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By Ralph C. Kirby

The U.S. produces about 34 percent of the world's aluminum yet must import 90 percent of the raw materials needed. There are abundant resources of aluminum-bearing minerals such as clay, anorthosite, alunite, shale, and dawsonite, but none of the numerous processes proposed for recovering alumina from them has yet proved economically competitive with the Bayer process using imported bauxite. To help develop an economically viable process for utilizing these resources, the Bureau of Mines is testing on a common basis several proudsing processing techniques. New improvements and approaches developed by industry and the Government are being evaluated on a mall scale to obtain enough information on which to form a judgment regarding the best processes for commercial adoption. A continuous miniplant having a feed rate of about 70 pounds per hour is being operated now to investigate the nitric acid process for recovering alumina from clay. Parts of this plant will be used subsequently for work on other processes for recovering alumina from clay, anorthosite, alunite, and dawsonite. Initial results of the operation and plans for the overall project will be discussed.

Jan 1, 1974

By A. Kenneth Schellinger

DURING the comminution of a brittle material in the presence of dry air, no known phase change or chemical reaction takes place. The energy changes associated with the comminution are those of the transformation of kinetic energy into heat energy and the energy absorption represented by the actual rupture of molecular and/or ionic bonds. The random nature of the actual grinding process in a tumbling-mill often precludes the effective application of a rupture force on each individual particle of brittle mineral present. The result must be a great deal of useless vibration on an atomic scale in both the brittle mineral and the grinding medium below the elastic limit, which vibration is eventually manifested as heat energy in the mill. The actual rupture of molecular, or ionic, bonds creates new surface on the brittle minerals; each square centimeter of this new surface then must possess a number of potential bonds, each of which could reform theoretically with the release of energy. The sum total of this potential energy of bonding per unit of new surface, minus bond satiation effects of the enclosing gas or liquid, must be the surface energy of the mineral. If the comminution of the brittle mineral were carried out within the chamber of a calorimeter, the energy released as heat could be determined rather accurately. Moreover, the total kinetic energy input to the comminuting mass (mineral and medium) conceivably could be derived by a suitable torquemeter and revolution counter if the whole calorimeter were revolved. The difference between these two energy figures should then represent the net energy (gross energy input-heat energy output) used in creating

Jan 6, 1951

By L Dyer, A Keith, G D. Corder

As mining activity moves to remote and less developed locations globally, a holistic approach to mine development is fundamental for achieving a balance between strong financial returns and corporate social responsibility and transparency. Key inter-related fundamentals such as social licence to operate, life-of-mine operational planning, minimising environmental impacts and, most importantly, attractive investment returns for the mining company all contribute to the viability of any new mining project.However, the typical practice in the mining industry is often to treat environmental and social/community aspects as separate compliance issues that are dealt with at minimum cost and disruption to the project and resulting operation. This often results in less than optimum environmental and social outcomes, and presents considerable liabilities at the time of closure when rehabilitation programs continue to require funding when all revenue has ceased.The five capitals model seeks to identify each of the key contributors to sustainable development as financial, manufactured/physical, social, human and natural to formulate a type of triple bottom line approach balancing these often competing project factors. The SUSOP® sustainability risks and opportunities framework, developed by the mining industry, bases its approach on the five capitals model and proposes an approach that breaks down enterprise silos to identify innovative solutions for life-of-mine sustainability. This framework has been developed with the nature of mining projects in mind in order to produce approaches and outcomes relevant throughout the life cycle from the planning phases, through project design and construction into operation and closure.This paper argues the need for a more holistic approach to the development and operation of mining projects, and presents case studies where a holistic approach has been applied, in whole or part, and discusses the lessons learned from these case studies.CITATION:Corder, G D, Keith, A and Dyer, L, 2014. A capitals based approach – leading innovation in planning for life-of-mine sustainability, in Proceedings Life-of-Mine 2014, pp 499–512 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By David Burgess

The paper describes experiments at the Somerset Mine, Colorado, under a cooperative agreement between U.S. Steel and the U.S. Bureau of Mines. A test was made of the tube bundle method of mine air sampling which was developed for European longwall mines; some 300,000 running feet of tubing provided continuous monitoring at 39 locations. Carbon monoxide concentrations were obtained with standard deviations of less than 1 ppm and oxygen concentrations with standard deviations of less than 0.20 percent. A base level of CO index (ppm CO evolved/pct 02 removed)) was determined to be 0-20 through most of the passageways of the mine. However, in one working section where the coal was initially hot (about 180°F within a pillar) the CO index was demonstrably higher, >20 trending upward to about 60 when smoke appeared and the section was sealed. The data are discussed in terms of laboratory experiments on CO evolution from coals.

Jan 1, 1975

By R. A. Limons

Natural ores, sinters, and pellets were subjected to a carbon monoxide reduction-disintegration test under laboratory conditions including a simulated blast furnace gas and a 1000°F temperature. The most significant findings were that: 1. Self-fluxed pellets broke down to a greater extent than either the acid pellets or the acid or self -fluxed sinter. 2. When pre-reduced, both the acid and self-fluxed pellets had very good resistance to breakdown.

Jan 1, 1964

By J. A. Thompson, M. A. Mayers

IN recent years, the problem of damage to coke-oven walls by expanding coal charges undergoing carbonization has engaged great attention on the part of research workers in this field, and has led to the development of many devices for estimating these pressures.1-14 Only in Russell's method11 and in the Koppers ovens7 are conditions quite similar to those in commercial ovens. Tests even in these ovens are empirical because no information has been published to permit an evaluation of "scale effects." Owing to the relatively large wall area in these test ovens, the average wall pressure determined may be lower than that existing in localized areas. This factor may be compensated for in part by the testing of coal charged into the test oven at a bulk density that is as high as the highest that is believed to exist in commercial ovens. Both of these lacks might be filled by the development of an adequate gauge for the direct measurement of wall pressure exerted by the charge in commercial coke ovens in normal operation. Previous attempts to elaborate such instruments7,15 have resulted in units which, because they had to be water-cooled, probably produced changes in the conditions of carbonization, and which had to be removed from the oven before carbonization was complete, to avoid their destruction. Late in 1941 the Coal Research Laboratory undertook to develop such a gauge, in which gas pressure was balanced against the charge pressure and which thus would not require water cooling, on a suggestion made in 1937 by one of the present authors and William B. Warren, a former member of the Laboratory staff. The gauge heads themselves were to be simple and cheap enough so that they might be discarded after each run if seriously damaged. This would permit them to be left in place throughout the carbonizing period, when they could be pushed out with the coke. The basis of the design, of which the latest exemplification is shown in Fig. I, was that as the internal gas pressure within a flexible metal envelope was increased, the flexible wall would move away from a stop when the gas pressure just overbalanced the charge pressure. If the stop were an insulated electrical contact, the point of balance could be indicated by the breaking of an electric circuit. It was anticipated that, while the instrument must operate at high temperature, the presence of a strongly reducing atmosphere throughout the carbonizing period would so reduce-the danger of scaling that mild steel could be used for the gauge. This expectation has been justified. Danger of attack on silica oven walls by the steel gauge body can be eliminated by cementing asbestos paper or an alundum or silica plate to the back of the gauge body. The gauge head itself has a relatively heavy mild-steel body, A, into which standard ¼ in. pipe B is screwed to conduct gas and electrical leads. The body is closed by a single bellows C. consisting of two annuli of 0.011-in. (0.28-mm.) cold-rolled shim-steel spot-welded together at their outside edges. The lower one is

Jan 1, 1944

By A Mackay

As a result of the explosion in the 512 panel at the Moura No 2 mine in 1994 the role of the ventilation officer (VO) to submit sealing plans (on behalf of the operator/underground mine manager) has become one of the key duties of the VO of an underground coal mine in Australia. The intent of a sealing plan is to document the controls used to manage the build up of flammable concentrations of gases, and for these controls to be reviewed by the industry regulators. These sealing plans have brought a large amount of focus onto the sealing process and served the industry well. The legislation does not define sealing, or when it begins, but throughout the industry typically sealing plans are submitted 30 days prior to the last seal being constructed. This practice appears to have originated from the Moura 512 panel being a standing bord and pillar panel and where the explosive gas mixture could only occur after it was sealed. However, since the Moura disaster the industry has become dominated by goafing style longwall mining. Goafing panels differ from standing bord and pillar panels in that they typically have an unventilated goaf that can potentially contain an explosive mixture from start-up. This was recently highlighted by the explosion and fire on Longwall No 1 Tailgate at the Blakefield South Mine in 2011. The author ponders whether the industry should revisit sealing plans to focus on the core hazard and define that sealing begins when flammable concentrations of gases are created. Although defining when mine sealing begins is the key outcome of this paper, the main point is that VOs and industry regulators need to clearly understand what can occur in the atmosphere of underground coal mines. CITATION:Mackay, A, 2013. A case for change - Defining mine sealing and understanding flammable mixtures during sealing, in Proceedings The Australian Mine Ventilation Conference , pp 307-310 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By John S. Carman

Our industry is in trouble. Real trouble. It has never been an easy, secure business. But to-day it is engulfed in revolutionary currents. No longer can there be reliance upon the checks and balances of market forces. Supply and demand largely dictated the economics of business enterprise in simpler days. To-day politics, in particular nationalism become increasingly dominant. And as governments expand and put out tentacles of interference in the direction of the mining industry, far too little understanding is evidenced as to how that industry works. Then there is something which is relatively new -stagflation. As the prices of minerals falls, the capital investment required for new extractive facilities soars at rates which far outdistance those which are cited by governments to indicate the magnitude of inflation. To illustrate; 1) In 1971 it was calculated that $355 million would be required to bring the Cuajone property in Peru into production. Five years later that stage was reached at a cost of $680 million. 2) With the Caridad mine in Mexico, estimated capital investment doubled between 1971 and 1976. 3) The requirements calculated for Cerro Colorado in Panama have risen in two years from $560 to $800. 4) The budget of $240 million for Sar Chesmeh in Iran in 1971 had become $500 million by 1976.

Jan 1, 1977

By B Belle

"Mines around the world are inherently and operationally diverse. Current methodologies for the design of mine ventilation and cooling infrastructure involve controlling major safety and health hazards. Globally, it can be estimated that mine ventilation systems from various commoditiescirculate over 150 000 m3/s of exhaust air through shafts. Additionally, over 2 000 000 workersare transported every day through shafts in labour-intensive mining countries like China, India,Southern Africa, and the Americas. A key objective of this paper is to share experiences and provide a case for the revision of ætime-honouredÆ ventilation design parameters based on a benchmarking exercise on design exhaust shaft velocity from various global operations (gold, diamond, platinum, coal and base metals). An active fi eld observation on exhaust shaft velocity has indicated that, regardless of the commodity or continent where the mine operates, almost all life-of-mine (LOM) design parameters provided are in the same range of 20 m/s to 22 m/s, which is not convincing considering signifi cant variations exist in shaft depths, geography, commodity, operating and capital costs. From a due diligence perspective, there are no documented views that are available on the most widely used design exhaust air velocity. Based on the global exhaust shaft velocity data, it is noted that a significant portion of shaft velocities are outside the current design velocity of 20 m/s (some operating up to 30 m/s) and other signifi cant portions of the exhaust shafts operate in the critical velocity range. In the case of Australian coal mines, limited data suggests that none of the mines have ever reached the LOM design exhaust shaft velocity. It is self-evident that when the shafts are not operating at their design quantities either the mine system resistance is low or the ventilation and main fan is operating ineffi ciently. The most common reasons given for not reviewing the shaft system were, ætime-honouredÆ design parameter are being used and cannot be changed, mine fan pressure limits, possible fan blade damage, possible spontaneous combustion risks, leakage or simply did not consider such a possibility. In conclusion, the study has reiterated the historic lessons that a safe and expensive airway should not be utilised uneconomically by circulating too litt le air through it."

Jun 1, 2012

By A. F. Stewart

Slope design in an open pit mine includes the determination of a number of parameters, including bench height, bench face angle and berm width. By way of a case history of two highwall slopes (160m and 220m high) excavated in dipping strata in an operating coal mine, this paper illustrates the influence that bench face angle can have on the stability of an entire slope. The two highwall slopes, the lower of which experienced significant instability, were excavated in essentially the same lithologic and structural environment, with the main differences between the slopes being the angle at which the bench faces were excavated and the excavating methods that were employed. In addition to describing the instability that occurred on one of the pit walls, relevant aspects of the engineering geology, slope design and excavation procedures are described.

Jan 1, 1998

By H Zhang, A Lawrence

To accommodate the fast growing need for services in Singapore’s Marina Bay downtown area, Marina South, the construction of a common services tunnel (CST) was required. The CST includes various services such as telecom cables, power lines and water pipes. A deep excavation and temporary earth retaining system (TERS) was required to facilitate the construction of the tunnels. Marina Bay is reclaimed land over thick soft marine clay which is likely to be still consolidating. The deep soft marine clay poses a big challenge for deep excavations in downtown areas where highways and sensitive structures are close by. This paper presents a case study of part of the CST Phase 1B and 2 at Marina South, in particular a 26 m deep excavation supported by a 46 m diameter temporary caisson. The construction started in late 2006 and the basic structure was completed in early 2011. The caisson was formed by 1.0 m thick overlapping diaphragm wall panels with a capping beam and three ring beams at different depths. Two-dimensional finite element analyses were conducted to predict the ground settlement, lateral displacement, bending moment and hoop stresses in the diaphragm wall and ring beams during different excavation stages. A comprehensive instrumentation and monitoring scheme was established to verify the design predictions, control excavation safety and trigger the contingency plan to protect public safety. The impact of construction activity, unbalanced temporary stockpiles and adjacent deep excavation for a mole removal will be discussed.CITATION:Zhang, H and Lawrence, A, 2014. A case history of a deep excavation in a big circular shaft in Singapore marine clay, in Proceedings 15th Australasian Tunnelling Conference 2014, pp 581–588 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By L. A. Pursell

The case history, which is the subject of this paper, involves the expansion of a lime plant in Texas. The major new production unit is to be a 545.45 tonne per day coal fired rotary kiln. Auxiliary facilities include additional quarry haulage equipment, modifications to the crushing plant, a hydrator, storage facilities, and a loading system. The existing plant consists of a high calcium limestone quarry, two coal fired rotary and 10 gas fired shaft kilns, nth crushing, screening, stockpiling, hydrating, storing and loading facilities. The proposed modification would increase quarry volume from 545,000 tonnes per year to 805,000 tonnes per year. The plan also includes the addition of dolomitic lime to the product line which requires the purchase and handling of 186,000 tonnes of screened, washed dolomite yearly. A decision to undertake such an expansion was previously a simple and straight forward process. Such a decision now faces a major and complicating obstacle which can delay the project, raise the expected cost, or prevent it entirely.

Jan 1, 1980

By C. D. Peters

The Bureau of Mines has been researching remote sensing analysis of an underground coal mining area in Utah and computer-aided methods of defining ground control hazards in this mining area. As a result of these studies, a preliminary potential hazards map was developed for the test site. This map is based primarily upon a lineament (linear feature) analysis of Landsat satellite data. Other data used were paleochannel location data, resistivity data, and information from surface and underground field checking of the lineaments and ground control problems in the mine. Lineaments proved to be reliable indicators of hazardous areas, although the type and degree of hazard varies with different lineament trends and the presence of other conditions such as lineament intersections and intersections with other geologic structures or with paleochannels. Lineaments were observed to match faults, joints, and/or joint trends in the area. The paleochannel data, derived from drill hole data, provided basic information about potentially hazardous areas in the mine by suggesting where paleochannels could cause instability in the roof rock. The ground control problem data served largely to define the relative degree of hazard associated with lineaments and the types of hazards encountered in the mine. Resistivity data helped confirm the presence of fractures where they were expected to occur both from surface geology and from the lineament data.

Jan 1, 1986

By SungJe Chi

Intrinsic remediation is the effect of natural attenuation mechanisms - dilution, dispersion, sorption/precipitation and biodegradation - reducing contaminant concentrations in ground water to specified levels at predetermined compliance points in the aquifer. Current monitoring and modeling for post closure was used to assess the current and long-term potential of intrinsic remediation of contaminated seepage originating from a large reactive (sulfidic) tailings impoundment near Questa, New Mexico. It is concluded that the natural attenuation mechanisms of precipitation within the tailings (as a result of buffering) and dilution/dispersion within the aquifer are currently active and likely sufficient to reduce contaminant concentrations to below state standards in the long-term. Other natural attenuation mechanisms such as sorption and biodegradation within the receiving aquife4s) were not assessed here, but are likely further reducing contaminant concentrations. Active interception and recovery of the seepage water is being maintained until monitoring demonstrates that intrinsic remediation has successfully achieved the level of water quality control required.

Jan 1, 2017

By Christoph Wels, Michael Royle, Shannon Shaw

Intrinsic remediation is the effect of natural attenuation mechanisms - dilution, dispersion, sorption/precipitation and biodegradation - reducing contaminant concentrations in ground water to specified levels at predetermined compliance points in the aquifer. Current monitoring and modeling for post closure was used to assess the current and long-term potential of intrinsic remediation of contaminated seepage originating from a large reactive (sulfidic) tailings impoundment near Questa, New Mexico. It is concluded that the natural attenuation mechanisms of precipitation within the tailings (as a result of buffering) and dilution/dispersion within the aquifer are currently active and likely sufficient to reduce contaminant concentrations to below state standards in the long-term. Other natural attenuation mechanisms such as sorption and biodegradation within the receiving aquife4s) were not assessed here, but are likely further reducing contaminant concentrations. Active interception and recovery of the seepage water is being maintained until monitoring demonstrates that intrinsic remediation has successfully achieved the level of water quality control required.

Jan 1, 2000

By W. C. Goldberg

This paper presents pit slope monitoring and back-analysis case studies con-ducted to evaluate and, if possible, stabilize slopes at the Berkeley Pit in Butte, MT. Two specific slopes were studied in detail. The first slope was determined to be near limiting equilibrium, as evidenced by its response to the initiation and cessation of mining, while the second failed on three occasions. Back-analysis of the failed slope verified the laboratory-derived geomechanical properties of the earth materials. Early detection of slope movement can show a need to take action, including modifying slope geometry, dewatering if the slope were wet, and/or investigating and implementing artificial supports. Monitoring slope displacements in open-pit mines can supply data for predicting collapses and preventing serious damage, injuries, and/or loss of life.

Jan 1, 1989

By W D. Rech, K W. Keskimaki

As an integral part of the conversion from rail haulage to conveyor haulage at Henderson, over six kilometres of drifting and several large complex openings were mined. The deepest of these areas was nearly two kilometres beneath the surface, bringing all of the challenges of rock stress and heat that come with mining at these depths. Though many mines operate at these depths, the development of the infrastructure necessary to support a 36 000 tonne per day caving operation brought some unique challenges to the development mining activity. The issues handled include: finding experienced staff for a æfast trackÆ development program; rock bursts and ground conditions; inflow of 50 degree centigrade water; acceleration of the project completion; large diameter raise boring and difficult muck handling.

Jan 1, 2000

By Karen Dawson

This paper presents a case study of the deformation-based design, construction, and performance of stone column ground improvement (GI) beneath a mechanically stabilized earth (MSE) wall and bridge abutment with heights up to 50 feet. As part of the widening of Interstate 5 (I-5) to allow High Occupancy Vehicle (HOV) lanes in Tacoma, Washington, a new approach and span over the Puyallup River will be constructed. During the soils investigation and design phase of the project, low plasticity silts (ML) inter- bedded with silty sand layers and organic silt where identified as being potentially liquefiable. Stone column ground improvement was designed using a deformation-based approach to address static settlement and seismic stability of the proposed MSE embankments. The deformation-based design of the stone columns resulted in significant savings over a limit equilibrium-based approach. This paper presents the results of sonic coring taken from the initial stone columns installed and compares these results to the real-time data acquisition reports from the stone column installations. Vibration monitoring results during stone column installation are included. Settlement monitoring at the face of the MSE wall and buried vibrating wire settlement monitoring elements are presented and compared to the original settlement predictions.

By Dominic Parmantier, Karen Dawson, Suthan Pooranampillai, Seungcheol Shin

"This paper presents a case study of the deformation-based design, construction, and performance of stone column ground improvement (GI) beneath a mechanically stabilized earth (MSE) wall and bridge abutment with heights up to 50 feet. As part of the widening of Interstate 5 (I-5) to allow High Occupancy Vehicle (HOV) lanes in Tacoma, Washington, a new approach and span over the Puyallup River will be constructed. During the soils investigation and design phase of the project, low plasticity silts (ML) inter- bedded with silty sand layers and organic silt where identified as being potentially liquefiable. Stone column ground improvement was designed using a deformation-based approach to address static settlement and seismic stability of the proposed MSE embankments. The deformation-based design of the stone columns resulted in significant savings over a limit equilibrium-based approach. This paper presents the results of sonic coring taken from the initial stone columns installed and compares these results to the real-time data acquisition reports from the stone column installations. Vibration monitoring results during stone column installation are included. Settlement monitoring at the face of the MSE wall and buried vibrating wire settlement monitoring elements are presented and compared to the original settlement predictions.IntroductionStone column ground improvement was implemented as a means of supporting mechanically stabilized wall approaches for a new bridge over the Puyallup River, part of HOV improvements to I-5 in Tacoma, Washington. The work discussed in this case history was part of the Washington State Department of Transportation (WSDOT) I-5/Portland Avenue to Port of Tacoma Road, Stage 1 Northbound HOV contract, developed as an early work element to a follow-on bridge construction project. The area requiring stone column ground improvement is shown in Figure 1. The improved ground supports permanent geosynthetic walls and embankments up to 50 feet high. This wall can be seen in Figure 1. The selected ground improvement primarily provides global stability of the soils beneath the walls during anticipated seismic loading and also reduces the time and magnitude of consolidation settlement under the weight of the planned embankment.Approximately 74,000 cubic yards of liquefiable alluvial soils were improved by stone columns. Stone column construction occurred in late 2010 and early 2011. This was followed by the embankment and wall construction. Settlement monitoring began with the embankment construction and continued into 2012."

Jan 1, 2017

By Suthan Pooranampillai

This paper presents a case study of the use of single axis cement deep soil mixing (CDSM) to deal with static settlement and seismic stability of the foundation soils under a reinforced soil slope (RSS) embankment up to 50 feet high. As part of the widening of Interstate 5 (I-5) to allow High Occupancy Vehicle (HOV) lanes in Tacoma, Washington, a new approach and span over the Puyallup River will be constructed. During the soils investigation and design phase of the project, low plasticity silts (ML) inter-bedded with silty sand layers and organic silt where identified as being potentially liquefiable. CDSM was selected to address the embankment foundation concerns and allow for future trenchless installation of utility lines beneath the embankment. The presence of a confined, artesian aquifer within the design depth of the CDSM led to the installation of a depressurization system to avoid an upward gradient through the wet soil-cement. In addition to addressing the design approach, the paper discusses the challenges associated with quality assurance of CDSM within the time constraints of an ongoing project. The limited recovery rate of conventional triple tube coring in the soil-cement and double tube wet sampling led to the use of sonic coring to provide a near continuous core of the soil-cement.