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By John E. Miller

Unit Rig & Equipment Co., manufacturer of Lectra Haul trucks, is continually studying methods of reducing the operating costs of large haulage trucks. Reduction of haulage system operating costs is an important goal that equipment operators and equipment manufacturers constantly try to improve on. One of the most variable and important factors affecting operating costs is actual truck operating practices. An examination was centered on methods to optimize truck utilization. It was found that a very effective method of accomplishing this goal would be an automatic truck control (ATC) system to automatically control a fleet of haulage trucks in a predetermined pattern. Economic studies were conducted which showed a very favorable reduction in mine operating costs by use of an ATC system. In 1970, Unit Rig & Equipment Co., in conjunction with SAAB-SCANIA began preliminary development of adapting, for truck use, a proven automated control system, previously used for train systems, small trucks, and military target vehicles. In 1974, the first prototype system was installed on a Lectra Haul M-100 and tested extensively at Unit Rig's test track in Tulsa, OK. This truck and system were then displayed publicly at the 1974 convention in Las Vegas. In 1976, the system was redesigned for production to maximize reliability, ease maintenance, and to accommodate future control and-status reporting developments proposed for haulage trucks. The new design equipment was manufactured, and a full system test will be conducted in an actual open-pit mine for an extended period to evaluate reliability, compile economic data, and obtain application information to evaluate complete mine haulage system conversions to ATC. System Description The ATC system is designed to provide automatic control of all the vehicle functions normally accomplished by the vehicle operator. The basic system consists of the on-board control equipment and the wayside control equipment. The on-board equipment receives commands from the wayside equipment and controls all the truck functions. In addition, on-board sensors monitor all critical truck functions and provide instructions to the truck and system to assure safe operation. The wayside equipment consists of a buried guidewire, block control units and a central controller which provides predetermined signals to the on-board equipment for speed control, steering, and for auxiliary functions (dumping, horn, etc.) through the guidewire located in the truck's path. The wayside equipment also controls vehicle separation, system status, and provides truck location to a central display panel. The central control panel can vary the speed level signals over any segment and can also command an emergency stop to halt all the units. [Fig. 1] illustrates a typical ATC installation. If ATC is used in operations which require flexibility and mobility at the end of the ATC guidance network, the trucks can then be operated by either radio remote control or manually to complete their assigned functions.

Jan 1, 1982

By Goran Mathisson

PLASMARED is a process in which one well established and one new advanced technology have been merged into a practical tool for production of high quality direct reduced iron at lowest energy consumption and costs. Before describing the process, we have to reiterate the simple fundamentals of making metallized iron from iron ores: The main components necessary are: - Iron oxide - Carbon and/or hydrogen - Heat

Jan 1, 1982

By C. W. Bollier

In recent years, Peabody Coal Company has enjoyed a great amount of success using roof trussing as a secondary support system. Since 1975, over 180,000 trusses have been installed in 12 different Peabody mines with varying geological conditions. Projections from Peabody, and throughout the mining industry, indicate a continuous growth in the trussing principle for roof control. Peabody's primary supplier has sold over 1,000,000 trusses to 50 different mines throughout the country. (1) Roof trusses provide an improved means of controlling difficult roof conditions which, in turn, improves worker safety and mine production. Since the original development of the truss, (2) the only major modification to the trussing procedure has been the addition of the resin point anchor system in the mid-70's. The resin point anchor was the catalyst needed to provide a reliable anchor and create acceptance of the roof truss by both management and labor. Peabody began using trusses in their mines in 1975. For the first few years, most of the truss effort was geared toward determining proper anchorage, spacing, and gathering historical data. In recent years, Peabody's activities have centered on the development of improving trussing procedures. Through monitoring and trussing activities, a number of areas of improvement have been found.

Jan 1, 1982

To develop a system which will effectively detect and extinguish fires in underground fueling areas while also providing a warning for nearby miners. Approach A system involving optical fire sensors. automatically-released dry chemical and aqueous film-forming fluid (AFFF) fire suppressants, and automatic alarms was designed from off-the-shelf, state-of-the-art components, and was in-mine tested at two mines in the two typical underground fueling area situations: fuel transfer areas and fuel storage areas. How It Works As mines become more mechanized, the number of fire hazards increases since fueling areas are more abundant. Fire hazards are especially serious in deep mines, since escape time is longer. To help solve this growing problem, the Bureau of Mines, in cooperation with the Mine Safety and Health Administration (MSHA) and the National Fire Protection Association (NFPA), has developed and in-mine tested a cost-effective fueling area fire protection system. The system was designed to be rugged enough for reliable, long-term use, yet to utilize state-of-the-art, off-the-shelf components to maintain cost-effectiveness. The system consists of cross-zoned, ultraviolet flame sensors used for quick response to fire, and a dual-agent fire suppression subsystem. A dry chemical is used for fast fire -knockdown," and AFFF (or "light water") is used for long-term, fire-securing capability. The basic components of the system are shown in the schematic illustration.

Jan 1, 1982

By Herbert R. Babitzke

The Minerals Availability System (MAS) was formally established by the Bureau of Mines in May 1975 to provide current appraisals of the engineering and economic availability of nonfuel minerals for consideration in the formulation of both domestic and foreign minerals policy, Domes- tic mineral property reports are developed by the Bureau's four Field Operations Centers, and foreign data are obtained under contract. This site-specific information is subsequently subjected to engineering verification and economic evaluation, and the results are analyzed and published as Minerals Availability System Appraisals. The deposit-specific data are also entered into the computerized MAS data base, where a subset of this information, the Mineral Industry Location System (MILS), is available to the public in the form of computer graphics and listings. Other MAS products are also described. The Bureau's MAS personnel are frequently involved in special engineering and mineral economic projects for other Federal and State agencies. MAS personnel also work closely with the private sector, both in the area of mining and processing cost estimation, and as a source of nonproprietary mineral deposit information.

Jan 1, 1982

Mine planning for ore recovery by open stoping and pillar recovery is becoming more sophisticated, but there are basic operating constraints which must be imposed if this planning is to realise the production results on which the mine is dependant. The production reliability of an open stope is usually a high priority and common design problems can be identified. A range of practical considerations which should be considered at the mine planning stage are reviewed including equipment performance, blasting technology, ventilation requirements, development layouts, lead time, ground conditions, support, backfilling and ore recovery.

Jan 1, 1982

By Raymond M. Kacmar

This paper describes the Bureau of Mines research program on the reliability of computerized mine-monitoring systems. The basic concepts of computerized monitoring are introduced along with its advantages and limitations. Current Bureau projects covering mine-monitoring systems are described, and some of the major areas of concern that should be addressed by future projects are outlined.

Jan 1, 1982

By Horace M. Varner

Under sponsorship of the USBM and later of the DOE, a new type of rotary rock drill has been developed by The Bendix Corporation. Originally developed for the production of holes for the installation of longer than seam height roof bolts, the flexible drill is a useful tool for many drilling applications. This drill allows hands-off or remote production of holes for increased drilling speed and greater operator safety in any strata suitable for rotary drilling. The paper discusses various applications and experience for the flexible drill system in coal mining, metal/nonmetal mining, and for general civil engineering uses. Manual, remote control, and automatic roof bolter modules are also discussed.

Jan 1, 1982

By Roy C. Bartholomae

An accurate characterization of the vibration environment and a vibration qualification test derived from it will be a very useful tool for manufacturers of instrumentation for use on underground coal mining equipment. Recognizing this, the Bureau of Mines sponsored a study wherein vibration levels were measured on mining equipment to form a basis for developing the required vibration test. The data base was composed of 160 samples taken at different positions on a variety of underground machinery. The data were analyzed and presented in a format typical of military vibration qualification tests. The form was shown to be virtually identical to the swept sine test envelope specified in MIL-STD-810B for tracked vehicles.

Jan 1, 1982

By Jerry W. Stengel

The Bureau of Mines subjected two manufacturers' chemical oxygen (K02) self-rescue breathing apparatus to a series of laboratory environmental treatments designed to simulate various conditions in underground coal mines. The environmental treatments consisted of extremes of temperature, shock, and vibration. The tests were designed to be used as predictors of the ability of the self-rescuers to survive those environmental insults with no degradation in their protection to the wearer. Based on the severity of the treatments, simulating conditions more severe than offered by the mining environment, the two apparatus tested should be able to withstand the abuse offered by the mining environment and still function as intended in an emergency. Correlation of these tests with results of long-term field evaluations is needed to provide confidence in the laboratory tests as predictors.

Jan 1, 1982

By Frank L. Marley

Mexican silver mining operations have existed prior to the sixteenth century. Recovery processes throughout the centuries were developed at the many mining localities and have progressed through smelting, the patio amalgamation process to cyanidation and flotation. A study of the present silver mining zones is reported in which the ores are evaluated in terms of the mineralogical constituents, their state in the matrix and the effects these are noted to impose upon the efficiency of recovery. Silver mineral identifications were by quantitative ore microscopic and scanning electron microscopic energy dispersive X-ray analysis.

Jan 1, 1982

By William R. Wayment, Wayne S. Cusitar

INTRODUCTION The process of mining removes valuable and eco¬nomically recoverable minerals from the earth. In the case of hard-rock mining, this process involves breaking and removing ore, while leaving the waste rock or host rock as intact as possible. Prior to mining, ground stresses exist in the ore and the host rock as a result of weight and tectonic forces; for the purposes of this chapter, the ore is considered to support the host rock on both the hanging and footwall sides. Two basic phenomena accompany mining. First, the hanging walls and footwalls tend to move together as the ore is removed. Second, high stress gradients de¬velop in the rock periphery of the opening; the magni¬tudes of the stress gradients vary widely, depending upon the local geometry and conditions. At various times, mining methods have used square¬set timbers, waste-rock backfill, alluvial sand fill, and tailings backfill materials, with or without cement, to replace the loss of support caused by the removal of the ore. Cut-and-fill mining has evolved to use hydraulically placed tailings for the backfill. In the stope, this fill provides massive support to the walls, thereby reducing stresses in the back. It also provides a floor from which men and machines can work to drill and blast, to haul ore, and to scale and bolt the back. In many cases, the addition of cement provides a competent free-standing wall when the fill is exposed during mining of adjacent stopes or during pillar recovery operations. In most cases, the use of fill does not eliminate standard tem¬porary or local roof control measures such as roof bolts and wire mesh. Fill Characteristics It is important that backfill used for ground support be of maximum stiffness in relation to wall closure. The stiffness of the fill is related to its placement bulk density or void ratio. In the case of cemented tailings, this is enhanced by the cement bonds. During stope closure, individual fill particles experience rotation and crushing at point contacts, but they are subject to little relative translation. The stiffness approaches infinity as the void ratio approaches zero, until the ground forces reach equilibrium, and closure stops. The gradation of particle sizes and minimal segregation resulting from good hy¬draulic placement both contribute to a high degree of early stiffness in the closure history of classified tailings backfill. This also implies that the fill should be resistant to creeping under high static loads. All mines experience shock loading situations such as blasting, and many mines experience rock bursts that can apply sudden and very high loads to the fill. Certain conditions of void ratio, particle size, and moisture con¬tent can result in mass fluidization of unconsolidated fill during such shock loading. Two key factors in avoid¬ing fluid behavior are the provision of a well-drained fill through desliming or classification and the achievement of a small degree of consolidation through the addition of cement in ratios as lean as 40 to 1 (2.4% cement). The acceptance of classified mill tailings as backfill material has been enhanced by its relative economy, including its source, preparation, delivery, and stope distribution. Transportation from the backfill prepara¬tion plant on the surface into the stope usually can be accomplished with low power consumption, with low labor costs, with few capital costs, and at high tonnage rates. An additional benefit is a reduction of the storage volume required for surface disposal of the tailings stream, with a resultant improvement in the environ¬ment. The costs of placing cemented tailings backfill generally range from $1.65 to $6.61/t ($1.50 to $6.00 per st) of fill depending upon the cement ratio used. Scope This chapter examines a major backfill program at a mine and mill complex where the backfill facilities are included as a part of the original planning. The backfill preparation plant is intended to make maximum use of remote controls and automation. The logistics asso¬ciated with material storage, handling, and metering in the plant are outlined. Important considerations in specifying equipment for typical service conditions are discussed. The fill delivery system is described, includ¬ing the boreholes, level lines, and stope distribution lines. Stope preparations for fill confinement and drain¬age are described, as are the techniques of placement and distribution. Methods of controlling and directing the flow of drainage water and slimes are presented, along with the facilities and equipment for clarification, pumping, and sludge removal. As shown in Fig. 1, the fill program encompasses most aspects of the mining and refining facilities, so the discussion is brief in each area. The preparation of backfill of a uniform and con¬trollable quality is presented here as a material handling problem. The balance of the presentation concentrates on the logic of the system, the costs where meaningful (in 1977 US $ unless otherwise specified), and some operating "tricks" that have contributed to system per¬formance and reliability. SURFACE PREPARATION PLANT A backfill preparation plant is required on the surface. This plant generates suitable fill material from the stream of mill tailings. Among the functions of the plant are: 1) Slimes are removed to improve the percolation characteristics of the fill; typically, particles finer than 325 mesh are removed from the tailings. 2) Tailings and sand storages are provided so that the steady stream of tailings produced by the mill can be accepted. Provision is made to accommodate the cyclic high-volume demand from the mine. 3) The plant stores the cement and contains meter¬ing and mixing facilities to provide fill of a controllable and uniform quality. 4) The hydraulic backfill delivery system is a part

Jan 1, 1982

By N. J. Ferguson

An upsurge in demand for Australian coal has seen a much needed programme for a new generation of coal ports. This paper discusses design concepts in planning a large modern terminal, with the 25 Nt/a Port Kembla and the 50 Mt/a Newcastle facilities as practical examples. The need is emphasised for a studied Master Plan, in-built materials handling flexibility and staged development. Trends in bulk ship design and loading methods are noted. Features of these Australian designs include methods of dealing with poor ground conditions, functional civil engineering for environmental protection and optimal marine structure designs.

Jan 1, 1982

By M. Y. Fisekci

Subsidence measurement methods, applied over the thick and steep seam mining in the Rocky Mountains Region of Western Canada are described. The studies to date indicate that two new subsidence monitoring techniques appear to be the most suited methods for our conditions. The computerized telemetry and aerial photogrammetry systems are being tested for the reliability of the systems during the winter months within the network of laser surveying over the workings of the new hydraulic mine. The site particulars and the mining method of the concerned area have been described briefly. The observation over the old hydraulic mine indicate that panels adjacent to each other do not obey identical subsidence phenomenon.

Jan 1, 1982

By Richard G. Burdick

The Bureau of Mines conducted this research to determine the feasibility of using soil redox measurements, a relatively new method in mining geophysics, to locate or define a variety of conditions that are hazardous or otherwise of interest to the mining industry. The method was used in three widely separated areas in an attempt to de- fine subsurface concentrations of methane, the edges of coal-burn areas, and a hydrothermal vein set. Both a description of the method used and test cases are given in this report.

Jan 1, 1982

By Francois E. Heuze

This paper summarizes the geomechanics programs conducted in two hard rock underground mining operations in the Western United States, between 1966 and 1981. The two projects were directed towards understanding the behavior of the rock masses, at the scale of the caverns. To this end, the emphasis was put on large scale field measurements, complemented by limited laboratory testing. The results of these observations were used to build realistic finite element models of the underground chambers. In the marble mine, at Crestmore, California, the models were applied to the structural optimization of the room-and-pillar pattern. In the granite mining, at Climax, Nevada Test Site, the models explained some unusual stress changes observed during excavation. Based on the large number of geomechanical techniques employed, specific conclusions and recommendations are offered regarding the quality, applicability, and usefulness of the various methods. The two case histories clearly indicate chat numerical models are extremely useful for a detailed understanding of the structural behavior of mine openings. To be realistic, these models must be based first and foremost on large scale field observations. The lessons Learned on these two projects also are directly applicable to the design and analysis of nuclear waste repositories in hard rocks such as basalt, granite, and welded tuff.

Jan 1, 1982

Despite modest improvements in the performance of domestic interest rates and gross national product,1 fixed investment in domestic producers' durable equipment continued to weaken during the second quarter of 1982 and declined at a 12.8 percent annual rate compared with the first quarter.2 Large declines occurred during the second quarter in expenditures on many of the major mineral-consuming industries such as aircraft, computers, agricultural and construction machinery and mining and oil field equipment. These data appear to be consistent with the low level of business investment plans for 1982 reported in the DOC's Bureau of Economic Analysis survey of expenditures on new plant and equipment.3 Domestic and foreign industrial production and mineral industry production activities continued to decline in the most recent period because of weak demand conditions (Tables 1 and 2). The U.S. mining production index declined 7.7 percent between April and June as compared with 1.2 percent for total U.S. industrial production (Table 1).

Jan 1, 1982

By L. H. Gevantman

A program for the compilation of evaluated physical and chemical numerical properties data is being pursued at the National Bureau of Standards within the Office of Standard Reference Data. This program is being sponsored by the Department of Energy and managed by the Battelle Office of Nuclear Waste Isolation in Columbus, Ohio. The intent is to assemble a reliable body of numerical properties data concerning candidate mineralogical materials in which high-level radioactive wastes are to be buried. The ready accessibility of the data to site designers and the credibility achieved through the evaluative process are designed to help assess and compare the feasibility of each candidate material for use as a disposal site. Both generic and site-specific data are to be assembled. To date, generic rock salt properties have been assembled and published by the NBS as NBS Monograph 167. Details of the effort to produce this book are discussed.

Jan 1, 1982

By John R. Parker

Work places of an underground coal mine are required (30 CFR 1719) to be illuminated while self-propelled equipment is used. Permissible machine mounted systems have been developed and applied satisfactorily to many mining operations. However, some low seam and thin seam equipment has been difficult to illuminate because reliable, direct current systems and compact, low output, low glare luminaires were not available. This program resulted in the design and prototype construction of compact, low glare luminaires and AC and DC power systems, particularly suited to resolving illumination problems on low and thin seam mining equipment. Design objectives were based on enhancing the prospects for thin seam illumination solutions through definition of a product which could challenge markets enjoyed by higher glare luminaires and through reduction of technical risks associated with any new product development as well as the MSHA certification process.

Jan 1, 1982

By Sehic OA

One aim of testwork and flowsheet development is to ultimately provide a reliable and flexible plant that is simple to operate and maintain. Testwork can indicate amenability of ores to CIP treatment and provide a basis for process design and economic appraisal. Batch cyanidation and CIP tests are often sufficient for small projects. Continuous multistage test rigs can be operated to simulate plant operation and to provide data for flowsheet optimisation. Operating requirements, gold recoveries and potential problem areas can be anticipated at an early stage with more confidence. Subsequent project development involving decisions on the basic flowsheet, equipment types and general plant arrangements are based on practical considerations and experience. Computer aided process modeling and economic appraisal can be useful in analysing various tradeoffs, firming up the flowsheet and equipment sizes, and in specifying operating targets for the future CIP plant. INTRODUCTION Carbon-in-pulp (CIP) technology which has developed rapidly since 1974 is now accepted as an economically and technically viable process for the efficient recovery of gold. This paper describes testwork and flowsheet development procedures used for CIP evaluation and design.

Jan 1, 1982