Search Documents

By Edward Jacobsen

The Oak Creek Power Plant in Oak Creek, Wisconsin is currently undertaking an expansion project. In order to supply cooling water to this facility, a 27' (8.2m) diameter tunnel will be bored, in rock; to connect to 4 vertical Intake shafts located approximately 1.5 miles (2.4km) offshore in Lake Michigan. In 2004, Case Foundation Company was awarded a lump sum contract to Install these intake shafts. When complete, the plant is expected to circulate upward of 2 billion gallons per day (7.5 billion liters) through this system. Two shafts were drilled in a (shortened) construction season in 2005 and the remaining 2 shafts and 4 liner assemblies were completed in 2006. Future connection to the tunnel, in 2007, will be accomplished by mining upward to reach the lower portion of each liner and then removing its internal bulkheads to permit the flow of the lake water into the tunnel.

May 11, 2007

By Robert B. Bittner

The new gated dam on the Monongahela River at Braddock, Pennsylvania, was built for the US Army Corps of Engineers using an innovative "In-the-Wef' technology. A key feature of this technology involves construction of the foundations through the water and later mating the completed structure or a shell of the structure to the pre-installed foundation. This paper presents a description of the structure, its foundation, construction sequence and design details required to successfully Implement this technology.

May 11, 2007

By F. Keith Jacobson

To be involved in the construction of a deep dredged caisson for a major bridge pier is one of the most rewarding and professionally challenging experiences one can have in the bridge construction business. That experience was doubled in the construction of the two deep dredged caissons for the Highway 82 Bridge over the Mississippi River near Greenville, Mississippi. The challenges and the construction risks associated with constructing these two dredged caisson pier foundations highlight the construction engineering innovation associated with major bridge pier construction. The 1,378-foot Main Span of the Highway 82 Bridge makes it the longest cable stayed bridge span over the inland rivers of the United States. The main piers for this bridge are supported on two dredged caissons measuring 80-feet by 122-feet in plan, founding 200-feet and 170-feet below the river surface. The challenges of constructing these caisson structures, sinking them through 70-feet of water to the river bottom and then excavating and further sinking them to the founding grade without exceeding the design tolerances, were enormous. The construction engineering opportunities for innovation included major breakwater structures to create a friendly environment in 11 fUsec currents, the first time use of Articulated Concrete Mattresses for river bottom scour control, unique air dome design to maximize the buoyancy of the caisson structure while floating, a caisson guide system to assure positive control and positioning of the caisson during the initial sinking phases. and a comprehensive sinking plan to assure maximum control and minimum risk. Many of the innovative solutions to the construction challenges on this bridge will be incorporated into future caisson construction projects on the lower Mississippi River.

May 11, 2007

By Dan Brown

Improvements in construction equipment and techniques in recent years have made possible the use of drilled shaft foundations in diameters and lengths not previously considered practical or feasible. Many highway bridge and other structures are now routinely founded on drilled shafts which -are 8 to 12 feet in diameter and extending over 200 feet in depth below grade. There are unique challenges associated with constructing such large and deep cast-In-place foundations and engineers should be aware of the special needs associated with site investigation, construction specifications, material requirements, and quality assurance. This paper outlines a number of special considerations for these foundations, along with strategies that may be employed to improve the reliability and quality of large drilled shaft foundations.

May 11, 2007

By H. J. lgner

Hydraulic fills are widely used in the tabular, steeply dipping stopes of the South African gold and platinum mines as an integrated process within a daily cycle of drill and blast. There is therefore only a small time window in which to fill the geotextile bags used as primary fill containment, without the risk of loosing production. Consequently, mines tend to increase the flow rate to the stopes, although this compromises adequate drainage, consolidation and strength development during filling. Recent underground measurements inside the geotextile bag have revealed that at high rates of rise and at 25 degrees dip, the backfill can remobilise within a limited area inside the geotextile bag during filling. This sudden downward surge of backfill exerts, for only a few seconds, additional loading on the geotextile, its supporting mesh and the props. This unstable behaviour poses a serious threat as it can push props out of place, thereby damaging the geotextile bag and causing a mud slide in the stope. To reduce the risk of accidents, the phenomenon of sudden slumping was further investigated for various filling conditions in the laboratory. The results confirmed that the maximum pressures associated with the sudden slumping can be more than five times those experienced during steady-state consolidation. Based on this new insight, the current best practice for hydraulic backfilling was critically reviewed. A practical approach to implementing meaningful standards is presented to ensure safe operations in relation to the consistency of the backfill quality and the appropriate matching of geotextile characteristics with backfill properties.

May 1, 2007

By J. H. Nantel

Indications are that underground mining is gaining favour with large and small mining companies due to environmental and sustainability concerns. Dramatic changes to mine fill technologies will be needed in order to keep pace with these emerging trends. The industry will be compelled to gravitate toward zero discharge mining operations. Innovative handling of mine tailings will become a focal point in this effort. The challenges are to use a greater portion of the residues and to manufacture a fill with better properties. This is a tall order that can only be addressed through a systematic research and implementation process involving mining companies, universities, research organizations, manufacturers and governments. The mining industry has to be at the forefront of this technology push in mine fills for the future mines. It will also be called upon to lead the way in other research areas. The industry will have to partner with other technology providers: universities, government laboratories and consultants.

May 1, 2007

By Ronald C. Schimmel

In 2006, the Corus IJmuiden pellet plant produced approximately 4.6 mln tonnes of pellets. Corus IJmuiden is about to increase its pig iron production to 6.4 mln tonne HM per annum. The burden of the Corus IJmuiden blast furnaces consists of approximately 50% high basicity sinter and 50% acid pellets, both produced in-house. To enable an increased iron production, the capacity of the pellet plant needs to be raised to 5.0 mln tonne per annum. The capacity is increased by modifications to the plant layout, which were implemented during the 2006 cold maintenance stop. In addition, the composition of the ore blends is optimised to gain productivity.

May 1, 2007

By K. K. Dehn

This study focused on determining the stability of thin shotcrete fill fences at a hard rock mine in northwestern Ontario during increased pour rates of paste backfill. Determination of the stability of the fence is needed for both personnel safety and to avoid failure of a fence. Failure of a fill fence during backfill activities would have severe impacts on production and potential hazards to nearby workers. Approved fill fences at the mine are a slender design of 10.5 centimeters of shotcrete applied to a rebar framework with burlap lined ?bedspring? backing. Approved mine standards dictate that fill rates may not exceed 1.5 meters of paste depth per 10-hour shift when pouring behind a flat fill fence. To decrease the backfill cycle time the study looked at fence stability during increased pour rates of 2.5 meters paste depth poured within a 10-hour shift. An instrumentation design was developed including pressure cells, strain gauges, and tilt-meters that were built into experimental fences to observe the effects of increased pour rates on lateral wall pressures, strain development in the rebar and shotcrete reinforcement, and physical deformation patterns along the face of the fence. The data was analyzed for overall stability.

May 1, 2007

By Michael W. Russnak

Productivity and operating expenses are everything when it comes to judging how well your mine and company are doing. Stakeholders are always looking at these numbers and trying to understand if productivity is improving, if operating costs are trending downward and what you are basing your decisions on. o make improvements you first need to understand how you are performing. If you can?t get this basic information, you will never improve. You will not be able to make simple decisions related to maintenance, operations or production. Forget about planning, as you will only be guessing based on the numbers some stakeholder or your executive wants to see. The problem miners run into is not that the data doesn?t exist; it does, but typically it?s raw, it?s everywhere and its volume is huge. Today there is more on-board computing capability in shovels than we had on our desktops three years ago. Add other mobile equipment, plant systems and multiple OEM vendors to the equation and the challenge is daunting.

May 1, 2007

By J. C. Johnson

Underhand mining with cemented mill tailings for backfill has proven to be a safe and effective alternative to conventional overhand mining for rockburst prone mines. The ability of the cemented sandfill to survive a rockburst shock wave without failing has been observed at mines in the Coeur d?Alene Mining District many times in the last twenty years. To better understand the dynamic loading of this commonly used support material the National Institute for Occupational Safety and Health (NIOSH) performed laboratory experiments using a split Hopkinson Pressure Bar (SHPB) to quantify the maximum stress and energy absorption of cemented mill tailings from the Galena mine. Cylindrically shaped cemented backfill specimens aged 28 days were placed in the split Hopkinson pressure bar testing apparatus and a dynamic load was applied. The measured peak dynamic compressive strength of the cemented sandfill was 10.6 MPa (1540 psi) and is approximately twice the static unconfined compressive strength (UCS) of 5.5 MPa (800 psi). These test data showed about 95% of the initial energy was reflected away from the backfill and only 5% of the energy was absorbed. This may help to explain why backfilled stopes could withstand seismic events up to 3.5 Richter magnitude (Ml). When a compressive rockburst wave impacts a stope a large amount of the stress and energy is reflected away. The reflected wave is a tensile wave which creates tensile cracks and spalling in the entire wall of the stope. The backfill supports the damaged wall rock and holds it in place. Some of the stress and energy of the rockburst is transmitted into the backfill and because the backfill is being dynamically loaded it has a strength that is twice its static value and absorbs a substantial amount of rockburst energy. Although mining in deep underground mines is an extremely hazardous occupation, the use of underhand mining with cemented backfill for static and dynamic ground control increases the safety of the workers.

May 1, 2007

By A. S. Nortjé

At South Deep Gold Mine longhole stopes are backfilled using a cemented Cyclone Classified Tailings in its hydraulic state. The need to contain the hydraulic fill until cured requires a barricade. Due to the massive size of the stopes, the tailings can exert enormous forces on any such barricade. Barricades have long been in use, but recent failures in Australia and the large rate of filling required at South Deep solicited a robust design. A robust design must examine all foreseeable failures and the barricade must be able to resist all expected and, within limits, unexpected loads. The design should also be simple to construct and cost effective, limiting the impact of construction errors and unnecessary delays to production.

May 1, 2007

By D. J. Hallbom

This paper presents a novel methodology for the hydraulic design of mine backfill distribution systems. The ?operating range? method uses the concepts of the hydraulic grade line and equivalent pipe length to determine flows and pressures as the pipeline route and static head change over the life of the mine. The operating range method is easy to learn because it is semi-graphical and uses well-known design concepts (e.g., the hydraulic grade line) and slurry design models (e.g., the Durand deposition velocity model). However, by changing the paradigm in which these concepts are used, the operating method allows all potential pipeline cases to be analysed simultaneously without the need to know the exact pipe routing. It also allows the hydraulics engineer to quickly identify ?pinch points? and ?slack flow? zones, to estimate the effect of changing the size or length of any given section of pipe, to assess the impact of changing the material properties of the backfill slurry, to size the slurry pumps, and to size and locate rupture discs when required.

May 1, 2007

By Li Xibing

The In order to mine safely with reasonable cost, it is necessary to research the fracture characters of backfill and its matches with rock mass. Four kinds backfill with cement-tailing ratio of 0.250, 0.125, 0.100 and 0.083 respectively were tested, and basing on stress-strain curves tested, the deformation characters and fracture laws as well as the damage constitutive equations investigated with damage mechanics whose calculating results are coincided with experiment results well were proposed. The results of damage analysis show that there have different damage characters in different backfill, e. g. the lower the ratio of cement to tailings the lower the damage values when stresses reach to peak value; the lower the content of cement the more rapid in damage and the more abrupt in breakage process. In addition, using catastrophe theory, an energy model was proposed for backfill and rock mass acted each other in mechanics, and the unstable condition of the system was obtained. Research results show that the higher is the stiffness of rock mass the more stable the system, and the lower is the ratio of cement to tailings, the more unstable the system will be. Further more, according to the catastrophe model proposed, the reasonable matches between backfill and rock mass were researched, and a calculation formula that designs reasonable strength of backfill during mining was put forward. It has been proved by practice that the model and theory researched in this paper can guide filling design in mining. Keywords: Cemented tailings backfill, constitutive equation, catastrophe theory, match of backfill and rock mass

May 1, 2007

By D. Allan Coutts

Demonstration projects using hydrogen as a fuel are becoming very common. Often these projects rely on project-specific risk evaluations to support project safety decisions. This is necessary because regulations, codes, and standards (hereafter referred to as standards) are just being developed. This paper will review some of the approaches being used in these evolving standards, and techniques which demonstration projects can implement to bridge the gap between current requirements and stakeholder desires. Many of the evolving standards for hydrogen-fuel use performance-based language, which establishes minimum performance and safety objectives, as compared with prescriptive-based language that prescribes specific design solutions. This is being done for several reasons including: (1) concern that establishing specific design solutions too early will stifle invention, (2) sparse performance data necessary to support selection of design approaches, and (3) a risk-adverse public which is unwilling to accept losses that were incurred in developing previous prescriptive design standards. The evolving standards often contain words such as: ?The manufacturer shall implement the measures and provide the information necessary to minimize the risk of endangering a person?s safety or health.? This typically implies that the manufacturer or project manager must produce and document an acceptable level of risk. If accomplished using comprehensive and systematic process the demonstration project risk assessment can ease the transition to widespread commercialization. An approach to adequately evaluate and document the safety risk will be presented.

May 1, 2007

By A. Sargeant

This paper evaluates the application of post consumer glass as a cementing agent in underground mine backfills. The underlying theory indicates that glass is pozzolanic and, when used in a finely divided form, behaves as an activator to generate binding products, thus contributing to the development of backfill strength. The objective of this study was to evaluate the strength performance of backfills when Normal Portland Cement is replaced with various percentages of post consumer glass. The study evaluated the performance of backfills prepared using tailings from three mines. Each backfill was prepared using unique recipes, and were evaluated at cure times of 7, 14, 28, 56, 112 and 224 days. Laboratory work involved visual, physical and chemical material characterization followed by strength evaluations. Results of strength assessment revealed that backfill prepared with glass is reactive and can contribute to the strength of backfill. The results also indicated that the reactivity of glass may be affected by the incorporation of slag within the recipe, the availability of lime and the level of hydration of the binders. The study concluded that, at 15 % glass replacement of NPC, backfill prepared with mine tailings, NPC and glass can achieve improved or equivalent strength performance compared to backfill prepared tailings and NPC alone.

May 1, 2007

By E. Fried

Cemented paste backfill (CPB) is an innovative tailings management method that consists in returning considerable amounts of mine tailings into the underground mine openings. The filled stopes thus participate to the ground support that allows maximizing orebody extraction and a safer environment for the mine workers. There are also significant environmental advantages of using CPB. Indeed, up to 50% of the concentrator tailings can be backfilled, leading to a smaller volume of problematic waste materials to be managed at the surface. Once the CPB is placed, or when the mine is flooded at its end-life, the backfill is subjected to underground water flows that may leach and spread the pollutants (mainly metals, sulphates, and acidity) which can contaminate the underground waters. The aim of this study is to characterize the leaching properties of CPB material and to identify the cement phases that ensure the metal fixation. A laboratory procedure was implemented consisting in the preparation of various paste backfill mixtures using sulphide-rich and sulphide-free materials, different types of binder, and mixing waters having various sulphates, copper and zinc concentrations. After 90-days curing time, the samples were submitted to column leaching tests. The CPB materials were flushed each day with 100 ml of deionised water during 100 days. The collected leachates were then analyzed for pH, Eh, electric conductivity and chemical composition. For some samples, a differential acid neutralisation test was carried out. The objective of this experiment is to dissolve selectively the hydrated phases by adding incremental acid concentrations. By analyzing punctually the equilibrated solutions, the composition of the dissolved phases and their metal content can be estimated. The leaching test results showed that the pH of the leachates remains alkaline during the test period. When the pH decreases under 10 (after 30 days), different behaviours in terms of chemical element release (especially for zinc) were observed. During the test, the oxidation of pyrite seems to slow down, probably due to passivating phenomena. Moreover, the differential acid neutralisation test results allowed a better understanding of the CPB mineralogy and the Zn-bearing cement phases. Zinc and the other metals seem to be fixed within a calcium-magnesium silicate.

May 1, 2007

By Georgia J. Lysay

The Kemess Mine tailings impoundment is retained behind an earthfill and rockfill dam that, when complete, will measure about 140 m in height with a crest length in excess of 1 km. Due to weak foundation conditions, the dam must be raised at a very flat downstream slope approaching 7H:1V. This requires an enormous volume of fill to construct the downstream shell of the dam, which has a low permeability clayey till core and is raised via the centerline construction method. For the initial years of annual dam raising, from 1996 through 2002, the downstream shell of the dam was constructed with non acid generating waste rock from the open pit, 7 km distant and requiring an uphill haul with obvious cost implications. To reduce costs, and to reduce waste haulage constraints on mining schedules, feasibility studies were initiated for raising of the downstream shell using cycloned tailings sand as opposed to open pit waste. This required inclusion of flotation cells for removal of residual sulphides from the tailings to produce the non acid generating product mandated for the downstream shell of the dam. These studies were positive, and cycloned sand construction was initiated in December of 2002. This paper describes the experience gained with cycloned sand construction for the dam. Unique aspects include environmental controls given the sulphide-bearing ores, preparation of the existing shell of the dam for subsequent placement of hydraulically placed cycloned tailings sand, on-dam settling ponds, water management issues, reclamation of the sand dam for erosion control commensurate with the wet climate, and use of the system to construct an above-water beach of non acid generating tailings to increase the closure security of the structure. A particularly unique aspect of the Kemess experience is hydraulic fill operations extending throughout the coldest winter months, as compared to other operations where such placement has traditionally been considered non-viable through the winter months

May 1, 2007

By Alyson Morley

The mining sector in Canada is facing significant challenges to develop a competent workforce, including increased technical and logistical operational demands, and the imperative to promote local content. There is an increasingly unpredictable labour pool which can be aging, or have skill shortages, or non-aligned skills. As globalisation continues, companies also require efficiencies during operation across various locations. AMEC has met these challenges in the global oil and gas sector by developing our Capability Development and Competence Assurance (CDCA) program. CDCA is applicable across all process industries, including mining. CDCA supports simultaneous consistency and flexibility by defining competence at task level, with corresponding best practice blended training programs, and evaluation criteria and processes. CDCA then defines role profiles mapped to local task definition. When combined with web-based technology, this granularity allows us to manage high volume workforces, while retaining individual learning plans and progression, aiding job satisfaction, and employee retention.

May 1, 2007

By P. D. Barrette

This paper deals with the flow of granular materials in bins. A hybrid Lagrangian-Eulerian numerical model is introduced. The model is based on Particle-In-Cell (PIC) advection, and continuum equations describing a Mohr-Coulomb criterion. Experiments were conducted to test and verify the performance of the numerical model. Tests were done using three types of particles. Measurements of material properties and flow rates were carried out. Video records were also obtained and used to examine flow patterns. The results indicate that the numerical simulations produce deformation patterns and flow rates which are in good agreement with the experimental observations.

May 1, 2007

By M. Fall

The progressive depletion of ore available at shallow depths in several underground mines around the world means that underground mining operations would increasingly be carried out at greater depths and therefore at higher temperatures. However, our understanding of the effect of hot temperatures on the response (mechanical, economical, environmental) of cemented paste backfill (CPB) is still limited. Hence, an extensive laboratory investigation was conducted to study the performance of young and aged CPB, in response to deep mine temperatures. Several CPB samples with different compositions, cured at different temperatures (20 to 50°C) and different times (7 to 160 days) were tested regarding their mechanical properties, economical performance (binder consumption) and microstructural properties. The results show that hot temperatures significantly affect the performance properties of CPB at young and advanced ages. An increase in the curing temperature leads to a considerable improvement of the rate of gain of CPB strength and also to a significant increase of the strength of CPBs studied. CBP samples cured at hot temperatures show lower binder consumption and finer pore structure. Results of this study could serve as background information for the development of optimal mine backfill design procedures.

May 1, 2007