Search Documents

By Gerald Verbeek, David Tara

"When selecting an impact hammer to drive a particular pile, the decision is often based on local experience. In those cases, the contractor falls back on previous experience or draws on the experience of the hammer manufacturer to select the hammer that will be able to do the job. Obviously, a more scientific approach would be to perform a pile driving simulation using one of several commercially available software packages (e.g., GRLWEAP, AllWavePDP or PDPWave).However, this type of analysis requires quite a bit more effort. First, an accurate model of the pile driving process has to be developed, which includes a model of the soil profile at the job site and input into the analysis program. Then, the model must be analyzed to assess whether the combination of hammer, pile and soil model work.Over the years, numerous individuals and organizations have tried to develop something that would fit nicely in between these approaches: something more advanced than a gut feeling yet something that could be done on the back of an envelope; in other words, a “Goldilocks” approach — not too simple, not too complex, but just right.Screening Tool CriteriaThe goals of the approach are twofold: (1) select the appropriate impact hammer to drive an open toe steel pipe or H-pile, and (2) then use the model for the subsequent high strain dynamic testing (HSDT). The Goldilocks approach centers around five different criteria.1. Maximum Driving StressTo minimize the risk of damage, the maximum driving stresses are generally limited to 80 to 90% of the yield stress (fy) of the steel section. This approach does not consider issues such as hammer alignment, initial imperfections, denting and/or elastic buckling, and pile material fatigue history. However, even when these issues are not applicable, limiting average stresses to 0.9fy or even 0.8fy does not necessarily mitigate the risk of pile damage (Mostafa, 2011)."

Jan 1, 2017

By B. Sivarama Sarma, Biswabikash Rout

"Seepage control has to be achieved with plastic concrete cut-off diaphragm walls in dam structures. Materials selected for construction of cut-off walls must be durable, impermeable and have stiffness comparable to the surrounding soil.Plastic concrete provides a feasible and economical solution for construction of durable and impermeable cut off walls for dam structures. Plastic concrete wall should not be understood as a concrete wall with similar mechanical properties of concrete used in buildings, piles and spillways sections. Though it consists of the same materials as those of conventional concrete it has the major differences in end product due to predominant addition of bentonite slurry in the mix with very high water cement ratio. This makes the hardened concrete with very low compressive strength less than 5MPa and high failure deformations after the peak load.This technical paper examines a case study, the typical specifications on demand for construction and the issues corresponding to misunderstanding of the material as a structural grade concrete material. Conclusions were drawn based on a few project site quality data and trial mix experimental data. The anomalies in specifications on demand for construction of curtain wall in a dam structure were removed with modifications.INTRODUCTIONDiaphragm walls which are constructed in trenches made of plastic concrete basically serve the function of seepage control under confined measures. They should have the ability to sustain and undergo large plastic strains as compared to conventional concrete. The three basic mechanical properties of plastic concrete cut-off walls are to have least permeability, minimum strength to retain its shape and ability to undergo large deformations under confined loading conditions. The constituents of plastic concrete are cement, bentonite, coarse and fine aggregates, chemical additives to improve flow of concrete and sometimes to retard the setting time and water."

Jan 1, 2017

By M. Z. Emad, M. U. Khan

"Coal mines opting for longwall mining or its variations rely on the main and tail gates for production. Stability of these entries or crosscuts is crucial in coal mining operations. Roof or strata failure can be fatal, may lead to property loss and delay in production. Failure of the gates depends upon many factors including the mining method, panel dimensions, pillar width, mine depth, caving rate, dimensions of gates and roof strength properties. In Pakistan coal is mined through a variation of longwall mining method with almost no mechanization while using timber as a primary support. Timber support as chock is very useful in coal mines especially in overhanging face. Similarly gate entries and coal faces are supported by chock supports throughout their length. In this paper the stability of the longwall gate is assessed for a typical coal mine in Pakistan by using finite element code. Numerical modelling considerations for gate entries are discussed. A model parametric study is performed for key factors. The results showed that the existing mining practice is not suitable and there is a need to review the mining approach. INTRODUCTION Main and tail gate entries leading to longwall mining panel play a crucial role in production cycle. Failure of any of these may lead to loss of life, property and production delays. The stability of gate entries depends primarily on the nature of loading and stresses incurred. It is relatively easier to assess the ground response to production for common longwall mining panel. In thin-seam coal mines the gate entries are generally supported throughout their length by timber made chock supports. The tailgates receive huge deformations and stresses during the mining and backfilling cycle. The chock supports are required to take care of rock falls leading to blockage of entries causing production delays and loss of capital. A number of supports are available for supporting the gate entries (Hoek and Brown 1980; Brady and Brown 1985). The support system can be selected based on load-deformation characteristics including the yielding behavior, pre- and post-yielding behavior (Barczak, 2003). The principal of support selection is that the support characteristics must match the ground response in order to maintain the gate entries (Mucho, et al., 1999). It has been observed that thin-seam mining (<1 m) is very challenging and it is necessary to develop an understanding of ground mechanics before the selection of an efficient support system Dolinar (2003). The chock supports have been tested for load-deformation characteristics in the laboratory (Barczak 2003). But the ground and support interaction, response and loads must be assessed for individual site. This can be accomplished by in-situ testing and observations at few locations. The generated data is generally insufficient for complete understanding. Numerical models can combine the data generated in the laboratory and on-site to fulfill the requirements."

Jan 1, 2017

By Z. Scopa, E. Tarshizi, R. Setterlind, L. Frost, R. Livernois

"THE MINES OF THE FUTURE The mines of the future present a host of challenges, which may appear exciting or daunting depending on one’s perspective. Whether some sectors of the public recognize it or not, the demand for raw resources is not going away any time soon. In fact, it is rising as global population grows, urbanizes and attempts to steadily increase quality of life. Yes, at the same time that much of the highly developed world is calling for greener goods, reduced consumption, and cleaner production, in other areas there are cries for clean water and sanitation, consistent energy supply, access to health care and education, personal security, and support for basic human rights. The balancing act for sustainable development of our global society is indeed precarious, and the mining community is necessarily a key player. Fortunately, many industry members have accepted this role and the responsibility to provide leadership and a solid foundation for progress. Looking ahead, we need new generations of leaders, many of whom will be mine engineers, which are ready to tackle all sorts of complex problems. There are tremendous needs just for technological innovations. Increasingly tough deposits will require that we continue to expand scale toward “super” pits and “deep” underground mining fully develop unconventional recovery techniques like in-situ leaching and gasification or deep-sea extraction, and seriously consider off-earth endeavors. Such work will take entirely autonomous equipment; novel separations, processing and recycling methods; and systems that can withstand extreme physical conditions – just to name a few. It will also take a level of systems integration never-before seen in our field, complete with big data issues, sophisticated analytics and modeling efforts, and cyber-security challenges. Moreover, increasingly complex environmental problems will require creative solutions. Addressing issues like pollution control across multiple media, emerging contaminants, optimal management of wastes, selective mining, and shared use of resources between mine operations and surrounding communities and ecosystems are among top priorities. Really, a complete paradigm shift must occur, such that our focus is on overall improvement of environmental conditions, rather than minimization of impacts. A similar shift will be required in the social realm. How can we make miners safer and healthier on-site and off? How can we contribute to communities such that they are better off, now and long-term, for having a mine next door? How can we help transform artisanal mining practices to also contribute to sustainable development? How can our work be a factor in increasing economic and political stability? How can we improve the public understanding of raw resources and the need for mining enterprises?"

Jan 1, 2017

By Camilo A. Alvarez, Stephen K. Harris, Brian R. Zuckerman, Philip J. Meymand, Danielle M. Steinmetz

"The sleek new air traffic control tower at the San Francisco International Airport stands at 221 feet tall and is set to replace the existing air traffic control tower by 2016. This aluminum-clad, torch-like structure and three-story Integrated Facilities Building at the base are situated between Terminal 1 and Terminal 2 adjacent to the tarmac. Berkel & Company Contractors, Inc. and Simpson Gumpertz & Heger Inc. worked in conjunction with structural engineers from Walter P. Moore Engineers and Consultants, geotechnical engineers from URS Corporation, architects from Fentress Architects, and general contractors from Hensel Phelps Construction Company on the performance-based design of a foundation to support this critical facility, which is located in a high seismic zone and situated on the very soft soil of the San Francisco Bay margin. With the loading demands and performance criteria established and Young Bay Mud thicknesses ranging from 44 to 47 feet thick across the site, the design team employed a total of 214 24-inch diameter Auger Pressure Grouted piles, which were drilled into the underlying Franciscan Formation as deep as 148 feet below existing grade. Pile reinforcement included full-length confined cages.The piles were designed to resist Maximum Considered Earthquake axial demands as high as 1,400 kips in compression and 700 kips in tension. The performance-based pile design included verification of shear capacity under double-plastic-hinge flexural mechanisms, verification of pile ductility via non-linear moment-curvature analyses, and consideration of curvatures due to kinematic as well as inertial loading.The team implemented an extensive pile load test program including a full-scale static compressive load test on a sacrificial test pile and five non-destructive high-strain dynamic load tests, four of which were performed on indicator piles that were later used as part of the foundation system. These piles were monitored with extensive embedded instrumentation throughout their length, including strain gauges and accelerometers."

Jan 1, 2017

By Sara Moshfeghi, Seyyed Majdeddin Mir Mohammad Hosseini, Abolfazl Eslami

"Due to variety of current pile bearing capacity methods based on the cone penetration test (CPT), for optimum design, it is necessary to evaluate the performance of such methods in different geotechnical conditions. Geotechnical databases including piling and in-situ testing records have been recognized as useful tools for analysis, design and economical construction. In order to evaluate pile bearing capacity methods, AUT-CPT&Pile database has been compiled including 450 full scale pile load tests and CPT sounding records. This database consists of different pile types with a relatively wide range of geometries and various soil conditions. Forty three records of piles driven in sand deposits were then employed to evaluate effects of ultimate capacity interpretation criteria from load displacement diagrams. The Davisson offset limit criterion, the Brinch Hansen 80% criterion and the load at the displacement of 10% of the pile diameter were compared to estimated capacities from ten CPT based design methods currently used in practice. The Brinch Hansen 80% criterion and the load at the displacement of 10% of the pile diameter lead to reasonable results, the Brinch Hansen 80% criterion showed less scatter. For evaluating the accuracy and the precision of CPT-based methods, the results were compared to estimated capacities. Results of comparison indicate that the CPT-based methods mainly predict the pile capacity withreasonable accuracy.INTRODUCTIONAmong the different approaches of estimating the pile bearing capacity, in-situ tests, especially, the cone penetration test (CPT) are favored due to the cone similarities with piles in modes of installation as well as fast and continuous profiling. This trend is practically well established where deep foundations are to be constructed in soft to medium subsoil deposits (Eslami and Fellenius, 1997; Mayne and Niazi, 2009).Employing different design methods results in a wide range of values which complicates the selection of an appropriate one to determine the pile bearing capacity. Several studies by Briuad and Tucker (1988), Eslami and Fellenius (1997), Abu Farsakh and Titi (2004), Schneider et al. (2008) and Eslami et al. (2011) confirm disparity of different design methods predictions. Thus, for optimum design, it is necessary to evaluate and compare the performance of current methods.Geotechnical databases are known as helpful tools in research and practical applications for optimizing analysis and design and are mainly used for management and interpretation of data, evaluation of design methods, calibrating LRFD or ASD design factors, etc. Pile lateral and axial load tests are examples of databases in geotechnical engineering. A summary of several CPT and pile load test databases is presented in Table 1."

Jan 1, 2017

By L. Wilfley, G. A. Calboreanu

"Wear resistant 25% Cr hard cast iron is a heterogeneous material containing 1,600 HV hard chromium carbides embedded into martensitic matrix. It is the most used cast alloy in wear operations of mining industry, chemical industry, fracking, etc. During the last decade the hard iron manufacturers increased wear resistance in the following ways: • Reduce / eliminate harmful retained austenite and chromium + carbon depleted areas especially within eutectic carbide cells. In Max5A the improved 25% Cr alloy brittle carbide eutectic cells are removed which increases toughness. • Delay delamination between chromium carbides and matrix particularly during sliding abrasion wear. Delamination commences at the weakest chromium carbide – matrix contact lines exposing chromium carbide to localized bending stresses which gradually chip carbides away. Once the chromium carbide base is removed accelerated wear degradation occurs. • Evenly randomize and avoid discontinuities in the chromium carbide network. When chromium carbides are perpendicularly positioned to the wear surface wear rate is minimized. On the contrary the highest wear rate takes place when 3D oriented chromium carbides are parallel with the wear surface. In this case chromium carbides cover top network discontinuities being just matrix supported which leads to rapid carbide cracking. The new hard iron discussed in this paper fulfils and exceeds the above requirements increasing the casting service life around 250% in various wear operations. Physical and mechanical properties of Max5A are compared with well manufactured Industry Standard 25% Cr hard iron. The paper presents practical accomplishments obtained in the USA, South America and India. INTRODUCTION The chemical composition of Max5A and Industry Standard 25% Cr are identical like specified by ASTM A532 Class III Type A requesting C = 2.0-3.3% and Cr = 23.0-30.0%. Manganese, silicon, nickel, molybdenum and copper contents are limited by maximum accepted quantities.[1] According to published data the eutectic chromium carbides chemical composition of 25% Cr hard iron is Cr = 54% and C = 8% which indicates strong depletion of chromium and carbon along chromium carbide - matrix interfaces. [2] The optimized Max5A microstructure has minimized retained austenite, is devoid of harmful carbide eutectic cells and has the most advantageous chromium carbide and secondary chromium carbide morphology. This favorable microstructure increases wear resistance, mechanical properties and corrosion resistance. The paper compares the Max5A microscopic features and mechanical – physical properties with similar properties of high quality Industry Standard 25% Cr."

Jan 1, 2017

By Gautam Benerjee, Veera Reddy Boothukuri, Bhattacharjee Ram Madhav, Panigrahi Durga Charan

"India’s tryst with mechanized longwall coal mining started with the introduction of the first self-advancing powered support longwall (PSLW) face at Moonidih Colliery of Jharia Coalfield in 1978 and at Godavarikhani (GDK)7 Incline of Singareni Collieries Company Limited (SCCL) in 1983. During the last 37 years, about 30 longwall units in Coal India, Ltd., (CIL) and 10 longwall units in SCCL have been introduced with powered roof supports of varying capacity, ranging from 280 to 800 tonnes, in many mines in India under varying geological and geotechnical conditions. The majority of the longwall faces in India have been worked under relatively shallow cover (up to 200m), and significant strata control problems have been encountered due to poor caveability of the roof, inadequate capacity of the supports, a lack of knowledge on longwall caving mechanisms, less than adequate strata monitoring systems, and the non-availability of quality spare parts, etc. This has resulted in structural damage to supports and increased downtime of the equipment, thereby making longwall mining in India a case of technology failure. Energy demand for a developing country like India with a population of 1.2 billion is huge, and the thrust on increasing coal production continues. However, the share of coal production from underground mines in India continues to decline (current share is around 6%) because of absence of successful mass production technology in underground coal mining. Under this backdrop, a high-capacity longwall with state-of-the-art technology was introduced in 2014 at Adriyala Longwall Project (ALP) of SCCL for the first time in Indian Coal Mining Industry. The first longwall panel (LWP) has been completed successfully. This paper highlights the major geotechnical challenges encountered during development of the longwall gate roads due to the presence of two overlying clay bands, significant in-situ horizontal stresses and the experience of using rigid (welded) steel wire mesh with resin-anchored roof bolts. Efforts have been made to analyze longwall weighting and caving behavior, such as main and periodic weightings, the effect of front and side abutment pressures, and the behavior of gate roadway support systems under immediate friable weak roof with overlying massive sandstone."

Jan 1, 2017

By B. Berg, J. Stephenson, J. Mansanti, C. Nyikos

"Intrepid Potash, Inc.’s Carlsbad East facility has refined sylvite and produced muriate of potash (MOP) since 1965. In addition to MOP, Intrepid Potash began recovering the mineral langbeinite from a mixed ore reserve in 2005. In 2011 a new langbeinite recovery process for the coarse (+850 micron) size fraction was constructed to enhance the overall langbeinite recovery. Based on the limited mixed ore reserve and an abundance of langbeinite ore reserves the transition of the East plant to a langbeinite only facility was targeted for 2021. Due to a decreasing grade of the mixed ore reserve, declining sales pricing, and high sylvite operating costs a strategic decision was made to accelerate this transition into 2016. To enable a successful transition, a fines recovery system needed to be developed, constructed and implemented. This paper describes the advancement of langbeinite processing at Intrepid Potash and the planning, development and successful execution of the transition to a langbeinite only operation. BACKGROUND Langbeinite (K2SO4·2MgSO4) is a double salt containing potassium sulfate (K2SO4) and magnesium sulfate (MgSO4). It is used as fertilizer and in the industry is described as Sulfate of Potash Magnesia. It is attractive as a specialty fertilizer and in addition to containing a ready source of a primary nutrient potassium, it also provides two secondary essential nutrients, magnesium and sulfur. It is especially attractive for chloride sensitive crops. Langbeinite has a specific gravity of 2.8, a Mohs hardness of 4.2, and is brittle thus very friable. It is the hardest of the saline minerals, and despite its relative softness on the Mohs scale can be very abrasive in process environments and in field applications, probably due to its conchoidal cleavage. Its solubility at 240 g/l is less than the solubility of sylvite (KCl) or halite (NaCl) and due to even slower relative dissolution kinetics washing with cold water has been a common practice for upgrading langbeinite ores. The solubilization/crystallization relationship for langbeinite is different from the majority of other evaporite minerals in that once langbeinite is solubilized it does not form langbeinite again. Instead it gives up one mole of magnesium sulfate, takes on various waters of hydration and precipitates out as either schoenite (K2SO4·MgSO4·6H2O) or leonite (K2SO4·MgSO4·4H2O) depending on temperature. Due to its partial solubility and phase transitions at its surface when exposed to moisture, there is strong cohesion between wetted particles; the resulting stickiness of the upgraded products can create significant materials handling issues unless processed in slurry form or at relatively low moisture levels. Langbeinite has been produced commercially from two locations, the Kalush and Stebnik regions in the Cartpathian Mountains of former Poland and now the Ukraine and from the Permian Basin in New Mexico (Garrett, 1996; Smith 1949). Current production is from two operators in the U.S., Mosaic and Intrepid Potash."

Jan 1, 2017

By M. Abdollahi, M. R. Khalesi, Y. Kianinia, A. Khodadadi Darban

High cyanide consumption during the processing of gold ores with high sulphide minerals can make the typical cyanidation uneconomic. Also cyanide is a toxic material and environmental concerns of cyanide compounds are serious. Optimization of cyanide consumption requires a methodology to estimate the amount of exposed cyanicides, the kinetic of their dissolution and estimation of formation of cyanide complexes which consume the free cyanide. In this paper, a methodology to estimate cyanide consumption by modeling the minerals and gold leaching kinetic based on a liberation model and speciation of all possible cyanide related species in the solution is presented. The results showed that this methodology could successfully estimate the cyanide consumption based on mineralogical data with very lower number of parameters compared to empirical models present in the literature, while it offers the prediction of formation of all cyanide complexes which could be used for optimization purposes.

Jan 1, 2017

By G-L. Wu, X-B. Liu, C-Y. Zhou

"The static recrystallization behaviour of Ti-Nb microalloyed high-strength steel during hot deformation was studied by conducting double-hit hot compression experiments using a Gleeble-3500 thermomechanical simulator. The effects of deformation temperature, strain rate, strain, and initial austenite grain size on the static recrystallization fraction are discussed. The static recrystallization kinetics were modelled, and the results show that the static recrystallization fraction increased with deformation temperature, strain rate, and strain and interpass time. The static recrystallization activation energy Qs was 326.05 kJ mol-1. Comparison of the experimental results and predicted results indicates that the effects of deformation parameters on the static recrystallization in multistage hot deformation are significant. The predicted results are in good agreement with the experimental results. IntroductionIn hot-forming processes, complex microstructures are often induced by multiple hot deformation mechanisms (Zhang et al., 2014; Liang et al., 2015). The softening behaviour during hot processing has generated considerable interest because component properties are influenced significantly by the corresponding microstructural evolution (Wu et al., 2010). It is well known that dynamic recrystallization (DRX); metadynamic recrystallization (MDRX), which occurs by the growth of DRX nuclei during intervals of deformation; and static recrystallization (SRX), which occurs by nucleation and growth during the intervals of deformation, can significantly alter the austenite grain size (Chen et al., 2015. Chen, Sui, and Cui, 2014; Mao et al., 2014). The long interpass times allow complete SRX to take place if the steel is being rolled above the interpass recrystallization stop temperature (Tnr), i.e. in the absence of carbonitride precipitation (Siciliano, 2000). In recent research, microalloying technology coupled with new-generation thermomechanical control processing (NG-TMCP) has proved efficient in achieving the proper balance between strength, toughness, ductility, and formability by means of a suitable combination of chemical composition and thermomechanical treatment parameters (Shukla et al., 2012; Bandyopadhyay et al., 2011). The alloying elements Nb, V, Ti are widely used in high-strength low-alloy (HSLA) steel to achieve the desired strength and toughness properties with solid-solution strengthening, precipitation hardening, grain refinement, and dislocation strengthening (Opiela, 2014; Chen and Yu, 2012). The wide applicability of alloying elements in HSLA steel is due to the fact that heat treatments are not required after forming of the parts, which results in time and cost savings."

Jan 1, 2017

By L. C. So, S. Faucher, S. Mostaghel, D. Sauter, S. -Y. Oh, S. K. Lee

"Molten material from pyrometallurgical furnaces is tapped at high temperature, carrying a large amount of heat. Traditional handling methods of slow air cooling or water granulation do not allow for the recovery of heat from slag and matte. Furthermore, water granulation adds an inherent safety risk of explosions. Recently, there have been numerous studies into processes attempting to recover waste heat. However, most of them have never been commercialized due to numerous challenges including scalability, cost, low heat recovery efficiencies, and difficulties in heat utilization. Ecomaister-Hatch has recently developed and commercialized a reliable and simple dry atomization system that allows for heat recovery while eliminating the use of water. Comparisons of pilot and commercialized dry atomization and heat recovery technologies will be presented and challenges of these technologies will be highlighted.INTRODUCTION Slag has traditionally been regarded as an undesired waste product from smelting operations with slag management focused on removal and disposal of “waste”. Over 500 million tonnes of slag are produced per year, carrying with it ~220 TWh of energy (Barati, Esfahani, & Utigard, 2011). Depending on the process, the energy content of slag ranges from 10-90% of the total energy input (Barati, 2011, Rodd, 2010). There has therefore been great interest in recovering energy from slag. Slag handling methods can broadly be classified into three categories: (1) dumping and slow cooling, (2) wet granulation and (3) dry granulation. As discussed below, only dry granulation routes are amenable to heat recovery. Slag dumping involves the slow cooling of molten material and crushing of the resulting solid. In this process, slag is dumped on the ground directly from furnaces or transferred to slag pots that are moved by rail or haulers and then dumped on the ground. The molten material is left to cool and solidify until it can be broken and handled by heavy machinery."

Jan 1, 2017

By E. Kumar, L. A. Kumar

"A methodology is proposed to develop an optimization model to understand the impact of transporting minerals, from mines to the final destination, on air quality. Recently, there has been increasing concern about the combined effects of multiple activities over many years, and the regional environmental changes brought about by a single project. Environmental issues in the iron ore industry have highlighted the need to broaden the cumulative impact assessment. In this study, we simulated the optimal routes and quantity of materials needed to meet the destination plant demand based upon environment constraints (level of air pollution), as well as the cost of transportation and availability of materials. Multiple scenarios were developed to analyse the effects of changes in routes, alternative transport system (or multi-modal split), traffic congestion, and the cumulative impacts on air quality. The air quality impact zones of the study area were demarcated using a GIS technique. The expected outcome of the study is the selection of a suitable transport system for a particular site with the least impact on air quality, including the transportation route, relative to the minimum cost of transportation of the minerals from the mines to their final destination. The proposed methodology is evaluated with a case study. IntroductionIn India, the process of environmental impact assessment (EIA) has been focused primarily on the local impacts of projects, without considering regional environmental effects. Environmental clearances for proposed projects are based on reports of local impacts. However, any developmental project poses a potential risk to the environment as a whole, and not just in the immediate vicinity of the project. Recently, there has been increased concern about the combined effects of multiple activities over many years—the regional environmental changes due to development of a single project (Dutta, Mahatha, and De, 2004). Environmental issues throughout the country, particularly in the iron ore industry, have emphasized the need to broaden the analysis to include the combined impacts, or those forecast for a proposed region, on an existing environment. The most significant adverse environmental consequences of iron ore transportation are the deterioration of biodiversity and air quality (Kumar and Ajay, 2015)."

Jan 1, 2017

By F. Hees, A. H. Bracken, L. I. Boshoff

"Biological cementation of the Mandena heavy mineral sand deposit in Madagascar was causing difficulty in dredge mining and hence in planning and control of production rates. An investigation was initiated to better evaluate the geotechnical properties of the orebody by defining the distribution and geotechnical properties of the cemented strata, in order to generate a site-specific geotechnical model for the deposit. The geotechnical characterization was developed by an integrated approach using several ground investigation techniques such as piezocone (CPTu) testing, geotechnical drilling, standard penetration testing (SPT), as well as laboratory testing. The final outcomes of the investigation included a 3D geotechnical model showing the distribution and extent of the cemented areas, as well as the typical geotechnical parameter ranges associated with each of the defined geotechnical units. The interpretations developed were incorporated into the mine and production planning to ultimately optimize operational planning and control.IntroductionQIT Madagascar Minerals (QMM) is a heavy mineral sand mining operation at Mandena, near Fort Dauphin in Madagascar. During the final planning and commissioning stages of the project, the need to fully characterize the unusual geotechnical conditions was identified and a geotechnical investigation became necessary.Nature of the problemDuring the commissioning phase it was found that mining production was being hampered by biologically cemented/indurated layers encountered within the sands. Closer inspection of the indurated horizons in the dredging face revealed that these layers contain a high loading of bacteria and fungi. It appears that the bacteria produce an extracellular (outside the cell) polysaccharide (i.e. sugar and carbon salts), which form a gelling biofilm to trap nutrients. There are a number of different bacteria. The fungi, on the other hand, produce a network of fibrous strands that bind the sand grains together. Thus both bacteria and fungi probably contribute to the ‘apparent cohesive’ strength or binding of the indurated sand (Lynn, 2008)."

Jan 1, 2017

By Martin McKinnon, Guy Reed, Russell Frith

"It is arguable that the development of reinforcing roof bolting systems has largely stagnated in recent times, primarily due to the prevailing industry view that few, if any, further improvements can be made to what currently exists. However, this paper contends that reinforcing roof bolting systems can be further refined by considering both the specific manner by which horizontally bedded roof strata loses its natural self-supporting ability and the specific means by which reinforcing roof bolts act to promote or retain this natural self-supporting ability. The Australian coal industry insists on minimising bolt-hole diameter to maximise load transfer and on targeting full-encapsulation by any means necessary. This has led to a significant, albeit unintended, consequence in terms of overall roof bolting effectiveness, namely increased resin pressures during bolt installation and the associated potential for opening bedding planes that may have, otherwise, remained closed during the bolt installation process. Given that the natural self-supporting ability of roof strata is strongly linked to whether bedding planes are open or closed, logically, minimising resin pressures should be a significant benefit. This paper focuses primarily on three key issues that relate directly to the function of the roof bolting system itself: (i) the importance of proper resin mixing in the context of maximising load transfer strength and stiffness, (ii) the importance of minimising resin pressures developed during bolt installation, and (iii) the importance of maximising the effectiveness of the available bolt pre-tension. All mine operators should be invested in improving the individual effectiveness of each installed roof bolt, even by relatively small incremental amounts, so this is an important topic for discussion within the mining community."

Jan 1, 2017

By Bora Okumusoglu, Devon K. V. Mothersille

"AnchorTest is an innovative software package, specifically developed for tablets, that permits ground anchor test data assessment and management in real time. The solution has two components: a front-end tablet app runs on the Apple iPad platform, and a back-end Cloudbased system running on Amazon Web Services with an online cross-platform website, which can be accessed from any PC, tablet or even mobile smartphone. This tool provides full data analysis and data management capabilities and portability to create greater efficiency in the anchor testing process. AnchorTest is programmed to accommodate the major international anchor testing codes and incorporates an intuitive user interface, which is revolutionary compared to conventional engineering software designs. The use of this tool creates an environment where the testing of ground anchors has effectively become a paperless exercise with greater efficiency and access to instantaneous feedback on the performance of anchors in relation to established acceptance criteria.Historically, project personnel record and analyze the results from anchor load tests using spreadsheets and a laptop computer and/or on predesigned paperbased test sheets (usually as a backup of the testing). In addition, the processing of the test results is not typically performed in real time as the testing progresses — the calculations and analysis are performed either afterward while still on site (if a field office is available) or after returning to the office. Undoubtedly, on larger projects containing numerous anchors where multiple anchor tests may be performed at the same time, processing, analyzing and accepting the load test data and results can be especially time consuming, which could cause delays to the construction schedule.DevelopmentThe need for a more automated and digitized approach to record, process and analyze the data from anchor load tests was highlighted at a deep basement project for a mixed-use development complex in Moscow, Russia. The diaphragm wall supporting the structure was approximately 1,970 ft (600 m) in perimeter length and about 148 ft (45 m) deep, with an excavated depth of about 82 ft (25 m), which required six levels of single bore multiple anchors (SBMAs). This project provided a challenge to recording, processing and signing off on the data generated from some 3,600 3-unit SBMAs. More specifically, for this project, three hydraulically synchronized stressing jacks were used to stress and proof test each 3-unit SBMA, which resulted in nearly 10,800 data plots of the load-extension tests being generated. This project served as the main impetus in the conceptual design and optimization of AnchorTest."

Jan 1, 2017

By Zbigniew Lubosik, Andrzej Walentek, Stanislaw Prusek, Sylwester Rajwa, Aleksander Wrana

"Underground coal gasification (UCG) provides a solution to supply electricity from high ash coal or deep deposited seams. The coal is consumed in situ, and, accordingly, the ash is left underground. UCG could play a major role in the future of coal, which is expected to fuel 44% of the world’s energy in 2030, in a more environmentally friendly and commercially viable manner. Nevertheless, it is known that the UCG can impact the environment. One of the most important factors in safe UCG process should be the evaluation of rock mass quality and the monitoring of its behaviour. The changes of rock mass parameters and quality have an influence on numerous aspects, such as subsidence and the stability of underground workings in georeactor vicinity, however, they also increase the possibility of pollutant migration through fractures and pores. These issues are especially important in cases of gasification conducted in an operating mine or on areas of high ecological vulnerability. This paper details observations made in two underground trials of UCG performed in Poland recently. The first of which is the Experimental Mine Barbara (under the project entitled HUGE-2 Hydrogen oriented underground coal gasification for Europe – Environmental and Safety aspects, (Wiatowski et al., 2015). The other trial has been conducted at an operating mine, Wieczorek, which is in the framework of a research project on the development of coal gasification technology for highly efficient fuel and electricity production (Czaplicka-Kolarz et al., 2013). During these trials, investigations were carried out aimed at assessing geomechanical parameters of rock mass and support behaviour in surroundings of UCG geaoreactors. Investigation comprises assessment of geomechanical parameters of coal, floor and roof strata, roof displacements, and concrete support strength parameters variation, as well as standing steel support load. Hydraulic penetrometer, endoscopic camera, Schmidt hammer, pull-out method, telltale, and ground penetration radar (GPR) were used in the investigation. Research conducted at both EM Barbara and Wieczorek Collieries revealed that the UCG process did not adversely affected the competency of rock mass (expressed by number of fissures and strength parameters of rocks), the stability of roadways and the support performance in the areas located in the vicinity of the georeactors."

Jan 1, 2017

By D. Sagara, V. G. Makhado

"A model based control strategy was implemented at Loulo Gold Mine in Mali, to stabilise the thickener underflow stream density. This stream acts as the feed to the leaching circuit. pH control of the leaching circuit was integrated with the model-based controller due to slow process dynamics that are not suited to PID control. The controller performance was quantified over a period of 6 months, and was compared to the performance before implementation. The model based controller reduced process variability for both thickener underflow density and pH considerably, and resulted in a reduction in flocculant and lime consumption of 9.32 and 6.55%, respectively. INTRODUCTION Reagent consumption in gold processing plants significantly contributes to the total operational costs. In a typical Carbon-in-pulp (CIP) circuit, the reagent consumption associated with leaching, adsorption, elution and regeneration contribute to approximately 15% of the total operational costs (Stange, 1999). At Loulo Gold Mine, the reagent consumption associated with leaching, adsorption, elution and regeneration contributes to 6% of the total operational costs. As such, a reduction in reagent consumption will present a significant opportunity for savings on operating expenditure. Variability in feed ore characteristics results in continuous changes in steady state operating regions, which presents process control challenges as a result of the long residence times in some of the process units associated with gold processing plants. Overdosing often occurs in the presence of process variability to ensure safe operation and to maintain recovery targets. As a means of reducing reagent consumption and accounting for significant changes in the feed to gold plants, some of the plants have resorted to improving their process control strategies around their circuits. This paper focuses on the implementation of a model predictive based controller at Loulo Gold Mine on their thickener and Carbon-in-leach (CIL) tank to: •,stabilise the thickener underflow density, and •,the CIL tank pH."

Jan 1, 2017

By J. Olson

"A model was developed to use near-infrared (NIR) analysis of pulverized ore samples to estimate the recoverable gold content for ores from the Barrick Cortez Hills underground mine. Current routing practices use a ratio of the cyanide soluble gold content and fire assayed gold (CN/FA) to classify ores as oxide or refractory. Prediction accuracy of the NIR model was equivalent to the CN/FA ratio. Prediction accuracy was improved by combining the CN/FA ratio and the NIR spectra. Bootstrap validation estimates the root-mean-square error to be 9.92% with an estimated r-squared value of 0.893. This model will allow more accurate estimates of the variability in recoverable gold content throughout this mine. These data will aid in building an improved geo-metallurgical model or in making better informed routing decisions during the production cycle.INTRODUCTION The contained gold of an ore available for cyanidation is often related to subtle variations in the mineralogy. It is difficult and expensive to collect enough mineralogical information in order to predict how the variable mineralogy will impact the metallurgical results and project economics throughout the life of the mine or mill. Near-infrared spectroscopy may be an effective tool to rapidly and inexpensively collect discrete, quantitative mineralogical data for minerals that contain transition metal oxides, metal sulfides with semi-conduction properties, rare earth metals, and some chemical groups having di-pole covalent bonds such as carbonates, sulfates, and various types of clays (Hunt, 1977). Near-infrared spectroscopy can be a powerful tool for geo-metallurgical characterization of deposits where the presence of these minerals has direct or indirect relationships to metallurgical results such as grindability, regent consumption, or recovery. Near infrared spectroscopy is a rapid analysis that measures the intensity of reflected light in the near-infrared spectrum. The ranges for the ASD-Panalytical units used in this study extend through the visible spectrum and into part of the UV spectrum, reporting reflection by wavelength from between 350 nm to 2500 nm. Absorption peaks visible in this range are a result of interactions with outer valence elections or chemical bonds. The location and intensity of the peaks vary depending on the chemical composition and crystal structure of a solid indicating the presence and abundance certain minerals (Hunt, 1977; Clark, 1984)."

Jan 1, 2017

By Chul Soo Park, Juhyung Lee, Duhyun Baek

"In this study the preliminary design of suction pile as the supporting system of the concrete floating structures was performed at the offshore pilot project area in Korea. The suction pile of the floating structures has to satisfy the lateral resistance against external force evaluated from the marine and structure conditions, as well as the penetration ability according to the soil and seepage conditions. In the design, the required penetration depths for lateral resistance were evaluated with different diameters of cylindrical steel suction pile, and the design suction pressures at each penetrating depths were assessed through the comparison of penetration forces and penetration-resistances. Finally, the optimal dimension of suction pile for the pilot project area was proposed.IntroductionInterests in sea spaces have rapidly increased around the world due to limitations in use of lands. Such increase has resulted in construction of numerous marine structures aimed at expanding the use of sea spaces and developing marine resources. South Korea also needs to secure construction technologies for floating infrastructures on its relatively deep seas. Foundations for floating structures consist of anchors and mooring systems rather than driven piles or cast-in-place piles, due to limitations in equipment operation or economic feasibility. Anchors and foundations used on the sea include drag anchors and suction piles, but the suction piles are more widely used for reasons regarding uncertainties of calculation of bearing capacity and construction. Large-diameter suction piles are generally used to utilize fully their penetration ability, which is proportionate to the square of the foundation diameter, and the length-diameter ratio (L/D) does not exceed 6 (Randolph et al., 2005; Andersen et al., 2005). Recently, a design and construction technology using group suction piles consisting of medium-diameter suction piles and concrete pile caps is being developed as an alternative to the conventional large-diameter mono suction piles. In addition, pilot projects involving the group suction piles of mediumdiameter are currently being reviewed for the southwest coast area in Korea. In this study, therefore, preliminary design for installation of medium-diameter mono suction piles as the supporting system of the concrete floating structures was performed, and suction pressures, penetration forces and resistances, and lateral loading capacity with diameters were reviewed."

Jan 1, 2017