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By Todd Kilduff, Paul Wilkinson

Microtunneling is rarely a straight forward “business as usual” endeavor. More often than not, these projects take twists and turns that require on the fly, out of the box solutions to get the project completed. This paper is a case history of a 63-inch diameter, Permalok, microtunneling project, extending nearly 700 linear feet under a hill forming the left-hand abutment to an earth embankment tailings dam. The job had three major and unexpected challenges that required unorthodox solutions. Challenge #1— Face Configuration: The Santiago Formation, a cemented sand formation with widely varying strengths, presented a challenge to configuring the face with regards to the number and length of pics and cutters. Subtle differences in type and size of the tooling had a big impact on the performance of the machine. Challenge #2—Eccentric Loading: Issues at the launch shaft with the Permalok pipe adaptors caused eccentric loading on the casing pipe. This issue resulted in overstressing and breaking of several pipe joints that ultimately led to seizure of the tunnel. Challenge #3—Back-tunnel Excavation and MTBM Recovery: There were many detailed considerations into excavating a recovery tunnel to retrieve the MTBM, especially being under a high hazard earth embankment dam.

Jun 13, 2021

By J. A. Botín

Investment decision for large mining projects imply an enormous financial risk and therefore, require a more complex risk evaluation methodology taking into account all sources of uncertainty from each process in the project value chain. Generally, the main sources of risk are those related to uncertainty on grade and other techical variables of the orebody. In this study, conditional simulation is applied to develop a risk management model to quantify and to manage financial risk associated to uncertainty on the grade of the orebody. The model was validated in case study on a real porphyry copper orebody in Chile.

Feb 23, 2014

By M. A. Cristovici

The possibility of using surfactants as wetting agents for the suppression of sulphide ore dust has been investigated. Numerous surfactants were examined to determine their characteristics and to investigate their ability to improve the wetting of the sulphide ore dust. However, the surfactants selected as suitable dust suppressors proved to have a negative effect on the flotation of the ore contaminated with such reagents. A method was developed to eliminate the detrimental influence of dust-suppressing surfactants. It consisted of surfactants adsorption on activated carbon and separation of loaded carbon prior to flotation. The technique is simple and requires minimal changes in the plant flowsheet.

Jan 1, 1990

By R. L. Grayson

A goal programming-based worker scheduling model has been incorporated in the Mine Management Support System (MMSS) for assigning workers to prioritized jobs on a shift basis. In the model the accomplishment of each regular and non-regular job is a goal. The objective is minimization of the deviations away from the goals. A number of coefficients are used as premultipliers of the decision variables in order to address practical considerations associated with the utilization of workers and the requirements of jobs. Some of these premultipliers will be updated expertly within MMSS, timely updating the statuses of the dynamic parameters.

Jan 1, 1991

By P. C. Kapur

For mineral processing spirals, mathematical force equilibrium models are sought to extend the spiral performance envelop. In Part 1 of this report, a complete geometric description of the helical spiral and its trough or channel contour is provided. The secondary circulatory fluid motion in the transverse direction that develops when water flows down a tightly turning curvilinear path and its implications for gravity separation are discussed. Different forces that act on the particle during its passage through the spiral are enumerated and quantified for a better appreciation of their relative contributions and roles in the separation process. Three force equilibrium models from the hydrology literature on sed iment transport are employed to simulate a typical spiral. While the results are promising in that the models mimic the broad performance characteristics of the spiral, what is needed is a more general spiral model taking explicit cognizance of the missing components essential to the spiral description. These are such components as centrifugal force and the steep tangential slope of the channel deck. Results of this latter exercise are deferred to Part 2.

Jan 1, 1996

By R. Bruce Tippin

because of the mineral's high monetary value and the spotty occurrence of free gold in the deposit. Setting up a plant sampling procedure by simply applying the usual statistical sampling theory was questionable. Two sampling concepts were considered in the sampling study: o a sufficient number of assays can be taken such that the average determined from these individual samples represents a known quantity of ore. o a sufficient weight of sample can be taken such that when assayed it represents a known quantity of ore. The test program included evaluation of sampling techniques, sample preparation and analytical methods. The overall sampling program is depicted in Figure 2.

Jan 1, 1985

By M. T. Ityokumbul

The liquid phase mixing in Western Research Centre (WRC) pilot plant flotation column with diameter of 0.76 m has been characterized using a salt tracer. The process variables studied were gas and liquid flow rates. The response of the column to a tracer pulse input was monitored at three axial and two radial locations. For all the experimental conditions investigated in the present study, radial and axial concentration gradients were not observed. It is thus concluded that the 2 tph flotation column is behaving as a well mixed tank. This finding is consistent with the observed poor recoveries of coarse fractions in the column flotation circuit. Based on the findings of this report, it is recommended that several schemes of reducing the backmixing be implemented and evaluated for their effectiveness in improving the column recoveries.

Jan 1, 1994

By R. Kramer, A. Habibi

A ventilation survey was conducted in an underground longwall trona mine. The mine is relatively shallow and categorized as a gassy mine. The ventilation system includes three intake and six exhaust shafts, and three surface axial fans ventilate the mine in a blowing configuration. Airflow quantity, pressure losses and air psychrometric characteristics were quantified, and the influence of moving cages and skips in the shaft examined. The benefits of utilizing high-accuracy digital pressure transducers and advanced psychrometers were seen when undertaking a “leapfrogging” survey to gather data needed to build a computer ventilation model. Two underground booster fans with VFDs are idle but available at the mine. The ventilation model was used to determine the optimal booster fan locations to decrease operating cost by reducing the load carried by the main fans. A leakage study was conducted to evaluate the effects on the system of additional pressure from a booster fan. The study finally prepares a future ventilation model for the next 15 years of mine operation and investigates the effect of proposed scenarios.

Jan 1, 2014

By M. Rieber

The recent history of the mercury market results almost entirely from U.S. Government actions. Its derived demand has been curtailed by U.S.E.P.A. mandates; its supply has been augmented by U.S.D.L.A. controlled stockpile releases. The resultant prices have altered its market structure, impacted mercury mining, refiners and recyclers, and affected international production and markets. From a marketplace product mercury is rapidly becoming a disposal problem. Other minerals may follow in its wake. This paper reviews developments in demand, particularly in relation to environmental constraints. Supply side impacts are considered. The impact of stockpiles, both as a market overhang and as a potential supply is reviewed. Government stockpile disposal activity is emphasized, but the size, estimated disposal rate, and quality of the private stockpiles are considered, as is the potential availability of additional material from shut-in mines.

Jan 1, 1995

By A. J. Guse

The primary limiting factor for hoisting capacity from great depths is the self-weight of steel wire ropes. Steel wire ropes are very suitable for mine hoisting due to their high strength and durability, but have the negative characteristic of a low strength/weight ratio. Also, as hoisting depths increase, the service life of steel wire ropes decreases due to the higher stresses and physical effects on the ropes. The significantly higher strength/weight ratio of synthetic ropes offers the primary advantage of hoisting a larger payload with a similar size rope and hoisting plant. The beneficial properties of synthetic ropes could be used to improve the overall economics of deep underground mining both for new deep shaft projects and for existing mining operations expanding to deeper orebodies. A research and development program has been initiated to evaluate the suitability of a fully synthetic rope for the mine hoisting application.

Feb 23, 2014

By F. J. Sotillo

"Scrubbing both horizontal (drum) and vertical (attrition) are considered simple unit operations in the beneficiation of phosphate ores. In general, the operating conditions are fixed at high solids content based on the experience of the engineering or equipment manufacturing company responsible of designing this beneficiation step. Nevertheless, scrubbing is a complex unit operation designed to clean the surfaces of phosphate mineral particles of slimes, break loose weak inclusions or attached particles of impurities, and break aggregates of clayish material. Therefore, it is considered that as high solids content as possible should be used to enhance particle-particle interactions (impact and rubbing) without taking into consideration the rheology of the system. However, scrubbing unit operations design requires studying the balance between the increase of particle-particle interactions with the cushion effect that may occur when slimes, clays and fines decrease the availability of free water increasing the apparent viscosity of the phosphate slurry up to that of a paste consistency. This paper presents data from laboratory tests to determine the best operating conditions for the design of these unit operations based on the highest P2O5 grade obtained with the lowest impurities for different size fractions. INTRODUCTION In the beneficiation of phosphate ores, unit operations such as horizontal scrubbing (drum) and vertical scrubbing (attrition) are considered simple unit operations. Therefore, little attention is given to the design of horizontal and vertical scrubbing during the basic engineering studies, and the detail engineering stage, the manufacturers recommending “standard” units and operating conditions based on their experience. Due diligence of several beneficiation phosphate plants at industrial scale indicates that a deficient scrubbing of the phosphate ore results in significant problems in downstream unit operations, such as classification, clarification, gravity separation, magnetic separation, flotation, dewatering, and filtration. Scrubbing is in fact a complex unit operation designed to clean the surfaces of phosphate mineral particles of slimes (clays and fines), break loose weak inclusions or attached particles of impurities, and break aggregates of clayish material. Two phenomena occur, the particle-particle interaction (impact and rubbing), and the rheological effects of releasing significant amount of fines into the slurry. Therefore, high solids contents are recommended to enhance the particle-particle interactions, which may result in a change in the rheological regime of the system due to the slimes, clays, and fines decreasing the availability of free water. This increases the apparent viscosity of the system up to that of paste consistency resulting in a cushion effect that suppresses scrubbing. Under these conditions, not all fines are release and rejected (deslimed), downstream unit operations being affected by the release of clays, resulting in P2O5 losses."

Jan 1, 2017

By P. Somasundaran

Three major types of solution chemical equilibria involving flotagents (Le. flotation reagents such as collectors, frothers and modifiers), minerals and solution play a crucial role in determining the behavior of complex flotation systems. Minerals of phosphates (apatite and francolite), tungsten (wolframite and scheelite) and associated carbonates (calcite and dolomite) are sparingly soluble in aqueous solution and form dissolved mineral species in bulk solution. Such dissolved species interact with mineral solids, often resulting in surface conversion of the minerals. In addition, they can interact with various flotagents and lead to surface or bulk precipitation and loss of selectivity in the flotation. Relevant solution equilibria of such sparingly soluble minerals and their interactions with oleic acid and structurally modified reagents were determined in this study using a multi-pronged experimental approach. Methods to manipulate and control the solution chemical equilibria and thus achieve selectivity in flotation systems are discussed.

Jan 1, 1990

By Jie Li, Longxiang Li, Wenbing Guo, Gaobo Zhao, Yuhang Hu

Surface subsidence caused by underground longwall mining is a very complicated process in time and space, influencing building and structures on the surface of the mining area, including houses, pipelines, and highway. The field monitoring data of surface subsidence are essential for protecting them. This study investigated the dynamic and residual subsidence characteristics of both the surface and the highway over a 730-day monitoring period on a longwall panel. Three monitoring lines (Lines 1–3) were established to monitor the subsidence process, and three stages were identified: initial stage of surface subsidence, active period of surface subsidence, and residual subsidence deformation stage. The maximum subsidence value on the highway (1,786 mm) was smaller than that on the surface (2,094 mm), and the maximum subsidence velocity on the highway (41.7–50.8 mm/day) was also lower than that on the surface (66.7 mm/day). During the residual subsidence deformation stage, both the surface and highway subsidence velocities decreased to below 0.6 mm/day. Furthermore, differences in subsidence characteristics between the surface and the highway were analyzed, with the subsidence value on the highway always being less than that on the surface, while the subsidence velocity during the residual deformation stage was not always lower. This could be attributed to the influence of dynamic loads from vehicles, which could induce additional residual subsidence on the highway. Further investigation into this phenomenon will be conducted in future research.

Jul 1, 2023

By D. Bristow, D. Baker, K. Awuah-Offei, A. ur Rehman

While a body of work exists on intelligent systems for guiding occupants out of buildings during an emergency, the problem of guiding miners out of a mine during an underground emergency has not been explored. Underground evacuation fundamentally differs from building evacuation because of differences in the regulatory regime and uncertainty regarding the number of occupants. The potential for implementing an intelligent miner guidance system is buttressed by the fact that miner tracking systems, along with communication and sensor networks, already exist in underground mines. This work presents a method based on a local positioning system, in the form of a network of “nodes” at major “intersections,” which can then be used to guide miners to safety. We have developed a path-planning algorithm, based on Dijkstra’s algorithm and the local positioning system that can provide miners with the optimal escape path in an emergency. The algorithm is validated with scenarios at the Missouri University of Science & Technology Experimental Mine demonstrating the potential to include smart technology in mine emergency management and response planning. INTRODUCTION Underground mines are hazardous environments with a higher than usual risk of safety emergencies where miners have to evacuate the mine to save their lives. Mines have always trained miners to evacuate or shelter-in-place in minimum time. Jalali and Norrozi (2009) opined that the three major components that help miners in case of emergency are pre-planned optimal escape routes, decreasing delays, and improving the education of miners. In fact, Goodman and Kissel (1990) suggested that fatalities arising from mine accidents could be reduced by 50% just by decreasing delays in finding the pathways in case of emergency. The proposed work can assist miners in finding escapeways quickly in case of emergency. It is very important to have a pre-planned evacuation strategy that is clearly communicated to miners to ensure the safety of all (Conti, Chasko & Wiehagen, 2005).

Jan 1, 2019

By R. Sellaro

It has long been understood that extended occupational exposures to respirable mine dusts can lead to chronic lung disease. In underground coal mines, CWP and silicosis are major concerns. While there have been many studies aimed at understanding total dust concentrations and silica content associated with different mining conditions (e.g., locations/occupations within a mine, cutting methods, geologic strata), little research has been completed to more comprehensively characterize respirable dust (i.e., by particle composition, size distributions, shapes). This preliminary study sought to characterize dust from an underground coal mine in Central Appalachia using scanning electron microscopy with energy dispersive x-ray (SEM-EDX). Respirable dust samples were collected from various locations in the study mine, and individual dust particles were identified and classified by mineral type. A continuous personal dust monitor was also used to estimate total respirable dust concentrations during sampling. Here we report initial results of this work, and discuss advantages and challenges of particle-level characterization of mine dusts in terms of occupational health research.

Feb 23, 2014

By M. Nambiar

Due to the remote locations of the mining projects and the demand for long transmission lines to provide electrical power, mining sites often operate with poor network power quality and low short circuit capacity. In order to cope up with this situation, more and more mining projects are considering the installation of appropriately designed Synchronous Condensers(SC) together with Power Factor Correction and Harmonic Filter System(PFC&HFS). The installation of these power quality equipments is viewed as a technological advancement in the mining application. An adequate level of short circuit power is essential and has to be ensured for the safe and reliable operation of especially large cycloconverter driven gearless mill drive systems used for grinding application. Increase in plant short circuit power is generally achieved by lowering the impedance of the supplying network. The SC also provides smooth voltage control during mill starting or major load trips, thereby regulating the plant voltage within the required limits. This paper will explore the impact, technical advantage and reasoning for the selection of the advanced hybrid technology mentioned above, in order to cope with the power system challenges for future mining projects. It also highlights the potential problems and how to address them carefully.

Feb 23, 2014

By K. T. Brashear

Since the MINER Act of 2006, the minimum static load of in-situ underground mine seals has been increased from 20-psi to either 50-psi if monitoring is conducted or 120-psi if left unmonitored. These minimum strength requirements in seals must be designed, built, and maintained throughout the lifetime of the seal. Due to this, it has become necessary to assess the effectiveness of non-destructive testing (NDT) technologies to determine seal integrity, which in this case, are explored using sonic waves and tracer gases. Through both small and large scale testing, two NDT methods will be evaluated for their abilities to determine integrity of the seal. A sonic wave technique to observe a change in wave velocity to identify faults within the seal material. As a NDT method, tracer gases may be used as a potential indicator of a connection between both sides of the seal material through a series of faults and cracks within the material itself. This paper reviews the history of underground mine seals and discusses the overall assessment of sonic waves and tracer gases to serve as NDT methods for estimating the integrity of these seals.

Feb 23, 2014

By U. Srivastava

In the processing of manganiferous ore, it is useful to control whether the manganese (Mn) goes to the iron product to produce ferromanganese, or to the slag for extraction as a high Mn product. This can be done by manipulating the thermodynamic conditions for manganese oxide(MnO) reduction to control whether it remains as MnO or converts to metallic Mn. Results are presented showing that during production of iron nuggets, reduction of manganese oxide (MnO) can be controlled by changing the furnace temperature and reductant composition appropriately.

Jan 1, 2010

By H. Cho

A study was undertaken to investigate the liberation behavior of coal macerals through size reduction and density separation. It was seen that the liberation of coal organic components could be achieved by size reduction, allowing selective separation of coal organic components. However, the degree of liberation is dependent on the history of coal: the extent of liberation decreased when the size of the primogeniture coal decreased. The liberation of coal macerals was analyzed by examining the Liberation Index. It was seen that although comminution produced fine particles enriched in inertinite (primarily fusinite and semifusinitie), these particles were less liberated than the coarser particles. However, the liberation of macerals increased when all the feed was ground to a finer size.

Jan 1, 1996

By M. Scaggs, K. Phillips

"Coal Worker’s Pneumoconiosis (CWP) is an occupational lung disease caused by chronic exposure to respirable mine dust. After decades of steady decline, CWP incidence appears to be on the rise since the mid-1990s, particularly in some regions of Appalachia. Alarmingly, many of these cases have rapidly progressed to the most advanced form of CWP, referred to as Progressive Massive Fibrosis (PMF). Most of what is currently understood about respirable mine dust has been gleaned from routine regulatory monitoring, which tracks total mass concentration of respirable dust (mg/m3) and, less frequently, silica mass content. This paper focuses on the use of thermogravimetric analysis (TGA) as a way to provide basic characterization of the whole composition of the dust, allowing it to be classified into three mass fractions – coal, carbonate, and non-carbonate minerals. TGA was conducted on 59 dust samples collected by miners from eight coal mines in central Appalachia, and the results are discussed in terms of differences between mines, regions, and primary occupations. Consistent with prior results on area dust samples from some of the same mines, results of the personal samples generally show that the coal mass fraction of the dust is relatively low. Carbonate and non-carbonate minerals thus tend to make up the bulk of the dust mass, and vary across occupations and specific mines. INTRODUCTION After nearly four decades of decline, the prevalence of Coal Workers’ Pneumoconiosis (CWP, or “black lung”) in the US has been on the rise since the mid-1990s (Laney et al., 2014; Laney et al., 2010; Suarthana et al., 2011; Pollock et al., 2010; Antao et al., 2005; Blackley et al., 2016). Particularly alarming is the number of cases of progressive massive fibrosis (PMF), which is the most advanced form of the disease (Pollock et al., 2010; Antao et al., 2005; Blackley et al., 2016; Laney et al., 2017). A recent study by Laney et al. (2017) observed 192 US coal miners participating in the Coal Workers’ Health Surveillance Program (CWHSP) who had been diagnosed with PMF since 2000. Of the 163 (85%) that had a normal radiograph on file to use as a baseline, 27 (17%) of these individuals had progressed from a normal radiograph to PMF diagnosis in less than 10 years. Moreover, 162 (84%) of the individuals in that study worked in KY, WV or VA, and 169 (88%) had only ever mined underground. Blackley et al. (2016) also reported on a group of 60 PMF cases that were discovered by a single black lung clinic in eastern KY. Since seeking care at such clinics and participation in the CWHSP are voluntary, and could be influenced by a number of factors, these recent reports may well overestimate the degree of resurgence in severe disease (i.e., versus disease that was previously under-reported). Even so, they highlight a critical need to better understand the cause(s) of disease development and progression – such that effective interventions can be devised."

Jan 1, 2018