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By A. Tordoir, S. S. Kanchibotla, W. Rogers, E. Engmann, B. Bisiaux, S. Ako

Blast-induced rock mass displacement can have a significant impact on ore loss and dilution. The mischaracterization of the grade boundaries both prior to, as well as a result of, blasting can lead to significant financial losses due to ore loss and dilution. Ore dilution occurs when waste material is miscategorized as ore and sent for processing or stockpiling, diluting the run-of-mine head grade and recovery. Ore loss takes place when valuable mineral is miscategorized as waste and sent to the waste dumps, thus never being processed and recovered. Extensive research has been conducted at the University of Queensland over the last fifteen years to understand the impact of blast movement on ore loss and dilution. Recent outcomes of this research have led to the development of innovative tools and techniques to measure and model blast movement. These techniques have been implemented at the Ahafo gold mine in Ghana to understand blast movement dynamics and to implement solutions to reduce blast-induced ore loss and dilution. These solutions are validated through controlled trials and have been incorporated into site standard operating procedures.

Jan 1, 2012

By W.A. van der Westhuizen

Mineral resource management has become a well used phrase in the mining and minerals industry. Mineral resource managers are being appointed in many mining and mining-related organisations. Every mineral resource manager has his/her own ideas regarding what MRM means. There seems to be a tendency to define MRM close to home; geology would apply MRM principles to their environment and so will metallurgy, planning, mining, survey and every discipline and participant in the mining value chain. What do we do in the MRM environment and what do we aim to achieve? Surely we must have goals: what are they? Is value tracking MRM? What about best practices? Let us start at the beginning: what do we want to achieve in any mining operation? The minerals industry would like to make money, now and in the future. This calls for serious management inputs. The most important aspect is a holistic management approach regarding the total mining value chain. Process optimisation follows with application of Mineral Resource Throughput Management (MRTM) and Process Flow Management principles. Once flow processes have been established the necessary condition driven standards and measurements will be installed to ensure continuity in applicable processes.

Jan 1, 2012

By X. Wang, Y. Luo

The propensity of coal spontaneous combustion can be evaluated using various laboratory testing methods, such as R70 adiabatic tests, thermal gravimetric analyzer (TGA) tests and critical self-heating temperature (CSHT) methods. Each of the methods has its unique characteristics and index for classifying the propensity of self-ignition of coals. Accountable relationships among the propensity indices of different methods should be established. Using the newly established R70 and TGA testing setups in our ventilation laboratory, samples from U.S. coal mines have been collected and tested. The TGA is a relatively new quantitative method. A test can be conducted in a relatively short time, within about one and a half hours, compared to the adiabatic tests. The temperature and weight of the sample can be measured with high precision and then used to determine the activation energy of the coal, which is a good indicator of the potential for self-heating. Under a specific experimental design, the TGA technique could perform the proximate analysis for determining coal quality parameters (e.g., moisture, volatile matter, fixed carbon and ash content). These parameters can be used in an empirical equation for assessing the potential for coal self-ignition. The trend of activation energies determined using TGA techniques is reasonably consistent with the trend of activation energies determined using adiabatic tests. As a case study, a comparative analysis of these two methods for determining activation energy was made on coal samples collected from Indiana. The kinetics of the spontaneous combustion mechanism has been explained. If the functional groups of a coal such as hydroxyl (-OH), carboxyl (-COOH), methyl (-CH3), etc., activate more easily with a small amount of activation energy at a relatively low temperature, the coal will have a higher potential for self-heating. With the kinetic and coal quality parameters determined by the TGA setup, it has been found that the coal with a low potential for self-ignition has low self-heating rate, a high activation energy and a high minimum self-heating temperature.

Jan 1, 2012

By W. R. Reed, W. J. Archer, A. B. Cecala, J. D. Potts

The U.S. National Institute for Occupational Safety and Health (NIOSH) uses light-scattering real-time dust monitors (nephelometers) in its research to develop dust controls to reduce respirable silica dust overexposures in miners. Recently, the model 1500-pDR, an active nephelometer (i.e., with cyclone and pump configuration), was introduced by Thermo Scientific. Testing was completed to ensure compatibility with the metal/nonmetal mine dust personal sampling unit (M/NMDPSU). Results of testing demonstrated that gravimetric concentrations measured from the 1500-pDR are comparable to the gravimetric concentrations measured using the M/NMDPSU, without need for correction, under commonly observed dust loading conditions.

Jan 1, 2012

By D. R. Tesarik, T. C. Trancynger, W. G. Pariseau

The Davis detector cavern was excavated on the 4850 Level of the former Homestake Mine in the mid- 1960s to house a novel neutrino detector developed by Nobel Prize winner Dr. R. Davis. The original cavern was about 9.1 x 16.8 x 9.7 m high, excavated in a Precambrian amphibolite known as the Yates unit and enlarged in 2010. In 2009, the National Science Foundation selected the site for development as a national Deep Underground Science and Engineering Laboratory (DUSEL). This retrospective rock mechanics study of the Davis cavern is intended to inform design of the much larger caverns and laboratory rooms being considered for the same 4850 Level. Provision for rock mass variability, sequential excavation, jointing and wall damage from blasting are included in analyses that were done using two different computer codes and methods (FLAC3D and UTAH3). The results are in agreement with observations and show that cavern stability is indeed the case. The main conclusions are: (1) if conventional scaling of laboratory rock elastic moduli and strengths is done, then 0.25 and 0.50 scale factors are reasonable, (2) measured statistical and spatial variability in rock properties should be incorporated into geomechanical analyses to better reflect reality, (3) discontinuities (“joints”) are essential to reliable analysis of excavation safety and when properly taken into account eliminate the need for empirical “scaling” of laboratory rock properties, (4) major geologic features such as rhyolite dikes and breccia zones may be important to excavation safety at Homestake and should be explicitly represented in analyses and (5) quantifying wall blast damage is important to engineering design of underground excavations.

Jan 1, 2012

By L. Zhou, A. Martikainen, G. Goodman

Continuous airflow monitoring can improve the safety of the underground work force by ensuring the uninterrupted and controlled distribution of mine ventilation to all working areas. Air velocity measurements vary significantly and can change rapidly depending on the exact measurement location and, in particular, due to the presence of obstructions in the air stream. Air velocity must be measured at locations away from obstructions to avoid the vortices and eddies that can produce inaccurate readings. Further, an uninterrupted measurement path cannot always be guaranteed when using continuous airflow monitors due to the presence of nearby equipment, personnel, roof falls and rib rolls. Effective use of these devices requires selection of a minimum distance from an obstacle, such that an air velocity measurement can be made but not affected by the presence of that obstacle. This paper investigates the impacts of an obstruction on the behavior of downstream airflow using a numerical CFD model calibrated with experimental test results from underground testing. Factors including entry size, obstruction size and the inlet or incident velocity are examined for their effects on the distributions of airflow around an obstruction. A relationship is developed between the minimum measurement distance and the hydraulic diameters of the entry and the obstruction. A final analysis considers the impacts of continuous monitor location on the accuracy of velocity measurements and on the application of minimum measurement distance guidelines.

Jan 1, 2012

By Victor Romero, Steve Redmond

All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, Inc. from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Any statement or views presented here are those of individual authors and are not necessarily those of the SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME.

Dec 1, 2011

By J Planner

As Australia’s coal and iron ore export volumes increase to meet international market growth, port terminals, mining operations and rail transport systems can be the source of increased dust emission. Current and future sustainable expansion must minimise dust emission from bulk handling and transport operations located in close proximity to residential areas. Lower level dust emissions can be controlled by operational measures such as water addition to products, and use of water spray on stockpile surfaces. Recent research has shown that higher levels of dust emission can be more effectively controlled by understanding and treating the dust characteristics of each individual bulk product. Application of this research, progressively being applied at Australia’s coal and iron ore port terminals and rail transport systems, is achieving compliance with health standards and minimising dust nuisance effects to an acceptable level.

Nov 22, 2011

By J Bassan

The mining industry is faced with imperatives to improve worker safety and productivity, adapt to skills shortages, high worker turnover rates, and provide more effective maintenance to new and ever more complicated plant and equipment. While more effective use of data combined with advanced analytics offers opportunities for improvement, providing this information to the worker in the field, in real-time, has proven expensive, cumbersome and ineffective. New capabilities are now emerging which address some of the limitations experienced to date. Augmented reality (AR) provides a means to overlay interactive digital information on top of the physical world. Combining the latest visual display, mobile computing and ‘track and trace’ technologies, AR provides an experience similar to a heads-up display in a fighter jet through small, personnel devices, such as smart phones or wearable glasses. Applying AR would allow a mobile worker to ‘see’ all relevant information for a given task, in the context of their physical environment and at the time they require it. The technologies behind AR are rapidly maturing and becoming available at a price point that is viable for commercial applications. It is anticipated that AR will become ubiquitous at a consumer level within the next five years. The specific challenges faced by the mining industry make it an ideal early adopter of AR technologies. This paper examines a number of use-cases of how AR can be applied to the mining industry and the benefits that can be realised. The paper will identify areas of further work and viable opportunities for immediate adoption within the industry.

Nov 22, 2011

By S Maryati

Surface mining activities disturb large areas, produce great sediment loads and tend to be a source of water pollution if they are not managed properly. Coal mining in Indonesia has a very high risk of soil erosion because the coal mining areas are generally located in tropical areas with a high average of rainfall (4000 - 6000 mm/year) and use surface mining methods. The main factors affecting erosion risk are climate, soil type, topography, vegetation cover and management factors. Thus, the monitoring of erosion risk in mining areas is very important due to the characteristics of coal mining in Indonesia. The objective of this research is to determine the ability of satellite images (remote sensing data) and geographic information systems (GIS) to provide an accurate and up to date spatial database for the monitoring of erosion risk in surface coal mining areas using the Universal Soil Loss Equation (USLE) method.The erosion risk analysis and spatial data processing are generated by the ArcGIS 9.3 software and need several data, namely: an erosivity map, erodibility map, a slope map, vegetation index map and land management or land cover map. The erosivity map is derived from the rainfall data, whereas the erodibility map is derived from the soil map. The slope map is derived from the SRTM-DEM (Shuttle Radar Topography Mission-Digital Elevation Model) and processed using 3D analyst tools. Furthermore, the vegetation index map and land cover map are derived from a satellite image using digital image processing techniques.This preliminary study produced results that show soil erosion monitoring, which is integrated with remote sensing and GIS technologies, has great potential for producing accurate, advance, and low cost erosion risk maps in coal mining areas. This map is very important for getting spatial distributions of the erosion and useful for developing erosion management plans.

Nov 22, 2011

By L Alem

In the field of mineral extraction, complex technologies are being introduced in mines, operators/technicians rely on assistance from an expert (or more) in order to keep their machines functioning. Personnel with such expertise, however, are not always physically on-site. There is a growing need for innovative technological solutions to support effective delivery, just in time, of remote guidance between an offsite expert and an on-site maintenance operator. To meet this need, we have, as part of our Human System Integration project within the CSIRO’s Minerals Down Under (MDU), Transforming the Future Mine theme, explored the usefulness of a number of emerging technologies including: augmented reality, wearable systems and touch table interfaces. This paper presents ReMoTe, an augmented realty system for remote guiding using a touch table interface for the expert station and a combination of augmented reality and a wearable system at the operator end. In designing this system we were interested in exploring the extent to which it can increase the productivity and safety of maintenance personnel. This paper also presents Mobile ReMote, our recent development of a fully mobile remote guiding system. In Mobile ReMote, both the expert and the operator are using a near eye display and wearing a light computer in a back pack. The expert is able to guide the operator using his/her hands on the virtual display, while the operator is able to see the instructions on the rear eye display. Workers in the mining industry are highly mobile, a mobile expert and operator station will meet this need.

Nov 22, 2011

By F Rashidinejad

Iran has had an active mining sector for some 7000 years. Exceptional in terms of its mineral diversity, Iran produces 62 minerals, and is ranked among the world’s 15 most mineral-rich countries. Many people around the world know Iran as one of the major petroleum exporters. Oil and natural gas dominate Iran’s economy, and oil exports provide the principal source of income, contributing more than 80 per cent of foreign exchange earnings. Transformation of Iran from an oil exporter to an independent country to oil has been on the table for many years, even before the Islamic Revolution of 1979. Development of the Iran’s mineral industry is one of the major replacements for petroleum exports. In the last decade, Iran invested billion dollars in the mining and mineral industry sectors and to increase the added value, tried to export processed minerals instead of the raw materials. In accordance with the ‘20-year Perspective 2025’ that targeted by the Supreme Leader, Iran will be a country with the first rank in economy, science and technology in its region. The objectives over this perspective include briefly increasing annual production to 55 Mt of crude steel, 800 000 tonne of copper cathode, 1.5 Mt of aluminium, 200 Mt mineral products, 300 000 tonne of zinc and 5 000 kg of gold. These goals are achievable in normal circumstances, but concurrency of the 20-year Perspective 2025 with commencement of the UN Security Council sanctions against Iran, frustrated objectives of the perspective, at least the ones related to the mining and mineral industry sectors. This paper tries to elaborate the development programs and following challenges for the mining activities of Iran by 2025.

Nov 22, 2011

By L Mottola

Three decades ago mining companies, principally in North America, aided by machine and explosive manufacturers, started significant attempts to develop and implement automated mining systems, mainly underground. These tended to be motivated by decreasing cost, increasing productivity, reducing labour requirements, and improving safety. These are important business drivers, however, little attention was given to the underlying goal of mining automation, namely to bring upstream processes in control and reducing variation, as seen in downstream mineral processing plants.This paper first reviews the nature of Lean Thinking and its application in the context of the growing commitments by industry to develop future automated mine production systems. The paper then makes reference to prior and current experiences in open pit blasthole drill and shovel performance monitoring, to demonstrate the principle that machine performance data offers as a means, not only to characterise the dynamic geological and working environment, but also to provide a foundation for automation. In this case, drill and shovel monitoring was originally motivated as a means to optimise blast fragmentation through more effective drill and blast designs that are based on an accurate determination of the bench geological and geotechnical characteristics, hence managing variation in the drilling and blasting process. This paper considers how automating and integrating such components of the mine production system would bring processes into a controlled state, creating value at the face, within a framework of Lean mining.

Nov 22, 2011

By H Jones

The paper outlines the adoption and evolution of ‘sustainable development’ as a concept in tailings management practices in the mining industry over the last 30 years. Over 500 lives have been lost in tailings facility accidents since World War 2. The paper outlines commonalities in many of these accidents, particularly the role of excess water. It considers the role effective tailings management can play in enhancing the social acceptability of mining in the future.Tailings management is a major operating cost at many mines while the cost of successfully closing tailings facilities is also very high. Current tailings management practices in the industry are outlined. The technical and engineering challenges of reducing potential risks associated with tailings by reducing water entrainment are described. The successful development of practical techniques to better manage tailings and reduce water consumption and wastage are described. For example, water removal in the alumina industry to produce a paste for dry stacking is now a reality.The future adoption of these new risk reducing techniques by the industry is discussed and the implications of the adoption or non-adoption of these techniques on the industry’s future ‘social licence’ is considered.

Nov 22, 2011

By I Villalba

The need to continue the development of the Ensham mine has led to blast up to 75 m to the Eastern side of a water dam in the vicinity of Ramp 23. The water dam wall is exposed to blasting over a distance of approximately 500 m. The first decision was to determine that the existing rock pillar between the Eastern side of the water dam and the blasting operations may not be less than 75 m in order to minimise the damage that the blast could generate to the dam wall. It was also necessary to define blasting practices to minimising the blast damage to the rock properties of the dam wall and to avoid adverse effects from vibration and gases generated by the detonation on structures.For this purpose analytical designs and test blasts were conducted to assess the ground vibration attenuation within the rock pillar. From this analysis, it was concluded that the best practice to reduce the rock damage was to create a zone of fractured rock adjacent to the side of each production blast. This fractured zone would create an effective filter both for vibration and for gases generated by the blast. This zone of fractured rock was created by firing two buffer rows. In terms of pattern size and powder factor the two buffer rows were designed just to generate a fractured rock zone. To date approximately 500 m have been excavated along the eastern wall of the water dam where each production blast was preceded by a Trim blast. This practice has given good results with regard to minimising the damage generated by production blasting.

Nov 8, 2011

By W R. Adamson

Cerro Vanguardia SA (CVSA), property of AngloGold Ashanti, mines gold and silver from a system of vetiforme orebodies located in the south of the Argentine Patagonia, in the Province of Santa Cruz.Surface mining techniques are applied to develop a series of narrow pits with an average waste to ore ratio of 26:1. This quite unique constraint brings into focus the need to maximise inter-ramp and final wall angles, leading to a strong need to optimise wall control drilling and blasting in order to reduce back-break damage to an absolute minimum.The paper describes a program of applied investigation and design modification implemented during?2008?and?2009 in?two?separate pits of Cerro Vanguardia. Three distinct yet complementary damage mechanisms were identified and observed during the field components of the work; vibration induced strain fracturing, surface cratering around blasthole collars and quasi-static loading and unloading of the surrounding rock mass as a consequence of poorly controlled confinement.With these mechanisms identified, a measurement, modelling and modification campaign was conducted in order to reduce the incidence of each source of damage. Interactive design analysis and modelling, near-field vibration measurement, video capture and the application of electronic initiation technology were supported by seed wave modelling and topographic evaluation of the achieved results.Results point to the usefulness of simulation techniques for determining optimum delay timing to reduce vibration impact, while the visualisation of explosive energy distribution produced by drilling and explosive loading decisions assists in reducing the probability of over-confinement.This paper presents relevant aspects of the two fieldwork campaigns:1) describing the application of the techniques, and2) summarising the results obtained.

Nov 8, 2011

By A J. Moore

Blasting operations in open cut mines results in airblast, ground vibration and rock movement with the potential for wild flyrock. In some mines there is a trend towards blasting closer to established infrastructure as extraction boundaries alter with increased resource prices and changed economic circumstances. Mine infrastructure in close proximity to blasting has the potential to be damaged by ground vibration and wild flyrock especially. To provide guidance for the determination of appropriate buffer distances and blast specifications, this paper describes methodologies that may be used to determine the potential for damage to infrastructure by predicting:dynamic blast;near field ground vibration levels;dynamic blast strains induced in infrastructure by consideration of ground vibration,ground strain and response amplification;potential for damage by comparing induced strains with allowable working strainsfrom structure design codes and serviceability requirements; andflyrock throw distances based on models developed from flyrock investigations.This report demonstrates the use of strain prediction methodologies developed during Australian Coal Association Research Programme (ACARP) Project C14057 for infrastructure such as conveyor belts, transmission poles and towers, buildings and bridges.

Nov 8, 2011

By N Elith

The explosives demolition of a post-stressed, steel reinforced, concrete road bridge in Australia’s capital city, Canberra. The bridge was 50 m from the new replacement bridge, 320 m from community structures and within five kilometres of the national parliament buildings. The job required multiple overlays of risk assessment, public relations, safe work procedures, specialised blast design, environmental predictions and flyrock controls. Project stakeholders included Worksafe, Roads ACT, bridge owners, consulting structural engineers, community groups and road users. The bridge precincts, including a major road underneath, had to remain operational to peak traffic in the days leading up to the demolition. The break-up and removal of debris had to be executed in just two days from Friday to have the road beneath re-opened for Monday morning city-bound traffic.In Canberra, all explosives demolitions are now viewed with particular caution after a demolition in 1997, during which a young girl was killed. Any approval requires that Explosives Regulations, AS2187 2006 and Worksafe processes are satisfied, and a convincing case presented for blasting as a safe and viable option.Our design used specialised shaped cutting and blasting charges to sever in situ concrete beams and tendons and to shatter components of the stressed concrete bridge assembly. We include comments on structural engineering reports dealing with pre-weakening mechanisms. The benefit of pre-weakening is that it reduces the amount of explosives needed to safely complete the job and facilitates quick removal of debris after the shot. The complementary skills of the team, each one an expert in his field, resulted in a highly successful demolition, praised by authorities as an outstanding example of controlled use of explosives.

Nov 8, 2011

By T N. Little

This review paper presents an integrated and practical insight to blasting geology and its importance. This approach involves developing blasting objective up front and implementing geology specific blast designs. The author refers to this approach as ‘starting at both ends’. There are many human-imposed controls on blasting operations, such as: safety, security, legislative, company standards, heritage, and environmental constraints. Thus it is possible for some operators to lose sight of the controls imposed by nature. This paper demonstrates how site geology controls or influences many aspects of the rock breaking processes and how a focus on this aspect has potential to add considerable value to mining operations. It is obvious that mining companies concentrate their efforts on economic/ore geology (good rock geology). However it is the author’s experience that they also concentrate on engineering geology (bad rock geology) only when forced to do so by the ground conditions, but seem to run out of puff before they apply blasting geology (big rock geology). This paper contains five main sections. In the first section, the impact of geological controls on blasthole drilling is briefly discussed in terms of drill selection, penetration rates, bit wear, blasthole stability, blasthole deviation, and health precautions. In the second section the geological controls on aspects of geometric design are reviewed. These include: hazardous minerals, valuable minerals, selection of the blasting techniques, geological structures, blasting direction, and blasting geometry. Section three overlaps with the geometric design section and deals with aspects related to explosives. Topics addressed include selecting the explosive type based on geology, distribution of explosive charge in space and time, explosive performance, and the rock response to explosive loading. In the fourth section, examples are given of the operational complexity needed to implement a blast to cater for difficult bench geologies, environment constraints, past mining (voids) and need for a high degree of quality control. Section five demonstrates geological controls on blast results. Blasting results include the muck pile characteristics, downstream handling and processing, damage to the remaining rock, and blasting emissions.

Nov 8, 2011

By D P. Blair

The theme of this conference is blasting productivity. This article only considers the technology aspect of this theme, and in particular, the collection and analysis of experimental data. In many cases, field trials are set up to collect data on variables such as fragmentation and vibration with the aim of comparing different explosive products and/or blast designs. An important aspect of such trials is the collection of sufficient data to draw sound conclusions. In this regard, there is no doubt that the scatter in real data is the root cause of all problems of obtaining misleading results due to an insufficient number of trials. This article shows that the typical one-off trial has a high probability of producing misleading information, which could be considered to be worse than having no information at all. Assuming that sufficient data has been collected, this article also highlights the methods that can be used to make the most of that data. These methods include the application of appropriate statistics that are dependent on the nature of the scatter in the data, and the use of some of the more recent filtering and spectral approaches that can be used to reduce the noise in measured blast signals and increase the resolution of their spectral characteristics.

Nov 8, 2011