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By E. A. Barrett

The U.S. Bureau of Mines (USBM) conducted experiments to determine if training using a latent-image, three-dimensional (3-D) slide simulation exercise improved miners' ability to recognize roof and rib hazards. The effectiveness of this innovative type of classroom training was investigated by measuring workers' performance on a hazard recognition task. The study was unique in that hazard recognition skills were assessed in the workplace using actual coal mine roof and rib hazards. Results showed that training with a latent-image, 3-D slide simulation exercise significantly improved each subject's performance on the in-mine hazard recognition task. Further, the USBM researchers concluded that transfer of learning from the classroom to the workplace occurred.

Jan 1, 2010

By David E. Siskind

The U.S. Bureau of Mines and the State of Indiana cooperated with AMAX Coal Co. and its consultants to determine the effects of coal mine overburden blasting on nearby pipelines. Five pressurized 76-m pipeline sections were installed on the Minnehaha Mine highwall near Sullivan, IN, for testing to failure. Four 17-to 51-cm-diameter welded steel pipes and one 22-cm PVC pipe were monitored for vibration, strain, and pressure for a period of 6 months while production blasting advanced up to the test pipeline field. In contrast to previous studies of small-scale, close-in blasting for construction, these tests involved overburden blasts of up to 950 kg per delay in 31-cm blastholes. Analyses found low pipe responses, strains, and calculated stresses from even large blasts. Ground vibrations of 120 to 250 mm/s produced worst case strains that were about 25 pct of the strains resulting from normal pipeline operations and calculated stresses of only about 10 to 18 pct of the ultimate tensile strength. No pressurization failures or permanent strains occurred even at vibration amplitudes of 600 mm/s.

Jan 1, 2010

By M. Gorman

The Mineral Park Mine is an open pit copper-molybdenum mine located in northwestern Arizona, approximately 74 miles southeast of Las Vegas, Nevada. The property has been owned by the Duval Corporation, Cyprus Mining Company and Equatorial Mining of Australia. Mercator purchased Mineral Park from Equatorial in 2003. Mineral Park commissioned a 25,000 tpd copper and molybdenum concentrator in November and December of 2008. The process includes two stage milling (SAG and Two Ball Mills) fed by primary crushed ore. Metals are recovered in a copper-molybdenum flotation circuit consisting of mechanically agitated roughers and cleaners. The copper- molybdenum flotation concentrate is thickened and further processed in the molybdenum flotation circuit which separates the copper and molybdenum minerals into salable concentrates. The molybdenum circuit also uses mechanically agitated cells. This paper describes the plant and some of the highlights of the commissioning process.

Jan 1, 2010

By Essie Esterhuizen, Michael M. Murphy, Chris Mark

"The design of underground coal mines requires a clear understanding of the overburden response, the loading of pillars, the loading of the gob, the pillar failure process, and the ultimate load carried by partly or fully yielding pillars. Very few highquality stress measurements of yielding pillars and gob loading have been made in full extraction mining. Well-calibrated numerical models can assist in providing a better understanding of the load and failure processes, provided the coal, the overburden, and the gob are all modeled with sufficient realism. A program of numerical model calibration and validation was carried out using FLAC3D.1 The models were calibrated against observed and measured performance of coal pillars and the overburden in operating mines to provide a basic set of input parameters that can be used to provide a realistic first estimate of expected ground response and pillar loading. Input parameters for modeling coal pillar response were based on data from triaxial testing on coal samples, combined with both matching the depth of failure in the coal ribs to observations as well as matching the peak pillar resistance to an empirical equation. The models were calibrated against strong roof and floor case histories in which the pillar strength is governed by failure and yielding of the coal within the pillar and the surrounding strata only had a limited impact on pillar strength. Input parameters for the overburden were determined from a large database of laboratory tests and model calibration against maximum subsidence and subsidence curvature. Further overburden calibration was carried out by matching stresses in the mining horizon to field measurements. Three examples of the application of the calibrated dataset and modeling methodology to field measurements are presented. The results show that a reasopable estimate of the in-seam stress distribution and overburden response can be obtained for both strong and weak overburden scenarios at various depths of cover.INTRODUCTIONThe planning and design of coal mine excavations requires reliable estimates of the expected strength and loading of the mine structures to achieve global stability. Empirical methods are widely used to estimate the strength and loading of coal pillars and have been incorporated into pillar design procedures, such as Analysis of Longwall Pillar Stability (ALPS) (Mark, 1987) and Analysis of Retreat Mining Pillar Stability (ARMPS) (Mark and Chase, 1997), that are widely used in the United States. ~umerical models are finding increasing application as a tool for underground mine design because of their. versatility and the ever increasing computational power available to mine designers. A prerequisite for the application of numerical models is the calibration of the models against observed rock mass response (Hoek et al., 1990; Skiles and Stricklin, 2009). The calibration process may include comparison of model results to measured stress and deformation and modifying the input parameters in a systematic manner to achieve a satisfactory agreement between the model results and measurements. Once models have been calibrated, they can be applied to evaluating similar mining layouts in similar geological conditions."

Jan 1, 2010

By N. O. Lotter

The reliability of a set of flotation results is key to minimizing project risk, either at the commissioning of a concentrator or at the point of implementing an improvement to an existing concentrator operation. High-confidence flotation testing (HCFT) was developed for this purpose and is part of the list of technologies at various scales used by Xstrata Process Support (XPS) in addressing these projects. The methodology is based on two principles: one, to ensure that the ore sample is representative and has been well-blended and subsampled; two, to perform the flotation tests in sufficient numbers of replicates with appropriate quality controls, so as to improve the reproducibility of the test data. Across ten years of research on this methodology at Xstrata Process Support, Sudbury, several improvements to the HCFT method and complementary connections between sampling and quantitative mineralogy have been developed. Two case studies are reviewed. These show the capability of this system in both optimizing an existing concentrator operation and in serving a new mine scenario. Further work to improve the efficiency of this procedure has been identified. Key words: Flotation testing, Flotation

Jan 1, 2010

By Jason Baird, Joshua Hoffman, Phillip Mulligan

The purpose of this report is to address the method of reducing the overall explosive weight of Explosively Formed Projectiles (EFPs) while still achieving satisfactory performance. This reduction is crucial in order to comply with outdoor explosives testing standards for Missouri University of Science and Technology’s (Missouri S&T’s) Experimental Mine. Initial EFP design testing exceeded given limitations, making reliable data difficult to ascertain. EFPs must be tested outdoors to allow for specific information recordings which aid in defending against them.

Jan 1, 2010

By Milos Bila

The second half of 2008 and the first half of 2009 brought up important anniversaries. My old passport from Czechoslovakia has a stamp with date 10-10-1968 at 10:00 AM, the exact time I crossed the border between the former Czechoslovak Republic and Austria. This date has an important meaning because I could not come back to my country for the next 21 years. The 40th anniversary of Soviet led invasion, which took place on the 21st of August 2008, revealed some unknown and long time kept secret news.

Jan 1, 2010

By M. Solomon

Crushers are designed and manufactured to survive the severe duty of mining environments worldwide. Under these conditions the crusher performance and availability is one of the critical factors in the mine?s production and profitability. Traditionally the development of these machines tends to be experience-based, incremental improvements in design due to challenges of different applications, duty, or manufacturing. In order to better serve the mining industry a new approach was taken to the design of primary crushers. This approach was to focus on safety and maintenance activities. The result of this effort is a new generation of gyratory crushers that can be serviced from above. Using the features of this new generation of crushers to their fullest extent crushing installations have improved safety, reduced design and construction costs, and lowered maintenance requirements. This presentation explores the benefits of two crusher installations utilizing top service crushers.

Jan 1, 2010

By U. Steiner

Electronic detonators have been in commercial use for a decade, with an excellent safety record. This paper lists known incidents involving electronic detonators. Typical standards required by regulatory bodies for static electricity and electromagnetic fields are reviewed. The performance of some detonators is compared to these standards; in general the minimum standards are easily exceeded. The general resistance of electronic detonators to extraneous electrical energy that can be derived from the body of test results is compared to danger levels for exposure of humans to these energies; it is shown that electronic detonators can safely tolerate higher electrical energies than people can. This comparison includes comparable data for electric detonators, which are shown to be more vulnerable to extraneous electrical energy than people are. Electronic detonators also bring significant safety benefits in blasting due to their testability, two-way communications, reliability, programmability and precision. The links between these attributes and enhanced safety are discussed with examples from actual blasting. Although electronic detonators are usually more vulnerable to extraneous electricity than non-electric initiation systems, the paper shows that the net safety benefit in handling and blasting is in favor of electronic detonators, which are the safest initiation system that has ever been offered to the mining industry.

Jan 1, 2010

By William K. Tolley

The U.S. Bureau of Mines (USBM) is currently investigating the electrochemistry of mineral flotation. A significant need in this area is greater reliability of sensors. The USBM is testing electrolytic methods to clean and condition redox-sensing electrodes to improve the reliability and extend the service life of these instruments in the harsh physical and chemical environment of mineral processing slurries. A novel method for removing scale from fouled electrodes has been developed that includes anodic polarization to 1.2 V versus the Ag/ AgC1 reference potential, followed by brief potentiodynamic conditioning. Laboratory results show that this technique removes calcarious deposits from gold sensing electrodes and returns the electrodes to useful service within approximately 10 min. Mechanical abrasion to remove the scale is thereby avoided.

Jan 1, 2010

By Matthew E. Meyer

The intent of this manual is to provide guidelines for observing and documenting the installation of ACIP piles. The manual may also serve as a guide for the training of inspection personnel. It is expected that the general guidelines and procedures described in this manual for the inspection and installation of ACIP piles will be supplemented by engineering judgment, local practice, and experience. ACIP pile construction procedures will vary depending on soil, rock, and groundwater conditions. This manual represents a wide range of possible applications in a variety of projects. It is not intended to be applicable in all situations nor replace engineering judgment for any given project. Therefore, an all-inclusive inspection manual is not considered practical or desirable. This manual should not be used to interpret or replace project specifications. It has, however, been prepared to complement the Augered Castin- Place (ACIP) Piles Manual model specification (DFI, 2003).

Jan 1, 2010

Australia is a hub for mining technology development. The paper describes many of the key players involved in mining research in this country along with some of the interesting research outputs to emerge over the past decade.

Jan 1, 2010

By J. C. Johnson

In situ stresses are important input data for the design of safe, stable stope layouts and extraction sequences. However, it is commonly assumed that normal and shear stress gradients in a stress field are negligible and, consequently, that stresses are uniform throughout the region of analysis. To evaluate these assumptions and to provide input data for an analysis of a shaft pillar mining plan, in situ stresses were measured at the Homestake Mine, Lead, SD, using overcoring on hollow inclusion cells and borehole deformation gauges. These measurements were used with conventional least squares, best fit data reduction schemes. The results showed that normal stresses within the shaft pillar were less than, but comparable to, those estimated from finite-element modeling. Shear stresses were an order of magnitude less than normal stresses and varied considerably from site to site. Possible causes of this variability include effects of scale, elastic moduli, anisotropy, and axial strain. Because of the variability, it is not possible to determine the magnitude of horizontal stress gradients.

Jan 1, 2010

By ?. ?ivkovic

The silicate slag and copper matte that are the byproducts of smelting copper in a reverberatory furnace contain SiO2, FeO, Fe3O4, CaO and Al2O3, and Cu, Fe and S, respectively. These components influence the oxide (Cuox), sulfide (Cusul) and total (Cutotal) copper content lost in the waste slag. This paper uses multiple linear regression analysis (MLRA) to determine the degree of influence. The results of calculations obtained using MLRA were compared to actual measured results and found to have a large degree of correspondence, with the coefficient of determination R2 = 0.975. These results indicate that slag composition and copper content in the matte influence the copper losses in the waste slag with a probability of above 97%. It was determined that, of the total copper content of the slag, 74% is in sulfide and 26% in oxide form, and that this ratio is not dependent on the slag or matte composition.

Jan 1, 2010

By F. C. Grensing, W. R. Crib

Copper-15 Nickel-8 Tin alloy is a relatively modern material, having been discovered in the 1970’s. It has complexities with casting, hot working and interdependent solid state phase transformations. A key to the high reliability manufacture of wrought rods, bars, plates and tube is the casting technology, which limits segregation, promotes microstructural uniformity and enables hot working. The EquaCast® continuous casting process has enabled the production of a broadening variety of wrought forms with typical yield strengths ranging from 100 to 180 ksi (690 to 1241 MPa) depending on size, shape and temper. This paper reviews the characteristics of wrought Copper-15 Nickel-8 Tin products which have registration in AMS specifications (4596 and 4597) and MMPDS-04 (CN-1) for use in aircraft. The design limits, microstructures, fracture characteristics and tribological behavior will be examined. This alloy system is emerging as a material of choice for aircraft bearings, corrosion resistant oil and gas exploration components, machinery and demanding off-road equipment applications. ToughMet® 3 is an alternative or upgrade to conventional moderate and high strength aluminum bronze bearing alloys.

Jan 1, 2010

By Jeremy G. Kress

We propose the discrete element method (DEM) as a complimentary alternative to analytical solutions and FEM models for the analysis of pile response. DEM is a novel approach to the engineering design of deep foundations which can be used to provide insight into the mechanics of soil-soil and soil-structure interaction. It is common to use analytical, empirical, and semi-empirical methods to predict pile behavior, where if granular properties, pile length, or load orientation change, then significant adjustments are made in the design sequence. DEM provides a more uniform approach in granular soils. Based on constitutive force-displacement relationships and laws of motion in rigid and elastic bodies, few changes must be made for a wide variety grain types, pile types, embedment, and load orientation. Preliminary results for simulation of a single pile are qualitatively consistent with results from conventional design procedures and also provide significant information not available from other analyses (e.g., local information about interface failure during shear). Importantly, these analyses are portable to a variety of pile types and installation procedures, which may not be the case for empirical approaches. Given consistent increases in computing power and rapid advances in model speed and sophistication, the DEM should prove to be a robust method for design and the analysis of pile response in granular soils.

Jan 1, 2010

By T. Narita

The diffusion barrier coating system (DBC system) was designed to suppress interdiffusion between alloy substrate and coatings in addition to ensuring slow oxide growth at high temperatures. In this report the concept of the DBC system will be introduced, and the results obtained for various heat-resistant alloys are presented. In this DBC system the s-phase of the Re-Cr-Ni system was selected as the barrier and is formed by electroplating Re-Ni and Ni films from aqueous solutions, followed by Cr and/or Al pack cementations. A typical DBC system consists of Ni-base superalloy / triple s-Re based alloy layer / ?’-Ni3Al and/or ß-NiAl (with or without Pt addition) / a-Al2O3. It was found that the DBC system maintained its structure for long time exposures because the s phase has tie-lines with the ? and ?’ alloy substrate and the ?’ and/or ß coating. The s-Re based alloy can suppress both the inward Al diffusion and the outward diffusion of alloying elements. The DBC system was successfully applied to various heat-resistant alloys such as Ni-Mo and Fe-Cr-Al based alloys, and these alloys with the DBC system were creep-deformed slowly under external applied stresses. A simultaneous diffusion coating process for Al and Hf was developed using Hf+NH4Cl+Al2O3 pack cementation. To obtain reliable and long-life coatings the combination of alloy substrate, coating, and external scale should be considered as a total system, to optimize oxidation resistance, structural stability, and mechanical properties.

Jan 1, 2010

By J. Wiedenroth

Since the end of the 1970s Pipe Conveyors have become increasingly important for conveying bulk materials because they have some specific advantages over conventional troughed belt conveyors. FLSmidth KOCH Pipe Conveyor represent the marked-leading know how of the former KOCH Transporttechnik GmbH, which belongs to the FLSmidth Group since January 2007. Pipe Conveyors from FLSmidth KOCH are already being used successfully at more than 260 locations around the world. Their special properties, their extreme flexibility, the horizontal and vertical changes in direction without transfer points, the small space requirement, the low-noise running and their optimum protection of environment and material without any additional casing mean that Pipe Conveyors can provide transport solutions that are often far superior to other conveying systems. The utilization of these many advantages will be illustrated in the following example of the world?s longest Pipe Conveyor at Cementos Lima, the Peruvian cement producer.

Jan 1, 2010

By J. K. Whyatt

The U.S. Bureau of Mines conducted an overcore stress measurement on the 5300 level of the Lucky Friday Mine, Mullan, ID, to investigate the stress regime around an experimental stope in a rock-burst-prone mine. The result indicated a stress field with unexpected magnitude and orientation [s 1 ?135 MPa (19,600 psi) oriented S 80° W). An unusual amount of rock-burst activity was encountered during subsequent excavation. A careful review of the overcore data suggested the overcore strain measurements were valid. Moreover, concentrated rock-burst activity suggested that the measured stress field did exist, but was localized and therefore did not represent the far-field in situ stress field.

Jan 1, 2010

By D. Rucker

Flow models are used to predict the extraction efficiency of metals in rock piles. These models typically use hydraulic parameters obtained through column studies, which assume that the material in the column wholly represents the entire pile and the parameters can be upscaled several orders of magnitude for model evaluation. This assumption fails for parameters that are spatially variable or scale dependent. To overcome these issues, measurements made directly on the heap at the appropriate model scale can be made with the electrical resistivity method. The method aims to map the variations in the electrical resistivity, which can be associated with moisture content, degree of fines, metal content, and leachate concentration. We present an example of calibrating the resistivity with borehole measurements of moisture using geostatistics to show how the resistivity method can be used to obtain a spatial moisture distribution. It was shown that cokriging the resistivity and moisture together gives a more reliable distribution.

Jan 1, 2010