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By Rajagopala Reddy Kallu

After the Sago and Darby No. 1 mine incidents, the new regulatory standards for the design of mine seals in underground coal mines of the United States require the mine seals to withstand higher explosion standards. This necessitated for the development of new design approaches and standards. For development of any new design standards or approaches a detailed understanding of effect of key influencing parameters on the stability of mine seal is a must. This paper attempts to address one of the factors, i.e. roof convergence, that play an important role in the stability of mine seal under explosion loading. Initially a couple of three dimensional numerical models were built and tested for different levels of roof convergence. These models confirmed that roof convergence has great influence on seal stability. A detailed study is undertaken, with some simple assumptions, to establish typical influence of roof convergence on the stability of mine seal under different levels of static explosion pressures. Three dimensional distinct element code 3DEC is used for this purpose.

Jan 1, 2007

By Deno Pappas, Chrisropher Mark, John Rusnak, Linda McWilliams

Mine planning for a new reserve is based on information obtained from exploratory coreholes. A critical component of an exploration program is the geotechnical evaluation. Poor assumptions about roof conditions greatly add to the risks of mining. Rock mechanics testing is central to a geotechnical exploration program. Typically, 3 to 5 uniaxial compressive strength (UCS) tests are made to characterize a particular roof unit at a given corehole. The average (mean) of these tests is taken as “The UCS” for that location. Isopach contour maps are then used to show spatial trends in roof strength. Two issues are raised by this traditional approach. The first is due to the large variability in UCS values that is typical even within a single unit from a single hole. The average UCS might be higher at Corehole A than it is at Corehole B, but the difference may not be statistically significant. The second issue is whether widely spaced coreholes can identify valid spatial trends in rock strength. The answer depends upon whether rock strength changes over distances that are longer or shorter than the corehole spacing. This is a classical geostatistical problem. While geostatics have been used to investigate many coal quality parameters, they have seldom been used to evaluate rock strength. This paper describes an extensive investigation of these issues conducted by the National Institute for Occupational Safety and Health (NIOSH) in collaboration with Peabody Energy. The study employed the Peabody Rock Mechanics Data Base which contains more than 10,000 individual test results. Data from four important roof units were subjected to statistical analysis: • Brereton Limestone above the Herrin 6 seam (Illinois) • Turner Mine Shale above the No. 9 Seam (Kentucky) • Sandstone above the Eagle Coal (West Virginia) • Shale above the Eagle Coal (West Virginia) The study did not find significant spatial trends in rock strength in any of the cases. Perhaps there are none, or perhaps the exploration coreholes were just too far apart to see them. These results have valuable implications for the design of geotechical exploration programs.

By T. J. Yeomans

"The Kidd Creek metallurgical site is situated twenty-six kilometres east of Timmins, Ontario. The site consists of a 4.5 niillion tonne per year concentrator, a 127,000 tonne per year electrolytic zinc plant and a 79,000 tonne per year copper smelter/refinery complex.The concentrator commenced operations in 1966 and was expanded to its present capacity in 1978. The zinc plant commenced operations in 1972, and the copper smelter/refinery in 1983.The concentrator tailings, and both liquid and solid waste products from the other plants are disposed of within a 1215 hectare tailings disposal area. Here, a method known as centraljzecl thickened discharge is used to form a stable cone-shaped hill. A low permanent perimeter dyke structure encloses the cone and directs cone run-off and thickener overflow to a treatment pond. After treatment with lime slurry, this neutralized effluent is recycled to the metsite and also discharged into the Porcupine River system.The tailings system has been in operation in its present form since 1972, upon completion of dykes and a 110 metre thickener unit. Underflow densities were continuously increased until thickener overloading became a serious problem. This necessitated the construction of a second 110 metre thickener, which was completed in 1983. Target densities have been achieved without difficulty since then.This paper discusses the operation of the tailings system, reviews past performance, and outlines future operations."

Jan 1, 1986

By A. L. Edwards

A two-year study focused on current noise exposure levels in the South African mining industry, aimed at helping the Mine Health and Safety Council of South Africa meet its milestones for eliminating noise-induced hearing loss (NIHL). Methods A multi-task methodology was adapted from international baseline studies to determine the exposure to noise in both large-scale and small- to medium-scale mines. Results On average, 66.7 per cent of the employees sampled in year 1 and 78.4 per cent in year 2 were exposed to noise levels of above the 85 dB A legislated occupational exposure level. Conclusions Information obtained through the study could be developed into a national personal noise exposure database, including audiometric results, equipment noise emission levels and initiatives for noise engineering control by mines and equipment manufacturers to facilitate targets of eliminating NIHL. Keywords Noise exposure levels, mining industry, noise-induced hearing loss

Jan 1, 2011

By L. M. Gould

"Syncrude Canada operates the largest oil sands crude oil production facility in the world and produces over 13% of Canada’s total oil requirements. To achieve this, Syncrude mines the oil sands in open pits, extracts the raw oil known as bitumen from the sand using water-based processes and upgrades it into sweet light crude oil by fluid coking, hydroprocessing, hydrotreating and reblending. The final product, Syncrude Sweet Blend (SSB), is sent by pipeline to three Edmonton area refineries and then to pipeline terminals which ship the SSB to refineries in Canada and the United States.As parts of the Mildred Lake base mine reached their economic life, they were replaced with new facilities at the Aurora Satellite mine. Aurora is situated on Oilsand Leases 10, 12 and 34, 35 km northeast of the Mildred Lake facility (Fig. 1).In 2000, the first hydrotransport low-energy extraction production train started up at Aurora. A second production train is scheduled for start-up in 2003. Open pit mining at Aurora occurs using two hydraulic shovels, two cable shovels, and trucks ranging from 320-ton to 380-ton payload capacities (Fig. 2).Once the oil sands is excavated, the trucks dump the ore into a crusher designed to break up the big lumps of oil sands and rock at peak rates of 11 000 t/hr. The ore is then transferred by conveyor to a surge pile and then to a mixing box which combines the oil sands with hot water. Following bitumen separation in the primary separation vessel, froth is delivered to Mildred Lake for processing via the intersite pipeline (Fig. 3).The goal of this paper is to illustrate how high precision shovel GPS (HPGPS) is being used at the Aurora mine to aid in mine planning. This can be accomplished by first describing the function of the mine planning department, describing the Aurora orebody, and finally explaining how the HPGPS system functions and how it is employed at Aurora.The short range mine planning department ensures a steady supply of ore is delivered to the plant at the desired grade in a sequenced and economical manner. This is done by creating a mine plan that consists of shovel dig locations that require the shovels to mine in a specified area at a specified elevation."

Jan 1, 2002

By Bruce Geller

The 2004 Prospectors and Developers Association of Canada (PDAC) conference contained an air of optimism and excitement that has not been seen since 1997. Many segments of the mining industry are alive and well. This is largely a reflection of improved metal prices, themselves due to the strong euro and improvements in Asian economies. Those factors offset higher oil prices, a weaker U.S. dollar and concerns about the Middle East. This report is an overview of the conference. It is supplemented by an examination of conference handouts, abstracts and a few complete papers that are on the PDAC’s Web site www.pdac.ca. Sixty PDAC 2004 abstracts are available at the same site, along with 15 complete papers in PDF format. The conference was held March 7-10 in Toronto, Ontario. It was attended by a record 9,200 delegates from 85 countries. About 8,000 people from 74 countries attended the 2003 conference.

Jan 1, 2004

By M. Kwasniewski, M. Takahashi

Prismatic samples of a medium-grained sandstone from Slask Colliery (Upper Silesian Coal Basin, Poland) were tested under uniaxial compression, conventional triaxial compression and true triaxial compression conditions. The conventional triaxial compression tests were carried out at confining pressure (p) equal to 12.5, 25.0 and 37.5 MPa. In the true triaxial compression tests the minimum principal stress (s3) was equal to 25.0 MPa and the intermediate principal stress (s2) was 1.5, 2 and 2.5 times higher than s3. Results of the studies show that confining pressure strongly inhibited dilatant behavior of rock samples tested under conventional triaxial compression conditions; the increasing confinement resulted in the growing compaction of the rock material. The effect of dilatancy was also highly suppressed by the intermediate principal stress. While important dilatant, negative volumetric strain corresponded to the peak differential stress at low intermediate principal stress conditions, at high intermediate stresses the rock material was damaged to much lesser extent. As a result, faulting of rock samples in the post-peak region was much more violent and was accompanied by a strong acoustic effect. Les échantillons parallélépipédiques du grès à grains moyens de la mine ‘Slask’ (Bassin Houiller de Haute Silésie, Pologne) ont subi les essais de compression monoaxiale (compression simple), de compression triaxiale conventionnelle (compression triaxale de révolution) et de compression triaxiale vraie. Les essais de la compression triaxiale conventionnelle ont été effectués à la pression de confinement de 12,5, 25,0 et 37,5 MPa. Dans les essais de compression triaxiale vraie la contrainte principale minimale (s3) était de 25,0 MPa et la contrainte principale intermédiaire (s2) était 1,5, 2 et 2,5 fois supérieure de s3. Il résulte des essais que la pression de confinement inhibe fortement le processus de dilatance dans les échantillons testés dans les conditions de compression triaxiale conventionnelle; l’augmentation de la pression provoquait l’augmentation du compactage du matériau rocheux. Le phénomène de dilatance était également limité de façon significative par la contrainte principale intermédiaire. Alors que l’importante déformation volumique négative correspondait à la contrainte différentielle ultime avec les faibles contraintes principales intermédiaires, dans les conditions de fortes contraintes intermédiaires, le matériau rocheux subissait l'endommagement de façon beaucoup moins importante. En résultat, la rupture des échantillons rocheux au stade post-maximum était beaucoup plus violente et accompagnée d’un fort effet acoustique. Prismatische Probekörper des mittelkörnigen Sandsteines aus dem Bergwerk ‘Slask’ (das Oberschlesische Kohlengebiet, Polen) wurden unter der einaxialen Druckbeanspruchung, konventionellen dreiaxialen Druckbeanspruchung und der echten dreiaxialen Druckbeanspruchung geprüft. Konventionelle dreiaxiale Druckversuche wurden bei dem Manteldruck von 12,5 25,0 und 37,5 MPa durchgeführt. Bei den echten dreiaxialen Druckversuchen betrug die kleinste Hauptspannung (s3) 25,0 MPa und mittlere Hauptspannung (s2) war 1,5-, 2- und 2,5-mal höher als s3. Aus den durchgeführten Versuchen ergibt sich, dass der Manteldruck die Dilatanzentwicklung bei den Probekörpern unter der konventionellen dreiaxialen Druckbeanspruchung stark bremst; die Erhöhung des Druckes rief die ansteigende Kompaktion des Gesteinsmaterials hervor. Die Dilatanz wurde auch durch die mittlere Hauptspannung beschränkt. Während die wesentlichen volumetrischen, dilatanten Verformungen der Grenzdifferenzspannung bei den niedrigen mittleren Hauptspannungen entsprachen, bei den hohen mittleren Hauptspannungen wurde das Gesteinsmaterial viel weniger beschädigt. Im Ergebnis war der Scherbruch der Gesteinsproben im Post-Peak-Bereich viel heftiger und mit kräftigen akustischen Effekten verbunden.

Jan 1, 2003

By S. Christiansen, G. R. Winslow, R. W. Kobler

Todays End of Life vehicles are shredded and their metal components recovered and recycled by standard methods. The remaining non-metallic fraction is shredder residue, and contains vast amounts of high value engineering plastics. None are today recovered. Discussed are the developmental approaches used in the first process to recover these valuable plastics. Examined are initial laboratory studies, pilot plant design and construction, product development, results, and flowchart explanations.

Jan 1, 2001

By J. C. Edwards

The National Institute for Occupational Safety and Health (NIOSH) implemented a real-time neural network system which can discriminate mine fires from nuisance diesel emissions as part of an atmospheric mine monitoring system in NIOSH?s Safety Research Coal Mine. The real-time response of a neural network to fire sensor outputs was demonstrated for coal and belt combustion in the presence of diesel emissions. The fire sensors consisted of an optical path smoke sensor, a carbon monoxide (CO) sensor, and two types of metal oxide semiconductor (MOS) sensors. The real time neural network was trained with coal, wood, and belt fire experiments with and without diesel emissions background. The trained neural network successfully predicted mine fires with these combustibles in the smoldering stage prior to the onset of flames.

Jan 1, 2005

Diesel Particulate Matter (DPM) is considered carcinogenic after prolonged exposure. With increasing use of diesel-powered mining equipment in underground mines, miner?s exposure to DPM has been increasing. Most studies on the issue has been DPM control measures with few studies on diesel exhaust propagation patterns after leaving the tailpipes. This study uses computational fluid dynamics (CFD) to investigate the airflow pattern in an underground metal/nonmetal mine for a single heading. Several high DPM concentration areas are identified in the study and common practices for compliance are suggested. Airflow and DPM distribution are compared between blowing and exhausting face ventilation systems. Suggestions are also provided for the protection of miners in the face area.

Jan 1, 2009

By P. Fredriksson, S. Seetharaman

In the ladle refining process, the ?FeO?-content of the ladle slag is of great importance in the chemistry as well as the energetics of the process. An optimization of the process requires an accurate knowledge of the thermodynamic activities of ?FeO? in the ladle slags. Due to the discrepancies in the existing data, renewed attempts are being made at the Royal Institute of Technology to generate reliable data for binary, ternary and multi component slags containing ?FeO? at steelmaking temperatures. In order to measure the activities of ?FeO? in the slags, a gas equilibration technique was employed in the present work. The slags, kept in Pt-crucibles, were equilibrated with a CO-CO2-Ar gas mixture and quenched after equilibration. The chemical composition of the slag was analyszed. From a knowledge of the thermodynamics of Fe-Pt system, the ?FeO? activities in the slag could be evaluated. The results of the present studies, together with other literature values, were optimized in the slag software, THERMOSLAG® developed in the Royal Institute of Technology, Sweden. The results of the optimization are presented. Model calculations were performed with the KTH slag software, THERMOSLAG®, by using plant data from OVAKO Steel, Hofors, Sweden. It was found that oxygen estimations in the metal from the ?FeO? analyses of slags, obtained by conventional sampling and analysis methods, where less reliable. Estimation of the oxygen levels utilizing the sulphur partition between the slag and the metal were carried out using the THERMOSLAG® software. Reasonable estimations of the oxygen contents in the metal confirmed that this could be a very useful tool for the plant operator. Keywords: ladle, thermodynamics, slags, ?FeO?, experimentation, modelling, sulphur partition

Jan 1, 2004

This article presents a proposal for the rehabilitation of the mined area of the Mogiana quarry. The Mogiana quarry produces material used in civil construction and is situated in the Brazilian State of Spo Paulo in the kilometre six of the Mogf Mirim - Itapira highway. The mineral exploitation in the Mogiana quarry provokes modifications in the environment such as alterations in the relief, vegetation, quality of the air, water and landscape. Through previous study of the area it was verified that after the closure of the exploitation the mine should be occupied mainly by pasturage. At the closing of the mine the exploitation benches, berms and slopes in general as well as the surrounding areas should be covered with a layer of soil and vegetated with native species in order to mitigate the negative impacts caused by the mine. The rehabilitation project of the area is based on the probable future use of the area, located between agricultural cultivations and cattle creation. The great alteration of the relief and soil would make future use of the area for agriculture difficult. It is more suitable t0 animal creation, mainly cattle. The high and thick rock slopes originated by the mining should be covered by vegetation, where possible, to reduce the negative visual impact. Obviously several measures will be necessary to reduce the impacts on the environment during mining. The final and definitive reclamation will only be possible after abandonment of the area. The main aspects of this reclamation process will be discussed in this paper.

Dec 6, 2010

By J. L. Green

Virginia-Carolina Chemical Corp., in its Florida Operations, uses both roller mills and ball mills in dry grinding of phosphate rock. The roller mills have been in operation since 1954 in the Mining Department. The ball mills were installed and put in operation in 1960 in the Harding Concentrate Superphosphate Plant. The roller mills in the Mining Department are used to grind phosphate rock for outside customers. This involves short notice orders of varying grinds, grades and types of rock. The ball mills grind phosphate rock for use in V-C's own phosphoric acid and concentrated superphosphate plant. These mills grind generally two types of rock for one grind. In 1959, a 10% speed-up was made in the operating speed of the roller mills. This paper deals with the operational gains and resulting cost savings which evolved from this speed-up, and compares the present operations of the roller mills and of the ball mills in grinding phosphate rock. In January 1959 it was decided to determine the feasibility of reducing the grinding cost on the roller mills, per ton of rock ground, by speeding up the mill 10%. At this time, one mill was completely reconditioned so it would be in top condition. Extensive tests were then run both before and after the mill speed-up to determine the resultant cost savings. These tests showed that, due to this 10% speed-up, the mill capacity was increased approximately 20% and grinding power costs per ton were reduced approximately 10%. Table I shows the results of these tests. Each test run actually represents several of the same type rock and grind, averaged together. Each test run lasted approximately three hours. The validity of these runs has been confirmed by subsequent operation in grinding over 1,000,000 tons of phosphate rock. Accurate records have been kept on power consumption and repairs as well as tons produced. Two types of feed rock were used for the tests — pebble phosphate rock and flotation phosphate concentrate rock. The pebble phosphate rock size is approximately 80-90% plus 20 mesh. The flotation concentrate phosphate rock size is approximately 15% plus 20 mesh and 95% plus 100 mesh. The same two types of rock feed were used for all the test runs. Test Nos. 1, 2, and 3 were run at the original mill speed of 85.5 rpm on the vertical shaft. Test No. 1 was run with a feed of high grade flotation concentrates; the desired fineness attempted was 70% passing 200 mesh. Tests No. 2 and No. 3 were run with a feed of low grade pebble. Test No. 2 was run for a desired fineness of 70% passing 200 mesh. Test No. 3 was run for desired fineness of 50% passing 200 mesh.

Jan 1, 1963

To improve the air quality in large-opening stone mines by developing better ventilation techniques, including appropriate fan selection in conjunction with air-coursing methods. Background Stone mines are the most common underground large-entry mines in the United States. Data from the Mine Safety and Health Administration (MSHA) for the year 2000 indicate that there were 162 active nonmetal underground mines in the United States, of which 117 were stone mines. Many underground stone mines are drift mines developed from previous quarry operations. Typically, these room-and-pillar mines have entries that are 20 ft or higher and at least 40 ft wide. These large dimensions lead to a very small ventilating pressure loss, even when significant air quantities move through the mine. This is especially true of drift mine operations where ventilating pressure losses of <0.25 in w.g. are common. Underground stone mines with shafts that are<200 ft deep typically have ventilating pressure losses that are <2 in w.g. The pressure losses through these mines are much lower than those of a typical coal mine or deep metal/nonmetal mine. Therefore, the ventilation techniques and principles are quite different. In addition, because of new MSHA regulations that limit the concentration of diesel particulate matter, these mines may need to greatly increase their ventilation airflow. Therefore, large-opening mines need a fan that can move large air quantities and operate at low static pressures. There are three fan types for mine ventilation: centrifugal, axial vane, and propeller. Centrifugal fans are uncommon in underground stone mines as they are often associated with mines requiring the highest of ventilation pressures. Axial vane fans are widely used in all types of mining operations. They are the most common fan type currently found in underground large-opening stone mines. However, they typically do not operate at low static pressures with high efficiency. Propeller fans are currently uncommon in underground stone mines. They are designed for low static pressures and large air quantities at higher efficiency. This fan type best suits the ventilation needs in large-opening stone mines?they produce large air quantities at low pressure losses. Mines with air shafts<100 ft long and at least 12 ft in diameter have fairly low mine static pressures and may also benefit from propeller fans.

Dec 1, 2002

By Ronald L. Cocklin, Vivian Patz

Blasting techniques are becoming increasingly sophisticated as the need for improving mining efficiency grows. One of the areas of blasting that has never been fully exploited, due to a lack of a control and reliability, is the initiation of explosives. Expert Explosives have taken on the challenge to not only provide an initiation system that offers control and reliability, but also provide benefits that are critical to enhanced mining productivity. These benefits can only be delivered through the medium of electronics and computer controlled systems.

Jan 1, 1995

By T. J. Batchler, T. M. Barczak

The Code of Federal Regulations (CFR) requires that the transverse load capacity of stoppings be equal to or greater than traditionally accepted in mine controls, which for block stoppings is generally accepted as 39 psf as referenced in the preamble to the CFR standard. This measure is based on physical testing of a freestanding wall in accordance with ASTM E 72 specifications, where our past research has shown that the dominant parameter is the tensile strength of the sealant. A new protocol based on rigid arch loading of the structure is proposed to determine the true transverse load capacity of block stoppings. Arching is achieved by the restraint of the stopping against the mine roof and floor, whereby compressive forces are developed within the wall. A laboratory procedure using the NIOSH Mine Roof Simulator (MRS) to simulate rigid arching of block stoppings was developed and results verified through full-scale in-mine tests. The rigid arch tests have demonstrated transverse load capacities more than an order of magnitude higher than the ASTM E 72 evaluation method from which the 39-psf requirement is derived. More importantly, the rigid arch tests have shown that the load capability is dependent on the physical properties of the block and geometric properties of the wall and not the sealant.

By Nic Slatalla

Acoustic emission monitoring techniques are a powerful tool for analysing deformation behaviour and fracture characteristics of rock samples under uniaxial loading. Uniaxial compression tests were carried out on three different types of sandstone for a better understanding of acoustic emission response with respect to rock deformation and damage develop-ment. All sandstone samples revealed congruent characteristic acous-tic emission patterns which correlated directly with distinct stress-strain stages. However, the acoustic response and development within the individual stages proved to be entirely different due to variations in their microstructure.

Jan 1, 2008

By S. Kittel, P. Galleguillos, H. E. Urtubia

The rougher flotation at Escondida consists of 80 cells of 100 m3 each, with injected air. Escondida has developed a system of automatic control of the rougher flotation using video cameras, which have been operating since 1997 for remote monitoring and manual control. Since 1999, an image processing software and a group of rules have allowed implementation of an expert system. To date, the expert system controls the superficial speed of each cell by adjusting the air flow and the froth depth of the flotation bank. Preliminary tests of the expert control on two of the eight rows gave 1.2% higher rougher recovery at a 92% degree of confidence. The proven benefits are already sufficient to move towards a complete plant implementation.

Jan 1, 2001

The objective in control blasting is to reduce overbreak to control the final pit wall slope, shaft, drift, ditch, bench, etc. to the final planned excavation limit.

Jan 1, 1991

By G. Konak

In-pit crusher location selection has had an important role recently, since increasing diesel prices. One way of reducing the haulage costs is to shorten the truck haulage distance by bringing the truck dump point into the pit. This study covers the work done on the optimum crusher location definition for a company that produces aggregate near Izmir, a city of Turkey located in the west. This paper will discuss the effects of pit geometry and mine access requirements on optimum crusher location selection that are mainly based on the establishment of minimum haulage distance. The method will be introduced first and then the computer algorithm developed for this study will be discussed later in the paper. Keywords: in-pit crushing, optimum location selection, optimizing haulage, computer aided design.

Jan 1, 2007