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By Kevin J. Ma, John Stankus

"In order to access remote reserve areas, some U.S. coal mines have to maintain aged underground entries for a great distance. However, high humidity, warm temperature, and time dependent deterioration can cause progressive roof deterioration and unexpected roof falls can, pose a great challenge to ground control engineers. With an active belt structure in place and limited space, re-bolting becomes very costly, less effective, and, sometimes, impractical and unfeasible. To gain long-term entry stability and serviceability, operators typically rehabilitate the aged belt entries by installing standing steel set supports. In the last several years, Keystone Mining Services, LLC, (KMS) has assisted many coal mines with their belt entry rehabilitation projects, evaluated the ground condition of various aged belt entries, and designed different standing steel set support systems. This paper presents a case study of a large-scale roof fall that occurred at an aged belt entry in a mine located in an eastern coalfield, analyzes root causes of excessive deformation of square sets that were installed in an adjacent entry, evaluates the adequacy of an existing rehabilitation square set, and develops remedial recommendations for future rehabilitation practice. Based on the case study, the paper outlines design guidelines for rehabilitation steel sets that include field evaluation, engineering considerations, design assumptions, steel structural analysis, and field installation quality control. INTRODUCTION With gradual depletion of shallow coal reserves, some underground coal mines have to maintain long-term entries (belt, track, return airway, etc.) for a great distance in order to access remote coal reserve areas. However, due to high humidity, warm temperature, and aging in the belt entry, roof strata weathering and pillar degradation become more and more severe. Progressive roof deterioration poses a great challenge to ground control engineers. Pillar rib sloughs at certain locations, entry width increases in some areas, immediate roof sags, immediate roof rock falls out between bolts, existing bolts lose functionality due to corrosion, cutters develop deeper in corners, and strata separation develops deeper up into the main roof. As a result, unexpected roof falls occur in a random manner resulting in loss of production, damage of belt structure, and even injuries to underground personnel."

Jan 1, 2017

By Jose R. Hernandez-Aguilar

"This paper revisits data from previous studies (Hernandez-Aguilar, 2010, 2011) to better understand the link between metallurgical performance and pulp-zone bubble size (Db) in full-scale flotation systems. To obtain conclusive evidence exclusively related to the pulp (collection) zone, the experiments were designed in those studies to control both the bubble generation method and the influence of the froth zone on the overall metallurgical performance in industrial and pilot-scale flotation columns. The results showed that Db had a significantly larger effect on the recovery of coarse (> 75 µm) particles compared to the effect on fine (< 16 µm) particles. It was observed that, under certain practical conditions, the recovery of coarse particles was close to zero, but dramatically increased by reducing Db. The evidence revealed an inconsistency of the so-called “k–PSb” model: at constant froth recovery, increasing Sb (i.e., the rate of production of bubble surface area) did not always result in higher recovery, as the model predicts. Furthermore, the evidence showed that it was not the Sb but the bubble size that proved to be a more reliable link to metallurgical performance. Only in the presence of suboptimal-sized bubbles (Db > 2 mm) did the froth zone seem to play a role, possibly reflecting an effect of pulp-zone bubble size on froth stability. However, the role of the froth was negligible for Db < 1 mm.High-resolution mineralogical measurements performed on process samples revealed that, regardless of the degree of liberation, Db had a profound effect on the shape of the recovery-by-size curve, particularly the coarse particle size fraction. This observation is key as it implies that the loss in efficiency associated with floating the coarse particles was not the result of neither particle hydrophobicity nor particle detachment issues: even in the absence of mechanical agitation, liberated and highly hydrophobic coarse particles did not seem to attach to the bubbles in the first place, an inefficiency that was corrected by reducing bubble size. The data analysis suggests that poor attachment efficiency can practically affect both fine and coarse particles but via different mechanisms which are discussed here."

Jan 1, 2017

By Lifeng Li, Jhon Silva-Castro

"Signature Hole Technique is one method to assess the vibration waveform of a production blast.Methematically, it is the convolution between a prior measured waveform of a single blast hole (signature) and a given time delay sequence (comb function). Being an advantage, the inverse operation of convolution, known as deconvolution, can be used to estimate the signature."

Jan 1, 2017

By Timothy C. Siegel, Paul J. Axtell

The Missouri Department of Transportation (MoDOT) recently replaced the Hurricane Deck Bridge that carries Highway 5 traffic across the Osage Arm of the Lake of the Ozarks in Camden County, Missouri. The former bridge was constructed in the 1920's and was supported on pneumatic caissons bearing on dolostone bedrock. The replacement structure is founded on drilled shafts socketed into the bedrock. During the design phase of this bid-build project, a baseline design was developed and Alternative Technical Concepts (ATC's) were allowed from approved contractors. Those ATC's were confidential and not shared between teams. Either the baseline design or the approved ATC design could be bid by the respective contractors. The baseline design included re-use of the 90-year old caisson foundations. Accordingly, an extensive evaluation of the caissons and underlying bedrock were conducted by coring, laboratory testing, acoustic tele-viewer (ATV), and cross-hole sonic logging (CSL) methods. The results of the investigation indicated the caissons were in excellent condition and suitable for re-use. However, a more cost-effective ATC was submitted, awarded, and constructed that did not re-use the existing caisson foundations but rather reduced the span lengths, increased the number of piers in the water, and supported those piers on drilled shafts. Interestingly, the difference in low bid price between the awarded ATC and the baseline design was less than one percent of the construction cost. This paper describes the multiple foundation designs that were necessary for this interesting project. The various foundation evaluations include the existing pneumatic caissons, large-diameter open-ended pipe piles to support the baseline design, and the design of rock-socketed drilled shafts that were successfully constructed in 2012.

Jan 1, 2017

By J. Sjöberg, T. Savilahti, S. B. Umar

"Sublevel caving in Malmberget mine results in mining-induced surface deformation. One of the currently mined orebodies is the Printzsköld orebody. As mining deepens there is need to assess the behaviour of the cave formed in the subsurface above this orebody. Numerical analysis was used to assess the effects of extraction to deeper levels and perform strength parametric studies. Stress redistribution was studied, and the results showed high stress buildups in the hangingwall and the crown pillar. Two failure mechanisms have been identified – shear and tensile. Reducing cohesion by 50% increased the area of the yielded zone by more than 100% in the hangingwall.IntroductionThe Malmberget mine is owned and operated by the Luossavaara-Kiirunavaara AB (LKAB) mining company. Iron ore is extracted by large-scale sublevel caving. The mine comprises a total of 20 orebodies, about 10 of which are in production today (Figure 1). The mine is located in the municipality of Gallivare, about 100 km north of the Arctic Circle (Figure 2).Successful sublevel caving requires progressive caving of the orebody after initial blasting. This results in caving of the hangingwall, sometimes all the way to surface, resulting in surface deformation. As mining progresses to deeper levels a larger area is affected by deformation. Over the years, extraction from the Malmberget orebodies has led to deformation of the ground surface, affecting residential areas and existing infrastructure.Forecasting the caving process is not straightforward as it can be rapid or slow, depending on the rock mass conditions, stress conditions, the failure mechanisms at work, etc. Moreover, several of the orebodies in Malmberget are non-daylighting, which makes reliable caving analysis even more difficult, primarily since there is less available experience from such cases. The present study was designed to improve the understanding of the caving and deformation mechanisms at Malmberget, and in particularly for the Printzskold orebody"

Jan 1, 2017

By T. P. Johnson, A. Vathavooran

"Conventional mining operations can produce a wide range of wastes containing gold and other precious metals but which are less suitable for processing by traditional methods. There are also types of ore that do not fit easily into a traditional processing flowsheet, e.g. because the refractory nature of their minerology or the combination of valuable metals is less suitable for traditional processes. Nevertheless, these potential sources of valuable metals remain unexploited resources that have attracted growing interest in the metals and mining industries over recent years. The challenge is therefore to develop and use alternative processing methods that have the flexibility of operation to cope with a wide variety of material types and tonnages, whilst providing high recoveries for valuable metals. Tetronics’ DC plasma smelting technology achieves industry-leading recovery rates for precious metals from a wide range of input materials and initial precious metal concentrations, whilst generating an inert slag-based material as a by-product (even when starting from a hazardous waste input material), approved within the EU for use in construction applications. This paper describes how this technology can be used as a key part of an overall process for the recovery of precious metals from these interesting materials.INTRODUCTION The extraction of gold from its ores by various forms of cyanide leaching has been practised by the mining industry for over a century (Minerals Council of Australia, 2005) and it remains the primary extraction method in a wide range of mining operations. The ability of cyanide to extract gold efficiently and quickly from lower grade ores without extensive additional processing, coupled with well-known methods to recycle the cyanide for re-use within the process mean it is often both the most economically preferable and environmentally acceptable method for recovering gold. As a result, 88% of all gold produced from mines in the USA in 2014 was recovered via leaching of open heaps or dumps (UGGS, 2016). Nevertheless, there are occasions where certain combinations of mineralogy and other circumstances reduce the effectiveness of cyanidation techniques, so that ever more elaborate additional processing steps are required, with inevitable increases in operating costs (Swash, 1988). In these circumstances, which are likely to be more common in future as ore qualities diminish, other methods of extraction may offer better alternatives. Whilst much less commonly used for Au extraction at present, pyrometallurgical methods are amongst the longest-established of these alternative approaches and merit serious consideration in such cases."

Jan 1, 2017

By M. Ge, C. Mborah

"The acoustic emission/microseismic monitoring (AE/MS) technique has widely been used in the mining environment for the monitoring of rock mass stability. A successful implementation of the method is hinged on being able to accurately determine the P- or S-wave arrival which is then used in the determination of the source of an event. Determination of the arrival phase is usually performed visually by a human expert. However, the mining environment is characterized by high noise levels and different noise types of varying intensities. Therefore, performing manual phase picking on time series data acquired from the AE/MS monitoring system can sometimes be tedious and time consuming if not impossible. In this paper, a proposal for improving manual P-wave phase arrival picks is discussed. The method involves the filtering of the AE/MS data using a stationary discrete wavelet transform (SDWT) method. After filtering, appropriate scales/levels of the multi-level decomposition process are then selected for further processing. The first step in the picking process after filtering, requires the computation of the signal power and the root mean square (RMS) using the signal amplitudes at each scale. The preliminary P-phase arrival time is picked using the results of the calculated power and RMS values respectively. The calculated RMS values are then superimposed on the calculated power values to determine the final arrival picks. If the arrival time picks obtained by both methods coincide or are within 5 to 10 sample points, the pick is considered reliable. The accuracy of the method was verified using AE/MS data from two datasets obtained from two separate underground mines. The results of the study showed that the picking method is reliable and robust. Based on the data studied, it can be concluded that the method will help reduce the time usually spent in processing AE/MS data from mines. INTRODUCTION A successful identification and location of the source of acoustic emission/microseismic (AE/MS) events is mainly dependent on the onset time of the P-wave phase. In many seismic networks, initial picks are performed by picking algorithms followed by manual picks by human experts. If the waveform signal-to-noise ratio (SNR) is low, the P-wave onset time picks by the human expert is generally reliable and accurate [1]. However, for waveforms with high SNR, picking of the P-wave onset could be a major challenge. Also, due to the volume of data acquired daily, manual processing could be stressful and time consuming [2]. These challenges continue to provide motivation for alternative means of providing reliable and efficient ways of improving manual phase picking. The AE/MS technique has been an intergral part of safety monitoring in mines [3] due to its capacity to identify zones of instability in a monitoring area. To obtain an accurate source of an AE/MS event however depends on the quality of the data used for P-wave phase picking [4, 5]. AE/MS data from mines are generally contaminated with excessive background noise generated by the different mining operations. The AE/MS signals of interest are mostly buried in background noise which makes it difficult to pick the P-wave phase arrivals [4]. Processing AE/MS data acquired in noisy environment remains a major challenge due to the weak nature of AE/MS signals [6]. As noted by [4] most of the data recorded in the mine environment are mainly due to events not related to AE/MS events of interest. The complexity of data in this type of environment makes the detection and picking of P-wave arrival by human experts a very difficult task."

Jan 1, 2017

By Tae Hwan Lee, Jun-Shin Lee, Daejin Kwag, Sangchul Bang, Gerard T. Houlahan, Moo Sung Ryu

"Geotechnical engineers have been installing innovative, permanent underwater foundation systems utilizing suction buckets for the offshore industry since the early 1980s (Senpere and Auvergne, 1982). This foundation system has been successfully used on numerous and various types of offshore structures in a wide range of environments. Suction buckets have numerous advantages compared to conventional underwater foundation systems. The more notable advantages include easy installation, large loading capacity, low noise and retrievability. The application of reduced water pressure inside the bucket facilitates the installation of the suction buckets, where a suction pump attached at the top of the bucket can accomplish the entire driving operation. Because of this efficient operation, very large suction buckets can be driven into the seafloor, which eliminates the use of a large number of small piles.In Korea, one of the most economical and reliable renewable energy sources is wind power; however, onshore wind power generation has encountered many problems, such as the lack of favorable sites and public concerns about noise and environmental damage. Consequently, offshore wind power generation has attracted increasing attention due to its abundant potential, high efficiency of grid connection, and availability of easy expansion.In November 2011, the government of Korea announced a national offshore wind power development roadmap, which targeted its offshore wind power generation with the goal of becoming one of the top three nations in the world for offshore wind power generation. Korea Electric Power Corporation Research Institute (KEPRI) is the main research arm of the Korea Electric Power Corporation (KEPCO) and conducts research and development on electricity, power generation, renewable energy and other energy-related matters. KEPRI ultimately provides forefront knowledge and leadership to KEPCO with respect to energy and related areas for its near- and long-term needs. Financial support for the overall project, of which the suction bucket foundation system installed for the pilot phase wind turbine is described below, was provided from the New and Renewable Energy Program of the Korea Institute of Energy Technology Evaluation and Planning funded by the Korean Government Ministry of Trade, Industry and Energy."

Jan 1, 2017

By B. Hohenstein, B. McBain, B. de Jong

"The automated fire assay system (Fast In-line Fire Assay or FIFA) has not found acceptance in the Au mining industry as the lower measurable limit of 0.20 ppm did not allow Au tailings to be measured with confidence. The development of arrested cupellation has overcome this hurdle which was a limiting factor in the FIFA 1 process. In the new automated fire assay process, automated sample preparation, fluxing, fusion and separation of a Pb button are essentially similar to the FIFA 1 process, albeit with some improvements. However, the game-changer is the development and incorporation of arrested cupellation into the automated system, now called FIFA 2. The purpose of arrested cupellation is to reduce the 50 g Pb button to a 5 g Pb button by partial cupellation in a specially developed arrested cupellation system thereby concentrating the Au in the Pb by a factor of 10 and in so doing moving them into higher concentration ranges in the mini-button where they can be read on the spark spectrometer. Results show that concentrations down to 0.02 ppm Au in geological materials can now be determined using arrested cupellation in the FIFA 2 process, an order of magnitude improvement over FIFA 1.INTRODUCTION Traditional fire assay for Au has remained virtually unchanged for 3000 years. It has survived for so long because it is accurate, has relatively low detection limits and is relatively inexpensive. However, it is labour intensive, has a long turn-around time (typically at least 7 hours), is environmentally unfriendly and exposes assay operators to potentially unsafe conditions (toxic fumes, toxic dust and extreme heat from furnaces). The NiS collection method is not as effective for the assay of Au as it is for the PGEs. A rapid, accurate, cost-effective method for the determination of Au and the Platinum Group Elements (PGEs) in geological materials would be a tremendous benefit to mining companies. Many of these objectives have been met by the FIFA 1 (Fast In-line Fire Assay) developed some 15 years ago in which automated methods have replaced the manual procedures which are part and parcel of conventional fire assay. However, concentrations below 0.2 ppm have been very difficult to achieve with sufficient reliability."

Jan 1, 2017

By Paul Suver

"The closed loop standing column well (CLSCW) system uses a closed circuit of water to develop the same thermal heat exchange characteristics that are achieved from traditional open circuit standing column well that uses the ground water directly. Pipe pile and pipe anchor foundations can be used as CLSCW components for ground source heat exchange. New data gathering and analysis techniques and equipment installed in the heat pumps allow any mechanical engineer to design the system without specialty engineering equipment and certifications.CLSCW Description:Closed end steel pipe of varying outer diameter (O.D.) is installed by various technologies at varying depths depending on subsurface geology. The wells are arranged as stand alone wells or in groups joined in parallel or in series or in a combination of both. These pipes may also serve a dual function as foundation supports, deep foundation pile, anchors or earth retention components. These wells are then internally coated to minimize corrosion. The wells are then plumbed and capped to create a vessel equipped with a supply and return water line.The stand alone well or group of wells is then used as a ground heat exchanger for a ground source heat pumps located in or around the building.The ground source heat pumps provide heating and cooling to the building either with a traditional ducted distribution system or with radiant heating and cooling. These systems can reach efficiencies three times greater than traditional gas fired heat sources and five times greater than traditional air conditioning sources."

Jan 1, 2017

By M. Pelegrin Rodríguez, J. Castellanos Suarez, R. Causse Miyares, A. Mosqueda Martínez, Rubén Aja

"This paper will describe the methods and the results of studies to integrate polymetallic nodule extractive metallurgy methods into existing and operating technologies or plants with the aim of reducing the capital cost of deep-sea mining challenges and to streamline the supply chain of raw materials where such opportunities exist (Moa Bay and others). It will also assess the possibility to carry out pre-industrial processing operations with productivity corresponding to pilot mining operation in the Clarion Clipperton Fracture Zone (5–10% of assumed annual production) with the use of existing facilities. The present study shows the results of high pressure acid leaching of polymetallic nodules (PN) mixed with laterite non-commercial ore. It also presents PN processing in the presence of ammoniacal tailings obtained from the Caron process. The experiments were carried out according to 24 full factorial design. The regression equations were determined for extractions of Ni, Co, Cu, Zn, Fe and Mn. The obtained results show that increasing temperature, the acid/ mineral ratio and the leaching time have a positive and significant effect on extraction of all the studied metals. However, increasing the tailings addition favors the extraction of the Co, Zn and Mn. The extraction of Fe diminishes, while the extraction of Ni is not affected. In the following conditions; 180 min, 260°C, 0.5 kg acid /kg minerals and 2.5 kg PN/kg tailing; the following extractions were achieved; 96% Ni, 90% Co, 97% Cu, 99.9% Zn, 43% Mn and 26% Fe."

Jan 1, 2017

By J. Eloranta

"Previous work indicated that the annual per-capita consumption of raw aggregate material averages about 10 tons; half of which is produced by blasting. Given a population of approximately 320 million in the United States alone, this amounts to 1.6 billion tons of blasted material annually. It was also estimated that up to 20% of the blasted material in aggregate operations is smaller than 6.35 mm (1/4inch) in size. Thus, about 320 million tons (i.e. 1 ton per capita) of byproduct is produced annually and sold at significantly lower prices or potentially discarded in waste dumps."

Jan 1, 2017

By Constantin Pitis, Paul Slatter, Behnam Pirouz, Laura Contasti, Markus Zeller, Sadegh Javadi

"The centrifugal slurry pumps feeding cyclones are critical components used in the grinding process. It is well known that for this type of pumps the performance degradation is very intense. To minimize downtime a complete stand-by slurry pump is always installed in a parallel circuit. The replacement decision of slurry pumps is sometimes set on specific periods of time that are empirically determined, based on previous experience; unless a pump failure triggers the second (standby) pump. Given the significant energy costs in the grinding process and a desire to increase competitiveness, engineers and scientists started research in this field while manufacturers also took actions in order to improve pumps reliability and performance. The lack of standardization regarding the methods used to benchmark and evaluate the energy performances of cyclone slurry pump systems in the mining industry makes it difficult for an enterprise to take informed decisions concerning the replacement or optimization of its process based on energy benchmarking of such slurry pump systems. This paper proposes a new methodology of benchmarking slurry pump performances using a new concept of Benchmark Energy factor (BEF) based on Mathematical Model Benchmarking. The concept of BEF has been proven successful in other industries. A new standard addressing the guidelines for benchmarking the energy performance of slurry pumps for cyclones was proposed within the Canadian Standards Association. This standard will provide a unified and consistent methodology for performing measurement activities with the ability to measure and verify the system energy performance in the field through the BEF approach. Practical examples based on the new concept are presented with comments."

Jan 1, 2017

By A-A. Bogno, M. Rappaz, J. Valloton, H. Henein

"Rapid solidification of Al-Cu droplets of eutectic composition was carried out using Impulse Atomization in an argon atmosphere, to study the microstructures forming at different cooling rates and undercoolings. Two distinct morphologies were observed within the investigated Al-33wt%Cu droplets microstructures: (i) A regular lamellar morphology and (ii) an undulated morphology. The volume fraction of each type of morphology was measured as a function of the droplet size and the nucleation undercooling was deduced using the hypercooling limit equation. The scale of the microstructures was determined through measurements of inter-lamellar spacing across and along the growth direction. Growth velocity and undercooling were deduced using Jackson and Hunt (1966) eutectic growth theory. Finally, mechanical properties were estimated through micro-hardness analysis using a Vickers hardness tester, revealing exceptional properties for an aluminum-copper alloy. Indeed, the hardness values, increasing with growth rate and undercooling, were 3 times higher than the values obtained in hypo-eutectic Al-Cu alloys.INTRODUCTION Eutectic alloys are very attractive due to their good fluidity allowing ready shaping of parts in casting processes as well as in thermal spray deposition. In addition, they yield microstructures with high mechanical properties, by the virtue of their scale/size which is defined by the solidification parameters and the thermodynamic and thermophysical properties of the given alloy. Therefore, it is important to understand the relationship between the microstructures and the solidification parameters of eutectic alloys in order to control their solidification path and mechanical properties. The latter could be improved by either adding an appropriate strengthening component to a base eutectic material (Böyük, MaraslI, Kaya, ÇadIrlI, & Keslioglu, 2009) or by refining the microstructures for more effective dislocation pinning (Campbell & Campbell, 2003). Tailoring the microstructure can also be beneficial to chemical (Freitas, Osório, Spinelli, & Garcia, 2014; Osório, Freire, Caram, & Garcia, 2012) or electrical (Kaya, 2012) properties of the material. Eutectic-type microstructures, usually formed from liquid (eutectic transformation) or solid (eutectoid transformation), are made up of two or more different phases, generally of lamellar or fibrous (rod like) morphologies (Kurz & Fisher, 1998). In general, a binary eutectic structure can be regular (when both phases are non-faceted) or irregular (one of the two phases is faceted), the two solid phases having roughly the composition of the liquid from which they are formed."

Jan 1, 2017

By Antti J. Perala, Teemu J. Yli-Kovero

"Efficient use of land is constantly requiring more underground construction. Minimized execution time and disturbance to surroundings and nearby structures are essential benefits for all construction techniques. To meet the demands of a modern construction project, suppliers have to be able to provide high-quality and tailor-made products just on time. RD pile wall is a retaining wall based on drilled steel pipe piles which are connected to each other with special interlocking profiles. RD pile wall is a solution which enables penetration of overburden soil, dense fill layers including stones and boulders, and embedding into the bedrock in one single operation. Several test installations and laboratory tests have been made to develop the system and to test and improve the water tightness of the wall. Beside these tests, RD pile wall has also proven its reliability in almost 70 projects. Largest project so far has been Pasila Tripla project in Helsinki, Finland. A permanent retaining wall with surface area of 18,000 m2 (193,750 ft2), excavation depth of 21 m (68 ft) and over 17 m (56 ft) of water pressure was made with 711 mm (28”) and 406.4 mm (16”) pile sizes. Piles were delivered to site in one piece with lengths up to 33.5 m (110 ft).INTRODUCTIONExcavations in cramped city centers and in between of existing buildings and other structures are facing more and more challenges. Installation of sheet pile walls is often problematic or even impossible due to obstacles in ground from old structures and due to demand to extend the excavations to even deeper and harder soil layers. Also installations of secant pile walls are facing difficulties due to cramped construction sites and constantly tightening execution times.On the other hand, an efficient and reliable piling technique suitable for the demanding soil conditions described above, percussion drilling, has been developed since the 1960’s, and especially from the mid- 1990’s, when the concentric drilling method with the ring bit and pilot was introduced. A new retaining wall application, the RD pile wall, was developed by combining that drilling method with the widely used retaining wall solution based on steel pipe piles and welded interlocks (a pipe pile wall normally installed with vibratory or impact hammers).PRINCIPLE AND MAIN BENEFITS OF THE METHODRD pile walls can be used in all soil conditions. Most beneficial the system is in extremely demanding soil conditions where the installation of traditional retaining walls is challenging or even impossible. The RD pile wall is a combination of drilled steel pipe piles and interlocking sections as shown in Fig. 1.Individual RD piles are connected to each other with interlocks welded to the piles on the automated welding line at the workshop. The matching dimensions of the drilling system and interlocking sections allow the installation of RD piles through stones and boulders and even into the bedrock, if necessary, in a single operation. Installation is done by a down-the-hole (DTH) hammer using the centric drilling system and oversized ring bits or a drilling system consisting of a pilot bit and reamer wings shown in Fig. 2."

Jan 1, 2017

By R. E. Vivas, J. A. Villa

"INTRODUCTION Located in the state of Colima, Peña Colorada is one of the largest iron ore operations in Mexico. The project is owned in equal parts by ArcelorMittal and Ternium. Though boasting a production capacity of 4.5 million tons of concentrate per year, Peña Colorada is faced with declining ore grades. In order to respond to this situation, Peña Colorada had to expand production even further. This expansion created various challenges that were overcome by the adoption and application of new technology. Examples of these technological innovations are discussed in detail in this paper and include improvements in geo-modeling, mine planning and mine operations. The successful implementation of these technologies paid for itself many times over, and has led to significant improvements in production and performance, while lowering the operating costs and reducing the variance between planning and execution. PROJECT OVERVIEW Peña Colorada is a mining company which produces about 30% of the iron ore in Mexico. This project generates about 1,200 direct jobs and 3,000 indirect jobs, making a significant contribution to the local economy. Similarly, Peña Colorada invests in its local communities through numerous educational programs, scholarships, university agreements, social development, environmental agreements, etc. Peña Colorada’s operations consist of an open pit mine located in Minatitlán and a pellet plant located in the port city of Manzanillo, as shown in the location map below:TECHNOLOGICAL INNOVATIONS Most mining projects around the world typically follow the logic of “mining the next best ore”. Consequently, head grades tend to decline over the life of the mine. In the case of Peña Colorada, a decline in head grade combined with a decline in iron ore prices forced the operation to adapt to a new business environment and adopt new technologies to face these challenges. However, the first step along this process was to increase the confidence and reliability of the resource model. This task involved additional drillhole campaigns coupled with more detailed modeling techniques. Once the block model was completed, new optimization studies and production schedules were evaluated with new optimization tools that unlocked significant project value in many aspects of the mine plan. Similarly, new geotechnical studies were prepared, which provided new guidelines for pit slope design, and new technology was implemented to monitor ground movement and slope stability. The picture below shows two sectional block model views in MineSight 3D, along with the pit designs and geologic solids"

Jan 1, 2017

By M. Tardif, F. L. -Lavoie, M. Ruel

"In mineral processing, it is often very difficult to reliably measure several key operation variables. The harsh environment and high temperature encountered in pyrometallurgy processes lead to some difficulties when selecting the instruments, valves and actuators. If an important variable cannot be measured or manipulated adequately, controlling it can really become a big challenge. Sometimes, it is simply impossible to find the perfect equipment for the task. To help overcome these difficulties, a different approach is required. This approach will not correct the inherent problems related to the instruments and valves, but will cope with these problems. This article will demonstrate how modern process control techniques can be used to solve complex problems while remaining easy to implement. In this article we will described how soft sensors and multivariable fuzzy logic control were implemented at Koniambo Nickel to stabilize the furnace feed and allow for safe and reliable operation of an 80 MW DC arc furnace.INTRODUCTION Process Overview The process plant at Koniambo Nickel SAS is located in the North Province of New Caledonia, 310 km north of Noumea. The nickel-bearing ore is mined in the nearby Koniambo massif. After being screened and crushed, the ore is transported to the processing plant using a 12 km conveyor. After stacking in two blending piles, the ore, containing 2.3% nickel, is fed to the processing plant where it will go through the NST process (Nickel Smelting Technology) before being sent to refining and shotting. This article will focus on the improvement to control of the NST processes. The first steps of this process consist of milling the ore and removing all moisture through calcining (Figure 1)."

Jan 1, 2017

By Johannes Labenski, Christian Moormann, Johannes Aschrafi

"Open steel pipe piles are used for various applications in costal engineering, port structures and increasingly important for offshore structures. During the installation of open steel pipe piles the formation of a plug has an influence on the installation process of the pile and also on the final bearing capacity. The formation of the plug depends on different factors, e.g. the pile diameter and the installation method. This paper starts with a structured overview about analytical methods (API, EAP-EAU, UWA-05, HKU-12, Modified API) to calculate the axial bearing capacity of open steel pipe piles. The numerical simulation of the installation process of open steel pipe piles has to fulfill high demands, i.e. to accurately represent the penetration of the pile inside the soil, the formation of the plug and also the stresses and strains during the installation. A numerical back analysis of a comprehensive field test, using the Coupled Eulerian-Lagrangian (CEL) method and a hypoplastic constitutive model for sand, reveals the stresses and displacements of the soil and of the piles. The analysis provides a comprehensive understanding of soilpile interaction.INTRODRUCTIONThe particular difficulty in the numerical simulation of plug formation, is that the effect of plugging inside open ended steel pipe piles has not been fully investigated. In scientific papers different approaches are documented to explain this phenomenon. Some are based on in-situ tests and others are based on numerical simulations. One of the challenges is to determine the end bearing capacity and shaft friction of the steel pipe pile. Different approaches have been developed over the years to determine them e.g. from Randolph et. al. (1991, 1994) and Paik et. al. (2003). Recent approaches are the ICP-05 Method (Jardine 2005), the UWA-05 Method (Lehane 2005) and the HKU-12 Method (Yu & Yang 2012a). A comparison of some methods can be found in Schneider et al. (2010). A plug inside an open steel pipe pile can be visualized as a spatial bracing of soil between the inner surfaces of the pile, cf. Lüking (2010).. However according to Lüking & Kempfert (2012) this bracing only exists for the height in the end of the pile equal to twice its diameter.To identify a plug inside a pile, there are different measurable parameters. One parameter is the development of stresses around the pile during and after its installation. Henke (2013) measured the inand outside horizontal stresses at the pile tip during the installation. The results showed higher stresses on the inside compared to the outside. To validate his measurements he performed a numerical back-analysis of the measured installation process and got matching results."

Jan 1, 2017

By Gabriel Walton, Sankhaneel Sinha

"Rib failures are a major hazard in underground mining. When pillars are subjected to loading, extensile cracks are generated parallel to the excavation boundary, which can manifest as rib falls. A common mitigation measure is to install supports, especially bolts, normal to the rib surface. The type and spatial distribution of these supports along the pillar is often based on experience rather than comprehensive analysis. Since conducting field experiments is often impractical and expensive, a convenient alternative is to perform 3D numerical modeling. In this study, FLAC3D has been used to capture the interaction of rib bolts and the failure processes governing the stability of pillars. An associated goal is to determine whether, at all, a continuum software is capable of modeling the effect of supports. The modeling involved two important steps: selection of a proper constitutive model, and, explicit simulation of rock bolts. Based on precursory work in the last decade, an S-shaped strength criterion was chosen that can describe the tensile fracture mechanism of rock at low confinement and shear failure mechanism of rock at high confinement. The built-in pile structural element in FLAC3D is a simplified representation of the complete bolt system. Hence, the different components of a rock bolt (i.e., steel, grout, steel-grout interface, and grout-rock interface) have been explicitly modeled within the rock mass and then tested for its ability to replicate the ground-support interaction behavior. INTRODUCTION Rib failure-related hazards and injuries have plagued the mining industry for decades (Mohamed et al., 2016; Iannacchione and Prosser, 1998). In highly stressed environments, excavation parallel cracks are the primary initiators of skin instability. In absence of any support, this failure can indirectly destabilize the excavation by increasing the exposed span of intersections and roadways. Over the last two decades, there have been numerous injuries (fatal and non-fatal) due to rib failures in underground coal/non-coal mines."

Jan 1, 2017

By Glenn J. Rix, Eduardo Tavera, Raphael Siebenmann, Zhongjie Zhang, Robert C. Bachus, Jongwon Jung

"The Louisiana Department of Transportation and Development (LADOTD) uses a variation of the FHWA-modified Gates equation to verify the nominal pile bearing resistance, typically on smaller projects where static load tests and dynamic monitoring are not practical. An inconsistency in the resistance factors for load and resistance factor design (LRFD) penalizes the target pile capacity needed during field observation if the LADOTD dynamic formula equation is used, which is unreasonable, and has created confusion among designers, consultants, district personnel, and inspectors in Louisiana. The objectives of this project are to recalibrate the FHWA-modified Gates equation and update the associated LRFD resistance factor for pile types and local soil conditions encountered in Louisiana. Improved consistency relative to the current design approaches will be achieved if the updated resistance factor matches or exceeds the worst-case resistance factor used by LADOTD, which will reduce confusion among users. Updating the resistance factor will also serve to increase confidence in the FHWA modified Gates equation, optimize the efficiency of the piles, and reduce project costs.IntroductionThe original 1957 Gates pile driving formula (Gates, 1957) is an empirically derived dynamic formula that is used to predict pile capacity in the field during pile installation. The original Gates formula tends to over-predict pile capacity for low driving resistances and under-predict pile capacity for high driving resistances (Hannigan et al., 1998). Thus, the Federal Highway Administration (FHWA) proposed a modified version of the Gates formula that addressed this limitation. The FHWA–modified Gates equation is:"

Jan 1, 2017