanical activation with calcium-based flux is found sustainable in the recovery of K-values from mica.

By İbrahim Çınar, Hakan Özşen

Mine workers in heavy and dangerous work are under several physical risk factors, for example temperature, humidity, noise, vibration, lighting and air velocity. Thermal comfort includes parameters such as air temperature, air humidity, air flow rate, radiant heat, metabolic rate and garment insulation. In this study, thermal comfort conditions were evaluated using thermal comfort indices defined as predicted mean vote (PMV) and predicted percentage dissatisfied (PPD) which were determined by measurements taken from an underground coal mine for approximately 100 days. Although the metabolic rate (light work) was kept at 2 met, it was found that predicted mean vote ranged between − 2.58 and 1.68. The predicted percentage dissatisfied index was found to reach 95%. According to the results, it can be seen that thermal comfort may have negative effects on occupational health and safety. The change in thermal comfort index values in the Soma Underground Coal Mine was investigated in detail and the reasons for the changes were determined. Furthermore, determining the optimal working environment for the mine workers was also an aim of this study.

By Paul D. Tomlingson

Modern production equipment has been designed with greater productive capacity and higher reliability to meet the rigorous operating demands of the mining industry. These improvements have also made the equipment more complex and challenging to maintain. Whether these equipment enhancements contribute to more effective mining operations depends on the overall quality of maintenance. Maintenance is not a stand-alone activity. Although its quality depends primarily on maintenance, cooperation and support from other departments, coupled with the skillful guidance of mining managers, greatly influence maintenance success. Therefore, maintenance risk management must look beyond maintenance itself. Successful maintenance risk management begins with an assessment of the maintenance-related interactions of all mining departments within the mine’s stated operating strategy.

Jan 1, 2005

By J. G. Pippenger

The mining industry has been Australia?s major economic driver over the past decade, contributing 8% to Australia?s Gross Domestic Product and 26% of Australian Stock Exchange Market capitalisation. Australia is the world's leading exporter in coal, iron ore, alumina, lead and zinc; and second largest in gold and uranium. While driving the economy, this resource boom has also created a demand for professional and operating talent that has far outstripped the capacity of Australia?s 21 million residents. I moved to Australia some 10 years ago and have not looked back. This unique island continent with its mix of Indigenous and diverse immigrants ? many still proud of their convict ancestry ? has offered life long memories both professionally and personally.

Jan 1, 2011

By Jacob Carr, Christopher C. Jobes, Chenming Zhou, LaTasha R. Swanson, Jennica Bellanca, Jingcheng Li

Magnetic proximity detection systems (PDSs) are used with continuous mining machines (CMMs) to protect miners from striking and pinning accidents. Generators are used in a PDS to create magnetic fields covering the space around a CMM. The PDS determines the proximity of a miner relative to the CMM based on the magnetic flux density detected by a miner-wearable component (MWC) and simultaneously alerts the miner and stops the motion of the CMM if the miner is within a proximity that creates a striking hazard. A stable magnetic field is essential to the accuracy of the proximity calculations performed by the PDS. This paper presents the results of a systematic study of the magnetic influence of two types of steel structures found near a CMM— the body of the CMM itself and the wire mesh used for roof and rib control. The results show that the steel of the CMM body can change the magnetic field distribution and also alter electrical parameters of a PDS by changing its generator current. The study also shows that, depending on the distance between the wire mesh and a generator, the magnetic field can also be altered.

By Jacob Carr, Christopher C. Jobes, Chenming Zhou, LaTasha R. Swanson, Jennica Bellanca, Jingcheng Li

Magnetic proximity detection systems (PDSs) are used with continuous mining machines (CMMs) to protect miners from striking and pinning accidents. Generators are used in a PDS to create magnetic fields covering the space around a CMM. The PDS determines the proximity of a miner relative to the CMM based on the magnetic flux density detected by a miner-wearable component (MWC) and simultaneously alerts the miner and stops the motion of the CMM if the miner is within a proximity that creates a striking hazard. A stable magnetic field is essential to the accuracy of the proximity calculations performed by the PDS. This paper presents the results of a systematic study of the magnetic influence of two types of steel structures found near a CMM— the body of the CMM itself and the wire mesh used for roof and rib control. The results show that the steel of the CMM body can change the magnetic field distribution and also alter electrical parameters of a PDS by changing its generator current. The study also shows that, depending on the distance between the wire mesh and a generator, the magnetic field can also be altered.

By Lawrence M. Gochioco

One of the best kept technology secrets in U.S coalmining history involved a robust coal geophysics program used by a local coal company to detect and map various geologic anomalies and man-made structures ahead of mining for nearly 15 years. Several original mine plans were changed as a result of findings from two-dimensional (2D) and three-dimensional (3D) seismic data. They indicated the presence of geologic anomalies in reserve areas that could adversely impact future mine development and longwall production. By combining the surface seismic and exploratory drilling methods, the coal company learned how to properly leverage its risk by gathering a lot of useful subsurface information before making major commitments.

Jan 1, 2005

By Y. V. Vasylchuk

This paper presents an algorithm for optimizing the classification of surface mine material subject to excavating constraints. High-resolution expected profit models are input and optimized to classification maps subject to site-specific rectangular excavating constraints. This optimization problem defies traditional closed-form analytical solutions; a practical heuristic algorithm has been developed to quickly determine the optimal final destination for the material subject to realistic constraints. The optimization is fast and generates results that achieve up to 98–99% of the total expected profit achieved with free selection. This algorithm provides a fast viable option for practical application in short-term grade control and in managing multiple realizations in long-term resource estimation.

By Y. V. Vasylchuk

This paper presents an algorithm for optimizing the classification of surface mine material subject to excavating constraints. High-resolution expected profit models are input and optimized to classification maps subject to site-specific rectangular excavating constraints. This optimization problem defies traditional closed-form analytical solutions; a practical heuristic algorithm has been developed to quickly determine the optimal final destination for the material subject to realistic constraints. The optimization is fast and generates results that achieve up to 98–99% of the total expected profit achieved with free selection. This algorithm provides a fast viable option for practical application in short-term grade control and in managing multiple realizations in long-term resource estimation.

By Brendan Demich, Joseph McGuire, Emily J. Haas

Near misses recorded and reported by workers can provide awarenessto the potential causes of injury and prompt safety management initiatives. Although most companies require near-miss reporting, it is unclear what the value of these reports are, if any, and how they influence subsequent actions or controls to reduce on-the-job risks. Researchers at the National Institute for Occupational Safety and Health (NIOSH) conducted a case study with an aggregates company in which near-miss reports were analyzed at each of their locations over an entire quarter during the summer of 2018. Within that quarter, workers recorded 249 near misses. Of those, 167 were valid near misses that occurred at work. Researchers coded the reports using a qualitative 5 × 5 risk matrix. Of the 167 near misses, 19% were deemed low risk, 25% moderate risk, 30% high risk, and 26% critical risk. Several patterns in the near-miss incidents were documented, including classification of incidents and common corrective actions referenced (i.e., elimination/substitution, engineering control or redesign, work process/procedures, and personal protective equipment). The analysis provides insight into ways that risk communication and management programs can be improved to reengage workers and their situational awareness on the job.

By G. Velarde

This paper presents the metallurgical results of column and stockpile leach tests with forced aeration to determine the usefulness of this process in the operational leaching at Sociedad Minera Cerro Verde S.A.A. The evolution of the aeration system is presented and also an innovative solution developed to overcome forced aeration’s main problem, which is the early obstruction of the aeration pipes located at the base of the stockpile, causing a decrease in air and oxygen levels and therefore a reduction in the metallurgical benefits.

Jan 1, 2006

By Eduardo Pimenta de Melo, Rambabu Pothina, Rajive Ganguli

Sensors are everywhere in the mining industry, with sensor information being used to monitor and operate processes. Therefore, when sensor information is wrong, economic losses can occur. Unfortunately, sensor errors are usually not detected till they become large. This is problematic as most calibrate their sensors no more than once a year (Beamex, n.d.). Using principles of data mining, where all relevant information is tapped to glean hidden information, Pothina [8] designed an algorithm to detect errors in temperature sensors in gold stripping circuit in Pogo mine, Alaska. This paper continued his work by analyzing the behavior of the algorithm on baseline data and testing the algorithm in new data and under more rigorous conditions. It also made a change to the algorithm. The modified algorithm performed very well in the new data. It also worked well under the new error conditions. Three types of errors were seeded, a fixed additive error (+ 2%), a fixed subtractive error (− 2%), and a noisy, normally distributed error, with a mean value of + 2%. Artificially seeded errors were detected within about 20 gold stripping cycles. Inherent bias in operation impacted algorithm performance by increasing the number of cycles needed to detect errors. This paper reinforced Pothina’s [8] conclusion that when data mining approach is used, sensor errors can be detected even when they are pretty low. Significant economic losses can thus be minimized.

By Jack S. Watson, Rasika Nimkar, Robert M. Counce, Matthew Gordy, Patrick Zhang

Waste phosphatic clay presents a difficult disposal problem and a significant loss of P2O5. Recent developments make this study on the use of phosphatic clay as a feed material for H3PO4 production worthwhile. (a) New data from Florida Industrial and Phosphate Research Institute (FIPR) suggest that the Bclay^ waste can be effectively treated by improved solid separation coupled with flotation to produce feed material for recovering additional phosphate. (b) The use of BOLI Flowsheet^ provides capability to predict performance of aqueous-based processes for a range of possible operating conditions. Using the new FIPR data and BOLI Flowsheet^ enabled the design of a new process that can potentially extend the usefulness of current P2O5 ore deposits. Predictions using OLI Flowsheet were able to identify process conditions that effectively overcome the difficulty of high Mg content of phosphatic clay. Estimated manufacturing cost in the current study lead to valuation of the P2O5 content of the phosphatic clay recovered/utilized at 60 to 70% of that of the phosphate rock feed material currently used. Phosphatic clay should be considered as a valuable material that is currently given zero value. The new FIPR data and BOLI Flowsheet^ enables the design of a new process that can potentially extend the usefulness of current phosphate ore deposits by extending the fraction P2O5 of recovered

By Fulvio Tonon

And Rabcewicz said ?tunnels should be driven full face whenever possible.? ADECO, which stands for ?Analysis of Controlled Deformations in tunnels,? now allows us to fulfll Rabcewicz?s dream in any stress-strain condition. In order to achieve that dream and its consequent control over cost and schedule, however, NATM must be abandoned for the ADECO. The paper presents the basic concepts in the ADECO approach to design, construction and monitoring of tunnels together with some case histories, including: full face excavation for Cassia tunnel (width of 22 m, height of 14 m) in sands and silts under 5 m cover below an archeological area in Rome, Italy; Tartaguille tunnel (face area > 100 m2) advanced full face in highly swelling and squeezing ground under 100 m cover where NATM led to catastrophic failure, France; and 80 km of tunnels (face area > 100 m2) advanced full face in highly squeezing/swelling ground under 500 m cover for the high-speed railway line between Bologne and Florence, Italy (turnkey contract).

By Ebrahim Farrokh

Ghomroud water conveyance tunnel project is under construction using shield Tunnel Boring Machines (TBM) for a total length in excess of 50 km. Phase 1 of the project included 36 km of tunnel divided into four lots (1, 2, 3, and 4) of nine km each. Lots 3 and 4 of this tunnel for a total length of 18 km were combined into one award and have been constructed using a double shield (DS) TBM or one path system. Extreme ground convergence in some sections of the tunnel has stalled TBM performance in early reaches, due to face collapse and shield jammings. This paper presents the latest update on the tunnel progress and impact of ground convergence on machine performance based on the information obtained from field observations. Also, the method and results of tunnel convergence measurements were studied in conjunction with geological parameters and an attempt was made to correlate TBM operational parameters and ground convergence. The result of the analysis indicates a good correlation between machine?s operational parameter and tunnel convergence and can be used as an indicator of the potential for high rates of convergence. An early warning on ground convergence is essential for taking precautionary measures to avoid TBM jamming and related long delays and costs.

By Andrew K. hg` Officer, A. L. Griffiths, J. Andrew Hindmarch, Gert Wittneben

Durban Harbour in South Africa is one of the continent’s busiest ports however the harbor entrance is currently too small for the new generation of container ships. There-fore it is to be deepened and widened by the National Ports Authority in the near future. An existing immersed tube tunnel carrying major sewer, water and other utilities under the harbor first needs to be removed and replaced by a deeper 4.4 m ID ser-vices tunnel. Construction of the deeper tunnel saw the first use of a slurry machine in South Africa and was required to negotiate grades up to 20%.

Jan 1, 2007

By C. D. Hebert, M. R. King

The 56,000' (17 km) long San Vicente Aqueduct Pipeline tunnel is being constructed using precast concrete rings to act as preliminary ground support through two sections of the bored tunnel with lengths of 9,450' (2.9 km) and 33,700' (10.27 km).The six segment bolted trapezoidal ring was manufactured using a combination of steel fiber reinforced concrete and self compacting concrete in vertical moulds. This paper briefly describes the design and function of the segments, and reviews the development stages of the concrete mix, and the advantages and disadvantages of the adopted manufacturing method.

Jan 1, 2007

By Jonathan Baggett, Nino Ripepi, Amin Abbasi, Richard Bishop, Juan Monsalve, John Hole

This work focuses on the operational and safety issues associated with karst voids in large opening underground mines. Issues include water inrush, structural instability, and engineering uncertainty in these environments. Coupled with the fracturing prevalent in folded sedimentary rocks, karst voids are complex and challenging ground-control risks. Traditional methods of predicting karst void locations, such as probe drilling, are impeded by the inconsistent spatial distribution and variable sizes of the features as reported by Li et al. (J Rock Mechan Geotech Eng:232–242, 2010) and Hassan et al. (Procedia Chem 19:737–742, 2016). Ground-penetrating radar (GPR) is a geophysical technique that transmits radio waves into a medium and subsequently detects reflected waves via a receiver. The travel time and energy of received signals are then processed and interpreted. The difference in conductivity and dielectric permittivity between limestone and open karst cavities causes strong reflections. GPR is frequently used as a geophysical surveying technique in several industries; however, there is a lack of published research on underground mining GPR applications as reported by Zhao et al. (2015a; Geophys J Int:62–71, 2015b) and Eskelinen and Pellinen (Constr Build Mater:888–898, 2018). The purpose of this work is to demonstrate the use of GPR in an underground stone mine and to discuss the importance of karst void detection ahead of mining.

By A. Yazadni-Chamzini

Considering the nature of open pit mines, harvest volume, it usually is required to remove a lot of waste to access to mineral planned grade. So, one of the most important part of open pit mines design, is waste dump site selection. Many factors are effective in waste dump site selection. These factors are sometimes in conflict with each other. So selecting the desired location for waste dump is a process complex and multi-criteria decision making. There are a variety of methods for decision making under complicated condition, such as fuzzy, Delphi, multi-criteria decision making and Expert system methods can be hinted. VIKOR method, which is one of the decision making multi criteria methods, is useful tool for decision-making. On the other hand with regard to uncertainty in decision-making, fuzzy approach is a useful tool for this purpose. This article has tried to select the best waste dump site in Sari Gunay Gold Mine by Fuzzy VIKOR. The results show that C position has a higher priority than other positions.

Jan 1, 2012