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By Graham Daws

State of the Art Room and Pillar mining techniques have been employed at two coal mines in the UK in the last two years. This paper describes the design of pillars and rockbolted support systems for Room and Pillar mining operations in these collieres. Within the last year, rock mass classification systems have been used in the design process of a room and pillar mining layout at one of these collieries. In particular, the roofbolt support system was detailed using these techniques and the support system was linked with operational aspects such as depth of cut. The depth of cut was initially estimated using rock mass classification systems and then verified by a stand up trial which was monitored remotely. The stand up time has a direct influence on the operational aspects of the mine and this is described. The design was verified by performance monitoring and the results are discussed. The importance of understanding the role of rockbolting is emphasised along with some examples of accurately determining in-situ bolt performance. The paper also recommends some modifications to rock mass classification systems when applied to underground coal mining operations.

Jan 1, 1998

An evaluation was made of the wear and performance characteristics of liter bars, and the cost-life effectiveness of backing materials for rotary-mil liners. In a large run-of-mine mil in which the liter bars were mounted on grid liners of austenitic manganese steel (AMS), the liners had an average life that was five to six times that of equivalent unprotected liners. For a single mil, this is equivalent to annual savings in the cost of materials of up to R320 000, and to a downtime of 100 hours. Of the five materials tested in a large pebble mil grinding quartzitic ore, AMS grids and 'white iron' blocks performed best on a cost-life basis, with possibly improved performance from a real white cast iron. (The 'white iron' was shown by microstructural analysis to contain flake raphite and pearlite, being in reality a grey cast iron.) The high-chromium white iron had by far the longest predicted life, with mild steel a surprising second. Rubber was shown to last well in this type of mil. The wear rates of liners change during their lifetimes. The protective effect of liter bars was clearly illustrated by the reduction of over 40 per cent in the wear rates of the liners when the lifter bars were renewed to a height of 80 mm from a fully worn height of 35 mm.

Jan 1, 1991

By Iain Weir-Jones

The efficient operation of an open pit mine presupposes that the slopes are maintained at an angle which closely approaches that of the ultimate stability of the slope. In order to do this in a safe manner, it is essential that the data relating to the behavior of the slopes be monitored and made available, through an instrumentation system, to the appropriate personnel so that soundly-based engineering decisions may be reached with the minimum of wasted effort. In addition to simply detecting potential failures, the system should also define what type of failure is developing; i.e., rotational, wedge, or dilational failures. Providing this data is the prime function of a stability monitoring system. Therefore, in an operating open pit mine, the instrumentation system must provide information which will have a direct bearing upon both the safety and the economics of the operation, as well as provide data which is pertinent to initial design, or to the re-design of slopes where developing instability is found to be a problem.6 It is possible to excavate pit slopes which will remain stable under extremely adverse conditions; however, such slopes would usually be so flat that they would tend to render the operation of a pit uneconomical which might otherwise be mined at a profit. On this basis, all practical pit slopes must be considered to be, to some ex- tent, unstable; if they are not, the design is too conservative and the mine is not returning its maximum profit. To reduce the problem to its fundamentals, one can simply state that the ideal pit slope design produces a slope which stands with zero maintenance for the entire life of the pit and then collapses into the final excavation as soon as the personnel and equipment have been removed. Such a design is impossible to achieve, but the fact remains that an efficient slope would hover on the edge of failure for the life of I the pit. As one retreats from this position, the profitability of the mine decreases because of an unduly conservative design.

Jan 1, 1975

By S. J. Bluhm

Recommendations are given for the design of multi-stage spray chambers in which air flows horizontally through water sprays. A detailed description is given of one such spray chamber at Hartebeestfontein gold mine that is used for bulk cooling of the incoming ventilation air, and that has been constructed according to these recommendations. A method for predicting the performance parameters of horizontal multi-stage spray chambers is given, and the method is illustrated with some examples. The method is equally applicable to spray chambers in which the water, rather than the air, is cooled.

Jan 1, 1979

By Peter N. Calder

There is little doubt that the stability of both highwalls and spoil piles is essential to efficient strip mining. Accurate determination of the appropriate geotechnical parameters will pay dividends during mining, but only if the mine operation closely follows the engineering plans which have incorporated These factors. Productivity is invariably higher in mines where failure of highwalls and spoil piles does not occur. This is the result of the reduced rehandle and better working conditions found in stable mines. Control of the waste piles and highwalls also leads to better coal recover since failures can result in the burial of uncovered coal, which is then lost to mining. Safety is an important consideration. The importance of providing a safe working place for employees and of protecting costly mining equipment is hard to overemphasize. For miners, working in areas where instability exists, the degree of hazard involved in their occupation is increased particularly where night operations are involved. It is true, too, that there have been many cases where loading equipment has been buried and severely damaged by failures.

Jan 1, 1980

By D. F. Malan

This paper gives an overview of the difficulties associated with determining the strength of hard-rock pillars. Although a number of pillar design tools are available, pillar collapses still occur. Recent examples of large-scale pillar collapses in South Africa suggest that these were caused by weak partings that traversed the pillars. Currently two different methods are used to determine the strength of pillars, namely, empirical equations derived from back analyses of failed and stable cases, and numerical modelling tools using appropriate failure criteria. The paper illustrates that both techniques have their limitations and additional work is required to obtain a better understanding of pillar strength. Empirical methods based on observations of pillar behaviour in a given geotechnical setting are popular and easy to use, but care should be exercised that the results are not inappropriately extrapolated beyond the environment in which they are established. An example is the Hedley and Grant formula (derived for the Canadian uranium mines), which has been used for many years in the South African platinum and chrome mines (albeit with some adaptation of the K-value). Very few collapses have been reported in South Africa for layouts designed using this formula, suggesting that in some cases it might yield estimates of pillar strength that are too conservative. As an alternative, some engineers strongly advocate the use of numerical techniques to determine pillar strength. A close examination unfortunately reveals that these techniques also rely on many assumptions. An area where numerical modelling is invaluable, however, is in determining pillar stresses accurately and for studying specific pillar failure mechanisms, such as the influence of weak partings on pillar strength. In conclusion, it appears that neither empirical techniques nor numerical modelling can be used solely to provide a solid basis for conducting pillar design. It is therefore recommended that both these techniques should be utilized to obtain the best possible insight into a given design problem. Owing to the uncertainties regarding pillar strength and loading stiffness, monitoring in trial mining sections and in established mining areas is also an essential tool to test the stability of pillar layouts in particular geotechnical areas.

Jan 1, 2011

By A. H. Swart, M. F. Handley

Unplanned stope panel collapses occur on most near-surface and shallow mines in South Africa. Although these incidents often occur during blasting, they pose a major threat to the safety of underground workers and the economic extraction of orebodies. Most stope panel collapses occur due to excessive panel lengths that are not designed according to a systematic design procedure or methodology. Instead, panel lengths are often dictated by the equipment in use and by previous experience under similar conditions. Hence, a rock engineering design methodology for the design of stable stope panels between pillars is of vital importance for optimum safety and production in shallow mining operations. Using the proposed design methodology described in this paper, rock mechanics practitioners and mine planners should be able to identify and quantify the critical factors influencing the stability of stope panels. The critical factors should then be used as input to the design of stable stope panels that will provide the necessary safe environment for underground personnel working in stopes. The proposed design methodology is an iterative process, which includes aspects such as rock mass characterization, estimation of rock mass properties, identification of potential failure modes, consideration of appropriate stability analyses and other elements of the rock engineering design process. This process continues after implementation. During monitoring, new data should be included in the database and the design process repeated on a regular basis. Design approaches included in the proposed design methodology include empirical methods such as different rock mass classification methods, analytical methods such as elastic and Voussoir beam analyses, kinematic analyses, probabilistic analyses, and numerical analyses. Keywords: stability, stope panels, design methodology, hard rock mines, shallow mining operations

Jan 1, 2004

By A. H. Swart

Unplanned stope panel collapses occur on most near-surface and shallow mines in South Africa. Although these incidents often occur during blasting, they pose a major threat to the safety of underground workers and the economic extraction of orebodies. Most stope panel collapses occur due to excessive panel lengths (resulting in excessive stope spans) that are not designed according to a systematic design procedure or methodology. Instead, panel lengths are often dictated by the equipment in use and by previous experience under similar conditions. Hence, a rock engineering design methodology for the design of stable stope panels between pillars is of vital importance for optimum safety and production in shallow mining operations. Using the proposed design methodology described in this paper, rock mechanics practitioners and mine planners should be able to identify and quantify the critical factors influencing the stability of stope panels. The critical factors should then be used as input to the design of stable stope panels that will provide the necessary safe environment for underground personnel working in stopes. The proposed design methodology is an iterative process, which includes aspects such as rock mass characterization, estimation of rock mass properties, identification of potential failure modes, consideration of appropriate stability analyses and other elements of the rock engineering design process. This process continues after implementation. During monitoring, new data should be included in the database and the design process repeated on a regular basis. Design approaches included in the proposed design methodology include empirical methods such as different rock mass classification methods, analytical methods such as elastic and Voussoir beam analyses, kinematic analyses, probabilistic analyses, and numerical analyses. Keywords: stability, stope panels, design methodology, hardrock mines, shallow mining operations

Jan 1, 2005

By E. N. Mounsey

The paper addresses the design of the Zhong Tiao Shan Company (ZTS) Houma Ausmelt Technology copper smelter in People's Republic of China. The smelter represents the third copper smelter development using Ausmelt Technology, the first large scale (35,000 tpy blister copper) and the first smelter to use the Ausmelt Technology smelting and converting process steps in separate TSL vessels in a continuously operated process. The project will be realised through the combined efforts of ZTS, Ausmelt and ENFI, the Beijing Non-Ferrous Engineering Institute who provided partial detail engineering services in China. Ausmelt will provide the technology licence, basic and detailed furnace engineering packages and additional technical services including cold commissioning support and hot commissioning supervision.

Jan 1, 1999

BECAUSE of the attention given in recent years to the flotation process, there is an extensive range of equipment available to any staff detailed for: the design of a flotation mill. This statement applies not only to the flotation machines, but also to equipment for crushing and grinding, elevating the pulp, dehydrating of concentrates, and the methods of driving the various equipment.Distributed through the Proceedings and Transactions of various metallurgical societies and journals there are many excellent descriptions of flotation mills, their equipment and performance.Whilst these articles describe-in many cases in detail-the equipment in the mills to which they refer, the reasons which govern the choice of each particular equipment are not usually given.

Jan 1, 1929

By C. R. Speers

The induced elastic stresses in the sidewalls of gold-mining tunnels at a depth of 4000 m in the Witwatersrand exceed the peak compressive strength of even the best-quality quartzite rocks. Laboratory tests measuring post-yield stress versus strain response show that brittle fracture occurs, followed by a loss in strength associated with strain-softening behaviour. Numerical modeling based on an assumed Mohr-Coulomb criterion fitted to the test results shows that large ongoing deformations of the sidewall occur, leading to total tunnel failure without adequate support. A methodology is presented to enable a quick assessment to be made of support requirements in terms of ground characteristic curves for numerically derived pressure versus displacement. From these curves, estimates can be made of the force levels for cable bolting and of the thickness and strength requirements for shotcrete linings. As an example of its application, the methodology is used in a comparison of the relative stability efficiencies of a square-shaped tunnel and a horizontal ellipse-shaped tunnel.

Jan 1, 1996

By A. Whillier

Recommendations are given for the design of vertical cooling towers for use underground in mines and a method is given for predicting the entering and leaving water temperatures when a given amount of heat has to be dissipated.

By N. G. W. Cook

When an excavation is made underground the original rock stresses are removed from the surfaces of the excavation. These surfaces converge to partially close the excavation and the superincumbent rock mass moves down towards the excavation. If the convergence of the surfaces of the excavation were controlled, energy generated by their motion against the controlling forces could be extracted. Since the total forces in the rock mass are not significantly affected by the excavation, stress concentrations arise around the excavation, which compensate exactly for those stresses no longer transmitted through the excavation. These phenomena give rise to two general principles which provide the basis for analyzing the effects of making any underground excavation. The first of these is that the total force resulting from the stresses across any plane in the rock, including any plane through the excavation, must be the same before and after the excavation is made. The second of these is that energy must necessarily be released as a result of making an underground excavation. It is instructive to consider the implications of these two principles for two extreme cases of material behavior between which the actual behavior of rock must lie, namely, the behavior of a fluid and the behavior of an elastic solid. For the purpose of analysis in this paper, an underground excavation is defined as an excavation in which the smaller horizontal dimension of any open void at a particular horizon is less than the depth of that horizon below surface. In the case of a fluid, any unsupported excavation would fill immediately, as a fluid cannot sustain shear stresses. For the same reason, stress concentrations could not arise and the forces across any plane would necessarily be the same before and after excavation. If the filling of the excavation were controlled by forces applied to the surfaces of the excavation, an amount of energy equal to the product of the fluid pressure

Jan 1, 1967

By N. G. W., Cook

When an excavation is made underground the original rock stresses are removed from the surfaces of the excavation. These surfaces converge to partially close the excavation and the superincumbent rock mass moves down towards the excavation. If the convergence of the surfaces of the excavation were controlled, energy generated by their motion against the controlling forces could be extracted. Since the total forces in the rock mass are not significantly affected by the excavation, stress concentrations arise around the excavation, which compensate exactly for those stresses no longer transmitted through the excavation. These phenomena give rise to two general principles which provide the basis for analyzing the effects of making any underground excavation. The first of these is that the total force resulting from the stresses across any plane in the rock, including any plane through the excavation, must be the same before and after the excavation is made. The second of these is that energy must necessarily be released as a result of making an underground excavation.

Jan 1, 1969

By R Brake

The Enterprise Mine Project (EMP) is being developed by Mount IsaMines Limited as the future source of copper ore at the Mt Isa miningand processing complex. Environmental engineering is one of the majortechnical challenges facing the project because of the depth of theorebodies, high virgin rock temperatures and hot ambient surfacetemperatures in summer. This paper discusses the engineering principles adopted by EMP to manage the risks associated with working in these adverse thermal conditions.

Jan 1, 1998

By P. J. Bethell

Background Increasingly complex geological conditions, with the presence of high ash binders in the mining horizon were encountered at the A.C. I. Dugout Mine near Price, Utah. This led to the production of high ash coal from the Dugout Mine during 2003 and 2004. This material had poor marketability and posed operating issues for the utilities burning the coal. Ash levels increased from typical levels in the 9-12% range to between 15 and 25%. etween 15 and 25%. Reviews of the mine plan and expected geological conditions indicated that further periods of high ash production could be expected. Action Plan Detailed sampling of the mine high ash production was carried out. The majority of the coal from the Dugout Mine is trucked to the Savage Coal Terminal (SCT) at Wellington, Utah where it is stored in multiple piles by quality. Coal at the mine is segregated by a CoalScan 2600, on-line analyzer into high ash, low ash and rock chute (waste material). From these piles, the material is crushed prior to shipment to SCT. The samples obtained from the various high ash piles were subjected to detailed sizing and washability analysis. Once this information was obtained, alternative circuit configurations were evaluated to process this material into a salable product. Water supplies in the arid terrain where the plant is located are scarce. This factor played a part in the final circuit design.

Jan 1, 2008

By Jim Dodd, Jim Paynter

"We would like to acknowledge the efforts of the following key people who helped to make this project a success.Ron Jung, instrumentation supervisor for the Golden Giant Mine, spent many hours reviewing process and instrument drawings, selecting instruments and providing hands on support during commissioning.Andy Keough, underground production supervisor for the Golden Giant Mine, was responsible for readying the underground distribution network for paste backfill.H.A. Simons Ltd. personnel who did an excellent job providing sound conceptual and detailed engineering.Fred Brackebusch, of Mine System Design who designed the paste backfill delivery systemPierre Lacombe, mill superintendent of the Louvicourt Mine, generously shared information and operating experience of their paste backfill plant.AbstractThroughout the 11 year history of the Golden Giant Mine, the primary backfilling method made use of consolidated rock fill. New backfill technologies have developed over recent years which now make it possible to use large quantities of fine mill tailings as backfill.In January of 1996, construction began on a new paste backfill plant at the Golden Giant Mine. Six months following, the plant was commissioned. This paper describes the design, commissioning and operational experience to date of the paste backfill plant."

Jan 1, 1997

By J. L. Taylor, E. B. Viljoen, W. M. Craig, A. M. McIntosh

The Chemwes uranium plant treats old gold-plant residues from the Sttifontein and Buffelsfontein Gold Mines by acid leaching, belt filtration, countercurrent ion exchange (ClX), and Bufflex solvent extraction (SX). The uranium is recovered by precipitation as ammonium diuranate. Absorption and elution in the CIX section are achieved in four NIMCIX columns operating as two parallel streams. Each loading column is 4,85 m in diameter and contains 12 absorption stages. The elution columns are 3 m in diameter and contain 8 stages. The eluant used is 10 per cent sulphuric acid at ambient temperature. During the commissioning and initial operating periods reported here, the plant yielded an average barren solution of 1,6 p.p.m. of U3O8 from a feed with a mean U3O8 concentration of 132 p.p.m. The U3O8 concentrations in the barren solution were better than 2 p.p.m. some 85 per cent of the time, and better than I p.p.m.73 per cent of the time. Investigations are underway to institute an automatic control system that will result in the U3O8 values on the resin and in the barren solution being maintained at or near the target values in spite of changes in the concentration of uranium in the feed solution.

Jan 1, 1982

The ore treatment expansion programme at Mount Isa Mines required the erection of a new lead-zinc concentrator to be known as No. 2 Concentrator. This concentrator was designed by Western-Knapp Engineering Company in conjunction with staff of Mount Isa Mines Limited. Metallurgical design followed conventional wet milling practice, but the size of many plant units is larger than previously used at Mount Isa. The. total capacity of the new plant is 150,000 tons per four weekly period, and the plant is designed to operate in two equal parallel sections.Erection was contracted on a turnkey basis, and the plant was commissioned as a production unit on 23rd June 1966.The existing concentrator, No. I, was converted to treat all copper ore, and the total capacity of the two plants is now 390,000 tons per four weekly period.

Jan 1, 1968

Economic conditions dictated the lead time from concept to commissioning of the Kambalda C.I.P. Plant. The high gold price prevailing at the time the Victory ore-body was discovered provided the impetus to establish a treatment plant with the utmost haste. Consequently only limited metallurgical testing was possible. Fortunately the Kambalda Metallurgical Department had experienced gold metallurgists among its' staff. This enabled a rapid assessment to be made of the ore types to be treated. Flexibility was the keynote in the plant design. Overseas practice and experience was drawn upon extensively, but it was known that problems uniquE to the Kambalda Plant would be encountered due to the high nickel content of the C.I.P. Plant feed and the difficult clays in some of the areas. These fears were well founded and problems have been experienced. However the plant design has enabled these problems to be absorbed, if not overcome, and design production rates were achieved and maintained within three month; of start-up.

Jan 1, 1982