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By Thomas M. Barczak

This U.S. Bureau of Mines report chronicles the historical development of longwall mining in the United States and speculates on future developments to the turn of the century. The involvement and contributions made by the Bureau during these developments are also discussed. Two major periods of history are analyzed: (1) from 1875 to 1950 when small advancing faces were operated manually, and (2) from 1950 to 1990 when mechanized extraction and powered roof supports provided a system to efficiently extract large coal panels. Five eras of technological development during the modern period are described and analyzed. These eras discuss the development of (1) mechanized extraction, (2) powered roof supports, (3) high-capacity roof supports, (4) shield supports, and (5) system automation. Current trends are analyzed in terms of longwall utilization, face production, support capacity, face widths, and new technological developments. From these analyses, the future of longwall mining to the year 2000 is speculated. It is concluded that longwall mining will continue to grow in importance during the next decade and that the next major technological milestone will be the realization of a fully automated longwall mining system.

Jan 1, 1992

By P D. Katsabanis, W Roberts

Commercial explosives exhibit non ideal behaviour which is very difficult to model. The fume spectrum produced by commercial explosives apart from its practical significance for underground mining is of great theoretical importance since it reveals information about the chemistry of the detonation process. Emulsions, watergels and dynamites were tested under various degrees of confinement in an one cubic metre closed chamber. Sand, concrete, steel and copper pipes were used to alter confinement. The degree of confinement was found to significantly influence the quantity (litres/kg of explosive) and the relative proportions of toxic and non-toxic fumes (percent of total fume measured). These results lead to further confinement testing using various rock materials. Fume results, and thus detonation performance were found to be dependent on the type of rock material used for confinement. Materials such as dolomite, limestone, and granite were found to result in a relatively high detonation efficiency of the subject explosive as shown by the distribution of detonation fume products. Conversely materials such as sandstone, talc and massive sulphide resulted in fumes suggesting low relative detonation efficiency. Fumes appear to be a sensitive indicator of the completeness of reactions occurring within the expansion zone of the composite emulsion explosive, while the detonation velocity is relatively insensitive to small variations in confinement. Estimates of sonic velocities of the confining rock materials were found to show no correlation with VOD results. However good correlation between fume results and sonic velocity suggests that the performance of an explosive as indicated by the resulting fume spectrum is affected by the degree of confinement.

Jan 1, 1992

I The South Platform of the Gippsland Basin is an extensive area of shallow basement covered by a relatively-thin Late Mesozoic-Cainozoic section. Although the sporadic exploration to-date has not resulted in any hydrocarbon discoveries, the area is under-explored and its taste potential has not yet been fully evaluated. The best potential appears to be in areas underlain by the Golden Beach Megasequence where structures are mainly related to basement fault blocks.

Jan 1, 1992

Determine the extent to which remote-sensing techniques, primarily lineament analysis, can be used to identify geologic structures that may affect the location and migration of subsidence over abandoned underground coal mines in the Colorado Springs, CO, area. Compile data using a geographic information system (GIS) to allow efficient and reproducible comparisons and analyses. Background The basis for evaluating abandoned mine land (AML) sites with remote-sensing techniques comes from past and ongoing Bureau ground control research using remote-sensing data to identify potential hazards caused by geologic structures (faults, joints, etc.) above active underground coal mines. Research showed that lineament (linear feature) analysis of Landsat Multispectral Scanner (MSS) images could indicate locations of fractures and fracture trends that had varying, but significant, impacts on the stability of mine openings. Such geologic structures should be identifiable over abandoned mines as well. If fractures are present, even if they arc not faults, they should represent areas of potential instability over these mines and, therefore, should tend to localize subsidence when it occurs, particularly for deep and moderately deep portions of mines.

Jan 1, 1992

By Stephen P. Signer

The U.S. Bureau of Mines is developing an intelligent system for roof' control that uses both an expert system and neural networks to improve the capability of mining engineers to evaluate roof support effectiveness for ground control in coal mines. The expert system com- pares roof support capacities with the support requirements estimated to be necessary to maintain entry stability. It does this by evaluating the results of tests on various types of roof support and establishing the maximum allowable load according to anchorage capacity and yield strength of the support. After the user enters geological information (rock properties, geometry of the opening, in situ stresses, bolt pattern parameters, etc. ), the expert system compares the predicted required loading to the roof support capacity and gives the operator advice on the adequacy of the design and how improvements could be made. A good source of the real-time data necessary to allow the expert system to make decisions will come from a roof bolting machine being developed by the Bureau of Mines. Researchers have collected data from a Western coal mine on drill bit position, penetration rate thrust, torque, and rotation rate. Using this information, two neural net- works were developed to identify different types of strata and features in a mine roof such as rock type, rock compressive strength and joint characteristics. The result is a system that can assist a mining engineer with design information that can be constantly updated as mining progresses.

Jan 1, 1992

By B. K. Cantrell, D. H. Carlson, W. F. Watts, K. L. Rubow

The use of diesel equipment in underground coal mines is controversial because the National Institute for Occupational Safety and Health (NIOSH) regards "whole diesel exhaust" as "a potential occupational carcinogen." Threshold limit values (TLVs) are recommended for the gaseous pollutants CO, CO2, NO, N02, SO2 and some hydrocarbons emitted in diesel exhaust. There is, however, no TLV recommended for diesel exhaust aerosols (DEA) nor is there a standard method for sampling these aerosols. The University of Minnesota and the USBM have collaborated to develop a personal diesel exhaust aerosol sampler (PDEAS) that utilizes size selective, inertial impaction and gravimetric analysis. During the field tests of this sampler, numerous air quality measurements were conducted in underground coal mines that used diesel equipment. The objective of this report is to present these data and to assess the impact of diesel face haulage equipment on mine air quality. Air quality data were collected in four underground coal mines. The mines used continuous miners and diesel haulage equipment. Daily samples were collected at the section intake, haulageway and on haulage vehicles. Both full-and partial-shift samples were collected using a variety of aerosol instruments. These included the PDEAS and the micro-orifice uniform deposit impactor (MOUDI) that sample the mine aerosol diesel exhaust fraction. Two of the mines were also monitored for the major gaseous constituents found in diesel exhaust CO, CO2, NO, NO2 and SO2. These measurements were made by either collecting bag samples for subsequent gas analysis or by Palmes dosimeters. Concentrations of CO, C02, NO, NO2 and SO2 were well below regulated levels. The mine average DEA concentration determined by the PDEAS in the haulageway for the three mines surveyed was 0.79 mg/m3, with a standard deviation of 0.19 mg/m3. DEA contributed 65% of the respirable aerosol, at this location. These results were the same as the mean DEA concentrations calculated from size distribution measurements obtained using the MOUDI. This was 0.78 mg/m3, with a standard deviation of 0.22 mg/m3.

Jan 1, 1992

By Singh RN

Monolithic packing systems have gained in popularity as a gate side packing method. However, there has been no detailed investigation to assess their underground strength behaviour. This work includes the laboratory and in situ investigation for strength behaviour determined on various monolithic packing materials namely Tekpak-XX, Hydropak-20, Hydropak-30, Astrapak-3R, Flashpak, Thyssen pack and Aquablends. A simple technique for assessing the pack strength was developed at the laboratory by using a penetrometer, of which penetration resistance can be directly correlated with the uniaxial strength of the pack. The in situ strength investigations were made on core samples obtained from three pipes inserted inside the pack, while the penetration test were made on the pack surface. The in situ results indicated that the packing material develops an inconsistent strength on various part of the pack which was mainly related to an inadequate mixing of grouts inside the pack.

Jan 1, 1992

By B. Andersen

An accurate knowledge of Interactions among mineral particles and between such particles and dissolved and precipitated species Is Important in developing efficient separation processes. In this investigation interactions in Florida phosphatic clay waste, that are relevant to dispersion and selective reagent adsorption, the two main prerequisites for selective flocculation, were studied. Initial studies with artificial slimes, consisting of pure clay and phosphate minerals, showed dispersion of artificial slimes to be relatively easy. The problems that were encountered during selective flocculation of the artificial slime were due to unselective polyacryllc acid adsorption on clay, which was caused by the presence of multivalent calcium ions on the exchangeable cation positions on the clay surfaces. This problem could be solved by exchanging calcium for sodium, which reduces the interaction between the polymer and the clay surface. This procedure, however, was not successful for mineral mixtures. Natural slimes were found to be much more difficult to disperse. This was attributed to the presence of cementing materials such as humic substances and Ai and Fe (hydr)oxide precipitates. Selective removal of these cementing materials resulted in good dispersion and partial separation. Further increase in separation of natural slime is likely determined by the presence of calcium on the clay surfaces, as was found for the artificial mixtures.

Jan 1, 1992

By Mills KW

Coal mine pillar design formulae available to mine planners are typically based on relationships determined for specific site conditions. Application of these methods is difficult when other factors, relating to mining or geological conditions, not specifically addressed in these relationships are encountered. A review of pillar design methods, coal strength properties and relevant field monitoring of pillar behaviour has shown pillar strength and deformational characteristics are extremely sensitive to in situ behaviour of the rock and other material components that make up the coal pillar system. A method has been developed that has been found to provide excellent correlation between existing field data using the strength and deformational characteristics of materials determined in selected laboratory tests. This method is based on definition of the loading conditions, accurate modelling of the strength, confining conditions and deformation occuring in the roof, floor and coal seam and definition of the in situ strength of coal based on underground monitoring of appropriately sized coal pillar. The design method is considered to provide an accurate and rigorous pillar design method that will give mine planners a more rational mine design capability which is based on the mine geometry and geological setting of the operation. It is envisaged that availability of such a method will allow significant optimisation of pillar layouts and more closely define the geological and mining issues that relate to pillar design optimisation.

Jan 1, 1992

By William P. Barnett

In 1988, the US Department of Energy's (DOE) Pittsburgh Energy Technology Center identified three coal cleaning options for achieving flexible environmental control strategies aimed at reducing energy-related SO2 emissions. These are selective agglomeration, advanced froth flotation and advanced cycloning. Each relies on maximum liberation of pyrite and other mineral matter through feed coal comminution to fine and ultrafine sizes. The National Energy Strategy (NES) and the Clean Air Act Amendments (CAA) of 1990 are examples of the nation's commitment to a clean environment. The need to use the nation's energy resources in an environmentally sound manner presents critical challenges and opportunities for coal preparation during the next decade, particularly regarding the control of SO2 emissions. The principal challenge is the development of cost-effective coal preparation approaches for sulfur removal beyond currently achievable levels. Opportunities are provided in the form of incentives associated with a novel system of SO, allowances and a policy environment based on the proper functioning of familiar market forces. An allowance, as defined in Section 402(3) of the Amendments, is "an authorization ... to emit ... one ton of sulfur dioxide." To achieve the objective of the Clean Air Act Amendments, SO, emissions will be eventually capped at 8.12 Mt (8.95 million st) annually by controlling the number of allowances issued nationally. By permitting allowances to be bought and sold once issued, the law encourages "overcompliance" as a source of profit for owners of excess allowances. Many details concerning the administration of allowance trading are not yet written.

Jan 1, 1992

By J. C. Gathje

The Robinson copper ores were mined for many years from pits containing varying ore grades, sulfide and oxide ore types, and differing mineralogy. The ores also contain gold and molybdenum values, and their recoveries are an integral part of the flowsheet development. Metallurgical responses were characterized using a standard flotation procedure. Further studies investigated primary and regrind particle sizes, reagents, and other variables. The metallurgical testing was supported by mineralogical studies. Results demonstrated a high degree of metallurgical success for flotation. Final copper concentrates ranged in grade from approximately 28 to 30% copper and copper recoveries were 89 to 95% based on laboratory and pilot plant data.

Jan 1, 1992

By John Dasher

One of our War Plants processed Bolivian concentrates as low as 17% Sn by the Arnhem process (pressure leach with HCL) and sent the waste acid down a ditch to Galveston Bay where the chlorides, mostly iron, hydrolyzed. Oyster men, and Texas, demandedimpoundment until a disposal process could be developed. A recycle process found by lab work was recommended, piloted and a plant built. This involved cementation of As Sb, Cu, Bi and Ag on light moving scrap iron and of Sn & Pb on Al turnings (then not recyclable), evaporation and crystallization of hydrous FeCl2, roasting crystals in a muffle furnace and absorbing HCI for reuse. The residue from leaching the low grade concentrates was floated to remove undissolved sulfides, classified and passed over sand and slimes tables to get a smeltable concentrate, a discardable sand tail and a slimes tail worth treating After desliming at 2 micro meters cassiterite, oxide flotation gave good, lab results; but commercial equipment wasn't adequate then. Chloride volatilization, with or without smelting gave high recoveries of Sn as SnCl2, whose marketing was questionable. I have heard this was finally fluxed and smelted.

Jan 1, 1992

By Moyes A. J

The Intec Copper Process uses a strong chloride electrolyte at atmospheric pressure and 80 - 85¦C to produce high purity, 99.99 per cent copper granules and elemental sulphur. A recent, exhaustive study by an independent, major Australian corporation has shown the capital cost of an Inter plant to be approximately half that of a copper smelter at the 200 000 tpa capacity level and approximately half the operating and capital cost at the 50 000 tpa level. The Inter process costs were also shown to be greatly superior to the best available leach/SX/electrowin technology. The process utilises a multi-stage counter current leach at 80 - 85¦C with the addition of air at atmospheric pressure to precipitate iron as a goethite type compound, followed by a two-stage purification process separating impurities in metallic- and other forms. Purified cuprous chloride/sodium chloride solution is fed to an electrolytic diaphragm cell where high purity copper granules are produced at current densities of 1000 - 1500 A/m2 withoutthe need for conventional electrode stripping. Power consumption is approximately half that of the cupric route. The product is suitable for the direct powder metallurgical conversion of the granules to products such as wire or strip. All the steps in the 'furnace free' conversion of copper mineral to product have been demonstrated The process can treat low grade and contaminated concentrates without penalty, thereby offering greater returns to the miner. Lead, zinc and silver may be recovered as metals, with the high oxidation potential of the electrolyte allowing extraction of gold at high efficiency. The gold is selectively precipitated on activated carbon with negligible copper and silver contamination.

Jan 1, 1992

It has long been recognised that Australia can benefit substantially in an economic sense from its rich resource base. The significant resources of the Gippsland Basin are a good example of the wealth of this nation. As cited in popular debate, Australia must value-add to its natural resources to ensure its long term economic prosperity. The significant oil, gas and coal resources of the Gippsland Basin have provided the Strategic Research Foundation with the basis for two major research and development initiatives ensuring the long term economic development of the Basin and Australia. The gas and coal reserves of the Basin together with the area's extensive history in electricity generation provide the rationale for establishing Ceramic Fuel Cells Ltd. A consortium comprising Australia's leading industrialist - BHP, State energy authorities and the Nation's major research and development organisations, has formed Ceramic Fuel Cells to undertake and manage research, development and commercialisation of solid oxide (ceramic) fuel cells which convert fossil fuels directly to electricity with greater efficiency and less pollution than existing technologies. The oil and gas resources of the Basin together with the valuable experience of the operators in recovering these resources, have provided the impetus to investigate the feasibility of a Marine Engineering Research Centre. The commercially oriented research, education and training objectives of the Centre are well supported by the leading industrialists in related industries.

Jan 1, 1992

By P. D. K. Robinson

In the second of a series of five colloquia with the theme Rescue 91 ..Survival Initiatives for the Mining Industry, the emphasis was placed on the harnessing of improved technology for the benefit of all the industry. The Colloquium was held at Mintek, Randburg, and attracted some 150 delegates and speakers from a cross-section of the industry. Eight papers were presented, and panel discussions were held to round off the morning and afternoon sessions. The purpose of the Colloquium was to allow mines and other groups to put forward innovative schemes in the management of technology that could be shared by everyone in their determination to ensure the survival of the gold-mining industry in the current difficult times. PAPERS The papers presented were as follows: The introduction of detachable bits at Cooke No. 1 Shaft, by C.A.F. Sweet of Randfontein Estates Survival through cost-saving measures in the engineering field, by E.J. Jurgensen of Freddies Survival through innovation, action, and a positive vision for the future, by G.C.V. Wade of Vaal Reefs Measuring misaligned guides, by H. Sperling of CSIR Rock-crushing innovations, by E. Trueman of Nordberg Improved explosives technology-has it been worth the effort? by RA. Lindsay of Sasol Cost savings through corrosion monitoring, by M. Tullmin of CSIR Enhanced efficiencies through technical developments in the survey departments, by D. Maree of Beatrix.

Jan 1, 1992

By Y. Zeng

Experiments were performed under batchwise wet grinding conditions with dolomite mineral. The vibration signal was received by an accelerometer and transmitted to a mini-processor. The signal was first stored on a digital tape recorder (OAT) in voltage format during the grinding tests. The original signal was then re-sampled and converted into data format for IBM or compatible personal computer by a digital oscilloscope. The root-mean-square (RMS) and power spectrum was estimated on the time-domain vibration signal. A partial correlation analysis was applied to the frequency-domain signal to detect the non-zero correlation between the frequency bands and the operating parameters. A multiple stepwise regression was used to locate the key frequency bands for describing a particular operating parameter. After vibration analysis, the operating parameters in grinding, for example, the mill speed, the powder filling, the pulp density, the pulp temperature and the particle size were found to be strongly correlated with a few frequency bands. The grinding process could therefore be monitored using the vibration signal.

Jan 1, 1992

By James A. Deeks

"Motor failures and equipment bearing failures are responsible for reduced productivity.With the introduction of computers and data acquisition systems, users are now able to monitor, report and trend deteriorating conditions and take corrective action before a critical shutdown occurs.This paper discusses the monitoring and trend analysis of' motors, and motor and equipment bearings. With today's digital electronics technology users are now able to monitor their equipment, detect deteriorating or abnormal conditions quickly, alarm the condition locally and or remotely, and decide if immediate corrective action is necessary or if it can be delayed until the end of a work Shift. All of this can be done long before any damage is done to the equipment.Monitoring Trend AnalysisIt is no longer necessary to compromise in selecting products, since state-of-the-art designs allow the adjustment in such small increments that the users are able to detect minute changes in a system's performance.Monitoring and trending of motors and equipment bearings is now available in economical packages which can be expanded as a system grows. Simply select the information you need, set the parameters, choose the scan time, and decide on the degree of reporting.Buffer storage of short-term monitoring of a number of analogue channels permit the user to view the recent history of motor data such as: motor average load, unbalance, motor current, ground fault, reserve thermal capacity, plus all of the settings of the protective device.A decision can be made to freeze the stored information after the motor stops or after the motor starts. Then the user is able to recall the conditions and diagnose the performance and the cause of the abnormal condition. Typical scan times range from ¼ second to 5 seconds ."

Jan 1, 1992

By A. E. Torma

In recent years the copper industry has gained considerable economic stability. An essential part of this industrial wealth is attributable to the successful application of bio-mediated heap and dump leaching techniques in the recovery of copper from low-grade resources. This study evaluated the leachability of a chalcopyrite conlentrate using naturally occurring mixed culture of predominantly Thiobacillusferrooxidans and Thiobacillus thiooxidans. For the effects-of pulp density, the overall reaction rate constant (k) and the order of reaction (n) have been determined to be 1.93 h-1 and 1.36, respectively. Cyclic voltammetric measurements revealed that intermediate reactions are involved in the chalcopyrite oxidation. Using the Price approach, it was shown that the dissolution of chalcopyrite is solid state diffusion controlled.

Jan 1, 1992

By John M. Ackerman

In the spring of 1988, Freeport-McMoRan Resource Partners Ltd. Partnership, IMC Fertilizer Inc. and Homestake Mining Co., as joint venturers, were awarded the sulphur lease for Main Pass Block 299, lease number OCS-G 91372. This was one of 11 leases awarded to the joint venturers. Following the initial discovery wells in December 1988, delineation drilling confirmed proven sulphur reserves of 68 Mt (67 million long tons). Proven, recoverable oil and gas reserves are 6.2 Mm3 (39.4 million bbl) and 1114 Mm3 (7.2 billion cu ft), respectively. Development of the sulphur mine was given approval as a fast-track project in 1989. The oil and gas reserves were acquired from the original hydrocarbon lessee in 1990 and were also given fast-track status. Fast-track for these projects meant design and engineering would not be complete before construction began. Joint venture The Main Pass Joint Venture is one of 13 joint ventures formed between Freeport and three other companies - IMC Fertilizer, Inc., Felmont Oil Corp., a wholly owned subsidiary of Homestake Mining Co., and Texasgulf Minerals and Metals Co. Felmont has since changed its name to Homestake Sulphur Co. Texasgulf assigned its interests to its parent company. Texasgulf did not participate in the Main Pass 299 joint venture. Joint venture negotiations, anticipating a lease sale in mid-1988, began in December of 1987. This joint venture, the first of its kind, was created to acquire offshore leases, explore, develop and mine sulphur. The Interior Department's Minerals Management Service (MMS) announced a lease sale date of Feb. 24, 1988 on the first business day of 1988. This greatly accelerated the joint venture negotiations. Of the 13 leases the joint ventures bid on, 11 were awarded. Freeport holds its interest in all the leases through its ownership interest in Freeport-McMoRan Resource Partners, Ltd. Partnership. Resource Partners is the operator on all of the leases.

Jan 1, 1992

Ohio has an estimated 46 billion tons of coal beneath 12,000 square miles of the eastern third of the state. Recoverable coal reserves within this vast area are estimated at 21 billion tons, 3.2 billion tons of which have been mined since 1800. Ohio is the eleventh-largest coal- producing state in the nation and ranks third nationally in coal consumption. Coal resources in Ohio lie in as many as 60 identifiable coal seams along the northwestern flank of the Appalachian coal basin. Except where interrupted by minor faults and erosional discontinuities, these rocks dip gently and uniformly to the east, simplifying the mining methods needed to extract the coal. Fourteen of Ohio's 60 coal seams are considered to be important, although only a small number of seams are currently being mined. Ohio first enacted a surface coal mining law in 1948, requiring in part a $100 per acre reclamation bond. Ohio progressively strengthened its surface mining law in 1949, 1955, 1959, 1961, 1965,1972,1975,1978, and 1981. At the time of its enactment, Ohio's 1972 mining law was one of the most stringent in the country. This law also created a state coal severance tax of four cents per ton to be used for abandoned mine land reclamation. Ohio received primacy to regulate the surface coal mining operations within the state August 16,1982. Its Abandoned Mine Land Program was approved on the same date.

Jan 1, 1992