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By L. Pretorius, S. Uludağ

This paper explores how to apply system dynamics principles to surface mining problems towards understanding the consequences of mining efficiencies. Some simulation examples related to machine and people performance have been used to demonstrate systems engineering concepts to mining engineers. The simulation tool used is Vensim, which is widely used in industrial engineering applicable to systems thinking, and systems dynamics. The science and mathematics behind the system dynamics as well as benefits and typical challenges are discussed to explore the applicability to mining problems. The benefit of having one less drill is easily quantifiable with the developed model which is one of many other measurable benefits, using the developed model. Some of the benefits of the improved quality of drill holes are not fully quantified as this depends on the mine specific inputs. There are examples of quantifying this in the other industries using system dynamics tools.

Sep 1, 2021

By Whitman E. Brown

"As part of a Nation-wide program of the United States Government to develop natural resources, funds were made available to the Bureau of Mines for the investigation of the ""Reduction of Iron Ores by Solid and Gaseous Fuels."" These investigations are concerned with the direct production of iron from its ores without the use of a blast furnace. Many processes have been proposed for the low-temperature reduction of iron oxides, but few have been developed to commercial use. High-quality sponge iron is produced com-mercially only in Sweden.The cost of iron production depends in part on the grade of the ore and increases with decrease in grade. The substitution of cheap natural gas in a sponge-iron process for expensive coke in smelting in the blast fry pace would partly compensate for the use of low-grade ores. If a process can be developed in which inexpensive natural gas can be used as fuel and reducing agent, the large deposits of low-grade iron ore and the natural-gas resources of east Texas may be utilized in the commercial production of sponge iron.Sponge iron may possibly be used to supplement scrap iron, pig iron, or, in special instances, wrought iron. Sponge iron will vary but slightly in composition and will contain little or no nickel, cobalt, manganese, copper, and other allowying metals. It is becoming increasingly difficult to obtain choice scrap iron of nonalloy composition. Pig iron contains 1.5 to 3.0 percent silicon and 3.0 to 4.5 percent carbon. Sponge iron generally contains less carbon than pig iron.The Madaras Steel Corp. in Longview, Tex., built a set commercial-scale sponge-iron plant which was intended to be operated in connection with a steel foundry. The process is based upon the reduction of preheated iron ore, with hot reducing gases under pulsating pressure. Although the Madaras Corp. had previously experimented with the production of sponge iron by reducing the ore with pure hydrogen, several attempts to use a re-formed natural gas as the reducing agent in this pilot plant were unsuccessful. The Bureau of Mines leased this plant and conducted an extensive investigation of the Madaras process on a semicommercial scale.The experiments were not entirely satisfactory, partly because of mechanical difficulties and partly because the reducing gas was not of the best quality. However, much information on the production of reducing gas by re-forming natural gas and on the reduction of iron ore with re-formed natural gas was obtained.The sponge iron produced contained approximately 0.1 percent phosphorus; and, after melting in an electric furnace, the iron contained approximately 0.15 percent phosphorus. The results of attempts to improve the ore by ore-dressing methods were not encouraging."

Aug 1, 1946

By J. A. Russell

IT IS the purpose of this paper to show how the design of the larger slope hoists in use in the mines of the Dominion Steel and Coal Corporation has tended to evolve ta suit the particular conditions of operation. These hoists are all used for hauling coal in trains or trips of pit tubs up the mine slopes, which usually follow the dip of the seam . As the mine is developed to the dip and the slope grows in length, the length of the rope and the size of the hoist required to handle it rends to become extremely cumbersome. It has been found that the best economic conditions of hoisting are obtained when the length of the slope is limited to about seven or eight thousand feet. Beyond this length it is necessary to offset to one side of the line of slope and start a second or auxiliary slope, which will be served by its own hoist installed underground. With this hoisting distance as a basis, we find that we can economically hoist the outputs required, usually about 1,500 tans per eight hours per slope, by hoisting the coal in trips of about twenty boxes. This, on the grades obtaining, will require a rope of about l 1/4in. diameter, running at a speed of 1,200 ta 1,800 feet per minute, and requiring from 1,200 to 1,800 h.p. at the hoist shaft. The tendency is for the rope speeds of the surface hoists to be a little higher than the underground hoists which relay to them, so that the surface hoist has a small margin of time in hand. The oldest surface hoists were steam-driven, but, with few exceptions, these have given place to electric hoists. With the exception of one hoist, which was altered in design, the steam hoists have not had the opportunity of evolving in the same way as the electric hoists, and will not be mentioned any further.

Jan 1, 1944

By David Mast, Irwan Halim, Seung Han Kim

Nowadays more infrastructure tunnel projects are procured using design-build method. In this environment, the Owner’s engineer would typically provide performance requirements for the design-builder, and the Contractor’s designer would work with the contractor to design the tunnel lining based on the Contractor’s means and methods and manufacturing process. This paper will describe the typical requirements provided by the Owner based on its design objectives, and the means and methods by the Contractor that would significantly impact the design. Project examples and recommendations for Owner’s requirements will be provided that can optimize the design and still achieve the Owner’s performance objectives.

Jun 13, 2021

By Mike Hall, Tim Kelly, Mohammad Reza Jafari, Ulf Georg Gwildis

"Qatar’s capital Doha is undergoing major infrastructure improvements including a multiphase stormwater management program. Although located in an arid climate, Doha experiences flooding during rainfall events. Dewatering operations and rising groundwater levels add to the management needs. To address those needs, construction of the Musaimeer collection tunnel along Doha’s southern rim is being followed by a marine outfall tunnel connecting a pump station to a dispersion field 10 km offshore. Qatar’s geology is characterized by sabkha deposits, a series of predominantly weak and karstic rock strata that creates challenging conditions for mechanized tunneling, as highlighted by the uncontrolled flooding of a tunnel boring machine (TBM) used on the Doha Metro tunnels. Risk associated with these challenges is magnified for the outfall tunnel by drive length, sub-sea elevation, and a single access point. This paper describes the outfall exploration strategy and design decisions made in light of experience gained during the collection tunnel construction. CONTEXT – STORMWATER MANAGEMENT PROGRAM Qatar has an arid climate with an average annual precipitation of less than 100 mm. Precipitation is mostly confined to the winter months when rare, but occasionally heavy rainfall events easily lead to flooding in Doha’s metropolitan area. Its coastal location and flat topography a few meters above the sea level mean that the depth to the groundwater table is generally shallow. The karstic aquifers in the regional dolomite and limestone series contain groundwater of high salinity, which is not suitable as a potable water source. For supplying Doha’s population of more than 900,000 (2014) with potable water, the Ras Abu Fontas seawater desalination plant is operated about 10 km south of the city. This potable water production capacity is crucial for Doha’s development and – in conjunction with overirrigation and leaking sewage tanks – is also the root cause for rising groundwater tables that have been observed over the past years."

Jan 1, 2016

By Euler De Souza, Kyle Penner

"Booster fans play an important role in assisting main fans by boosting the air pressure of the ventilation air passing through it. The correct placement of underground booster fans in a mine is a critical decision since it not only influences the mine’s operational capacity in terms of costs and efficiency, but also affects safety and environmental conditions. There are many booster fan installations around mines that are inappropriate, in some cases resulting in system failure (fan stall) or in a major negative impact on mine production. Inadequate booster fan placement has resulted, in some cases, in extensive air leakage which has compromised the economics of the operation and, in other cases, in recirculation of contaminants which has seriously compromised safety. This paper provides guidelines for proper design and siting of booster fans underground, to not only achieve an economic ventilation system but to create safe work conditions and efficient atmospheric conditions. Procedures for the planning, installation, operation and maintenance of booster fans are also presented. A case study illustrating the design and siting of a major booster fan installation in a potash mine, supported by computational fluid dynamics analysis, is presented.INTRODUCTIONIn large underground operations with complex ventilation networks offering high resistances, the never ending increased required quantities of air can almost only be supplied through use of high pressure main fan systems. These fans may, in effect, induce significant leakage losses in the system, having a negative impact on safety performance. In such cases, booster fans can be designed to decrease the main fan pressures and reduce the leakage flows, improve system efficiency and reduce costs. In well designed systems, booster fans can thus be used to redistribute the airflow and assist the main surface fans.When the pressure supplied by the main fans is insufficient to meet the ventilation circuit pressure requirements, booster fans are placed in strategic locations where pressure boosting is essential. Booster fans are typically sited in sections of the circuit offering high ventilation resistance and requiring this form of ventilating air motivation. Booster fans are thus required when the mine expands, and so the resistance of the ventilation network, and the primary fans no longer can supply the required pressure and flow."

Jan 1, 2019

By Jon Pocock, Ashma Singh

The traditional approach for the beneficiation of South African siliceous sedimentary phosphate ores has been reverse cationic flotation. The robustness of this approach, however, has been a concern due to its sensitivity to parameters such as slimes content, headgrade ( P2O5 and SiO2 content), reagent dosages and conditioning times. The phosphate mineralisation for the ore body under investigation is predominantly carbonate fluorapatite composed of mainly quartz and apatite and minor amounts of chlorite, ilmenite and carbonates. Beneficiation of low grade sedimentary ores containing calcareous impurities, such as calcite and/or dolomite in addition to siliceous gangue, is required to meet the increasing demand; therefore, much research has been carried out to find an alternative technique to beneficiate this material. This paper investigates traditional flotation approaches versus the currently adopted ‘Crago Process’. Comparative results are presented in terms of upgrade potential for the production of concentrate rock for downstream applications. The novelty of the ‘Crago Process’ lies in its double stage approach, i.e. direct fatty acid flotation followed by reverse cationic amine flotation. The Crago process was able to achieve higher upgrades reporting at 32.1% P2O5 compared to conventional cationic flotation only achieving grades of 18.5% P2O5. Furthermore, the recovery gain was 3%.

May 13, 2023

First, a classification of the various primary sources of feed materials for the production of cobalt is presented from a mineralogical point of view : sulfides, arsenides, sulfo-arsenides and oxide minerals. Each of these cate- gories will be characterized by its behaviour towards concentration methods, taking account of the presence of the associated minerals of other metals and of the nature of the gangue minerals. Then, for each category of cobalt bea- ring ores, typical flowsheets of treatment will be presented and discussed and the characteristics of the cobalt concentrates produced will be under- lined having in view their subsequent processing by pyro - and (or) hydrome- tallurgical methods.

Jan 1, 1988

By Ellsworth Daggett

THE system of pitwork used with the Cornish pumping engine, and which, for want of a better name, we may call the Cornish system of pitwork, consists essentially of a series of plunger-pumps, situated one below the other, in a shaft or incline, the plungers being operated by a rod called the pitman or pump-rod, which must, therefore, extend from the motor at the surface to the lowest pump. The subject will be best understood by reference to Fig. 1, in which k may be taken as typical of the ordinary plunger-pump, in which S is the suction pipe, u, the lower valve situated in the H piece T; v, the upper valve situated in the valve-box O; I, the mounting-pipe or column through which the water is carried to the surface; L, the plunger-barrel, and P, the plunger working through the stuffing-box, and actuated by the branch rod r, which is attached to the main pump-rod, R. The action of the pump is as follows : On the ascent of the plunger, acting now by suction, the water flows from the reservoir through the valve u, into the barrel, L. On the descent of the plunger, the water is forced up through the valve, v, which acts merely as a check valve, into the pipe, I, through which it is, at each successive down-stroke of the plunger, forced upward until it reaches the next reservoir, from which it is taken by another similar pump, and so on until it reaches the surface or drain-tunnel. The pump is obviously only single-acting, i. e., it acts only during one-half of its entire stroke. The weight of water raised during the up-stroke of the plunger is equal to the weight of a column of water whose base is the area of the plunger and whose height is the mean distance between the plunger-face and the surface of water in the lower reservoir, a distance not usually exceeding 12 or 15 feet, and which obviously cannot under the most favorable circumstances, exceed 25 or 30 feet. The water forced up during the down-stroke is equal to the weight of a column of water whose base equals the area of the plunger and whose height equals the length of the mounting column above the mean position of the plunger-face, say from 150 to 300 feet. Almost all of the useful work, therefore, is done on the de-

Jan 1, 1879

By M. C. Holton

South Africa has the world?s largest in situ deposits of platinum group metals, but economically exploitable resources are shrinking due to escalating costs and technical challenges. The South African National Research and Development Strategy comments that an increase in the knowledge intensity of the resource-based sectors is required to turn these resources to account. Highly trained human resources, continuous improvement, technological innovation, and smart acquisition of know-how will become the major differentiators in the global mining market. Mechanization and, ultimately, automation in mining have the potential to reverse the negative mining trend and resolve safety and other challenges. However, the adoption rate of mechanized mining in platinum (and hard-rock gold) has been slow for various reasons. Changing systems from conventional drill?and-blast to continuous mechanized mining is a big step-change endeavour. The problem of transformation is discussed, and the discipline of systems engineering is examined because of its successful application in aerospace and defence.

Jan 1, 2012

By B. Qiu

The large surface ground movements induced by underground mining could threaten the safety of the pipelines laid across the subsidence-prone area. Existing analytical methods for the stress analysis of buried pipeline over mine subsidence area were based on the assumption of ?thin? pipeline, which limited their applicability. This paper presents the improved model with the capability to determine the stress distribution of the ?thick? pipeline. The pipe-soil interaction in this model was also updated to adapt various pipe soil contact conditions. In addition, the time-dependent effects of dynamic subsidence effects were also added to the model. A case of protecting a long section of a buried large-diameter pipeline over two longwall panels in a shallow mine is shown. The stress distribution along the pipeline is determined and the overstressed sections are identified. A partial uncovering plan was developed based on the predicted stress and complicated terrain at the site.

Aug 1, 2013

After a stagnant performance in 1982, gross national product (GNP), industrial production, and employment increased during 1983 in nearly all industrial nations, with the U.S. performance generally leading the uneven worldwide recovery. Real U.S. GNP increased 3.3 percent in 1983 (table I). Although investment in nonresidential structures declined, total nonresidential fixed investment in the United States was up 1.5 percent following a 1982 decrease. The increase in worldwide industrial activity and demand in 1983 put greater pressure on prices in many countries. Prices increased from less than 3 percent in the Federal Republic of Germany, Japan, the Nether-lands, and Switzerland to as much as 10 percent in nearly all the other Organization for Economic Cooperation and Development nations. The annual inflation rate in the United States was 4.3 percent (based on the GNP fixed-weight price index).

Jan 1, 1984

"The development of non-destructive testing (NDT) methods for deep foundations occurred in several parts of the world, gradually coming together into the present state of the art. The compilation of this brief NDT history is the best effort of several knowledgeable members of the Deep Foundations Institute (DFI) Drilled Shaft Committee, coupled with the recollections of several historically important contributors to the science. It is not intended to be exhaustive, but rather concentrates on the origins of the methods in common use and on which this manual focuses.Modern NDT methods, and the spread of knowledge about them, have expanded through application to real foundations projects by the original researchers, sometimes inspired by their own curiosity, sometimes to respond to the cost and time limitations imposed by static testing, and sometimes to address the questions raised on research projects funded by large government agencies such as the Federal Highway Administration (FHWA) in the USA, and various European transportation agencies. Initial attempts were primitive by today’s standards, and equipment limitations often restricted successful application to relatively simple cases. As electronics improved and confidence in them increased, the early researchers began commercial promotion of their methods, published their findings in professional journals, and shared experiences at conferences held by such groups as the DFI, the International Association of Foundation Drilling (ADSC), the International Conferences on the Application of Stress-Wave Theory to Piles and other venues such as ASCE and Transportation Research Board (TRB) conferences.NDT methods were developed to fill a need to assess the quality assurance of deep foundation elements. New pile types and higher design loads prompted engineers to verify the safety of their foundations via additional testing during construction. Static load testing was the traditional method to assess performance, and this method has been used for centuries and perhaps even millennia.Relatively recent alternatives to static load testing for determining the capacity of drilled shafts include the bottom load test method. This method uses a jack embedded in the lower portion of the pile (bottom load test) and was first reported to be used from Canada in the early 1970’s (Gibson& Devenny 1973). The concept immediately caught on in Israel, where it was used as a quality control measure for small-diameter piles drilled in rock (then a new technology). The method was later patented in the US by Jorj Osterberg, and offered as a commercially available service in thelate 1980s (Osterberg, 1989)"

Jan 1, 2004

By Larman J. Heath

Liquid incendiaries were burned within the interstices of several different types of sandstone cores to determine the technical feasibility of increasing sandstone permeability by this method. Fuel-oxidant mixtures were tested in 186 cores; six cores exploded when ignited. In virtually all instances, the explosion completely pulverized the sandstone cores. In addition n those cores damaged by explosions, 24 cores were fractured so severely that permeability tests were impossible. Although combustion gener¬ally increased the permeability, specific mixtures at given pressures were inconsistent in their ignition and burning behavior. Tests indicated that the heat of burning incendiaries significantly increased sandstone permeability. The improved permeability ratios were usually less than 2, but one was 10.3. Permeability alteration by other in situ methods was not as effective as that by flame propagation.

Jan 1, 1971

By David Dreisinger

The cyanidation of copper containing gold ores results in the co-dissolution of copper along with gold. Copper dissolution results in elevated cyanide consumption that may make the treatment of the gold ore uneconomic. Copper-cyanide species in gold mill effluents may increase the environmental toxicity of the gold mill solutions. The objective of this study was to examine the use of solvent extraction to recover the copper cyanide species from gold mill effluents. Solvent extraction with Cognis (formerly Henkel) reagents LIX 79 and LIX 7950 was studied. Excellent extraction of copper and cyanide was achieved using pH control in extraction. Copper and cyanide may be stripped from the reagents using basic eluants. Various routes for copper and cyanide recovery from the strip solution were studied. Excellent results were obtained using electrowinning in both divided (Nation membrane) and undivided cells. Cyanide recovery was obtained by AVR treatment of a bleed stream from electrowinning. Full results of solvent extraction, copper and cyanide recovery are reported.

Jan 1, 1998

By D. M. Ziebarth

"Normal sequence of operations to develop a new underground mine is: construct and outfit headframe for shaft sinking, sink shaft, construct and outfit shaft sump, develop shaft station and shaft bottom steel. In an effort to reduce the overall project schedule, an innovative plan was developed to install service shaft steel below station level, prior to the completion of the shaft sinking effort. To better evaluate the construction of this substantial steel tower, a preliminary constructability evaluation was conducted, including the best method of supporting the main tower; from the bottom, middle or top of the tower. The design criteria and plan involved: •,Develop access from existing service shaft, 25 km underground •,Use of materials to maximize strength while minimizing corrosion exposure •,Estimating the location of the shaft centerline •,Over excavating the station and shaft below station to allow future shaft steel repositioning •,Designing the tower steel for modular installation •,Incorporate commissioning considerations, such as suspension of the cheese weights during steel installation •,Provision for covered stair access to shaft bottom •,Enclosed shaft envelope with open panels to allow visibility and ventilation The design approach was innovative and this paper will describe the design principles and challenges encountered while providing insight into the solutions developed and implemented; especially the modular construction and installation methodology. INTRODUCTION In an effort to expand the mining operations, a plan was developed to construct a new service shaft closer to the new mine workings and convert the existing service shaft to a production shaft at the Potash Corporation of Saskatchewan Inc. (PCS now Nutrien) Rocanville Potash mine in southeast Saskatchewan. The new service shaft required a multi roped friction hoist operating a cage / counterweight, rope guided conveyances to support the operational requirements. The service shaft is an integral part of the mining infrastructure as it provides access to the underground workings, transport personnel and materials underground for operation and maintenance of the mine. The shaft also allows for services required for safe operation of the underground mine, power supply, controls, communication, dewatering and fresh water supply."

Jan 1, 2019

By Xin Tan

In this paper, two types of low-grade complex zinc oxide ores (sandstone and limestone ores) from Yunnan province, China were investigated. A large number of argillaceous and alkaline gangue makes it infeasible to treat the ores with heap leaching. Although wet metallurgy can be considered, the lower efficiency of liquid-solid separation, the high cost, and low revenue limit this technology to be put into practice in large-scale. In order to solve this problem, a new technology combining mineral processing method with metallurgy technique is studied to process this refractory ore that consists of sandstone ore with 5.84 per centZn and limestone ore with 6.50 per centZn. The results of the tests showed that zinc can effectively be recovered from two types of the ores by using the new technology, and the acid consumption can be remarkably reduced. For sandstone sample, 82.96 per cent Zn was recovered by flotation and final Zn recovery by flotation+ hydro-metallurgy can be up to 78.17 per cent from the ore. In addition, for sandstone, acid consumption can be reduced from 270kg/t by direct acid, leaching to 76.92kg/t by flotation + hydrometallurgy combination. For limestone sample, 85.90 per centZn was recovered by flotation and totally 80.95 per cent Zn can be recovered by new technology which is a combination of mineral processing and metallurgy. Besides, H2SO4 consumption can be reduced from 450kg/t for sandstone originally to113.79kg/t after using new technology. One merit of this new process technology is that the zinc sulfides and oxides can be recovered without desliming in the flotation cells at the different stage and make sure the concentrate products as a good feed for hydrometallurgical technology. This study provided pretty good technical support for tapping low-grade refractory zinc oxide ores. Keywords: low-grade zinc oxide ores, limonite, non-desliming beneficiation, flotation + hydrometallurgy combination

Sep 1, 2012

By R. A. Hemstock

"Simple classification systems are now being used which will describe adequately the surface vegetation, the topography and the peat for any muskeg condition. Good progress is being made in determining some of the mechanical properties of muskeg and it is apparent that the science of soil mechanics will apply largely to these studies. Correlation is also indicated between shear strength as determined by the shear vane tester and vehicle performance. Several tracked vehicles are now available which perform well in muskeg and advances in this field have come rapidly in the past few years. Testing is under way on the largest of all muskeg vehicles -the thirty-five ton Musk Ox. This vehicle will fill the last gap for the oil industry and will make possible the movement of large drilling rigs at any season of the year."

Jan 1, 1960

By J. Y. Hwang

The relationship between coal characterization and physical cleaning has not been well understood due to the complex nature of coal. Therefore, it is difficult to apply the results of coal characterization to predict and evaluate the performance of a physical separation (e.g. flotation). Eight U.S. bituminous coals were analyzed and studied petrographically in conjunction with washability and flotation tests. The results show that grindability correlates to ash and fixed carbon contents; liberation determined directly by petrographic techniques is close to liberation determined indirectly by washability; and an ideal separation efficiency can be determined by measuring the inertinite content and the washability separation efficiency using a heavy liquid with a density of 1.4. The ideal separation efficiency was attained for most coals by packed column flotation. The ideal separation efficiency can be used for comparing process technologies and process parameters.

Jan 1, 1988

By R. J. Thompson

Well-designed and maintained haul roads are the key to minimizing truck haulage onroad hazards and costs, as well as increasing productivity. In practice, however, designing and managing a haul road for optimal performance is often difficult to achieve, especially when resources assigned to design and construction are constrained. By understanding how a road design is developed from geometric, structural, functional and maintenance considerations and, critically, the interplay between these components in design and operation, optimal performance can be achieved. This paper briefly summarizes the evolution of mine haul road design, from the seminal USBM work of Kaufman and Ault in 1977, through to current geometric, structural, functional and maintenance management design components. These augmented design and management guidelines have been developed over the past decade, both in response to the requirements of mine operators for safer and more efficient haulage systems, the truck manufacturers’ requirements for a more predictable and controlled operating environment and the recognition of human factors as a significant contributor to haulage accidents. While the human factor is the most problematic to address in a road design, the paper shows that the more that is known about human error, the better a road can be designed to accommodate those actions or non-standard practices that would, on a poorly designed road, invariably escalate an error into an accident.

Jan 1, 2010