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By Wojciech Szczepiński, Dominik Gächter

In early 2020, the construction phase began for the new complex of buildings for Radium Hospital in Oslo – the leading facility for cancer treatment in Norway. Settlements in the surrounding area, caused by pore pressure changes, allowed for the introduction of an alternative solution for the construction of the excavation pit. The presence of solid bedrock and sensitive clay – the same material that causes major landslides in the Scandinavia – in the excavation pit, lead to a combination of techniques, which were never applied in Norway before. For the stabilization of the clay Dry Deep Soil Mixing was applied to allow safe execution of the geotechnical works. Interlocking Bored Piles with footbolts and Jet Grouting columns, in combination with anchors, provided the retaining structure for the excavation pit. Rock injections were performed to avoid any ground water ingress into the pit. Underpinning of fully operational, adjacent buildings was carried out with jet grouting columns. These works were performed from the basement of the hospital and the ‘ACI – Acoustic Column Inspector’ was used to ensure proper installation of 2 m diameter columns to a maximum depth of 25 m. The buildings were later founded on Steel Core Piles, the most common pile type in Scandinavia.

Oct 1, 2021

By Yanxu Shen, Cheng Liu, Zhijie Chen, Hao Chen, Huimin Gao, Zijie Ren

Fluorite, a kind of critical non-metallic minerals, is the primary source of industrial fluorine. Sodium oleate (SO) is commonly used as the collector of fluorite ores. However, because of its some features (such as the low solubility, high solidifying point, and poor dispersion of SO) at low temperatures, it profoundly inhibits its collecting ability as well as the flotation performance. Herein, we have developed a low-temperature-resistant collector for the efficient flotation separation of fluorite from quartz. The advantages and disadvantages of the SO and sodium petroleum sulfonate (SPS) were analyzed by comparing the performance under different temperature conditions. The results of flotation tests suggest that SPS exhibited much better collecting performance than SO under low temperature. The flotation mechanism of the two collecting agents were further analyzed by contact angle measurements, zeta potential measurements, Fourier-transform infrared spectroscopy (FT-IR), and flotation kinetics. The results indicated that both collectors can selectively undergo electrostatic and chemical adsorption with fluorite, with no adsorption on quartz surface. The sulfonic acid group in SPS is a hydrophilic functional group, which has a relatively higher solubility in water. Therefore, the water solubility of SPS is better at low temperatures.

Sep 30, 2021

By A. Halim, A. Martikainen, S. GYAMFI

This paper outlines a unique case of the development of strategies to reduce ventilation and heating costs in Konsuln iron ore mine in northern Sweden. The mine, located just south of Luossavaara-Kiirunavaara Aktiebolag’s Kiruna iron ore mine, was developed as a test mine from 2018-2020 for the Sustainable Underground Mining (SUM) project. Besides functioning as a test mine, Konsuln also contributes to ore production. The existing mine ventilation system was designed for the current production rate of 0.8 million tons per annum (Mtpa). There is a plan to increase this rate to between 1.8 and 2.0 Mtpa.

Sep 30, 2021

By MATT RENAUD, Mustafa Kumral

As high-quality mineral deposits are thoroughly exploited, mines of the future will have to move towards more remote and lower quality projects. With these projects comes an increased business risk to the operator. Even now, mining companies often turn to foreign countries for new deposits to produce, introducing the concept of country risk into their portfolio. Furthermore, feasibility studies often fail to accurately quantify the risks associated with various projects, and as such, this study proposes a technique of risk quantification which can both aid mining companies to evaluate the viability of investment and assist in risk disclosure to public investors for the mining industry of the future. This paper aims to quantify the effects of country risk on the valuation of potential mining projects, using a combination of modular and risk-weighting techniques to evaluate the country risk premium (CRP) required to obtain capital for operation of risky foreign mining projects. The techniques proposed in this paper are demonstrated using fictional examples and then evaluated for accuracy against a recently developed debt-funded precious metal project in a country in the Americas.

Sep 30, 2021

By P. Samanta, Mohammed N. Azad, Gustad F. Taraporewalla, A. K. Mukherjee, Abhay S. Patra, D. Sachinraj

Beneficiation of coal is a water intensive process, and the water is recovered in downstream operations in the high rate thickener (HRT) and vacuum belt filtration (VBF). Clean coal particles entering the HRT have an inherent tendency to enter the overflow because they are extremely fine and hydrophobic. Hence, flocculants (polymers) are used to floc the ultrafine particles so that they settle and enter the underflow. Ultrafine coal particles (−37 μ), which are highly hydrophobic, if present in the stream, will not be efficiently captured by using flocculants alone. This is observed in the normal plant operation at one of the beneficiation plants in the Jharia region, Jharkhand, India. Approximately 6–7% of the feed to the HRT enters the over flow (supernatant water). Hence, this amount of clean coal particles is not recovered and account for production losses. A comprehensive settling and dewatering test work was conducted with clean coal slurry using several commercially available reagents. Studies were also done on different combinations of reagents, including coagulants and surfactants along with flocculants, to improve the settling behavior of the coal particles. The reagents were assessed based on their performance with respect to settling rates, overflow water clarity, and compaction of the underflow solids. Emphasis was given to the ability of the reagents in compacting thickener underflow to higher densities so that maximum water could be recovered from the thickener. Pretreatment of highly hydrophobic coal slurry with a combination of coagulant and surfactant followed by flocculation showed very good settling characteristics with clear overflow.

Sep 30, 2021

By Jogeshwara Sahu, Sapan Kumar Kandi, SANDEEP KUMAR JENA, Sachida Nanda Sahu, Sarada Prasad Das

The present article reports the recovery of potassium from mica scrap using carbide lime waste and NaCl. The acid leaching of mica [4 M H2SO4 at 90 °C] can recover a maximum of 25% potassium. However, in the chlorination roasting (with CLW and NaCl) water leaching process, it was possible to recover potassium to the tune of 94% [900 °C, 50 min roasting; mica:CLW:NaCl 1:0.75:1]. The formation of water-soluble phase like sylvite (KCl) and water-insoluble phases like anorthite ( CaAl2Si2O8) and nepheline ( NaAlSiO4) confirms the complete breakdown of the mica crystal structure. The extraction mechanism proceeds with the formation of a transition state followed by the release of potassium as KCl. The characterisation studies using ICP-OES, XRD, FTIR and FESEM support the proposed extraction mechanism. The salt produced by the evaporation of roast-leached liquor confirms the presence of sylvite and halite only, which can be separated to get the fertiliser grade KCl.

Sep 29, 2021

By S. Rukhaiyar, M. Ramulu, G. Pradeep, P. K. Singh, P. B. Choudhury

The drill and blast method is the most prominent rock excavation method used in mining and civil engineering projects. The ground vibration is the most undesirable effect of the blasting and needs to be controlled. The blasts are designed so that ground vibration at nearby structures must remain under the prescribed limit. Various empirical blast vibration attenuation models have been presented to estimate the ground vibration for designing purposes. These models assume ground vibration as a function of distance and maximum charge per delay. United States Bureau of Mines (USBM) model is most commonly used for the blast design. However, the uncertainty associated with these models is seldom characterized, thus diminishing its reliability. The probabilistic Bayesian approach associated with the Monte Carlo method can easily quantify uncertainties associated with the model and its parameters. Thirty-three blast vibration observation data from a granite quarry in Kerala, India, is used to estimate the probability distribution of model parameters. Markov Chain Monte Carlo (MCMC) approach is used for sampling 12,000 samples for obtaining the posterior distribution of parameters. The uncertainty associated with model parameters is quantified from the posterior distribution, and this is further used to estimate the credible and prediction limits of the model. The point estimate of the most optimum value of the parameter is estimated using maximum-aposteriori or MAP estimate. The model parameters are also obtained using the commonly used least-square error method, which is a maximum likelihood estimation or MLE approach. It has been observed that the accuracy of the model obtained using both MAP and MLE approach is almost equal. However, the MAP estimate as per Bayesian probabilistic analysis has the added advantage that it can estimate the uncertainty of parameters as well as the model, which is not possible using the MLE approach.

Sep 27, 2021

By JESSICA W. A. AZURE, Samuel Frimpong, AZUPURI G. A. KABA, FORSYTH A. KADINGDI, PROSPER E. A. AYAWAH

This study developed machine learning (ML) models for predicting rock formation reactive forces experienced by a hydraulic shovel bucket during excavation. To do this, rock formation in the form of muckpile was modeled as granular ball elements in three-dimensional particle flow code (PFC) using linear bonding logic. A typical field-size hydraulic shovel bucket modelled in AutoCAD was used to excavate the rock formation and the three-dimensional shovel bucket resistive forces required to cut through the rock formation were measured and recorded. The experiments involved different muckpile height, bulk densities, repose angles, and average fragment size. Six ML algorithms, artificial neural network (ANN), K-nearest neighbor (KNN), linear, random forest (RF), regression tree (RT), and support vector machine (SVM), were evaluated on their ability to predict the shovel bucket resistive forces. The input variables used for the prediction of the resistive forces were the muckpile bulk density, angle of repose, height, and fragment size. The results showed that the ML techniques are useful and reliable methods of predicting rock formation resistive forces based on the rock formation properties. This research is a preliminary step towards developing reliable models for accurate prediction of excavation forces/torques which could potentially enhance hydraulic shovel process automation.

Sep 27, 2021

By Ayman A. El‑Midany, Hassan E. El‑Shall, Kerri‑Ann A. Hue

Modification of clays is necessary for the zearalenone (ZEN), as long-chain mycotoxins, removal. The organic-cations were usually used to modify the clay hydrophobicity to accommodate the large mycotoxin molecules. In this study, tri capryl methylammonium (TCMA) chloride and common corn oil were used in clay modification. Several characterization techniques such as XRD, FTIR, and TGA were used to identify the d-spacing changes after modification either by TCMA or corn oil. The results of applying the TCMA-corn oil-modified clays in ZEN removal indicated a noticeable improvement where more than 90% of ZEN could be removed in vitro at acidic and neutral pH values. The success of eliminating a high percentage of ZEN molecules is due to the expansion of intergallery spacing as a result of TCMA surfactant intercalation within the clayforming layers. The removal percentage does not depend only on pH but also on the amount of clay used. In addition, the ZEN removal in the presence of corn oil is better at acidic pH and small clay amount where the ZEN can be fully removed.

Sep 27, 2021

By ERIK CHARRIER, HUGH MILLER, JOSEF BOURGEOIS

In this study, a unique excavation system was characterized, utilizing waterjet technology as the primary tool for material removal during rehabilitation of reinforced concrete and shotcrete structural liners. Through empiric testing, this research seeks to validate the hypothesis that waterjet removal of these support systems will result in less unintended damage than conventional removal methods. The intent is to develop a viable technology that will reduce the collateral damage caused to surrounding liners during excavation, improve the adhesion between shotcrete and the substrate for longer lasting ground support, and improve overall safety for workers in underground environments. An analysis on the fracture mechanisms and operating parameters of each method was completed. Instrumented shotcrete panels were physically tested and examined through visual inspection and ground penetrating radar (GPR) to compare substrate damage according to each testing method. After testing was completed, the data strongly indicates that waterjet cutting causes less collateral damage to the surrounding intact liner and substrate when compared to that of conventional impact hammers. This research is intended to provide a scientific basis for additional applied research in the rapid excavation and repair of shotcrete support systems.

Sep 23, 2021

By Xiaobo Zhang, Panshi Xie, Xiaobo Wu, Ding Lang, Jiandong Yu, Yongping Wu, Kun Feng

In a fully mechanized top coal caving mining process, the mechanical properties of the top coal deteriorate constantly, and the stability of the support is determined by the boundary position of the top coal entering the limit equilibrium state. Top coal flaking occurs more easily along the advancing direction owing to an increase in the distance of the boundary from the wall. Moreover, the strength of the coal seam is an important factor that determines the boundary position. The equation of the top coal limit equilibrium zone boundary, used in fully mechanized top coal caving mining, was determined based on the limit equilibrium theory, continuum damage mechanics, and the Hoek–Brown rock empirical strength criterion. Using the RFPA3D and UDEC numerical analysis methods, the effect of top coal strength on the mechanical behavior during the mining process was determined; and the space–time relationship between the top coal deformation failure, damage evolution, and boundary of the limit equilibrium zone was established. The results revealed that when the coal mass entered the limit equilibrium zone, accelerated crack development, accelerated damage, and axial unloading occurred. Moreover, an increase in the coal seam strength caused the boundary of the top coal limit equilibrium zone to be closer to the wall. By comparing the numerical results with the theoretical results, the overall trend was found to be consistent, allowing the verification of the rationality and reliability of the determination equation of the boundary position of the limit equilibrium zone.

Sep 21, 2021

By Yinan Zhang, Y. Luo

Most of the reported coal spontaneous combustion events occur in surface and underground mines where low rank coals (i.e., subbituminous and lower for this particular studies) are extracted indicating their high propensities for spontaneous combustion. Low rank coals have high moisture content (15 to 45%) and are capable of absorbing more moisture in dried condition. However, it is hard to induce the initial stage of self-heating process for the low rank coal using the current laboratory R70 testing method — a method widely used in the coal industry. Like a sponge, dry low rank coals can absorb water vapor in the air while the heat contained in the moist air is transferred to coal and served as the required activation energy to initiate the coal self-heating process. In order to prove this theorem and quantify the effects, the R70 adiabatic oxidation testing method has been improved to introduce a controlled moist flow into the coal reaction vessel. Tests using the new method and its setup on low rank coals showed that the initial self-heating process of coal sample can be greatly accelerated by the added water vapor — impossible with the regular R70 method. Once the self-heating is sustained, the removal of air moisture can further accelerate the process.

Sep 17, 2021

By Qingqing Huang, Aaron Noble

The Mineral & Metallurgical Processing Division (MPD) of the Society for Mining, Metallurgy & Exploration held the first MPD Student Video Contest during the spring of 2021. The event showcased the work of 18 graduate and undergraduate students from several U.S. and international institutions. The contest began in January when students submitted a onepage abstract for judging. Over the next several months, they developed a three-minute video that further explained their research findings. Both the abstract and video were evaluated by a panel of judges, and the top-placing participant was recognized at an MPD virtual event held on June 10.

Sep 13, 2021

By Sherif Elfass, Gary Norris

Bi-directional load testing of drilled shafts has been widely adopted as a means to evaluate their load carrying capacity. However, in order to reach failure, most of these tests are carried out on sacrificial shafts using expensive sacrificial elements such as hydraulic jacks. A proposed low-cost bi-directional testing technique is discussed. It mechanically loads the end bearing soil below a drilled shaft, against its side shear resistance. The technique was originally established as an alternative to post-grouting to reliably account for the forfeited end bearing resistance. However, since it loads the shaft in a manner similar to conventional bi-directional tests, it can be used to not only load test sacrificial shafts, but production shafts as well. Furthermore, unlike conventional bi-directional load tests, the load is applied through surface jacks. These jacks, along with other load test components, are movable and can be reused to load test all the shafts of the project thus presenting an economic benefit. The concept of this technique has received favorable feedback from a few consulted departments of transportation, and while promising, has not been field tested to date. A U.S. patent was issued for the tip loading module and the loading technique described.

Sep 8, 2021

By Yazen Khasawneh, Osvaldo P. M. Vitali, Mohammad Nassim

The demand for renewable energy is growing as the conventional energy resources are becoming more limited and we are more conscious about the negative impact of conventional energy sources on the environment. Wind turbines technology is evolving in a fast pace, the towers are becoming taller, and the rotors are getting larger. The challenge is to maintain the Levelized Cost of Electricity (LCOE) as low as possible to ensure a sustainable and an economically feasible energy supply. Thus, the foundation systems for wind turbines should evolve to meet the increasing load demand, while reducing the LCOE. In this paper, an innovative foundation system for onshore wind turbines is presented. The new foundation system is the conventional P&H tensionless pier foundation (PHTP) with a reinforced concrete collar at the top of the pier. 3D FEM modeling was conducted to assess the benefits achieved by adding a collar at the top of the PHTP foundation. The numerical results show a significant performance enhancement of the proposed foundation system over the conventional PHTP foundation. The enhanced foundation system also has an economical advantage because the depth of the pier can be greatly reduced while maintaining a superior performance.

Sep 8, 2021

By Jamey Rosen, Georgette Hlepas

Verticality data collected from panel and pile elements of seepage barrier walls describe the shape and position of those elements in three dimensions. These data are used to determine if a barrier wall is constructed as designed and if it meets the owner specifications with respect to tolerance (i.e., if each element is sufficiently close to vertical) and overlap (i.e., do adjacent elements overlap sufficiently to prevent leakage). Contractors use verticality data to confirm that their work matches the design, and owners use verticality data to verify the contractor’s work and confirm that specified criteria were met. Project Information Management Systems (PIMS) technology has been applied to the management, visualization, and analysis of verticality data. This paper will provide examples of how contractors and owners have used a PIMS to compile and synthesize data collected during excavations (e.g., from Cutter Soil Mixer and Hydromill drill rig telemetry), and from measurements of completed excavations (e.g., using the Koden ultrasonic tool), and used those data to model excavation geometry. We will present case studies of using these models to estimate backfill placement volumes, and to evaluate the verticality tolerance and overlap between elements.

Sep 8, 2021

By Hamed Layssi, Farid Moradi, Thomas Tingson

This paper describes the feasibility and pilot study of of using existing non-destructive testing solutions for evaluating structural integrity and mechanical performance of mass concrete foundations. This paper includes two pilot studies using well-known NDT methods (i.e., Crosshole Sonic Logging and seismic tomography) for new applications (i.e., NDT inspection of mass concrete foundations). In the first case, we will examine an existing mass concrete foundation block with internal cracking, which has negatively impacted the strength and stiffness of the foundation block. A combination of pulse velocity and 2D tomography was used to evaluate the structural integrity in the foundation block. In the second case, the quality and integrity of newly built mass foundations were evaluated using Crosshole Sonic Logging (CSL). The methods are combined to locate potential sub-surface defects such as large voids and discontinuities. This paper aims to study the effectiveness of the NDT methods of Deep Foundations to assess the quality and structural integrity of new and existing mass foundations and explore the opportunity to extend the capabilities of these tests beyond their conventional use.

Sep 8, 2021

By Jewels Stover, Charles A. Luxford

Oklahoma City is undergoing a replacement program for an existing 66in (1.675m) water pipeline that conveys raw water from Atoka Reservoir to the City. This pipeline currently crosses the Canadian River on elevated piers and is subject to flood hazards. To replace the existing pipeline and mitigate flood damage concerns, two parallel microtunnels will be constructed below the river channel. Access is from construction shafts located near the midpoint of the tunnels; opposing drives are launched from each shaft. This geometry dictated shafts of significant depth – exceeding 120 ft. (37m). To accommodate the casing pipe segments and microtunneling machines, a minimum shaft diameter of approximately 34 ft. (10.4m) was required. Due to the difficult geologic setting, a reinforced secant pile compression ring is specified by contract in the top 70 ft. (21.3m) of these construction shafts to provide a very low permeability support system.

Sep 8, 2021

By Paul R. Lear

Sustainability continues to be an important aspect of remediation and infrastructure projects. Deep soil mixing (DSM), a common construction and remedial technology, can easily incorporate the following sustainability best management practices (BMPs), including Minimizing Total Energy Use and Maximizing Use of Renewable Energy; Minimizing Air Pollutants and Greenhouse Gas (GHG) Emissions and Maximizing Use of Machinery Equipped with Advanced Emission; Minimizing Water Use and Impacts to Water Resources; Beneficial Reuse of Materials/Reduction of Materials and Waste Reduction; Use of Local Labor and Supplies. This paper focuses on the sustainability of DSM treatment and provide carbon footprint calculations at least one completed DSM project which used these sustainability BMPs to demonstrate the environmental impact of the sustainability.

Sep 8, 2021

By Eric P. Bregman, Justin Zarrella, Ryan M. Coulson, Connor Johnson

Within a prominent Boston, MA suburb are a pair of historic stone and mortar structures built in the late 1800’s. Both the Main House and Carriage House have been maintained and occupied throughout their rich history, but renovations were needed to address structural concerns and building code compliance issues. The focus of this paper is to detail an innovative underpinning design that addressed ongoing settlement issues at the Carriage House. GZA GeoEnvironmental, Inc. (GZA) partnered with Phoenix Foundation Company, Inc. (Phoenix) to design foundation wall support systems for Consigli Construction Company (Consigli) that would effectively underpin the historic field stone foundations. Originally, conventional concrete pit underpinning and jet grouting were contemplated as methods for support. However, due to the age and condition of the existing foundations, worker safety concerns, and the risk of additional structural damage, GZA/Phoenix elected to pursue a less traditional approach. The alternate design consisted of micropiles used for combined temporary and permanent foundation support. The load transfer system included steel headers with needle beams cored through the field stone foundation walls and reinforced concrete grade beams/pile caps. To validate design performance and ensure worker safety, GZA installed a fully automated survey monitoring system to record lateral and vertical building deformations. This included real-time email alert notifications to inform the Project Team of any threshold exceedances. From the start of micropile drilling through full load transfer to the temporary support and permanent foundation systems, the underpinning performed as designed resulting in less than 3/16-inch of vertical and horizontal deformations observed. This magnitude of movement is less than half of what is generally accepted deformation tolerances for masonry structures and considered exceptional performance. The focus of this paper is to provide additional details on the unique design, sequencing, installation, and performance of the underpinning systems.

Sep 8, 2021