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U.S. Borax’s mine in California’s Mojave Desert is the source of nearly half the world’s supply of refined borates. These minerals are used in hundreds of products, including essential plant nutrients that increase crop yield and quality, and safe building products that protect homes from insects and the elements. Borax’s workforce is also safe. In fact, it is among the safest in the nation. In 2003, the company was recognized by the U.S. Mine, Safety and Health Administration (MSHA) for achieving the best safety record among large U.S. mining operations. It was also recognized by its parent company, Rio Tinto, for achieving the best record among its nearly 80 worldwide mining operations. Borax’s safety performance is five times better than the national average. And its workforce recently achieved more than two million hours without a lost-time injury.

Jan 1, 2004

By I. J. Duckworth

Due to improved, stringent safety regulations, many modern road tunnels are statistically safer, per kilometer, than above ground roadways. However, the public perception and reaction in the event of a serious tunnel fire is very different to that associated with a surface incident. Vehicle fires in road and rail tunnels are recognized to represent an immediate and extreme danger to the patrons of those systems. Unlike workers in the mining and civil construction industries, the general public are neither trained nor equipped to fight fires or evacuate under deteriorating smoke conditions. Accordingly, for the majority of modern transportation tunnels the ventilation infrastructure is sized on the requirement to control the combustion products from worst-case fire scenarios and to provide a tenable evacuation route for the tunnel users. It is common for these same emergency ventilation systems to be employed, often in a reduced capacity, for other operating modes such as the dilution of pollutants during congested traffic conditions. This is one of the fundamental differences to mine ventilation, where primary ventilation systems are not typically sized based on fire scenarios. This paper presents an overview of the subject of fires in vehicular tunnels. This includes a brief history of major transportation tunnel fires followed by a discussion on the resulting legislation and standards that govern the design and operation of tunnel emergency ventilation systems. A summary is provided on the common criteria, theory, and design techniques that are employed during tunnel emergency ventilation systems design. Information is provided on fire detection and suppression, with a discussion on the growing acceptance of wet suppression as a means to mitigate major fires in road tunnels worldwide.

Jan 1, 2009

By Antonio De Biase

In October 2006, a 7m Double Shield TBM, boring through very poor volcanic formations, was pushed back by fluid mud, which presence had not been detected during previous field investigations, due to the high covers characterizing the majority of the tunnel axis. The present work describes the investigations made to gain better knowledge of the conditions in front and all around the TBM, the special measures implemented, the exploratory and bypass tunnels excavated, the extraordinary occurrences came true during the execution of these tunnels, the drainage campaigns, the design of the chamber excavated to free the TBM, the dismounting and restarting of the TBM.

By John E. Tilton

During the past several years — much to the delight of producing firms and countries — copper prices have surged from under $1 to more than $3/lb. Anyone familiar with the industry also knows that since the early 1970s the long-run trend in real copper prices has been significantly downward. This sharp contrast between short-run and long-run trends raises the issue of the forces behind these developments. What has been driving short-run prices up and long-run prices down? Simple economics suggests that it is all a matter of supply and demand. When demand is rising faster than supply, prices will rise and vice versa.

Jan 1, 2006

By Scott Ellenbecker

The formation in Newmont Mining?s Phoenix Mine near Battle Mountain, NV contains high levels of abrasive quartzite as well as gold, copper and silver. Newmont started mining operations at Phoenix (formerly Battle Mountain Gold) three years ago and the planners knew they were working with a challenging geological formation. But as it turned out, it was more challenging than anticipated. Mine manager Mark Evatz said, ?Anything that touches Phoenix rock wears fast. The rock fights back here.? To contend with the hard conditions, Newmont uses Atlas Copco?s Pit Viper 271 (PV-271) blasthole drill. Because of the hardness of the rock, drilling at Phoenix requires hammer drilling and the mine uses Atlas Copco TD65 hammers with 171 mm (6.75 in.) bits. The mine?s PV-271?s are outfitted with a single 41 m3/min (1450 cfm), 2.4 MPa (350 psi), oil-flooded air compressor. Phoenix has six Atlas Copco PV-271 drill rigs plus an Atlas Copco DML and a DM45 midrange blasthole rig. The mine?s goal is to keep 3.6 Mt (4 million st) of muck in inventory to stay ahead of the shovels and support needed operational flexibility (ore control related). Drilling efficiency has been a continuous point of improvement since operations began at the mine. The single-pass depth capability of 16.5 m (55 ft) on the PV-271 helped with that. Originally, the plans called for 6-m (20-ft) bench heights, supported by 7-m (23-ft) drill depths, and time spent moving from hole to hole was eating up productivity. Drilling on that plan resulted in drilling an average of 14 m/h (47 ft/hour). When depths were changed to 13-m (44-ft) drill depth, supporting blasting of 12-m (40-ft) benches, they were able to use the single pass capacity of the PV-271. Performance increased to more than 18 m/h (60-ft/hour) an hour. Although the drill depth change largely supported the improvement, other aspects of continuous improvement associated with improved knowledge of the Pit Viper drills helped as well.

Jan 1, 2009

As the 2009 George Fox Conference neared its conclusion, Arthur Silber, project chief of the Mass Transit Tunnel (MTT) project was able to pull away from the constant buzzing of his Blackberry long enough to give a short presentation and a significant piece of news to the record 318 attendees at the Graduate Center, City University of New York regarding the MTT project. ?As the former administration (The Bush administration) was leaving office, we were told that Congress was notified of the FTA?a (Federal Transit Authority?s) intent to issue final design construction approval to us,? Silber said of recent advancements concerning the $7.2-billion dollar project. It will add passenger rail service from New Jersey to New York City as part of the Access to the Region?s Core project in the form of the Trans Hudson Express Tunnel (THE tunnel). ?That 10-day waiting period ended yesterday (Jan. 26).? In days leading up the Fox Conference, those involved in the tunneling industry, and the MTT in particular, had a lot to be optimistic about. The MTT received environ-mental approval on Jan. 14 (see page 9) and, with the acceptance of the final design, the multi-billion dollar project moved that much closer to a ground-breaking ceremony. So close, in fact, that before leaving his office for the conference, Silber posted the contract documents and plans for the Manhattan Tunnel project online at www.arctunnel.com (an indepth look at the project from Silber is on page 22). While many were interested in the progress of the project, Silber also spoke about the new plans for the cavern complex at the New York Penn Station expansion. The original plans called for two lines that would come into a large cavern complex with a north and south cavern to access the trains. After numerous core samples were taken from the streets of Manhattan, it was deter-mined that this design was not feasible and changes were made that will include a deeper cavern under Sixth Avenue, with 14-m (45-ft) of cover with a 30-m (96-ft) wide cavern that resides entirely under 34th Street. The cavern was also moved 20 m (60 ft) to the west to remain at least 61 m (200 ft) away from New York City Water Tunnel #1. The new design will include three-over-three track arrangement. The mezzanine will be 46 m (150 ft) below street level at 8th Ave, Silber said.

Jan 1, 2009

By P. K. Das, S. K. Singh, C. C. Chang, E. C. Wang, R. B. Roberts

As part of the New York City’s redevelopment of the far west side of mid-town Manhattan, this project will add 1.5 miles of twin bored tunnel to No. 7 Subway Line. The proposed alignment extending from the Times Square Station west beneath 41stStreet turning south under Eleventh Avenue and terminating at 25th Street will include two new stations. The tunnels and station caverns will be primarily constructed in the Manhattan Schist, and will pass in close proximity to several major overly ingstructures. This paper discusses the lithology and structural discontinuities of rockmass along the project alignment, tunnel and cavern rock loading, groundwater hydrology, groundwater quality, groundwater treatment and sustainable design.

Jan 1, 2005

By R. K. Singhal, H. Sahay

Introduction In terms of the world's recoverable coal reserves, Canada ranks 10th, providing 0.6% of the world's total. The US is first with 27.8% and the Soviet Union follows with 24.1%. Figure 1 shows the principal coal mines in Canada. Several provinces contain substantial coal deposits, but the largest deposits are found in the western provinces of Alberta, British Columbia, and Saskatchewan. Conservatively, 90% of the lignitic, 80% of high volatile bituminous, and nearly 100% of subbituminous, and low and medium volatile bituminous coals are located in these three provinces. During the past decade, Canadian coal production of all types increased from 18.8 Mt (2 million st) in 1972, to 25 Mt (28 million st) in 1975, to 61 Mt (66 million st) in 1984. About 38 Mt (43 million st) of this output was classified at thermal and 23 Mt (25 million st) as coking and metallurgical coal (Table 1). The three western provinces currently produce 57 Mt (62 million st) of coal - 95% of Canada's total. The remaining 3.6 Mt (4 million st) (5%) is produced in Nova Scotia and New Brunswick on the east coast. The majority of western coal (98%) is produced by surface mining methods. On the east coast, though, mining is predominantly underground and only 15% is produced on the surface. In 1985, Canada exported close to 28 Mt (30 million st) of metallurgical coal and thermal coal. During the same period, 15 Mt (16 million st) of coal were imported, mostly from western US for use in Ontario and Quebec. Almost 60% of the imported coal was used for thermal applications. The remaining 40% was metallurgical coal for the steel industry. It is generally cheaper to import coal into central and eastern Canada from the eastern US to augment local supplies rather than from western Canada. This is mainly because of high transportation costs. Mining methods The suitability of mining methods in a particular area depends largely on the geological setting. Geology, therefore, simplifies or adds complexities to mining operations, directly affecting the economics. It also influences the flexibility required from the min-

Jan 9, 1986

By Wolfgang Gütter

India is targeting to boost its electrical capacity from 100 GW to 200 GW within the next 10 years. The National Hydroelectric Power Corporation (NHPC) has decided in2001 to take execution of the 800 MW Stage-II of the prestigious 2,051 MW Parbatihydrol electric project in Kulu district of the northern province Himachal Pradesh. Two parallel 30° inclined underground pressure shafts of 1.542m in length each will be excavated in different geological formations and lined with hexagonal concrete segments by a hard rock double shield TBM. That kind of heading will be a novelty to India and an innovative method for inclined pressure shafts. The 4.88m Mitsubishi DSTBM will be assembled underground on a swivelling steel platform especially designed for the launching as well as for the acceptance of the TBM in the upper cavern of each shaft. The hexagonal segmental lining system causes a significant higher job safety than an open TBM with conventional support. Each ring consists of four honeycomb segments with 20 cm thickness. After finalisation of the excavation a steel liner will be installed and concreted. The Joint Venture Jäger-Seli will perform the two pressure shafts as a sub-contractor for the Indian company Gammon India Ltd.

Jan 1, 2005

By J. Finch, R. McIvor

This paper presents the development of a new grinding circuit steady-state modeling system. It is fundamentally based on the “functional performance equation”, which has now been used to improve the performance of numerous grinding circuits. This equation characterizes the two distinct efficiencies that are at work in a ball milling circuit, and how these relate to overall circuit productivity. It does so based on the particle size chosen to distinguish between coarse and fine (product size) material. Now, by applying it to all the material size classes, a simple yet reliable ball mill model was created. Combined with cyclone recoveries, the complete, detailed grinding circuit performance can be exactly reproduced mathematically by the computer program. It can then be used with separate process equipment application engineering methods to systematically engineer grinding circuit improvements. The development, features, uses and limitations of the system are described.

Jan 1, 2007

By F. E. du Plessis, P. De Waal

Through the development of innovative in-line mineral quantification sensors, the possibility has arisen to apply modern control theory to implement automatic process control for electrostatic high tension (“HT”) roll separators. A pilot-scale set-up was constructed to enable continuous tests to be carried out. A typical dry mill feed was continuously pre-heated and separated with a modern lab scale HT roll machine. The mineralogy as well as mass-flow of the non-conductor stream was quantified in-line, and the combined streams were re-circulated in an endless loop by a combination of vibration feeders and a bucket elevator. A fractional factorial experiment was executed to determine the most significant control parameters of the HT roll separator. Then a multi-input, multi-output dynamic model of the HT electrostatic separator was extracted by the application of standard system identification techniques for automatic control. The most important control variable to ensure a stable product grade could be identified. This allowed a robust single-input, single-output controller to be implemented. The process variable and set-point was mineral grade and the control variable was electrode voltage. Roll speed was manually adjusted while the mineral grade was kept on set-point by the control system. The roll speed, where maximum mass flow and therefore maximum yield was produced on-grade, could therefore be rapidly determined. Atmosphere humidity and ore temperature served as disturbances. Some other adjustable parameters were kept constant during the experiments, namely feed mineralogy, splitter settings and feed rate. Delivery of maximum yield, with a controlled grade, can improve production while reducing the burden of complex manual tuning. Manual tuning previously involved coping with multiple parameters with uncertain cross coupling influences on the end result. Even the end result was typically only known after completion of mineral assays. Automatic grade stabilisation and yield optimisation for a HT roll separator bank requires in-line measurement of mineralogy and mass flow, as well as the implementation of a robust process control system.

Jan 1, 2005

By William R. Yernberg

The combined 78th Annual Minnesota Section of SME Meeting and 66th Annual University of Minnesota Mining Symposium was held April 19 and 20, 2005, in Duluth, MN. More than 300 mining professionals, including engineers, executives, mining managers and suppliers, from throughout the United States and eastern Canada attended the meeting. This year’s theme was “Global Demand: A Window of Opportunity.” The meeting included a keynote address, technical presentations and a trade show. The atmosphere at this year’s meeting was upbeat. The iron ore mining industry in Minnesota is experiencing one of its biggest turnarounds in history. Because of greater demand, iron ore prices increased 20 percent during 2004 and 71.5 percent so far in 2005.

Jan 1, 2005

By J. E. Friant

Until 1956, drill and blast was the only way to excavate rock. In that year, a tunneling machine using disc type cutters economically bored a small Toronto tunnel. Its amazing 105 ft/day set a new world record and set the stage for a new industry. The Disc Cutter Role in Excavation Mechanical excavation of hard rock is by now deeply ensconced in the heavy civil construction industry. All over the world, from the Swiss Alp Melange to Hong Kong Granite, to New York Gneiss, huge Tunneling Boring Machines (TBMs) create transportation, water and sewer tunnels. Powerful machines, boasting as much as 6000 hp, bore through rock, excavating in excess of 1400 tons per hour. The tool that makes this tunneling phenomenon possible is the single blade, rolling disc cutter. These hardened steel discs, from 15 1/2 to 19 inches diameter are arranged on a rotating cutterhead, to cut concentric circles in the rock. As the machine is propelled forward under great pressure, rock below each cutter is crushed. But the efficiency of the cutterhead is derived from the science of cutter spacing (distance between cutter paths). The majority of the rock excavated is not crushed, but flakes off in chips and chunks. No pick, tooth, or drag type cutting tool can duplicate the performance of a disc cutter. The economic use of drag type tools is limited to as low as 5,000 psi UCS rock strength in massive formations. In weakly bonded, foliated rock, drag tools do better, but are still limited to rock generally less than 15,000 psi.

Jan 1, 2002

By H. Lowers, P. Hageman, S. Diehl, D. Fey

Understanding relationships between mineralogy, texture, microstructural features, and element distribution and residence in minerals, is critical for accurate modeling of mineral weathering in waste-rock piles. The morphology of minerals and deformation structures, such as veins and faults, are important factors that control: (1) fluid access to the mineral surface to initiate dissolution, (2) the distribution of trace elements, and (3) formation of secondary minerals. We characterized the mineralogy, textures, and chemical properties of waste-rock material at three sites at scales ranging from outcrop to micrometer scale. A comprehensive hand-sample to thin-section scale methodology utilizing light microscopy, scanning electron microscopy, electron microprobe, and laser ablation ICP-MS was used to thoroughly characterize the waste-rock material.

Jan 1, 2007

In this paper, a mixed integer linear programming (MILP) model for the short-term scheduling of open pit mines is formulated. The proposed model aims at sequencing the blocks extraction over multiple short-term periods. The model takes into account multiple processes, waste dumps, and multiple stockpiles. The short-term scheduler makes a decision on the period, destination, and route that ore and waste are supposed to take to minimize costs while meeting all the mining and processing constraints. The destinations of the extracted materials are also controlled by their rock types. A monthly short-term production scheduling case study of an iron ore deposit is carried out over a year to validate the model.

Jan 1, 2011

By R. E. Ray

Compared to conventional fully ducted axial and centrifugal fan systems, jet fans can offer a number of advantages for control of smoke during fire emergencies and dilution of diesel engine exhaust products in vehicular and rail tunnels. The success of jet fan applications is the result of a balance between the temperature de-rating of the fan, buoyancy forces and the installation momentum transfer efficiency. This paper provides a case study of a unique application of vertically-mounted jet fans in ventilation shafts used to provide both emergency ventilation and pollution control for an overbuild created by the construction of a series of commercial high-rise residential buildings over a portion of an existing passenger rail line. A detailed evaluation of a set of shafts for one building is presented, including a discussion of the calculation methods used to estimate the required jet fan capacity and the results of the subsequent numerical analysis using Computational Fluid Dynamics to simulate the performance of the jet fans during train car fire emergencies.

Jan 1, 2009

By Keith E. Meyers

Condition monitoring is a viable troubleshooting practice among many industries to extend equipment performance, minimize unplanned downtime, reduce maintenance and repair time and costs, and increase related aspects of plant safety. But obstacles abound for mining, mineral-processing and cement operations striving to implement the technologies. Harsh machine environments can muddy efforts. High vibration in machinery can interfere with wide-spread rollout. Staff expertise or skills may be lacking. And costs may be prohibitive. Fault detection has emerged as a practical and cost-effective solution to identify process and machinery faults before failure interrupts productivity or jeopardizes worker safety. Fault detection can be a stand-alone system or connected to plant automation.

Jan 1, 2005

By K. M. Stone, N. J. G. Masson, A. C. Woollett

The Jabali zinc deposit, in Yemen, contains at least 9.4 Mt at a grade of 10.7% zinc, 2.2% lead and 77g/t silver. The zinc occurs as smithsonite with minor hydrozincite. The Jabali ore does not produce a zinc concentrate of sufficient grade to be acceptable to conventional smelter/refineries, and it has been necessary to formulate a less conventional development plan. This involves the construction of a mine and concentrator at Jabali and a metal production facility using a new flowsheet designed specifically for the treatment of oxide material, at Yanbu, in Saudi Arabia. In order to give the facility the necessary economies of scale, the Jabali concentrate will be supplemented by feed from other deposits, this may be either oxide or sulphide material. The paper outlines the geology and proposed mining and treatment operations at Jabali, the flowsheet for Yanbu and presents preliminary costs for both operations

Jan 1, 2002

By T. Arthur Palm, Stephen L. Bessinger

San Juan Coal Co. (SJCC) operates an underground coal mine near Farmington, NM. Continuous miners and a longwall produce 6.3 to 7.2 Mt/a (7 million to 8 million stpy). SJCC is owned and operated by BHP Billiton. The coal seam at SJCC has been shown to have a propensity for spontaneous combustion. As such, during the feasibility study for this project, it was elected to use a bleederless ventilation system on the longwall. Due to the combination of spontaneous combustion, methane liberation and, to a lesser extent, hydrogen sulfide, a typical wraparound ventilation system would not be appropriate. Three-entry gate roads are developed, and the longwall gob is sealed as mining progresses. SJCC uses a nitrogen injection system to continuously inertize the gob.

Jan 1, 2007

By Wu Xueling

9K medium was used to isolate iron-oxidizing bacteria from 27 sump water samples collected from Dexing Cop-per Mine, Chengmen Mountain Mine and Yin Mountain Mine, Jiangxi Province, China. Lead acetate and silver nitrate were used to enrich metal-resistant iron-oxidizing bacteria from the above water samples. Isolate 16 was isolated from the sample taken at Dexing Copper Mine. Growth experiments indicated that when incubated under lead acetate (3,500 mg/L), isolate 16 still carried out ferrous ion oxidation, while isolate H1, a less resistant strain taken at Yin Mountain Mine, had a tolerance level of only 400 mg/L. When assayed with other metals, i.e., Ag+ (240 mg/L), Hg2+ (0.9 mg/L), Cu2+ (32,000 mg/L) and Mg2+ (22,500 mg/L), isolate 16 still carried out ferrous ion oxidation while, on the other hand, isolate H1 exhibited much lower tolerance levels, i.e., Ag+ (60 mg/L), Hg2+ (0.1 mg/L), Cu2+ (19,000 mg/L) and Mg2+ (13,500 mg/L). Based on 16S rDNA sequence data, isolate 16 and H1 were both identified as Acidithiobacillus ferrooxidans.

Jan 1, 2007