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By Georgene Renner, Chee Theng, William Gleason

"In February 2018, drawn in part by the states’ proud mining heritage, SME took its Annual Conference & Expo to Minneapolis, MN for the first time. More than 5,000 people and 554 exhibitors converged on the Minneapolis Convention Center for three days of networking, exhibiting and technical sessions.The state’s mining legacy, one that continues today, is fueled in large part by its vast iron ore resources in the northern part of the state. The historical significance of the mines in the Mesabi Range, otherwise known as the Iron Range north of Lake Superior, cannot be understated. “Mining is a way of life here,” said U.S. Congressman Rick Nolan of Minnesota’s 8th Congressional District. A native of the Iron Range, the three-term U.S. congressman was one of the featured speakers of the opening keynote session. “We like to think we contribute enormously to the well-being of this country and the world. We were the source of the iron ore and steel that helped win two world wars. And we like to think that we are part of the progress that has taken place in the United States ever since.” Nolan kicked off the keynote sessionthat focused on innovation and its part in the mining industry. The session included Rene Aquilar, vice president of corporate affairs and sustainability, Antofagasta Minerals Group; Bob Anderson, vice president for research and development, 3M; Rolf Weberg, executive director, Natural Resources Research Institute, University of Minnesota-Duluth and Christopher Beck, executive vice president and president, Nalco Water. The panel session looked at U.S. and global minerals production, and the importance of the United States to maintain a major role in the minerals industry, both as a producer and as a technology leader. The panel also touched on the global mining industry and the issues that impact mining around the world. Sustainability, the use of water in mining and earning a social license to operate were among the topics discussed by the panel.Speaking of the importance of mining, Nolan conceded that talking about the benefits of mining to the crowded auditorium at the SME conference might be akin to a preacher speaking to the choir, but, following the adage that all politics are local, he continued to illustrate his point by emphasizing the importance of mining to the Great Lakes.“A study by Homeland Security concluded that 13 percent of the nation’s GDP comes out of Lake Superior through the locks at Sault Ste. Marie and most of that is iron ore,” said Nolan. “That study found that, if those locks fail, it would create a national depression. It would put millions of people out of work. That ore and those minerals supply the steel mills, the auto industry, the heavy industrials. They are the heart of our economy. The study concluded that if the states that make up the Great Lakes were a nation, it would be the fourth largest economy in the world.”"

Jan 5, 2018

By G. ALBORNOZ, S. Utili, A. AGOSTI, C. VALDERRAMA, R. PELL, N. Morales

The steepness of the slopes of an open pit mine has a substantial influence on the financial return of the mine. The paper proposes a novel design methodology where overall steeper pitwalls are employed without compromising the safety of the mine. In current design practice, pitwall profiles are often planar in cross-section within each rock layer; i.e., the profile inclination across each layer tends to be constant. Here instead, a new geotechnical software, OptimalSlope, is employed to determine optimal pitwall profiles of depth varying inclination. OptimalSlope seeks the solution of a mathematical optimization problem where the overall steepness of the pitwall, from crest to toe, is maximized for an assigned lithology, geotechnical properties, and factor of safety (FoS). Bench geometries (bench height, face inclination, minimum berm width) are imposed in the optimization as constraints which bind the maximum local inclination of the sought optimal profile together with any other constraints such as geological discontinuities that may influence slope failure. The obtained optimal profiles are always steeper than their planar counterparts (i.e., the planar profiles exhibiting the same FoS) up to 8° depending on rock type and severity of constraints on local inclinations. The design of a copper mine is first carried out employing planar pitwalls, secondly adopting the optimal pitwall profiles determined by OptimalSlope. The adoption of optimal slope profiles leads to a 34% higher net present value and reductions of carbon footprint and energy consumption of 0.17 Mt CO2 eq and 82.5 million MJ respectively due to a 15% reduction of rockwaste volume.

Feb 9, 2022

By Fredy A. Elorrieta Agramonte, Gabriel von Rickenbach, Roberto Luis Fonseca, David Córdova Rojas, Rolando Romero, Rico Brändle

The mine’s economic life is dynamic by nature. Some factors that create this scenario are the need to recognize new exploitation areas, the evolution of the mineral prices and the development of new technologies to access them. The dynamics of mining development, especially in the underground environment, changes significantly as the stages unfold. In many cases the final solution differs greatly with the initial. The frequent presence of new conditions and factors often cause the mine to develop in a quasi-permanent transition stage, which could be characterized by the generation of dynamic micro-seismic events that could cause rockburst damage in some specific areas. Although they may be infrequent, these dynamic events can have an important adverse impact on mine safety and causes serious losses. Also, changes in the production schedule during exploitation could be a big issue if the problem is not effectively addressed. When the transition of the mine to an active micro-seismic environment begins as an unforeseen scenario, it is frequent to use static ground support systems as they are readily available. Traditionally, the support systems used are reinforced shotcrete with a middle layer of Welded Standard Wire Mesh (WSWM) and Chain Link Standard Wire Mesh (CSWM) of reduced gauges, i.e. wires less or equal than 4 mm in diameter. Although, this support system is used to control static instability problems, there is no good reference of its energy absorption capacity under dynamic load conditions, creating uncertainty in the effectiveness of controlling rockburst events. These support systems are analyzed at the present paper, testing the reinforced shotcrete layer with 4 mm diameter of WSWM and CSWN under dynamic load. Additionally, the influence of the use of high tensile strength steel wire in the meshes (HSWM) compared to the previous ones, is analyzed to assess the scope in controlling rockburst events and keeping the safety of underground environment.

Apr 26, 2022

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 J. C. Watts

Monitoring and control of conventional industrial wet grinding circuits is conceptually straightforward. However, since production objectives and operating constraints can vary widely from plant to plant, there is probably no single overall grinding circuit control strategy which is "best" in all cases; in-variably some compromise is necessary between performance desired under ideal conditions and performance achievable in practice. The recent advent of relatively low cost, reliable, high speed small computer systems is revolutionizing daily operations in increasing numbers of metallurgical processing plants. Of special power and capability is a hierarchical computer network like that currently in use at the Pinto Valley Operations of the Cities Service Company. Several satellite processors for key plant areas communicate with a master computer operating under a powerful multitasking real-time operating system. Hardware and software structure is such that downtime on one of the processors -including the master -does not have a major impact on overall system operation. Admittedly, the powerful, core efficient table driven satellite software, which handles process/computer communication, calculation of nonmeasured process variables, and basic Direct Digital Control functions, is difficult to modify. However, important high level process monitoring, report preparation, graphic display, and supervisory control functions -including economic optimization -can be implemented by project engineers at the plant site. Thus, for example, new control strategies can be quickly examined and rapidly evaluated. Such computer monitoring capability also permits use of short duration process pulse tests for approximate dynamic modeling and rapid calculation of controller tuning constants for single loop dominant systems. Following a brief back-ground discussion of the Pinto Valley Project, we present some of the more interesting results and conclusions of our work over the past year.

Jan 1, 1978

By B. J. Arnold

Coal blending inherently means homogenizing a mixture of coals so that, overall, the properties of the blend meet some specifications for maintaining power plant performance and emission requirements. In common practice, however, coal blending is at best coal mixing. If necessary, more sophisticated blending systems can produce a more homogeneous feed by using accurate weighing devices and on-line coal analyzers coupled with sampling systems. Blending can be accomplished at the mine, on stockpiles, and from bins, bunkers, and silos.

Jan 1, 1994

By M. S. Prasad

In earlier work it has been shown that paper filler clay products can be obtained from primary kaolin deposits of Minnesota. The objective of the current work was to reduce silica and iron contaminants and to maximize kaolin recovery to higher value products suitable for paper coating. This results in achieving a finer and cleaner product conforming to paper coating specifications. Cationic flotation and high gradient magnetic separation were used to remove free silica and iron, respectively, while attrition grinding and ultrasonics have been examined for particle size reduction. The results of this work are presented and discussed particularly with respect to application-oriented product properties. Budgetary estimates are presented for a 200,000 ton/year processing plant based on the process flowsheet developed and optimized by the study.

Jan 1, 1991

By D. L. Crouse

The worldwide talc industry has experienced significant changes since the 1980's. Consolidation of companies and operations in Europe, Australia, and North America has altered the face of supply and distribution. Imports of Chinese and Australian crude have increased competition and product options. The number of processing operations without local mines has moved competition closer to the market area. Quality controls related to ISO certification and tighter specifications demanded by the customers have altered the way our mines and mills operate. Ceramics, coatings, and paper applications continue to consume the majority of processed talc.

Jan 1, 1997

By P. J. Best

Due to its low mine production costs, competitive rail rates and low sulfur content, the Southern Powder River Basin (SPRB) now commands 30 percent of the U.S. utility coal market. In 1996, production exceeded 260 million tons, a growth of 110 million tons since 1989 and 15 million tons over 1995. Continued growth is expected as the second phase of the Clean Air Act Amendments (CAAA) looms. This growth will be the greatest in the southern part of the basin, where coal quality is higher. This article is an overview of supply and demand issues affecting markets for SPRB coal. It reviews the current markets for SPRB coal and addresses future prospects for market expansion.

Jan 1, 1998

By P. James

"INTRODUCTION Control of target stream pH is very important in leach mining and treatment of MIW (mining influenced water). On the production side, solution acidity can impact SX (solvent extraction) effectiveness through PLS (pregnant leach solution) and raffinate pH. Many older operations and legacy mining sites generate ARD (acid rock drainage) that is too weak for profitable metal production by conventional means and faces costly wastewater treatment for mitigation and disposal. For wastewater and environmental treatment, neutralization to precipitate and remove metal contaminants to clean the wastewater is the dominant approach. Traditional lime neutralization and precipitation is most often used but results in large amounts of mixed metal sludge requiring costly disposal. Blue Planet Strategies (BPS); which focuses on improved resource utilization targeting electrolytic treatment and waste conversion into resources, has developed a new “reagentless” neutralization process. Electricity is utilized in its proprietary DEMET™ (Dynamic Electrolytic Metal Effluent Treatment) platform capability to controllably raise target stream pH. The method offers a simple, low-cost approach yielding cleaner treatment chemistry. It can result in less sludge generation and enables possibilities to selectively recover contaminants as potentially saleable products for new revenue generation to offset further offset treatment costs. DEMET Overview BPS’s patented electrolytic DEMET platform leverages solid scientific and chemistry foundations through its advanced design to achieve capabilities and performance not previously realized. DEMET technology combines separated compartment electrolytic cell functionality with proprietary advanced dynamic electrodes and cell configurations to achieve a variety of chemistries and processing targets.[1-6] DEMET‘s unique elements can yield higher processing rates at practical efficiencies, lower energy consumption, plus improved processing stability and lower maintenance requirements due to enhanced resistance to cell fouling and shorting; while also thwarting cross stream (catholyte vs. anolyte) contamination. Consequently, DEMET can provide a superior, extremely versatile, and more cost-effective electrolytic treatment option where a multitude of FEED and PRODUCT stream combinations might be employed in comparison to traditional tankhouse electrolytic cells."

Jan 1, 2015

By Gregory M. Rumbaugh, Todd R. Kostecki, Christopher Mark

From 2015 to 2021, five massive pillar collapses occurred at four underground stone mines in the eastern USA. These events resulted in powerful airblasts that damaged mine infrastructure and mobile equipment, seriously injured miners, and disrupted underground travelways. Each of these pillar collapses propagated through the overlying strata, causing a subsidence sinkhole on the surface. Pillar collapses are particularly hazardous for miners because they can occur with little warning and can affect miners that are far from the pillar collapse area. The following case studies show that certain factors may increase the likelihood of a pillar collapse. For instance, each of the 5 events involved at least 12 benched pillars with width-to-height ratios (w/h) of 0.8 or less. This study elaborates on these factors and proposes a framework to assist mine operators where they identify similar hazards.

Jul 24, 2023

By M. Fig, A. Juganda, M. Zurhorst, J. Brune, C. Strebinger, G. Bogin

"Understanding the airflow patterns in and around the longwall panel can help to identify poorly ventilated areas that may be prone to methane accumulation. Ventilation network modeling provides quick simulation time, and flexibility in adjusting airway parameters and ventilation controls. Such modeling is effective for analyzing linear ventilation networks in underground mines, but cannot compute flows in caved areas of hard rock mines or longwall gobs. The use of Computational Fluid Dynamics (CFD) enables a more detailed investigation of the interaction between the airflows in these caved areas but requires much longer computational times, designing complex meshes and determination of a variety of modeling parameters. Airway friction factors and ventilation controls are simple to implement in a network model but can be difficult to model and adjust in CFD. This paper will focus on using mine ventilation network simulation to identify and analyze key parameters that are affecting airflow distribution in and around the longwall panels, prior to more detailed analysis with CFD modeling, using the example of a longwall coal mine. INTRODUCTION In longwall coal mine ventilation systems common in the U.S., the main purpose of bleeder ventilation is to dilute methane gas and prevent the formation of explosive gas mixtures in the caved, poorly ventilated gob areas and adjacent mine workings. In longwall operation, these critical areas include the development headings inby the longwall face, and the gob. Methane-air explosions in these areas may be ignited by spontaneous combustion, rock-on-rock friction and other sources. Although rare, ignitions due to rock-on-rock friction caused by roof falls caving into the longwall gob are possible and were suspected in the Willow Creek mine explosions in 1998 and 2000 (Elkins et al., 2001; McKinney et al., 2001). Rock-on-rock frictional ignitions are difficult to prevent, as they occur in inaccessible areas. Therefore, rendering the gob area inert is essential to prevent the formation of explosive mixtures. Research by Gilmore et al. (2015) and Brune et al. (2015) has shown that gob inertization can be a difficult or impossible when using bleeder systems, since the flow of gases through the gob depends on the gob permeability and the amount of fresh air leaking from the face and the immediate roof caving conditions cannot be controlled by the mine operator. Having the ability to predict the location where explosive gas zones (EGZs) form inside the gob will be helpful for designing the best ventilation setup to minimize explosion and fire risks."

Jan 1, 2018

By D. Robert Weir, Verner B. Sefton

The reduction roast-ammonium carbonate leach-hydrogen reduction process for laterites has been under development by Sherritt Gordon for the past 20 years. The process can treat high iron or low iron laterites, with some process modification, and gives extractions of 88-93% Ni or 82-88% Ni, respectively. Five campaigns on a 1 tonne per day Pilot Plant and four campaigns on a 35 t/d Demonstration Plant have been carried out on laterite from three different deposits, and many other laterites have been investigated in the laboratory. The Marinduque Surigao Nickel Refinery in the Philippines was designed on the basis of this work. The process comprises roasting to selectively reduce the nickel and cobalt in the laterite, leaching the calcine in ammonium carbonate to dissolve the metals, recovery of cobalt by precipitation of a mixed metal sulphide, concentration of nickel from the carbonate solution by basic nickel carbonate precipitation and recovery of high purity nickel by hydrogen reduction of nickel from ammonium sulphate solution. Ion exchange has been developed as an alternative to BNC and for recovery of trace nickel from BNC barren liquor. Details of the development of some of the process steps through the laboratory to commercial plant are discussed. The process metallurgy has been confirmed in the commercial plant.

Jan 1, 1979

By Martin N. Kelley

The Great Belt Link is a $3.5 billion fixed link across an 18 km (12 mile) wide body of water that separates the island of Zealand, on which Copenhagen is situated, and the main land mass of Denmark, Jutland, which is part of the European continent. The project consists of three main contracts. The first contract is an 8 km (5 mile) long, two-bore railway tunnel for the eastern half, the second contract is a 6.6 km (4 mile) combination railroad and highway bridge for the western half, and the third contract is a 6.7 km (4 mile) long high-level highway bridge for the eastern half. This paper will discuss the Eastern Railway Tunnel Project and the methods of construction that the joint venture consortium plans to use, along with its equipment selection. The ground conditions to be encountered begin with glacial tills, which are a mixture of clay, silt, sand, gravel, cobbles, and granitic boulders. The boulders can be up to 1-3 m (3-10 ft) in diameter. Underlying the till is a marl which is sometimes highly fractured with hydrostatic pressures of up to 8 bar. About 40% of the tunnel is in till and 40% in marl, with the remaining 20% being a mixed face of the two formations.

Jan 1, 1991

By I. B. Tulu, M. M. Sears

"In 2015, 40 longwall mines provided nearly 60% of the US coal production from underground mining methods. This represents a substantial, yet gradual increase from just under 50% over the last 5 years. As a result of this increased production share, the percentage of ground fall related fatalities in longwall mines has also increased when compared to all US underground coal mines. Additionally, about 80% of ground fall related fatalities have occurred in areas where the roof was supported. In an attempt to better understand the status quo of current US longwall support practices, a sample of 21 longwall mines were visited, representing about 40% of the currently active longwall mines in 4 of the 5 major US longwall producing regions. The resulting data was obtained from a wide variety of overburden depths, geologic conditions, mining heights, ground conditions, support practices, and gateroad configurations. The data collected is reported using both qualitative and quantitative methods. The results from the research update previous efforts in classifying mining accidents and injuries as well as current support practices. This data provides a necessary background for future research aimed at further reduction of ground fall accidents and injuries. INTRODUCTION Maintaining ground stability in gateroad entries is essential for longwall productivity and safety (Campoli, 2015). In 2015, 148 unintentional roof falls were reported in US longwall mines. About 34% of these resulted in mineworker injuries. Safety considerations not only include injury from roof and rib falls but also egress from the longwall face during an emergency (Mucho et al., 1999). Over the past 30 years, a number of researchers have studied longwall tailgate support performance (Mirabile, 2015). This research aims to take a snapshot of the ground support installed in modern US longwall mines and provide a supplement and update to the overview provided by Barczak (2005). This will provide a framework for future research into improving gateroad support systems. BACKGROUND Large unplanned roof falls at or above the primary support or those impeding travel and/or ventilation must be reported to the Mine Safety and Health Administration (MSHA). Reportable roof falls, normalized based on production in million metric tons, generally relate to the amount of roof exposed during the mining process (Pappas and Mark, 2012) and provide an evidence-based statistical background for this review of current support practices. Figure 1 shows the reportable roof fall rate in US underground longwall mines for the period 2006-2015 (MSHA, 2016). Over the past decade, roof fall rates have shown a gradual decrease with numbers now at a rate nearly half of what was observed just five years ago. However, over the past few years, roof fall rates in US longwall mines appear to have stagnated at levels just over 1 per 2,000,000 tonnes mined."

Jan 1, 2017

By Marko Oosthuizen, Charl P. Botha, Lidia Auret, Annelette Malan, Marthie de Leeuw

Flotation performance is affected by upstream disturbances (e.g., mineralogy, water quality, flow rate) and controlled variables (e.g., pulp level and air addition). Process disruptions can lead to undesired conditions, such as pulp overflowing flotation cells (with insignificant/absent froth, and thus no valuable mineral concentration). Early detection and appropriate intervention of pulping events improves concentrator performance. An approach to real time flotation pulping event detection by means of convolutional neural networks is presented, including a case study of the industrial application of this technology on three flotation banks.

Feb 22, 2026

By Daniel A. Payne

For many years underground mining in the Sydney Coalfield has suffered from the effects of high horizontal stresses. It is only in the last 15 years that they have come to be recognized, understood, predicted and even avoided. This paper relates experiences in three coal mines in three different seams in the Sydney Coalfield. The effect of the direction of the principal horizontal stress on the direction of drivage of gate roads, access roadways and longwalls is described. Results of a monitoring program to measure the change of magnitude and direction of the principal horizontal stress in the gate roads as a result of longwall mining are also presented as well as the effect of the direction of principal horizontal stress on the shape of sandstone/gas outburst cavities.

Jan 1, 1998

By G. F. Revey

Most commercial explosives contain 70 to 94% ammonium nitrate, by weight. When portions of these explosives end up in shot rock and ore, through spillage or incomplete detonation, ammonia and nitrates leach out of them and into ground water. In recent years, State and Federal regulators have been applying more stringent water quality standards, particularly at new mines and development projects. Bulk ANFO, a mixture of ammonium nitrate and fuel oil, is the explosive of choice at most mines, when mining conditions allow it. ANFO use is desired because it less costly than other explosives, but when spilled it dissolves readily in water. Several case histories in the United States and Canada show a clear connection between uncontrolled losses of bulk explosives and high nitrate levels in mine effluents. Mining companies have tried several approaches to reduce ammonia and nitrate levels in groundwater. They either control explosive losses, or they treat mine effluents at the end-of-pipe. This paper addresses the former solution --controlling explosive losses. For both packaged and bulk explosives, guidelines designed to limit losses during storage, handling and use, are described in detail.

Jan 1, 1995

By Joshua Cole, Joshua Sovechles, Christian Cardoso, Guillermo Bermudez, Martta Hirsi, Joshua Dettamanti, Rabia Abbasi

The implementation of technological advancements in flotation is key to optimize performance in mining operations. Consequently, flotation cell’s performance is highly dependent on the effectiveness of the mixing mechanism. A more efficient flotation mixing mechanism is likely to improve metallurgical performance and optimize energy consumption, which is the motivation for Metso’s journey to develop the latest iteration of FloatForce®. Looking to test the new design at plant scale, Metso approached the Kennecott Copperton concentrator, which is continuously looking for different venues to improve metallurgical performance. In this context, a test campaign was conducted to implement this new flotation mixing mechanism in their rougher circuit during 2024. The industrial trial consisted of several sampling campaigns assessing different operational parameters for comparison purposes around a 300m3 flotation cell. The effect of the new flotation mixing mechanism on the cell’s power draw was also studied. The results of this trial at Kennecott are presented in this paper. Overall new flotation mixing mechanism, FloatForce+ was seen to perform as well as the original FloatForce.

Feb 1, 2025

By R. L. Grayson

Evidence has accumulated indicating that cultural change toward safer workplace behaviors is beginning to occur systematically in the coal industry. Through a range of programmatic mining company successes, enforcement and litigative actions, economic responses to competition, and integrated efforts by federal and state agencies, a broader participation of safety and training professionals is being achieved to address prioritized workplace problems at mines. Small steps in workplace-related improvements have been realized already, but the trends in industry safety statistics, coupled with focused programmatic initiatives, indicate that more definitive and systematic steps are occurring to improve safe behavior in the workplace routinely.

Jan 1, 1996