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"Editor’s note: Each year, Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue, all the while doing their own jobs. Thank you to the industrial minerals annual review editor, to the Industrial Minerals and Aggregates Division technical committee chair and vice chairs, and to the authors of the individual commodity profiles.Jim Norman, member SME, of Tetra Tech, is the industrial minerals annual review editor.Vishal Gupta, member SME, of EP Minerals LLC, is chair of the Industrial Minerals &Aggregates Division’s Technical Committee.The technical committee vice chairs include:• Vishal Gupta, member SME, of EP Minerals LLC, Agricultural Materials.• Joe Garska, member SME, of Imerys, ceramics and refractory materials.• Stanley Krukowski, member SME, of the Oklahoma Geological Survey, chemical raw materials.• Russell Winn, member SME, of R.E. Janes Gravel Co., chemical raw materials.• Justin Zdunczyk, member SME, of Pike Industries, construction aggregates.• Jerry Gauntt, member SME, of Golder Associates, fillers and pigments.• Ebrhaim K. Tarshizi, member SME, of the Michigan Tech, sorbents, filters and process aids.• Daniel T. Eyde, member SME, of St. Cloud Mining, specialty minerals.Their help makes possible this July industrial minerals issue. On behalf of ME readers, the editors thank them.Virta, R.L. U.S. Geological Survey, National Minerals Information CenterFour companies - H.C. Spinks Clay Co., Inc., Imerys, Old Hickory Clay Co., and Unimin Corp. - mined ball clay in four states in 2013. On the basis of preliminary data, production was 1 Mt (1.1 million st) with an estimated value of $47 million. Production increased by 3 percent in tonnage from 973 kt (1.1 million st) with a value of $45.1 million in 2012. Tennessee was the leading producer state accounting for 64 percent of domestic production, followed by Texas, Mississippi and Kentucky. About 67 percent of total ball clay production was airfloat, 22 percent was crude or shredded and 11 percent was water-slurried.ConsumptionIn 2013, domestic ball clay producers sold clays to the following markets: ceramic floor and wall tile (44 percent); exports (21 percent); sanitaryware (18 percent); miscellaneous ceramics (9 percent); fillers, extenders, and binders, and unspecified uses (4 percent each), based on 2012 end use patterns and current markets. Other markets accounted for less than 1 percent of the remaining ball clay sales or use. Sales reported for the manufacture of fiberglass or most filler, extender, and binder applications were likely to have been mainly kaolin mined or purchased by the ball clay producers.PricesThe average value of domestically produced ball clay was approximately $47/t ($43/st) in 2013 compared with $46/t ($42/st) in 2012, on the basis of a preliminary survey of domestic ball clay producers. The unit values of exported and imported ball clay were $126/t ($114/ st) and $373/t ($338/st), respectively, in 2013, compared with $62/t ($56/st) and $314/t ($285/st), respectively, in 2012. Unit values for most large export shipments increased in 2013, and a larger number of low-tonnage, high-value export shipments were shipped in 2013 than in 2012, resulting in a doubling of the average export value. Two low-tonnage, high-value shipments in 2013 accounted for the increased value of imports."

Jan 1, 2014

By F. Scott Carpenter

During the past several years, more frequent reference to Wollastonite has appeared in print, both in this country and abroad. The reason for this is the apparent growing interest in this mineral as it approaches commercial maturity. Twelve years ago, wollastonite was available in only limited commercial quantity. In 1933, a deposit in California was worked for a short time to provide a calcium silicate raw .material for the manufacture of mineral wool* It was not until the spring of 1953 that Cabot Corporation put into operation a modem commercial plant to produce this material in a variety of grades. These grades covered both a range of particle size and of particle shape. At that time, applications for wollastonite were largely speculative, although a few commercial applications in glass frits and welding fluxes did exist, For all practical purposes, it was a new material for which few commercial uses had been fully proven.

Jan 1, 1964

By Robin Dill, Julian Prada, Kathryn Kelly, Brian Hann, Todd Moline

Narragansett Bay Commission’s (NBC) Pawtucket Tunnel Project includes construction of the 11,600-ft long, 30-ft ID, deep rock tunnel. This paper presents insight into the features and benefits of lump-sum, design-build that led NBC to select it as the project delivery method. The use of a design-build contracting process that included proprietary meetings to discuss and obtain feedback on Alternative Technical Concepts as well as to facilitate reaching consensus on modifications to the GBR-B is also described. The discussion includes features and benefits of design-build process that not only addressed NBC’s desired outcomes, but also allowed the Design-Builder to propose several innovative changes to the Base Technical Concepts included in the bid documents, and to develop a GBR-C that was compatible with their proposed means and methods of construction and addressed what they believed to be the more significant subsurface risks on the project.

Jun 13, 2023

By Donald W. Gentry

This section deals with one of the most fascinating aspects of mining the evaluation of mine investment opportunities. Be-fore proceeding further, it is important to clarify the meaning of some fundamental terms used frequently in the text. 6.0.1.1 Mine Valuation vs. Evaluation The words "valuation" and "evaluation" in a mining context are often used interchangeably. However, for the purposes of this section, a distinction is made between the two terms in accordance with commonly accepted practice. The word valuation in a mining project context has the rather narrow meaning of placing a dollar or other currency value on the worth of the project as a whole. In other words, the value of a mining project refers to a measure of the desirability of ownership of that property. As such, the major item of interest is, "what is the mine worth?," or `what is the value of the mine?" The value of a mining project may actually be determined in the marketplace at any specific point in time, or it may be estimated by one of several methods. The topic of mine valuation is discussed in more detail in Chapter 6.1. The word evaluation in a mining project context connotes the broader meaning of determining the numerical values of all

Jan 1, 2008

By Chris Roos

The mining industry has made strides in planning for operations to be safe for the workforce and public, to protect the natural environment, and to maximize value for shareholders. However, many of the techniques used to accomplish these goals are based on estimated models of mineral content, production efficiency, and economic performance. The industry has begun to recognize the need for understanding the uncertainty in these models, how it affects their decisions, and what the potential impacts are for each project. The challenge has become how technical professionals can effectively communicate the impact of this uncertainty and its importance to both technical and non-technical audiences. This paper presents mining engineers (and other technical professionals) with traditional and modern principles of data visualization and technical communication that can assist with communicating the effects of uncertainty in the mine planning process.

Jun 25, 2023

By C. S. Todd, R. L. McNearny, S. Dun, P. Clark, P. W. Conrad, X. Liu, J. Q. Wu, H. Rhee, W. J. Elliot

Soil erosion is strongly related to soil hydraulic properties. Understanding how surface coal mining affects these properties is therefore important in developing effective management practices to control erosion during reclamation. To determine the impact of mining activities on soil hydraulic properties, soils from undisturbed areas, areas of roughly graded mine spoil, areas with replaced topsoil before seeding, and revegetated areas at the Rosebud Mine in Eastern Montana were evaluated. Field and laboratory studies were conducted to determine the soil hydraulic properties of the four representative areas, including particle-size distribution, organic matter content and saturated hydraulic conductivity. Using this data, Water Erosion Prediction Project (WEPP) simulations and risk analyses were performed to investigate mining’s effects on changes in soil erosion potential. Significant differences were seen in the hydraulic properties of the soils in the representative areas due to the mining and reclamation practices at the mine. The WEPP simulations show that the potential for soil erosion increases as a result of mining activities disturbing the soil. The simulations also indicate that the erosion potential may return to pre-mining levels over time with effective revegetation practices.

Jan 1, 2015

By Christopher Mark

Six decades ago, the most dangerous job in the USA was mining coal underground. Roof falls were responsible for half of the deaths, killing about 100 miners every year. Fast forward to 2016 and zero roof fall fatalities. Just three miners were killed by roof falls during the following 6 years. How did the mining community achieve this historic goal? This paper starts by analyzing the roof fall fatalities in 1968, categorizing them by their fundamental cause. Then, it shows how each type of roof fall was reduced over time, using snapshots of the fatalities occurring in subsequent decades. Along the way, it evaluates the influence of the regulatory environment, changing mining methods, and better ground control technology. The study found that in 1968 more than half of roof fall fatalities at large mines were attributable to an inadequate safety culture. The immediate effect of the 1969 Coal Mine Health and Safety Act was to reduce the riskiest activities, like needlessly going under unsupported roof. Other hazards, like large roof falls, required technological developments before they were brought under control. Roof Control Plans, which the US Bureau of Mines had been advocating since the 1920s, played a significant role throughout the process.

Mar 12, 2024

By Jürgen Kretschmann

The European climate and energy framework for 2030 is highlighting the reduction of man-made CO2 by increasing the use of renewable energy to mitigate climate change. In this spirit, Germany has decided to erase the coal use as an energy source by 2038 completely. Inevitably, this strategy promises a feasible, responsible, and sustainable post-mining management, because 200 years of coal mining have created numerous challenges necessary to tend to once the mining ends. Thus, the Research Institute for Post- Mining (FZN) at the TH Georg Agricola University in Bochum, Germany, has developed a holistic approach to meet these postmining challenges including further expertise present at our university. Here, the four strategic research pillars are (1) technical geoecology and hydrogeology to avoid and mitigate risks underground, (2) geomonitoring to evaluate and protect the surface, (3) industrial heritage preservation and engineering to secure and reuse brownfields such as mine sites, and (4) economic transformation planning of mining regions to enable a prosper future for generations to come. In all efforts, we aim to achieve the fundamental goals of the UN to deal with the resources of our planet responsibly and sustainably. Furthermore, we are synergizing increasingly with national and international networks in the interest of social, economic, and environmental stakeholders.

Jul 23, 2020

By Fiona Woody

Lime and calcium products are essential building blocks to the modern world, used to purify drinking water, preserve foods, control pollution, improve crop yields, stabilize soil, pave roads and support the production of steel, cement, glass and many other industrial processes. While lime is essential to society, it also has a sizable carbon footprint. Approximately 30 percent of the scope 1 greenhouse-gas emissions generated during lime production are related to fuel combustion, while the remaining 70 percent are created by the unavoidable chemical reactions during calcination.

Feb 1, 2026

By Oluwafemi Salami

Conducting full-scale fire experiments in underground mines is difficult and expensive. Sometimes, it is impossible to carry out fire tests in mines due to the danger they pose to mine workers and the underground facilities. However, understanding the potential occurrence of fires in a mine and their dynamics is critical to developing an appropriate emergency evacuation plan, fire suppression, and firefighting techniques. In this study, a numerical fire model using computational fluid dynamics (CFD) with fire dynamics simulator (FDS) 6.7.6 was developed to examine the influence of tunnel bifurcation on maximum temperature beneath a tunnel ceiling. The model was validated using full-scale experimental data. The maximum ceiling gas temperature predicted using FDS and measured maximum smoke temperature during the experiment shows good agreement. The study shows that bifurcation could lower the maximum ceiling temperature of fire-induced smoke in a subsurface environment. The findings from this study apply to the broader field of ventilation and fire life safety in tunnels and other underground environments.

Jun 23, 2024

By J. C. Draper

The Duquesne Light Company and GAI Consultants, Inc. conducted a demonstration program aimed at establishing permanent vegetative cover directly on acidic, deep coal mine refuse. Several plots were treated with formulas varying in soil amendment application rates and plant species. Periodic monitoring of refuse chemistry has indicated when maintenance applications of seed and soil amendments were required. To establish drainage control, the site had to be regraded. The most successful formula was applied to the entire site. Specific treatment for acidic spots has been initiated. Results of the program indicate that adequate permanent vegetation has been established.

Jan 1, 1983

By R. L. Virta

Four companies ? H.C. Spinks Clay Co., Inc., Imerys, Old Hickory Clay Co., and Unimin Corp. ? mined ball clay in four states in 2013. On the basis of preliminary data, production was 1 Mt (1.1 million st) with an estimated value of $47 million. Production increased by 3 percent in tonnage from 973 kt (1.1 million st) with a value of $45.1 million in 2012. Tennessee was the leading producer accounting for 64 percent of domestic production, followed by Texas, Mississippi and Kentucky. About 67 percent of total ball clay production was airfloat, 22 percent was crude or shredded and 11 percent was water-slurried.

By Angela Binder, Mareike Schubert, Yichen Jiang, Sandra Nowosad, Oliver Langefeld

GermanyINTRODUCTIONThe mining industry is currently characterized by various factors such as environmental impact, resource scarcity, social responsibility and geopolitical uncertainty. The production of minerals required to meet the demand for renewable energy is expected to increase by 500 % by 2050, particularly for critical minerals such as graphite, lithium and cobalt 1. Easily accessible deposits are often depleted, meaning that deeper and more complex deposits need to be developed. Furthermore, investors’ value systems have shifted towards more sustainable practices. Alternative approaches to solving this problem are therefore currently being developed, such as the Modular Mining Systems concept for scalable and adaptable mining projects 2. Many mining companies have also taken important steps to become more sustainable, implementing measures such as proactive closure strategies, restoration programs and the development of renewable energy projects. In the European Union, laws such as the Critical Raw Materials Act and the Net Zero Industry Act support the mining industry 3,4. They see it as important for the energy transition and promote more sustainable ways of working in the industry Particularly negative environmental impacts such as land degradation, scarcity of local water resources, water pollution and greenhouse gas emissions are ingrained in society’s memory. Despite these efforts, the public image has not yet changed. To change this perception, the industry must strive to better communicate its sustainable practices and the steps it is taking towards a more responsible and sustainable future, promote transparency and build trust.Digitalization, automation and electrification are driving the digital transformation in mining. However, their implementation can lead to higher capital expenditure, limiting their adoption across the industry. Furthermore, implementing new technologies can be a daunting task for any organization. Change management comes into play when introducing such disruptive technologies. It involves preparing an organization for change, potential resistance and establishing effective communication. This helps to ensure that the implementation is successful and the benefits of the new technology are maximized. Digital transformation requires well-trained, young mining, electrical, mechatronic and software engineers with a deep understanding of information systems. Unfortunately, the industry faces the enormous challenge of attracting this younger generation, who have little interest in the extraction of raw materials. The need for action is compounded by an aging active workforce heading into retirement and the forecast of increasing demand for critical minerals.In this challenging environment, the concept of Blue Mining with its constant further developments represents a promising approach. This implies a shift from a linear to a sustainably oriented circular economy. For the mining industry, this specifically means the introduction of innovative technologies, the increased recovery of materials from waste and the consistent questioning and application of circular principles along the entire life cycle of a mine. Such a change can not only reduce the environmental impact, but also contribute to economic resilience and increased social acceptance of mining.

Feb 1, 2025

By Lee W. Saperstien

At the heart of the mining process are a number of basic and fundamental tasks whose regular and repeated performance constitute the mining cycle. As will be discussed presently, these tasks are the basic components of the mining system. Section 9, Production Operations, provides the mine designer and engineer with an understanding of these tasks and with sufficient design principles to allow this person to create an efficient mine system. This section is meant to be an introduction and adjunct to subsequent sections that describe specific mining systems. However, sufficient design information is included here for the independent design of mine systems that may not be described elsewhere or for subsequent verification of existing designs. For the purposes of this section, mining subsumes excavation; thus this material applies to any excavation process. Accordingly, this section is written in general enough terms to include both surface and underground mining. It may be used also for civil engineering excavations that often involve the same steps. Obviously, the actual procedures undertaken in any specific mining system will appear to be very different from those taken in any other system. This is certainly true when comparing surface with underground methods. Yet the fundamental principles are often the same. This segment is written to explicate the basics. Wherever appropriate, the section will suggest the differences between the application process to surface or to underground mining.

Jan 1, 2008

By W. W. Kephart

The glass container industry is the largest producer of glass in the United States. As of this writing, there are approximately 89 active domestic production locations. In 1984, the industry shipped 11.8 million tons of glass containers. Approximately 70% of this production was clear or flint glass, 20% amber, 7% green, and the remainder miscellaneous colors. Although the production of nearly 12 million tons of glass is impressive, anyone following the industry over the last five years is aware that the industry has changed from a pattern of growth in the 1970's to one of maturity in the 1980's. Some observers, less generous, perhaps, have described the 1980's as a period of decline. In 1981, there were 119 production facilities which produced 13.2 million tons of glass the previous year. This equates to a 10% reduction in glass container production from 1980 to 1984, with a corresponding impact on the segment of the industrial minerals producers serving the container glass industry, as shown in Figures 1 and 2.

Jan 1, 1986

By Daniel M. Flanagan

"Editor’s note: Each year, Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue, all the while doing their own jobs. Thank you to the industrial minerals annual review editor, to the Industrial Minerals & Aggregates Division technical committee chair and vice chairs, and to the authors of the individual commodity profiles. Jim Norman, member SME, of Tetra Tech, is the industrial minerals annual review editor.Joe Garska, member SME, of Imerys, is chair of the Industrial Minerals &Aggregates Division’s Technical Committee.The technical committee vice chairs include:• Hyunjung Kim, member SME, of Chonbuk National University, agricultural materials.• Xihui Lin, member SME, of Kemira, ceramics and refractory materials.• Nikhil Gupta, member SME, of Virginia Tech, chemical raw materials.• Adam Rodriquez, member SME, of Penn State, construction aggregates.• LeDeana Roberts, member SME, of Imerys, fillers and pigments.• Harsha Kolla, member SME, of ChemEOR, sorbents, filters and process aids.• Edgar Blanco, member SME, of FLSmidth, specialty minerals.Their help makes possible this July industrial minerals issue. On behalf of ME readers, the editors thank them.During the past 25 years, U.S. ball clay production (the quantity sold or used by domestic producers) increased from 788 kt (869,000 st) in 1990 to an alltime high of 1.31 Mt (1.44 million st) in 2003 (Fig. 1). Housing construction within the United States, a leading market for ball clay-based ceramics and sanitaryware, began to decline in 2005, which resulted in a considerable decrease in sales of ball clay that continued through the 2008-2009 economic recession. After bottoming out at 831 kt (916,000 st) in 2009, ball clay production steadily increased through 2015 (Fig. 1). Estimated sales in 2015 were 36 percent higher than those in 1990 and 18 percent lower than those in 2003.Four companies (H.C. Spinks Clay Co., Imerys S.A., Old Hickory Clay Co., and Unimin Corp.), mined ball clay in five states during 2015. An estimated 1.7 Mt (1.18 million st) of ball clay valued at an estimated $47.5 million was sold or used by U.S. producers, a 4-percent increase from 1.03 Mt (1.14 million st) valued at $45.2 million in 2014. Approximately 65 percent of total ball clay production was air-float, 25 percent was crude or shredded and 10 percent was water-slurried"

Jul 1, 2016

By Ritika Kundu, Moussa Wone, Amanda M. Morgan, Tatiana K. Proctor

The Piney Branch CSO 049 Storage Tunnel (PBST) will be the last major project for the DC Clean Rivers Program. The project includes construction of a 2,200-foot-long, 18-foot-internal-diameter storage tunnel; two connections to combined sewer infrastructure; and two shafts. Major challenges include excavation underneath an existing live outfall that must remain in service; excavation of the tunnel through several areas of low rock cover and mixed-face conditions; and negotiations with a variety of federal, regional, and local stakeholders to address project impacts. This paper describes the overall project scope; geotechnical conditions along the alignment; design and construction challenges; and construction procurement.

Jun 23, 2024

By Sheshang Singh Chandel, Prvan Kumar Katiyar, Navneet Singh Randhawa, Prince Kumar Singh

Mineral process wastes, such as metallurgical slags nowadays, are of significant metals and materials resources in the circular economy. The usability of iron-making slag is well established; however, steel slag still needs to be utilized due to various physicochemical constraints. In this context, we have reviewed the global steel slag generation, processing, characteristics, and potential application with suggestions for futuristic possibilities to address the technical, economic, and environmental aspects of steel slag recycling. The steel slags inherit characteristics from ore chemistry and their processing routes, which may be Blast Furnace-Basic Oxygen Furnace (BF-BOF) or Direct Reduced Iron-Electric Arc Furnace (DRI-EAF) steel-making routes with/without treatment in a Ladle Furnace (LF). The average generation of slags in BOF, EAF, and LF processes accounts for 110 kg, 70 kg, and 40 kg per tonne of steel, respectively. Considering global steel production of 1878 million tonnes in 2020, the associated slag by-products possess a significant resource of major components like FeO, CaO, SiO2, Al2O3, etc. Selecting a recycling technique depends on the slag's end use, logistics, and physicochemical characteristics. BOF and EAF slag are used ~ 48% in road construction applications and ~ 10% for industrial specific metallurgical use. EAF slag is preferred as cementitious material as compared to BOF. Hot-stage modification of BOF slag has emerged as a preferred method to achieve desired chemical and subsequent mechanical properties for end use. BOF slag has high carbon dioxide sequestration potential for in-plant remediation among steel slags.

Nov 20, 2023

By Aaron Noble, Mahmud Esad Uluer

Respirable coal mine dust (RCMD) is one of the biggest occupational health hazards for underground coal miners. Dusty mining environments can cause long-term health problems, including pneumoconiosis and progressive massive fibrosis. The Mine Safety and Health Administration (MSHA) has recently revised regulations promoting enhanced dust mitigation technologies, which have sparked renewed interest in the development of dust mitigation technologies. The flooded bed dust scrubber (FBS) is one of the most widely used technologies; however, it is limited by technical challenges, the most notable being the potential to clog. Recent studies have shown that applying vibration to filter mesh can improve the overall efficiency of the scrubber and that the system can be readily integrated to existing continuous mining equipment using an energy harvesting approach. In this follow-up study, the impact of mesh design and surface modification on system efficiency was examined using different vibrating liquid-coated stainless-steel mesh panels in a laboratory-scale FBS. Based on the two-way interaction data from a multi-factor experimental design, the results show that the performance of the system can be optimized by using hydrophilic 20- or 30-layer filters and by excitation frequencies between 67 and 134 Hz. This laboratory study suggests that a 20-layer mesh screen with hydrophilic surface applications and optimized vibration parameters can perform similar to that of a 30-layer static mesh, which is typically used in industrial units.

May 23, 2024

By Jamal Rostami, Manso Deen Sesay, Sydney Slouka, HUGH MILLER, Anshuman Mohanty, Midhat Sajad, Kun Zhang

The lack of progress in controlling pulmonary diseases such as pneumoconiosis cases in recent years necessitates additional studies on dust generation and the characterization of airborne dust. Studies are underway by a NIOSH-sponsored project to observe the characteristics of the dust generated by pick cutters under various wear levels. This research performed a full-scale linear-cutting-test matrix on eight coal samples with various bit penetrations, spacing, and wear conditions. The specific energy and resulting PSD (particle size distribution) of airborne dust and material left at the cutting surface were measured and analyzed. The dust concentration was determined using the NMAM (NIOSH Manual of Analytical Methods) 0600 method. For fines, the PSD was characterized using Laser Diffraction, measuring percent channel and aerodynamic diameter, while Imagej, a virtual sieving application, was used for larger particles. The results show that for a new bit, as the cutting depth and spacing increase, the specific energy and dust generation decrease. The size and shape of the dust particles have been analyzed, and the observed trends are discussed in this paper.

Feb 1, 2025