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By N. Careddu

In recent years, slabs with a rough surface have captured a large share of the ornamental stone market. However, the main technologies used for this type of treatment are based on mechanical shock (bush-hammering) or thermal treatment (flaming or flame-finishing). These traditional technologies are widely used, but have many limitations that decrease their usefulness. The purpose of this study was to develop a technology that enhances the natural colors of the rock and produces a rough surface without compromising its mechanical characteristics, in contrast to traditional technologies. This report shows the technical, economic and aesthetic results obtained with a new water-jet treatment and compares it with competing technologies.

Jul 1, 2010

By P. R. Pereira

This paper presents a comparison between the simulations of a semi-empirical model and a theoretical model for the prediction of radial stress in rock. The results of the simulations were compared to the results of a field test. The comparison of the radial stress predictions shows that in the semi-empirical model use of the plane wave approximation as the basis for the prediction of the radial stress provides a much better result than the theoretical model. The theoretical model includes the correct elastic wave geometry and theory but fails twice, firstly by considering the charge as a point (unit) energy source therefore; and secondly by using a Delta function with a very sharp rise and decay time to simulate, with no distinction between non-linear and linear zones, the attenuation of the energy per unit volume at the shock wave front as the wave moves away from the borehole. The results of the semi-empirical model were within the same order of magnitude as the results from the field test whereas only one result from the theoretical model came close to the result of the field test. However, even this closer result for the theoretical should be taken with caution as there was no measurement in the field test made at this distance from the borehole. Finally, because of its potential portability, convenience, and cost-effectiveness the theoretical model can be a most valuable tool for mining and civil construction operators in the early design of blasting rounds and of the mining operation itself.

Jan 1, 1993

By Yerkezhan Madenova, Kairat Kalmurzayev

This study intends to demonstrate the engineering application of ground penetrating radar (GPR) that would enable site engineers to prevent the high cost of blind drilling. At the tailing dump located in Zhairem Mining and Processing Plant, the challenge of sheet pile driving is encountered due to the indefinite watertight clay layer deposition depth that serves as a protective layer against groundwater contamination. A numerical model of the soil underlying the tailing dump is built using the existing hole data to compare and confirm the existing geological cross sections for three profile lines along the south and southeast parts of the tailing dump. GPR is employed to investigate the subsoil geological structure and detect the watertight clay layer deposition. On the basis of radargrams tied to the existing borehole data in the numerical model, 21 drill hole locations are suggested to assess and confirm the clay layer depth along profile lines at the tailing dump. The drilling results of the suggested holes confirmed the expected depth of the clay layer. It is concluded that GPR is a practical and economic subsurface mapping method that can prevent the high cost of blind digging of the ground and orient the drilling operations effectively.

Jan 12, 2023

By Matthew A. Omofoma, Andrew P. Hampton

The application of the Cyprus Cyanisorb process was investigated using a pilot scale facility at the NERCO DeLamar Silver Mine (DSM) in Owyhee County, Idaho. The purpose of this process is to remove cyanide from the DeLamar mill tailings slurry prior to its introduction to the tailings impoundment. This will maintain the tailings impoundment solution in a detoxified condition and thus prevent migratory bird mortalities. The cyanide removed is to be collected and recycled to the mill. The process successfully recovered approximately 90 percent of the weak acid dissociable cyanide (WAD), reducing the effluent tailings cyanide concentration from about 300 ppm to less than 20 ppm. This was accomplished by stripping the slurry with air in a packed tower and recovering the volatilized HCN in a packed absorption tower. Data were obtained for the design of the full scale facility including the stripping and absorption towers, currently under construction at the DeLamar Mine site. Finally, test results indicated that the final pH of reneutralization can be optimized to provide for minimal gold and silver losses, while selectively precipitating unwanted metal impurities (Zinc, Selenium, Iron, and Copper) from solution

Jan 1, 1992

By Richard L. Sanford

This paper summarizes the results of the development of a Directory of Computer Programs Applicable to U.S. Mining Practices and Problems. The Directory is funded by the U.S. Bureau of Mines and includes a sampling of computer usage in operating and manufacturing companies, consulting firms, computer companies, research organizations, universities, and various U.S. government agencies. General references to computer applications throughout the mining industry are discussed as well as the availability of programs to interested organizations or individuals.

Jan 1, 1978

By B. Briggs

Over the past 15 years, the tunneling industry has pushed towards a higher degree of mechanization in nearly every phase of construction. The overall objective of the mechanization was to increase production and the level of safety in tunnel operations. However, the overall complexity of some systems have been a hindrance to a seamless transition to the newer technologies as increased maintenance requirements and re-training of skilled workers has altered the benefit curve for some innovations.

Jan 1, 2010

By Ricky Chipka, Roshan Thapa, Richard Yovichin, Greg Rogoff, Patrick Niemuth

A 4.5-mile-long, 96-inch-diameter outfall pipeline was constructed between North Texas Municipal Water District’s proposed Sister Grove Regional Water Resource Recovery Facility and the Stiff Creek Discharge Structure. Two TBM-mined tunnel segments were excavated for the outfall pipeline through rock and mixed-face conditions within the Austin Chalk Formation. The TBM mining performance was tracked in detail and evaluated during mining. This paper discusses the TBM configuration, TBM utilization, advance rates, and challenges of both tunnel segments.

Jun 13, 2023

By Bo Hyun Kim, Mark K. Larson

This study was developed as part of an effort by the National Institute for Occupational Safety and Health (NIOSH) to better understand rock-mass behavior in longwall coal mines in highly stressed, bump-prone ground. The floor-heave and nofloor- heave phenomena at a western US coal mine could not be properly simulated in numerical models using conventional shear-dominant failure criteria (i.e., Mohr–Coulomb or Hoek–Brown failure criterion). The previous numerical study demonstrated these phenomena using a user-defined model of the s-shaped brittle failure criterion in conjunction with a spalling process in the FLAC3D numerical modeling software. The results of the FLAC3D modeling agreed with the observations of the relative amounts of heave from each gate-road system. However, the FLAC3D model adopted many assumptions and simplifications that were not very realistic from a physical or mechanical perspective. To overcome the limitations of the FLAC3D model, 3DEC modeling in conjunction with the discrete fracture network (DFN) technique was performed to better understand the true behavior of floor heave associated with underground mining in an anisotropic stress field. The effect of stress rotation in the mining-induced stress field was considered by using a different geometry of rock fractures in the coal seam. The heterogeneity of the engineering properties (i.e., cohesion and tensile strength) were also considered by using Monte Carlo simulations. Consequently, the 3DEC models using the DFN technique resulted in predictions of floor heave that agreed with observations of the relative amounts of heave from each gate-road system, but the cause of heave was mainly related to the degree of anisotropy instead of the size of the pillar.

Apr 14, 2022

By R. L. Unger

Restricted fields of vision are a common problem with underground mining equipment. Also, when lighting systems are provided, they may be positioned where they cause glare. This restricts the visibility around the machines even further. To help address these problems, the U.S. Bureau of Mines has developed a PC based software package to aid in the analysis of certain human engineering aspects of mining equipment design. The software is available for use by equipment manufacturers and mining companies for design work on new machines, as well as for evaluating proposed modifications to existing machines.

Jan 1, 1994

The National Institute for Occupational Safety and Health (NIOSH) conducted field tests to evaluate the effectiveness of a wet head continuous mining machine for reducing dust exposure for continuous miner operators. Wet head technology delivers water via sprays to the continuous miner?s cutter head as opposed to traditional standard sprays located on the boom and body of the mining machine. The sprays, positioned directly behind each bit on the cutterhead, deliver water at the point of attack, serving to cool the bits during mining to reduce the potential for frictional ignitions. The sprays also flood the coal with water to potentially suppress dust generation. Dust surveys were conducted at several mines to evaluate the wet head?s effectiveness to control respirable dust exposure at the continuous miner operator location and in the immediate return. Results show that the wet head miner generally improved air quality at both sampling locations to varying degrees in some, but not all, mines when compared to a continuous miner with a standard spray system.

Jan 1, 2010

By J. P. Kennedy, O. A. Bascur

Large metallurgical complexes have more data than a small city and these data change as internal and external conditions evolve. Staffing turnover hinders experienced-based decisions especially with simple tools like spreadsheets. Lack of current information can contribute to decisions that result in significant deterioration in the quality of operation. Timely, unified information from sophisticated analyses presented to the broadest possible reach will improve operation. The major innovation is the addition of the web browser to the suite of software people will use with no training – the other two are spreadsheets and graphical presentations – and the consistent organization and transformation of the real time data to support broad access. This paper describes the data transformations and presentation methods necessary for a Web view, especially the special needs of real time data and analysis required for active operations decision-making. Many people inside and outside the complex, not just operators, need timely information that is abstracted, aggregated, organized and unified. Unification and aggregation of real time data presented via the Web opens a new paradigm for collaboration. The analysis tools are as important as the data. These rule-based tools add significantly to the operations database in the form of results stored for viewing with plant data. Mining and metallurgical plants already use many sophisticated analysis tools such as predictive maintenance policies based on statistical analysis vibration analysis, and oil and lube analysis for critical equipment. These add real time events, similar to an alarm package, and unified production information to the operational database. Simple models are used on line to create key indices that provide a real time indication of performance. Key indices include metrics for losses due to plant availability, performance efficiency, and overall process equipment effectiveness. These additional data in the operations database are used for early fault detection, increased production, better quality, higher availability of equipment and faster detection of process bottlenecks. An important feature is the ability for people to create their own key indices and store the results for use by anyone in the plant historian, but accessible by a browser. Keywords: plant information, principle components analysis, data reconciliation, gross error estimation, Internet, Word Wide Web

Jan 1, 2002

By C. D. Harrison, J. W. Parkinson

This paper compares the ash slagging potential of Illinois No. 6 seam coal as raw coal, as commercially cleaned coal processed in a baum-jig plant, and as coal cleaned to a reduced ash specification at the Electric Power Research Institute's (EPRI) Coal Cleaning Test Facility. The comparison is based on ASTM ash fusibility data, a slagging index, gravity fractionation analyses of critical mineral matter compounds, and comparative pilot combustion tests. The first three grounds of comparison are laboratory data. The final comparison involves burning about 13.6 t (15 st) of each coal at Conoco's 4.40-kW/h (1.5 million-Btu per hr) test combustor. The evidence of these four comparisons indicates that lowering the ash specification of coal before combustion can significantly improve the ash slagging characteristics of Illinois No. 6 seam coal.

Jan 1, 1987

By Franziska Günther, Helmut Mischo

The calculation of costs for an underground mine, as well as the planning of the equipment and materials to be used, is a complex and time-consuming process. The estimation depends on a multitude of parameters, and all mining processes are interconnected. A novel tool has been developed that enables automated calculation of underground mines and allows for the comparison of the effects of changing individual parameters. Previously, changing individual planning parameters often necessitated a complete recalculation of the mine. The newly developed calculation tool provides an innovative planning aid that allows for more efficient and accurate mine planning and cost estimation. The tool enables the user to implement continuously up-to-data costs and prices. This allows for more accurate planning data and results. The underlying concept of the calculation tool, its implementation at a planned quartz porphyry mine in Germany, and the verification of the tool at an existing underground mine will be presented.

Feb 1, 2025

By Kyle A. Perry, Ethan A. Steward

The mining of underground coal presents several hazards for miners, including the risk of an explosion fueled by methane gas and coal dust. Methane gas, produced during coal formation, can continuously leak into old workings and build up through its lower explosive limit. Underground coal mines are required to maintain safe conditions, either by ventilating old workings or sealing them off using approved methods. Seals must be designed to withstand instantaneous pressures for a minimum of four seconds. A design strength of at least 50 pounds per square inch (psi) is required for atmospheres monitored and maintained inert, 120 psi for non-inert or not monitored, and greater than 120 psi for special cases. Due to the high cost and testing environment availability, most mine seals are designed through calculations and computer modeling and not subjected to full-scale testing in a representative environment. High pressure is not the only threat that mine seals may be exposed to. During an underground explosion, pressure waves and gas expansion may propel common mine items and objects to a high velocity, generating enough energy to damage mine seals and reduce their strength. Damaged mine seals may fail to contain their rated pressure, allow high pressure gas and fumes to vent through the seal during an explosion, or allow gasses to leak through the seal later after an explosion has occurred. This paper examines the effects of high velocity impacts of common mine materials and items on a reinforced mine seal rated to 120 psi.

Jun 2, 2023

By George P. Tateosian

Merchants perform a number of functions in the copper market. As a major distribution arm of the copper industry, they secure scrap and other copper bearing materials for processing into usable refined shapes. These are ultimately sold to fabricators. Merchants ' hedging and arbitrage activities help keep values in proper relationship from product to product or region to region. Through these switching and trading operations, they optimize the flow of copper from mine to consumer. And finally, merchants act as a repository for copper units during times of surplus and a stockpile from which to draw during tines of shortage.

Jan 1, 1979

By Robert W. Bartlett

Heap biooxidation of sulfidic refractory gold ore requires large amounts of oxygen, as shown in Figure 1. Bacteria, Thiobaci/lus ferrooxidans, are donnant at oxygen concentrations below about 3% in air (1 ppm in aqueous solution) because ofmonod kinet­ics. Hence, the maximum possible utilization is only about 75%, and it may be much less than that due to poor air sweep effi­ciency. At the maximum oxygen utilization, an ore containing two percent pyrite requires nearly 100 cubic meters of air per tonne (4,000 cubic feet per ton). The stoichiometric air require­ment to oxidize arsenopyrite is similar to that of pyrite. While the leaching solution percolating through the heap introduces some dissolved oxygen, the amount is insignificant because of the low solubility of oxygen in water, 7 to 8 ppm at atmospheric saturation. There are only three ways to provide oxygen to the heap: either air flow by natural convection, diffusion of oxygen from the surface (through stagnant air in the air-filled void space in the heap), or forced air ventilation of the heap. Each of these processes will be reviewed.

Jan 1, 1996

By R. Grandori, L. Pellegrini

The construction of the La Joya hydropower plant (Costa Rica) was awarded by the Spanish power company, Union Fenosa, to the Italian Joint Venture formed by the companies SELI SpA and Ghella SpA. The project, located in a mountainous region of central Costa Rica, includes a 7.9-km-long head race tunnel having an excavation diameter of 6.18 m. A double-shielded TBM was selected to perform the tunnel excavation, which involved mainly volcanic rocks in variable but generally very weak conditions. The tunnel crossed long and continuous sections in completely weathered rock masses with no residual cohesion and with high water inflows. The paper describes and analyzes: The special methods adopted to overcome these sections with the TBM includ-ing face stabilization by chemical grout and foams as well small by-pass tunnels in the crown combined with TBM advance/support The grouting design and the grouting method that was implemented to meet the waterproof design specifications and restore the original groundwater level in the mountain The additional geological investigations performed to improve the knowledge of the rock mass in front of the TBM and the outcomes of these investigations The performance of the TBM in different ground conditions and on average along the entire tunnel Finally, the author’s comment about the possibility of implementing and improving the technologies experimented with in this project in future similar applications.

Jan 1, 2007

By Francesco Chiappalone, Daniele Nebbia, Lance Waddell, Greg Colzani

As part of the 3RPORT Project, a 5-mile tunnel is being excavated underneath the three rivers of Fort Wayne using a 19-foot diameter Slurry Tunnel Boring Machine. The groundwater pressure at the tunnel axis ranges from 4.5 to 5.3 bar. The rock mass hydraulic conductivity is very high with water inflows up to 10,000gpm imposing significant challenges to the project. After excavating 1,550-feet of the TBM tunnel, major leaks between the tailskin and the segmental lining were observed, indicating the potential deterioration of the tailskin brushes and the need for inspection and eventual replacement. The first part of the paper describes the planning of the intervention, including the design of the polyurethane grouting campaign, the procedures developed for the execution and the controls established during construction to timely assess the presence of potential hazards. The second part of the paper focuses on the experience gained during execution and lesson learned to prevent future occurrences of this nature.

Jun 13, 2021

By M. S. Prasad

This paper presents the process methods of beneficiating various copper-cobalt and copper-zinc ores mined by Gecamines in Zaire. Geology and mineralization of both sedimentary and vein type deposits are described with special emphasis on the production of oxide, dolomitic and sulfide concentrates. Description of different types of concentrators and their treatment methods are discussed for the production of sulfide, oxide and dolomitic concentrates. Production of concentrates, their consumption and stocks are briefly reviewed. Modernization of the concentrators with substantial investments on grinding, classification, flotation methods and tailings treatments are also discussed to improve the metallurgical efficiency of the concentrators with a view to improve the production of concentrates both qualitatively and quantitatively.

Jan 1, 1990

By Derek Brennan, Donald Brennan

"The existing Rondout West Branch Tunnel (RWBT) is part of the Delaware Aqueduct which has been in service since 1944 and accounts for more than 50 percent of New York City’s water supply. In early 2015, the New York City Department of Environmental Protection contracted Kiewit-Shea Constructors, AJV (KSC) to construct the Rondout West Branch Bypass Tunnel project (Rondout) in order to mitigate the leakage of 132 million L/ day (35 million gpd) of water from two areas of the existing tunnel; the Roseton and Wawarsing areas.The scope of the Bypass Tunnel 2 project is separated into two distinct phases. Phase 1 consists of completing the shaft sinking to a depth of approximately 274 m (900 ft) at shaft 5B, 213 m (700 ft) at shaft 6B and the excavation of approximately 3,850 m (12,500 linear ft) of tunnel at a diameter of 6.6 m (21 ft 7 in). This phase also includes the installation of 2,804 m (9,200 linear ft) of 4.8 m (16 ft) diameter steel interliner pipe through the new bypass tunnel with cast-in–place concrete liner for a finished diameter of 4.2 m (14 ft). Access chambers at the top of shafts 5B and 6B will be constructed for access and housing of the mechanical and electrical equipment for supporting pumps and valves.Included in phase 2 is the additional excavation from shafts 5B and 6B to the RWBT, and the drainage tunnel to remove ground water infiltration from RWBT. This work will be completed during a scheduled shutdown of the RWBT and will include approximately 31 m (100 ft) of excavation of the two connection tunnels. Additionally, construction of the permanent plugs within the RWBT will be undertaken. Figure 2 shows the layout of the work.Access to the work through the deep shaft at site 5B was critical to the success of the project. The hoisting system needed to be multi-functional to handle the different types of construction from drill and shoot of the shaft, starter and tail tunnel, the assembly of the tunnel boring machine (TBM), the excavation of the TBM tunnel including the supply of the precast segmental liner, the grouting operations, the installation of the steel interliner pipe and the cast-in-place concrete as well as ingress and egress of personnel. The production of the TBM operations was critical to the schedule of the project. This required a quick cycle for muck haulage and supply of the precast segmental liner in order to keep pace with the excavation time of the TBM. For TBM assembly, components were limited to a maximum weight of 104 t (115 st) for a single lift. Various cranes were analyzed for hoisting, however, none would meet all of the citeria. Therefore, the project team selected a specialized hoisting system designed in house in conjunction with Timberland Equipment Ltd. that consisted of a total of 14 separate hoists and winches with a total of more than 2,833 kW (3,800 hp)."

Mar 1, 2019