Search Documents

By M. A. Bartkoski

Today?s surviving companies are being pushed to a heightened level of excellence due to market changes. Therefore, new business strategies must be explored. This paper offers a sequenced plan to retool, empower, and organize the entire team for a common goal. Integrity Process is an operating system that is very comprehensive and is integrated in every part of the business. It relies on a detailed prevention concept intertwined with accountability that produces individual efficiencies and team effectiveness. Integrity Process focuses on the importance between working from commitment motives versus compliance fears. The results are balanced in priority and truly yield a win-win for the owners, management, workforce, and the community. Integrity Process can and is being used in any industry that is challenged to optimize the relationship between people and process.

Feb 23, 2014

By Daniel G. Ganey

Kerr-McGee Coal Corporation has used diesel face haulage and support equipment at its dual-seam Galatia Mine in Southern Illinois since production activities commenced in 1983. The mine began production from its lower seam, the Harrisburg No. 5 coal seam, in October 1983 and from the upper Herrin No.6 coal seam in April 1985. Before production began, the company developed a program designed to make use of the flexibility offered by diesel equipment. While productivity was an important goal, the top priority of the program was to provide a safe and healthy work environment for the miners. Management believed that high productivity would naturally follow. History has proven this belief to be true.

Jan 1, 1990

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 Michael F. Gleason

In 1986, Gold Fields began negotiations with a large Nevada electrical power utility to supply power for its Chimney Creek Mine In northern Nevada. After the long negotiations reached an impass over various costs associated with the power line, a decision was made by Gold Fields to generate its own power. Self-generation is not uncommon overseas, but it is rare for any but very large or very small operations in the United States. Surprisingly, under certain conditions a mine can generate its own power profitably and Gold Fields has found that the associated operating and maintenance problems are minimal. The following report details what factors went into this decision and how it works. Hopefully, it can serve as a guideline for those who may find themselves in a similar position.

Jan 1, 1990

By Joseph M. Zigich

The Anaconda Minerals Company operates a molybdenite and copper producing mine and mill facility near Tonopah, Nevada. Included with the milling facility is a ferric chloride leach plant for removal of copper mineralization from the molybdenite concentrates. Discussed are the engineering and construction schedules associated with the leach plant. The chemistry associated with the process along with a description of the process flow, equipment, and operating parameters are contained in the paper.

Jan 1, 1983

By Karl R. Zipf

A tube bundle system (TBS) is a mechanical system for continuously drawing gas samples through tubes from multiple monitoring points located in an underground coal mine. The gas samples are drawn via vacuum pump to the surface and are typically analyzed for oxygen, methane, carbon dioxide and carbon monoxide. Results of the gas analyses are displayed and recorded for further analysis. Trends in the composition of the mine atmosphere, such as increasing methane or carbon monoxide concentration, can be detected early, permitting rapid intervention that prevents problems, such as a potentially explosive atmosphere behind seals, fie or spontaneous combustion. TBS is a well-developed technology and has been used in coal mines around the world for more than 50 years. most longwall coal mines in australia deploy a TBS, usually with 30 to 40 monitoring points as part of their atmospheric monitoring. The primary uses of a TBS are detecting spontaneous combustion and maintaining sealed areas inert. The TBS might also provide mine atmosphere gas composition data after a catastrophe occurs in an underground mine, if the sampling tubes are not damaged. TBSs are not an alternative to statutory gas and ventilation airflowmonitoring by electronic sensors or people; rather, they are an option to consider in an overall mine atmosphere monitoring strategy. This paper describes the hardware, software and operation of a TBS and presents one example of typical data from a longwall coal mine.

May 1, 2013

By L. Alan Weakly

The Powder River Basin is the largest strippable reserve of compliant coal in the United States. It is the mother lode, for this Basin is currently supplying 25 percent of the coal produced in the US annually. This paper updates what has happened in the Basin since 1993 in terms of increased production, higher productivity, changes in mine ownership, safety statistics, new equipment, latest coal technologies, and electrical deregulation ramifications.

Jan 1, 1998

By Nick Rose, Mathieu Veillette, Matthew King

"The Teck Highland Valley copper (THVC) mine is located approximately 55 km (34 miles) southwest of Kamloops and approximately 20 km (12 miles) west of Logan Lake, BC, Canada (Fig. 1). Mining at THVC is conducted at three openpit operations comprised of Valley, Lornex and Highmont with a total annual output on the order of 300 kt (330,000 st) copper concentrate and 5 kt (5,500 st) of molybdenum concentrate. The Phase 8 pushback in the Valley Pit (Fig. 2) was mined from 2011 to 2016. Successful slope steepening occurred in the later stage of the pushback with the implementation of presplit blasting in 2015 and 2016.This article summarizes the investigation and design approach including: structural analysis, kinematic assessments of bench breakback potential, development of discrete fracture networks (DFNs) to characterize discontinuity fabric, rockfall modelling, 2D anisotropic limit equilibrium and 2D distinct element modelling, assessment of potential kinematic failure modes affecting double benches with 3D distinct element modelling and improved blasting techniques using e-dets. THVC is currently undertaking a mine life expansion involving the pushback of the west wall of the Valley Pit above Phase 8 to extend the mine life to 2029. Engineering geologyThe east wall slope in the Valley Pit is comprised of a 350-m (1,148-ft) thick sequence of glacial valley sediments that occur along the Highland Valley (Fig. 2), exposing an overburden slope up to about 225-m (740-ft) high below the crest of the ultimate east wall. The glacial overburden units consist of pro-glacial outwash and glaciofluvial deposits, glacial outwash sands and gravels interbedded with till and alluvial fans consisting of cross-bedded sands and sandy-gravels. Lacustrine sediments occur within the mid to lower portion of the glacial sequence and contain intervals of low-shear-strength clays and silts. Two large (1.3 and 7 Mt or 1.4 and 7.7 million st) waste rock buttresses were required to maintain slope stability using slot-cut and fill mining methods, as described in Fortin et al. (2011).The Valley porphyry deposit occurs in the central portion of the late Upper Triassic Guichon Creek Batholith, which intrudes assemblages of the Permian Cache Creek and Upper Triassic Nicola groups. The Valley deposit occurs in an area of intense fracturing near the intersection of the northerly trending Lornex Fault and the northwest to westerly trending Highland Valley Fault."

Apr 1, 2019

By O. D. Staman

The risk assessment project examines the likelihood of inorganic contaminants from copper dump-leaching operations to contaminate domestic water supplies. The project examines contaminant transport by modeling contaminant movement from the base of a leach pile through the unsaturated zone and into the saturated zone. The modeling effort is unique in that it models infiltration, contaminant transport in the unsaturated and saturated zone combined with geochemical modeling of the unsaturated zone. The project incorporates probability theory to reflect the uncertainty of hydrogeologic parameters.

Jan 1, 1994

By Martin P. Schroeder

"Challenges have emerged as subway systems age and as new tunnels are bored in congested corridors or in high-risk environments. To help public transportation agencies address tunneling challenges, the American Public Transportation Association has convened numerous independent industry peer reviews composed of top experts in their fields to come together and provide recommendations and solutions. This paper provides case histories of peer reviews that include topics such as boring through toxic soils, boring underneath existing tunnels, retrofit of tunnel ventilation systems, and mitigation of water intrusion. Peer reviews are applicable to all tunnel projects worldwide. The paper will highlight the conditions of these challenges, peer review recommendations, steps taken to reach agreement, and the successes that resulted, which led to major changes, new legislation and reduction of risk. INTRODUCTION Public transit agencies face many challenges in maintaining and expanding safe transit operations, especially as systems age, ridership expands, and budgets remain flat. The development of new industry standards and federal safety regulations places further demands on transit systems, with compliance often taxing in-house resources. Studies of the state-of-good-repair across US public transit systems indicate a current backlog of $84 billion in maintenance projects, which will require an investment of $18.2 billion per year to eliminate the backlog by 2030[1]. Systems not in a state-of-good-repair may not operate efficiently, may not be available to meet the growing ridership demands, and may not meet required safety goals or reduction of risk. Innovation is another clear need transit agencies have for improving system performance and lowering operating costs.To meet these challenges, transit agencies often turn to industry peer reviews for guidance and recommendations as part of their overall strategy to maintain and grow the safe operation of their systems. As a service to its members, the American Public Transportation System (APTA) has developed an industry peer review program designed to give agencies opportunities to learn from each other and help them address challenges in operations, engineering design, and construction of their systems. Over the past 20 years, APTA has performed hundreds of peer reviews covering all aspects of transit system operations from fare collection to agency organization, project delivery methods to safety culture, and engineering design including tunneling and tunnel fire ventilation. As rail transit systems expand to meet increased ridership, it is often necessary to bore new tunnels for alignments in congested areas where surface rights-of-way are lacking. Such proposed alignments can pose significant challenges for transit agencies, as they contend with various tunneling problems."

Jan 1, 2016

By A. Noble, R. Q. Honaker, J. Werner

Recovery of rare earth elements (REE) from coal-related resources has recently received significant interest due to supply concerns and their key roles in critical industries and defense-related technologies. An integrated flowsheet consisting of sorting, crushing/grinding, physical separation, acid leaching, solvent extraction, and selective precipitation was designed to achieve continuous production of rare earth products from various coal-related resources such as coarse refuse and acid mine drainage. A pilot plant was constructed that enabled continuous testing of the circuitry on a range of different coal-based feedstocks. Despite achieving significant success in producing high-grade rare earth oxide products, low REE recovery values and high operational costs necessitated a re-evaluation of the process flowsheet. This article describes the circuitry improvements that were based on both laboratory and pilot plant test results. Roasting as a pre-leach treatment was found to significantly improve the leaching rate and overall REE recovery values. After roasting West Kentucky No. 13 and Fire Clay coal refuse materials at 600 °C, REE recovery increased by 60 and 40 absolute percentage points, respectively. Rare earth concentration in the pregnant leachate solution (PLS) was increased to around 700 ppm prior to solvent extraction using a staged precipitation method. REEs in the precipitate were re-dissolved, purified, and extracted from the PLS using solvent extraction and selective precipitation to values of around 80%. As a result of the improvements, chemical consumption in the acid leaching and solvent extraction processes was significantly reduced. A techno-economical assessment of the improved flowsheet indicated significant commercialization potential.

By Richard A. Thomas, Liming Yuan, Lihong Zhou, James H. Rowland

Hydrogen (H2) gas released during battery charging can result in cross-interference for carbon monoxide (CO) sensors used for early fire detection and compromise the integrity of the mine atmospheric monitoring system (AMS). In this study, a series of laboratory-scale and full-scale experiments were conducted to evaluate the responses of different CO sensors to H2 gas. In the laboratory-scale experiments, constant H2 concentrations in the airflow, from 100 to 500 ppm, pass through sensors. While in the full-scale experiments, increasing H2 concentrations generated as a byproduct from charging the batteries at the battery charging station rise to the sensors under different ventilation scenarios. The H2 concentrations at the CO sensor location were measured using H2 sensors and were correlated with the CO sensor response. The effects of ventilation and sensor location on the CO sensors responses were also analyzed. The results of this study can help mining companies to select appropriate CO sensors and improve the deployment of these sensors to ensure the safeguard of underground miners.

By J. Swanepoel, J. H. van Laar, J. C. Vosloo, W. A. Pelser

Deep-level underground mining costs in South Africa are continuously rising due to the increased depth at which gold is being mined, resulting in a rise in virgin rock temperature and an increase in cooling requirements. Therefore, mines must evaluate various ventilation and cooling optimisation projects required to be implemented throughout their life of mine (LOM). This study develops a method to identify and prioritise large capital expenditure (CAPEX) underground environmental improvement projects, to improve thermal comfort underground. The solution presents a ‘multi-criteria decision-making’ (MCDM) process, incorporating the ‘analytic hierarchy process’ (AHP) and the ‘technique for order performance by similarity to ideal solution’ (TOPSIS) into the method to provide for scientific decision-making. These projects are evaluated based on four criteria, namely project risk, the impact on the underground thermal comfort, cost, and implementation time. This study’s solution uses ventilation simulations to determine the impact of the projects on the underground environment. The identification and evaluation of an environmental improvement project to best suit the current economic climate, while improving underground conditions and decreasing the safety risk is an essential aspect of the solution developed in this study. The method was implemented on a mechanised deep-level underground mine and showed that surface refrigeration is the most suitable alternative, which was implemented at the case study mine as validation of the developed solution. The study proves that the MCDM method is an adequate solution to incorporate subjective criteria into the decision-making process, resulting in a scientific and structured approach to making significant and complex decisions.

Feb 17, 2023

By J. O. Down

St. Marys Cement Company operates two cement plants in Southern Ontario, Canada. The original plant, located at St. Marys, a town 20 miles north of London, Ontario, began operations in 1912. A second plant, located at Bowmanville, Ontario, 40 miles north east of Toronto, began operations in 1967. In June 1973, St. Marys Cement began feasibility studies of modernizing their wet process plant at St. Marys. Over its 61 year life, this plant had been expanded from 335 m. tons per day (375 s. tons per day) to 2000 tpd (2200 s. tons per day), with all the original equipment retired several years ago. The objectives of the feasibility study were to develop a conceptual plan for a dry process plant and to de-, fine the appropriate process method and equipment. This study proceded along four fundamental fronts: a) How could the clay raw material, a glacial till with up to 20% boulder content, be processed in dry form and beneficiated? b) Were the raw materials suitable for the most efficient form of dry process kiln, the 4-stage preheater? If a 4-stage preheater kiln is selected should it utilize a precalciner? c) What type of clinker cooler should be used? d) What environmental constraints would be imposed on this plant and how can they be reconciled with capital and operating limitations? During the feasibility stage, pilot plant work was done on two possible solutions to the clay problem, operating plants in Europe were visited and discussions held with kiln and mill vendors.

Jan 1, 1977

By L. Yuan, J. H. Rowland, D. Bahrami, R. Thomas

Blasting is the main method of production in many non-coal underground mining operations and produces multiple toxic gases as a result. The Mine Safety and Health Administration (MSHA) requires mine operators to measure the level of toxic gases in mines as frequently as necessary to ensure they are below regulatory safety limits. The current practice uses portable gas monitors to check the concentrations of toxic gases after a fixed post-blast time. This paper studies the application of a gas monitoring system in the return entry of a limestone mine to determine a safe re-entry time. The National Institute for Occupational Safety and Health (NIOSH) conducted such a monitoring program in a limestone mine from September 2016 through May 2018. NIOSH/PMRD (Pittsburgh Mining Research Division) is endeavoring to develop workplace solutions to improve detection of and reduce the risk of hazardous conditions. This study showed that the use of gas monitoring in the return air can be a useful tool at the mine operator’s disposal to detect and reduce the risk of hazardous conditions and also to reliably estimate the re-entry time.

By J. D. Miller

The fossil resins of certain western coals are of significance and of sufficient value as a chemical commodity to justify a fossil resin industry. At the present time these valuable fossil resin resources, worth more than $0.50/lb as a chemical commodity, are being burned as fuel for electric power generation. This waste of our fossil resin resources corresponds to a loss in revenue of $200 million per year -equivalent to the value of the coal itself! Improved process technology for the recovery of fossil resin is under development and includes selective flotation of fossil resin from fine coal streams and solvent refining of the fossil resin flotation concentrate to produce a premium resin product. The most recent developments in process technologies are discussed with respect to separation efficiency and product quality. It is clear that the development of a fossil resin industry should not be limited by process technology.

Jan 1, 1994

By Howard S. Avery

The wear resistance of an alloy in heavy mill liner sections may be quite different from that of the same alloy in small balls and other light sections. This fact was established by means of a well standardized laboratory test that was validated for ball mill service. The salient properties of mill liner alloys, including austenitic manganese steels, medium alloy hardenable steels, and abrasion resistance cast irons are described, critically compared, and quantitatively ranked in terms of mill liner service. Where they are tough enough the high-chromium and other martensitic cast irons (e.g. Ni-Hard) promise maximum economy, but their section sensitivity is a limitation. To overcome this an extensive research program studied over a hundred experimental alloys, ranking them for heavy section abrasion resistance by means of the laboratory test. Computer analysis of the results provided a parabolic formula in terms of composition, the apexes of the parabolas providing optimum wear resistance. From the extensive family of parabolas one apex was selected for intensive study in experimental liners, pilot plant production, development of quality controls, and finally full scale production. This is a 19% chromium iron critically alloyed with nickel and molybdenum and hardened by heat treatment. It has excellent resistance to various types of abrasion, but its chief advantage is in heavy mill liner sections, where it has about 25% better abrasion resistance than the best of the quality controlled chilled Ni-Hards. It is also tougher. After production problems were solved, a number of ball and rod mill tests were arranged on a guaranteed performance basis. Two of these, representing about 138,000 pounds of mill liner castings, have recently confirmed in service the superiority that was predicted by the laboratory tests.

Jan 1, 1969

By Brian G. White

The Coeur d'Alene Mining District of northern Idaho is remarkable for its number of large ore bodies and for the amount of its historical production of lead, zinc and silver (Fig. 1). Since veins were first discovered in 1884, more than 127 Mt (140 million st) of ore have been produced from narrow, high-grade veins. Mining continues at the Lucky Friday, Galena and Sunshine mines (Fig. 2). All have been in production for decades. At these mines, more efficient mining and exploration techniques have reduced costs while adding significant new reserves. Even the old Bunker Hill Mine, where ore was first found in 1875, continues operation on a limited basis, partly involving production of world-class pyromorphite specimens. Until recently, the Coeur Mine was also a profitable silver producer. Other large producers have included the Star-Morning, Hecla, Page, Standard-Mammoth, Hercules and Gold Hunter mines (Fig. 2). The first deposits were discovered by prospectors who spilled over from the Murray gold mining district, 24 km (15 miles) to the north. The Bunker Hill Mine was founded the year after the first veins were discovered. Bunker Hill has now operated for more than 100 years. Production includes 2.3 Mt (2.6 million st) of lead, 1.1 Mt (1.2 million st) of zinc and 4.1 kt (132 million oz) of silver. Total district production through 1996 (Springer, 1997) amounted to 7.3 Mt (8.1 million st) of lead, 3 Mt (3.3 million st) of zinc, and 34.5 kt (1.109 billion oz) of silver. This record establishes the district as the largest recorded producer of silver in the world, while also yielding major quantities of lead and zinc. Only Potosi, Bolivia, may have produced more silver, although records are unclear. Despite the district's longevity, historic production and current activity, the published literature on the district lags behind with regard to recent concepts of district geology. The most recent comprehensive US Geological Sur- vey (USGS) bulletins (Hobbs et al., 1965; Fryklund, 1964) are dated. Much research in the last half century has been short-lived or geographically restricted because the district is large and its geology is complex - and even this research tends to remain unpublished. Thus, it has been difficult for in- [ ]

Jan 1, 1998

By L. Yuan, J. H. Rowland, R. A. Thomas, D. Bahrami

Blasting is the main method of production in many non-coal underground mining operations and produces multiple toxic gases as a result. The Mine Safety and Health Administration (MSHA) requires mine operators to measure the level of toxic gases in mines as frequently as necessary to ensure they are below regulatory safety limits. The current practice uses portable gas monitors to check the concentrations of toxic gases after a fixed post-blast time. This paper studies the application of a gas monitoring system in the return entry of a limestone mine to determine a safe re-entry time. The National Institute for Occupational Safety and Health (NIOSH) conducted such a monitoring program in a limestone mine from September 2016 through May 2018. NIOSH/PMRD (Pittsburgh Mining Research Division) is endeavoring to develop workplace solutions to improve detection of and reduce the risk of hazardous conditions. This study showed that the use of gas monitoring in the return air can be a useful tool at the mine operator’s disposal to detect and reduce the risk of hazardous conditions and also to reliably estimate the re-entry time. INTRODUCTION Underground miners are at risk of overexposure to toxic gases from various sources. Production blasting operations using explosives in underground mines are a source of multiple toxic gases that could be harmful and even fatal to humans if prolonged exposure occurs beyond the safe limits. According to Code of Federal Regulations, Title 30, Part 57.5002 [1], metal and nonmetal mine operators must conduct gas, mist, and fume measurements as frequently as necessary to determine the adequacy of control measures to protect miners from overexposure to harmful gases. MSHA will inspect mine operators’ activities to verify the evidence of such measurements [2,3]. Continuous gas monitoring in the return air is an effective way to make sure that toxic gas concentrations at the working areas are kept below the regulatory limits before the return of miners. Toxic gases can enter the mine atmosphere from different operations, such as welding, combustion, and blasting. The main gases produced from blasting are carbon monoxide (CO), carbon dioxide (CO2), nitric oxide (NO), and nitrogen dioxide (NO2). Other gases are produced in small amounts and, therefore, were not considered for this study. Related regulatory and recommended exposure limits of CO, NO, and NO2 gases are summarized in Table 1 [4].

Jan 1, 2019

By E. Spencer

Overexposure to hazardous noise has been found in most mining sectors, with up to 100% of the surveyed workforce experiencing a noise dose over the Mine Safety and Health Administration (MSHA) permissible exposure level (PEL). As a result, miners show elevated rates of hearing impairment of 70-90% by retirement age. To help manage noise exposures, the National Institute for Occupational Safety and Health (NIOSH) developed the Determination of Sound Exposures (DOSES) software and implementation guide for use by mine management and safety personnel. The software relies on a time-motion study that profiles the worker?s daily activities. Observations about the worker?s location and tasks or other activities are recorded along with the start and end time, to determine the duration of the tasks, so they can later be matched up with the noise data. The software gives the user the option of assessing dose relative to the MSHA PEL, the Action Level or the NIOSH Recommended Exposure Limit. The software generates a variety of interactive onscreen displays showing where, when, and how the worker?s noise dose accumulated. It also can generate customizable printed reports. These outputs can be used to highlight the tasks, locations, and times that are associated with the greatest amount of the worker?s noise exposure. DOSES simplifies the record keeping and analysis associated with time-motion studies and worker noise exposures, so mine management can make engineering noise control or administrative control decisions to limit the noise over-exposure of their workers.

Jan 1, 2010