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By D. A. Peterson

Laboratory testing was completed to determine the effectiveness of a fiberglass cable bolt (FCB) as a cuttable rock support for a continuous, hard-rock mining method. The FCB consists of four Polystal tendons combined in a node/antinode fashion, with polyvinyl chloride (PVC) spacers forming the anti-nodes. The largest ultimate pull-out load achieved by the FCB was 22 t (48,400 lb) at 89% of the tendons' theoretical pullout load. This premature tendon failure is accredited to: • differential stresses within the tendons and • differential tendon displacement. An increase in pull-out resistance for a given embedment length is due to: • increased bond area, • reduced interfacial shear and • "wedge" effect. The critical embedment length was found to be 40% less than for conventional steel cable bolts (SCB) at a 127-mm (5-in.) node spacing. An FCB can have up to a 92% increase in load-carrying capacity over a conventional SCB at equal embedment lengths. The load carrying capacity is equivalent to SCB at a 960-mm (37.8-in.) embedment length. Though the FCB is 7.5% more expensive than the conventional SCB (installed), this cost may be offset by increased performance. FCBs are a potentially viable support alternative for continuous hard-rock mining.

Jan 1, 1993

Since first introduced, the coal mine roof rating (CMRR) has been widely accepted as a tool for geologic characterization and mine planning. This paper discusses the application of the CMRR to another practical ground-control problem: extended cuts. Extended cuts, i.e., cuts greater than 6 m (20 ft) in length, are commonly used with remote-control continuous miners. Extended cuts can greatly increase productivity, but they have been associated with a number of fatal roof-falls. When extended cuts are attempted in weak roof material, the roof may collapse before it can be bolted Until now, it has not been possible to predict where conditions may not be suitable for extended cuts. In this study, data on the CMRR and extended-cut experience were collected at 36 mines in seven of the United States. It was found that, when the CMRR was greater than 56, deep cuts were routine in nearly every case. When the CMRR was less than 37, extended cuts were almost never taken, and, when the CMRR was between 38 and 56, extended cuts were sometimes, but not always, feasible. The data also show that extended cuts are less likely to be stable if either the entry span or the depth of cover increases.

Jan 1, 2000

By C. R. Stephan, N. B. Greninger, W. A. Slivensky

The U.S. Bureau of Mines and the U.S. Mine Safety and Health Administration (MSHA) are participating jointly in a research program to evaluate strength characteristics and air-leakage resistance of various proposed seal designs for use in underground coal mines. Over 20 full-scale seals were constructed in the Bureau's experimental mine at the Lake Lynn Laboratory, air-leakage tested, then subjected to pressure pulses of 0.14 MPa or greater. A discussion on the experimental procedure, construction techniques, and the explosion and air-leakage test results is presented. Four types of construction material were used during this seal testing program: solid-concrete-blocks, low-density foam blocks, cementitious foam, and wood blocks. Only one of the solid-concrete block designs using a mortared thick wall survived the explosion and air-leakage tests. Most of the low-density foam block and cementitious foam seal designs were judged to meet the requirements to be considered a coal mine seal. One of the wood block convergence seal designs failed explosion testing. Based, in part, on these research findings, several alternative seal design constructions using low-density foam blocks, cementitious foam, or wood have been approved by MSHA for use in coal mines.

Jan 1, 1993

By T. X. Ren, J. S. Edwards

Although much work has been carried out in order to understand the mechanism of spontaneous combustion and hence minimise its potential risk, the spontaneous combustion of coal continues to be a problem in coal mining. The Department of Mineral Resources Engineering of Nottingham University has been active in conducting fundamental research into the problem of spontaneous combustion of coal. For years standardised adiabatic oxidation tests have been used to identify coals and other carbonaceous materials liable to spontaneous combustion. Recently the apparatus has been computerised and coupled with an expert system known as ESSH to evaluate the potential of self-heating of coal on the basis of intrinsic coal properties, geological settings and mining techniques. A numerical model has been developed to study the aerodynamics of airflow in the wastes of longwall coal faces. The Computational Fluid Dynamics approach is being explored to simulate airflow behaviour and nitrogen inertisation processes within the goaf. Such a model would be used in locating the areas most liable to spontaneous combustion and improving the utilisation of nitrogen. It would also be possible to determine the most likely path ways of combustion/heating products so as to provide an indication of the most appropriate locations for fire detectors.

Jan 1, 1997

By John P. Dunford, Lewis A. Martin

Researchers from the Spokane Research Laboratory, National Institute for Occupational Safety and Health, in cooperation with engineers from the Department of Mining and Geological Engineering, Montana Tech, Butte, MT, conducted tests to evaluate the tensile strength, fiber count, and adhesion of shotcrete applied to panels at the Chief Joseph Mine, a research and training facility operated by Montana Tech. The tests were conducted in the mine ramp 45 m (150 ft) inward from the access portal at a 15.25-m- (50-ft) long test area divided into five 3-m- (10-ft) long sections. The shotcrete was applied with an Aliva 240.5 machine fitted with a predampener. Different amounts of fiber were entrained for each panel. Background data for the tests were obtained from earlier tests in Nevada, where the typical amount of fiber in the shotcrete is 6.54 kg/m3 (11 lb/yd3). All shotcrete was applied to a minimum thickness of 76 mm (3 in). Cylindrical cores were drilled at the wall-rock interface, and adhesion was tested after 28 days of curing. The goal of this research is to reduce the need to install multiple supports at the advancing face by creating a safer mining system that limits the time miners are exposed to unprotected roof.

Jan 1, 2005

By L. W. Saperstein

In this paper, a number of novel hypotheses that provide a fresh perspective on the characterization of strata movements associated with longwall mining are developed by analyzing subsidence measurements with an influence-function-based computer program. Using an inverse application of the traditional influence-function technique, easily obtained surface displacements are used to analyze some of the complicated, expensive, and difficult-to- measure movements of the intermediate roof strata in a longwall panel. The primary hypothesis developed by this analysis proposes the existence of an area of partial roof caving near the edge of a panel called the "edge effect." A secondary hypothesis, interrelated with the first, promotes the importance of the effect of gate-entry closure on the observed strata movements. Both the primary edge-effect hypothesis and the secondary hypothesis concerning gate-entry closure are justified and quantified in an extensive analysis of surface subsidence that uses supporting information from related theories, design criteria, and in situ measurements. Next, the edge effect and the gate closure hypotheses are extended further and used to provide an explanation of the complex subsidence interaction of adjacent longwall panels in what is termed a "redisturbed" effect. Finally, the importance of accurately understanding these longwall strata movements for proper subsidence prediction or gate design is stressed.

Jan 1, 1988

By J. Scott McDougall, J. Herman P. Eng. Vanderlaag

An underground mine fire can seriously threaten the lives of all personnel in the mine. This fact makes fire emergency planning a high priority in the mining industry. The optimum warning alarm must be fast and able to reach all miners, regardless of their location or work activity. Current means of fire warning are varied, and include such methods as stench, telephones, and word-of-mouth (messengers). Unfortunately, none of these methods are entirely satisfactory. A novel fire warning alarm which enables instantaneous warning of all underground personnel, the Canary Nine Messenger System, has been developed by VLF Magnetic Systems Inc. in conjunction with Noranda Technology Centre and the U.S. Department of the Interior - Bureau of Nines. The warning is sent by an electromagnetic signal which penetrates through mine rock to receivers housed in the battery packs which also power each miner's cap lamp. A loud buzzer in the integrated battery/receiver unit and the flashing of the cap lamp alerts miners to incoming messages. Testing of prototype equipment has demonstrated that the transmitted signal is capable of penetrating through over a mile of mine rock and activating the receiver. This report describes the theoretical basis for through-the-rock ultra-low frequency electromagnetic transmission, and the design of recently available transmitter and receivers.

Jan 1, 1995

By Richard Hogg, Erol Kaya, Jan M. Mutmansky

Characterization of the size, shape, chemical composition, and mineralogical content of mine airborne dusts generally requires a larger mass of dust particles than is typically collected using traditional sampling devices. In this paper, the general design of a passive dust collector is described and the field results are presented. The collector was constructed of galvanized sheet metal duct with a resin-coated honeycomb to provide an elutriation-type system for particle collection. Several versions of the collector were used in the field portions of the research. The dust samples collected from underground coal mines were found to possess angular particle shapes, relatively consistent size distributions, and elemental compositions that showed relatively little variation, at least for the more prevalent elements. In addition, the distributions of particles sizes obtained from the passive dust collector appear to be similar to those of samples collected at the same time in a conventional personal sampler except that the passive device seems to collect a larger quantity of coarse, non- respirable particles. Conclusions on the suitability of this dust collector for collecting characterization samples are presented. In addition, the potential for using such a dust collection system for supplying dusts for biomedical research is discussed.

Jan 1, 1993

By S. Atak, G. Bulut

The xanthate adsorption mechanism on pyrite was investigated with an emphasis on solubility studies. Additionally, adsorption studies, Eh and infrared spectrophotometer measurements were performed. Pyrite floats at pH levels between 3 and 6 using ethyl and amyl xanthates with a maximum at pH 4. The solubility of pyrite in the absence and presence of xanthate was investigated in detail with respect to pH and conditioning time. Experimental results showed that the solubility of pyrite increases from 60 to 120 ppm (10-3 to 2x10-3 mol/ L) in the presence of xanthate at pH 3. Fourier transform infrared (FTIR) spectra of ferric xanthate, dixanthogen and pyrite conditioned with xanthate indicated that dixanthogen is the only species that can be determined on the pyrite surface. Adsorption tests showed that the highest level of xanthate adsorption was in the acidic range; yet higher adsorption densities were detected in neutral solutions compared to alkaline conditions. Electrochemical data suggest that the doubling of the iron concentration is due to the reduction of ferric ion to ferrous by xanthate while xanthate is oxidized to dixanthogen. Dixanthogen formation together with the hydrophobic iron hydroxy-xanthate complex on the surface is proposed to be responsible for pyrite flotation. Key words: Flotation, Pyrite, Adsorption, Xanthate, Dixanthogen

Jan 1, 2003

By F. Forbes

For many years, the Machinery Division of Dravo Corporation has been designing and constructing bins and hunkers as part of overall plant facilities. We have designed bins to handle a variety of materials including coal, coke, iron ores and concentrates, sintered and pelletized ores, calcined and raw limestone, bentonite, alloys for BOF shops, and even cast iron chips from machining operations. We, along with everyone else in this business, have had our bin problems. The bins either plug, rathole, segregate, wear out, flood the discharge device, or overload it. Surprisingly, sometimes they have worked. As engineers, it has long concerned us that something as important as bin design should be so imprecise and that it has been so conspicuously avoided in research and in literature. In past years, rule-of-thumb design criteria had been to keep the sides of the bins as steep as possible and the outlets of the bin as large as possible. This criteria led to the design of bins with 600 to 700 side slopes and table feeders which were very large. Unfortunately, this meant trying to fit tall, skinny bins into a layout where minimum building height was required for obvious economic reasons. Like everyone else in the industry, we found that this design procedure was expensive and ineffective.

Jan 1, 1968

By G. P. J. Schmitz, F. S. Gouws

In flotation processes the structure of the froth phase contains a wealth of information regarding the behaviour of the plant. Various structural features of the froth phase provide an indication of the froth viscosity, froth stability, mineral content, bubble size, etc., which can all in turn be related to the performance of the plant. In this paper the application of machine learning techniques to exploit information from digital images of the froth phase of industrial flotation plants is discussed. This includes both connectionist techniques to identify control decisions necessary to maintain optimal operation of the plant, as well as symbolic methods, such as induction techniques. Both approaches are used to classify froth structures based on statistical features derived from digitized images of the froth surfaces. It was found that backpropagation algorithms perform significantly better than either non-incremental or incremental induction. Backpropagation algorithms requires significant user input in order to optimally train the neural network as opposed to induction, which requires little user input. In contrast to back propagation, decision tree induction produces easily understandable decision trees which can be incorporated into a rule base or an expert system. Finally, incremental induction provides a simple means to smoothly and continuously adapt induced rules to follow changing process conditions.

Jan 1, 1996

By Gerrit V. R. Goodman, Fred N. Kissell

The issue of miner safety in case of an underground mine fire has been extensively examined by both government and industry. These efforts have intensified in recent years following a number of fatal fires at underground coal mines. As a result, there is an increasing interest in the reliability of coal mine escapeways during a mine fire. This paper discusses the use of fault tree analysis for evaluating escapeway reliability. A fault tree is developed using standard logic formulations. It is later evaluated using commercially available software. The computer model uses Boolean reduction to obtain the minimal cut sets and minimal path sets of the tree. A brief analysis is also conducted to determine the occurrence probability of the TOP event. This study shows that fault tree analysis is a viable means of analyzing escapeway reliability. The cut and path sets reveal those event sequences leading to fatalities. Such information is useful in safety training and accident prevention. The probability of the TOP event shows the frequency of occurrence for fatalities in an underground mine fire. The usefulness of this value, however, is limited by the accuracy of the data for the initiating events. For mining events, the data is difficult to estimate precisely.

Jan 1, 1989

By William Highton

If the economic situation in the Western World evolves on a path similar to that of the past decade, then we Mining Engineers must accept that one of the major cost factors in the production of deep mined coal is going to be that of labour. Whilst not trying to over-simplify matters it does appear that one of the ways of maintaining acceptable coal costs is by obtaining more coal without increasing manpower. One such way could be an increase in the use of the retreat method of mining. The paper theorises and illustrates case studies to show that as the Mining Industry extends the use of Longwall retreat mining systems in coal seams where the risk of spontaneous combustion exists, then the use of bleeder entries should be questioned. In addition to the spontaneous combustion risk, bleeder entry systems where the ventilation flow is not fully controllable cannot be construed as a safe and reliable method of controlling high rates of methane emission. These two major aspects alone should be sufficient ground for Mining Engineers to re-consider the practice of using bleeder entries. An alternative "The Back Return System" appears to offer most of the advantages for controlling the environment, without the disadvantages of the other system.

Jan 1, 1980

By Severn P. Brown

Cement plants in the central Hudson River valley utilize limestones of the Helder-bergian Series of the Lower Devonian. Chiefly calcilutites, calcarenites, and cherty calcisiltites, these rocks represent progressively deeper environments, from lagoonal to neritic, with scattered reef deposits. Stratigraphic continuity is marked, and a layer-by- layer analysis shows strikingly constant chemical compositions. The structural picture varies from flat-lying and relatively unfaulted beds on the northwest, through gently folded and faulted beds on the north, to complex overturned beds with closely spaced imbricate faults on the south. Operating techniques are simpler in the north, where grade control is effected chiefly by the initial layout of the faces. In the south, grade control requires flexibility and frequent adjustment of faces or scheduling. A system of quarrying along strike has been developed, grade being computed from a cumulative foot-per cent graph of the critical oxides in each mappable layer. Balancing shovel production among the many faces is simplified by comparing production requirement ratios with ratios of the various types of rock in each face. Drilling and blasting limits are geologically controlled if warranted, or large blasts embracing several rock types are shot and the resulting pile of broken rock is staked along shovel limits.

Jan 1, 1966

By Peikun Liu, Guangyu Sun, Raja V. Ramani, Shambhu Sharan, Raman Srikanth, Bharath K. Belle

The contribution of the various outby sources to the contamination of the panel intake air has been the subject of a relatively small number of studies. In this paper, after a brief review of past studies, results from recent experiments on rates of contamination of intake air by outby dust sources are presented. Present study indicates that each outby source by itself may not be a major contributor. The loading point in the continuous miner section did not appear to be of major concern from contamination point of view. Belt entry including transfer point contributes significantly to the intake air dust level, though reentrainment was not a major source of dust. In longwall panels, the stageloader-crusher was the most dominant source. The panel-to-main belt transfer point was not a major source. Taken collectively, the contribution of all outby sources can be significant. In one longwall section, at the beginning of the longwall face, the contribution of all the outby sources and the headgate cut-out operation was observed to be about 80% of the permissible exposure limit (2 mg/m3). In modem high production longwalls, the application of effective dust control measures to reduce the dust generated from the outby sources is essential to achieve compliance with the dust standards.

Jan 1, 1997

By Rajiv Hadkar, M. D. McKinley, J. B. Hiskey, B. J. Scheiner, G. W. Warren

Flyash from municipal solid waste incinerators containing roughly 13 to 15% Zn, 2% Pb and 0.2% Cd is an attractive material for simultaneous metal recovery and detoxification. Results have shown that Pb in flyash is present as PbSO4 and PbC12 and that about 70% of the Zn is present in the form of soluble amorphous compounds. Leaching results in a number of acid and basic lixiviants show that acid leaching is clearly more effective than basic leaching which is limited by low solubility of Cd and Zn. Cementation in acid solution with pH < 1 promotes redissolution of the precipitated metal. Successful zinc electrowinning from chloride leaching solutions has also been demonstrated, although Pb2+ and Na+ can be potentially detrimental. The presence of Pb2+ can prevent deposition of metallic Zn, forming zinc oxychloride, ZnC12.4Zn(OH)2, instead. High concentrations of Na+ can also result in precipitation of NaCl. This investigation has shown that hydrometallurgical treatment of MSW flyash through leaching, cementation and electrowinning is a potentially feasible method for simultaneous detoxification and recovery of metal values. Several issues have also been identified which would require further investigation for final process development.

Jan 1, 1993

By C. H. Lee, F. Concha, L. G. Austin, P. T. Luckie

The Concha-Almendra batch-settling treatment for concentrated suspensions of single-diameter spheres has been modified. This modified version is used in the differential equations of simple batch settling of a particle size range of different density materials. The equations have been programmed for a finite difference solution, and a number of test cases have been analyzed. By cutting the settling column at a fixed fractional height, the material below this height can be treated as underflow and the material above as overflow. The predicted partition curves obtained from treating the settling in this way have Sharpness Indices in the range of 0.5 to 0.6, in the absence of dispersion effects. The Sharpness Indices decrease as dispersion increases. When the feed size distributions are of the Rosin-Rammler form, the partition curves (corrected for the bypass fraction) fit the Rosin-Rammler equation with reasonable accuracy. The predicted Sharpness Index of a component of a mixture of two materials of different densities was unchanged from that of the same materials settled alone. However, for the same, feed size distribution and volume fraction of solids in the feed, the heavier material settled faster, and the lighter settled slower, than when settled alone.

Jan 1, 1993

By A. T. Visser

The expansion of surface mining has led to the development of very large off-highway trucks capable of hauling payloads in excess of 290 t (320 st). Mine haul roads have historically been designed empirically, relying heavily on local experience; the trend in increasing truck size will thus render the current pavement systems inadequate. Because truck haulage costs can account for 10% to 50% of the total costs incurred by a surface mine, not only would the maintenance costs of existing roads of inadequate design increase, but vehicle operating and maintenance costs would increase prohibitively. Thus, there is a need for improved design technologies encompassing the construction and management techniques of mine haul roads appropriate for the wheel loads of vehicles now in use. This paper presents the different components of a mine haul road design and management system and demonstrates the value of its application through case studies. The system has been applied at several South African surface mines, and distinct benefits have been derived. The improved structural design of a new road resulted in a 29% saving in construction costs and provided better service, while the optimal selection and management of wearing course materials provided better functionality at lower total transportation operating costs.

Jan 1, 2000

By A. T. Visser

The expansion of surface mining has led to the development of very large off-highway trucks currently capable of hauling payloads in excess of 290t. Mine haul roads have historically been designed empirically, relying heavily on local experience; the trend in increasing truck size will thus render the current pavement systems inadequate. Since truck haulage costs can account for 10%-50% of the total costs incurred by a surface mine, not only would the maintenance costs of existing roads of inadequate design increase, vehicle operating and maintenance costs would also increase prohibitively. There is thus a need for improved design technologies encompassing the construction and management techniques of mine haul roads, appropriate for the wheel loads of vehicles now in use. The aim of the paper is to present the different components of a mine haul road design and management system and to demonstrate the value of its application through case studies. The system has been applied at several South-African surface mines and distinct benefits have been derived. The improved structural design of a new road resulted in a 29% saving in construction costs and also provided better service, whilst the optimal selection and management of wearing-course materials provided better functionality at lower total transportation operating costs.

Jan 1, 1999

The US economy grew at a rate of 4% in 1994 and the gross domestic product rose to $6.74 trillion. With 261 million people - 605,000 in mining, including petroleum -the United States has l 10 million dwelling units and 200 million licensed motor vehicles. New private housing units authorized in 1994 rose 14% to 1.4 million units. New car production rose 11 % to 6.6 million units, while truck and bus production rose 30% to 5.2 million units. The inflation rate was less than 3% and the prime rate of interest averaged 7.15%. The producer price index (1982 = 100) for fuels and related products and power was down 4% to 78, while metals and metal products rose 5% to 125. Chemicals and allied products rose 3% to 132, and non-metallic mineral products rose 3% to 124. The merchandise trade deficit rose 25% to $166 billion. Disorder in the former Soviet Union led to substantial dumping of mineral materials. With vast mineral resources, the former Soviet Union land area totaled 22.4 million km2 (8.6 million sq miles). In comparison, the North Ameri¬can Free Trade Agreement (NAFTA) area (United States, Canada and Mexico) totals 21.4 million km2 (8.3 million sq miles).

Jan 1, 1995