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The Hunter Valley Rail Project (HVRP) represents most of the coal producers using the Hunter Valley Rail System in NSW to haul coal to the port of Newcastle. This system carries over 70 per cent of NSW's coal exports, comprising over 30 per cent of total Australian coal exports. Hunter Valley coal is the largest export industry in NSW, and one of its largest export growth opportunities. However, the industry is under intense pressure in international markets from existing and new coal producers and from other energy sources. Whilst potential growth in demand is substantial, particularly for thermal coal in Asia, excess world supply has pushed prices down, and this underlying trend may well continue. The industry has lost international competitiveness and as a result, investment has dropped 44 per cent over the last two years. The industry must be rapidly structured to compete and attract investment on the basis that these pressures will continue. Substantial productivity improvement and cost reductions must be made for the industry to regain competitiveness, otherwise growth will not occur and the industry will decline, with serious implications for the Australian and NSW communities. The introduction of internationally competitive rail freight rates is an urgent and essential part of this process. It is the key objective of the HVRP.

Jan 1, 1995

By Yoginder P. Chugh

Beginning in 2010, a scientifically-founded water spray system for continuous miners (CMs) has been in development at Southern Illinois University that significantly reduces respirable dust exposure for workers in the face area (patent pending). It includes engineered sprays around the cutting drum, outer bitring sprays, chassis sprays and side cutter boom sprays. About 3.6?4.5 m behind these sprays are additional sprays that cover the area between the CM chassis and the mine roof and ribs. The innovative spray system uses approximately the same volume of water as spray systems currently used on CMs and with similar operating pressures. The innovative spray system design also takes into consideration coal dust wettability. An Illinois mine decided to implement these concepts on a CM during the rebuild stage. Dust control performance of the rebuilt CM was evaluated using gravimetric dust sampling and real-time monitoring with multiple personal dust monitors. The average results based on gravimetric sampling of about 105 cuts show about 30 and 20% reduction in dust exposure for the miner operator and the haulage unit operator, respectively. Visibility in the mining areas was also significantly improved. Since the initial demonstration, the coal company has implemented the system on all of their operating CMs.

Aug 1, 2013

By A. A. Schipaanboord, S. J. Dasselaar

"With the growing global demand for strategic metals, commodity prices are rising and the scarcity of some metals is increasing. Europe’s technology sector is also affected by this growing shortage of metals. Securing the supply of critical metals is now a major element in Europe’s economic strategy. The Blue Mining and Blue Nodules projects have been initiated to principally advance deep sea mining technology beyond current TRL-levels.These critical metals are found inside so-called “polymetallic nodules”, lying on the seafloor in deep-sea environment. These nodules have a typical abundance of 10-25 kg/m2 and a size range of 10-125 mm.Harvesting the polymetallic nodules is challenging. Two main methods of harvesting or collector equipment are distinguished: hydraulic and mechanical. Over the last year, Royal IHC has designed, build and tested a full-scale hydraulic collector. Meanwhile, a mechanical collector is being developed.First, a scaled version of the hydraulic collector was developed and tested in order to have a proof of principle. The development as well as optimization were aided by multiphase CFD simulations."

Jan 1, 2017

By Gerhard Richter, Norbert Asamer, Gerwald Decker

At various stages during their manufacturing processes - from casting to finishing before delivery - semi-finished steel and special alloy products must be cut and surface-treated as well. The requirements for the individual conditioning steps, however, can be quite different. For example, the work piece can be hot, warm or cold. At any rate, the product must always be perfectly prepared for the next manufacturing step - reliably, in the shortest-possible time and at the lowest-possible cost. For cutting and grinding, BRAUN has developed innovative technologies and highly flexible, tailor-made solutions which meet these requirements in the most optimal way. In particular, BRAUN’s cutting and grinding technologies can also be used for large-scale products.

Oct 1, 2019

By I D. Gregson, A Gandhe, A S. Garcia, K M. MacAndrew

"Falls of ground still cause around one-third of all underground mining fatalities. The recent introduction of mechanised room and pillar working into Indian coalmines is an example of the application of new design by measurement and safety monitoring strategies, which can be used to reduce falls of ground risks in mines.Rock Mechanics Technology, now part of Golder Associates UK Ltd (Golder), is providing rock bolt support and pillar design services to the mines using a design by measurement approach. This involves in situ monitoring to confirm support and pillar designs and pillar extraction sequences.Site examples are given of the support designs determined and the monitoring programs undertaken for both design and safety.Routine safety monitoring of roof movement using telltales is also described. A new auto warning telltale has been developed specifically to warn of imminent caving as pillars are extracted.The approach used by Golder has played a major role in ensuring the success of these projects. As a consequence, mechanised room and pillar working is now firmly established in India, and wider application is planned to help meet future demand for coal.The experience confirms that the design by measurement method for this application has important advantages over conventional design approaches using analytical or empirical methods. Firstly, it measures the design performance or outcome rather than trying to calculate or predict it. Secondly, it provides the opportunity for the design to be adjusted to obtain the optimum outcome. Thirdly, it can do this at a local level, so that the support design can be matched to changing conditions to give the most cost-effective design. Finally, it incorporates long-term monitoring of support performance, again at a local level, so that subsequent change can be identified to enable corrective measures to be implemented in a timely manner and to ensure that ground control safety is maintained.CITATION:MacAndrew, K M, Garcia, A S, Gregson, I D and Gandhe, A, 2014. Application of design by measurement for support and pillar design in mechanised room and pillar coal mining in India, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference, pp 65–76 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 5, 2014

By T. M. Barczak, S. C. Tadolini

Reduction in the recovery time required and improvements in safety during a longwall face move have compelled coal mine operators to examine and use pre-driven longwall recovery rooms. The recovery entry is developed at the longwall stop position and supported ahead of time so that the required combinations of standing and internal sup-ports can be installed before the longwall face approaches. A calibrated three-dimensional finite element model, developed in conjunction with an underground test area, provided the critical components and design principals for a comprehensive parametric study. The study indicates that vertical, horizontal, and shear stresses concentrated on the outby abutment pillar corner of the recovery room resulting in deformations in the immediate roof above the primary roof support anchorage level. The results of the numerical model and field site observations indicated that the combination of the internal bolting system and the standing concrete supports are critical for the successful and safe extraction of the longwall equipment. Cable supports installed at and angle over the pillars can help stabilize the disturbed zone above the adjacent fender and outby pillars, however; standing supports are required in most sedimentary roof conditions to increase stability and assure a safe longwall extraction.

Jan 1, 2004

By Gurupraveen Ramanathan

Shallow-dipping orebodies (45°–60° dip) present significant challenges for underground longhole stoping, particularly due to limited gravity flow, drill misalignment near the footwall, increased potential for dilution from hanging wall overbreak, and deviation from drill string sagging at shallow angles. These geometrical and operational constraints often lead to unblasted ore wedges and excessive overbreak when standard practices are applied. This study develops a structured, data-driven framework to optimize longhole stoping in such conditions by integrating five key focus areas: (1) mining method selection, (2) stope and drift design, (3) drill and blast optimization, (4) equipment selection, and (5) performance evaluation. The suitability of longitudinal longhole stoping was validated for narrow vein geometries using orebody analytics and prior case studies. Geometric modeling was employed to determine optimal stope height (15–20 m) and stope width (1.5–2.5 m), with drift widths adjusted based on orebody dip to maintain drill access and minimize unbroken ore. Drill and blast design emphasized sequential blasting over multi-ring methods to improve void control, reduce wall damage, and enhance fragmentation. Specific burden and spacing guidelines (e.g., 1.8–2.3 m burden; 2.5–3.0 m spacing) were applied based on stope width and dip angle, and patterns were selected based on geometry—dice-5 for narrow stopes, and 3-hole rows for wider stopes. Drill rigs—including top hammer and ITH models from Sandvik, Epiroc, Boart Longyear and CMAC-Thyssen—were evaluated for compatibility with drift dimensions and alignment accuracy. Equipment was matched based on dip, drift width, and the ability to access the footwall at shallow angles. Sensitivity analysis quantified how changes in geometry, drilling accuracy, and blast design affect ore recovery, dilution, and operating cash flow. Results show that tailored drift and stope geometries, combined with proper blasting and rig selection, can boost ore recovery to over 95% and reduce dilution to below 5% in optimal conditions. This methodology offers a practical and economically optimized solution for shallow-dip mining scenarios.

May 4, 2025

By M. Vondersaar, B. Bulnes

Quemetco, Inc.,. as a subsidiary of RSR Corporation, operates one of RSR's three secondary lead smelters in the City of Industry, California, next to a residential area within Los Angeles County. The Reverberatory furnace serves as the main reactor for melting lead grid and paste recovered by the battery crushing system. Feed material is introduced via screw conveyor after drying in an upstream rotary kiln. Slag produced by the Reverb flows directly to an electric arc furnace. Products from this one-pass furnace system consist of soft lead bullion from the reverb, hard lead bullion from the arc furnace, and a non-hazardous slag from the arc furnace. Furnace bullion is processed into finished product in a six-kettle refinery. An overview ·of plant operations is presented. Where applicable, references will be made to changes that have taken place during the last decade.

Jan 1, 2000

By N. W. Xu, C. Sha, F. Dai, Y. G. Zhu, B. Li

Underground caverns stability and excavatability of rock masses are of significance in geotechnical engineering, in both design and construction stages. Risks associated with underground group caverns of Houziyan hydropower station in southwestern China are growing as a result of continuous excavation-induced unloading. To improve our understanding of the underground caverns instability and resolve the complex subsurface conditions of the highly fractured rock mass, a high resolution microseismic monitoring system was established in the deep underground caverns, pursuing the relationship between the measured data about microseismic activity and excavation damage zones of surrounding rock mass. Through analyzing the tempo-spatial distribution of microseismic activity, excavation damage zones and potential risk regions in underground caverns were identified. Furthermore, the correlation between microseismic activity and pre-existing geological structures, as well as traditional monitoring was analyzed. In order to validate the correlation between seismicity and potential slip surface of underground caverns, a model was implemented into numerical code to further evaluate the deformation and stability of surrounding rock mass. The monitoring results demonstrate that microseismic events mainly occur at high stress concentration regions, which coincides with the results obtained from numerical analysis. Therefore, the comprehensive method incorporating microseismic monitoring and numerical analysis, as well as traditional monitoring and filed observation has been proven to be very promising in deformation and even instability prediction of surrounding rock mass in underground caverns subject to delineation of potential slip surfaces and excavation damage zones.

Jan 1, 2015

By Jiwen Zhang

Abstract Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

By Jiwen Zhang

Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

By O Bøckman, E Thisted, K H. Esbensen, U Thisted

Process industry measurement systems, once installed, are often interpreted as static black boxes delivering correct values as long as not proven otherwise. After first implementation and set-up with a distinct sampling frequency, they often run ‘forever’ without checking if this frequency is still appropriate with respect to changed raw materials characteristics, different process conditions or changed customer specifications. Failure detection is based on operator experience and skills (often close to an art form) and/or from control measurements of reference samples. This may well be too late for many industrial process contexts. An appropriate sampling frequency is a critical success factor for valid monitoring and control.Based on the methodology of variographic analysis we here illustrate how to design/re-design/optimise an industrial measurement system in terms of sampling frequency, discretisation and accuracy based on customer specifications. We also show how variographics can be used to monitor for deviations. We use experience from process industry to show how these methods can be used not only for product characterisation, but also for monitoring input factors, process indicators and measurement of these. The information hidden in the vast amounts of data that is continuously created in modern process industries can be utilised to cut costs in the measurement activities and at the same time contribute to early error detection. We illustrate by case examples from production processes at a nickel refinery, supporting the Lean and Six Sigma methodology. This will provide a standard operating procedure for monitoring the stability of measurement systems, and provide a basis with which to discuss how a variographic approach can be integrated with the Lean and Six Sigma approach as an online tool to map, characterise and validate measurement systems and thus avoid more cumbersome measurement system analysis in full detail.CITATION:Thisted, E, Thisted, U, Bøckman, O and Esbensen, K H, 2017. Variographic case study for designing, monitoring and optimising industrial measurement systems – the missing link in Lean and Six Sigma, in Proceedings Eighth World Conference on Sampling and Blending , pp 359–366 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By N Tuffs, R Peace, S Xue

Mine gas control is a major issue in most of the gassy underground coal mines, due to its direct impact on safety, production delays and cost of production. Analysis of the gas data, from different collieries in Australia showed that longwall gas emissions have increased substantially over the years. Simply increasing the number of goaf holes in the panel or decreasing goaf hole spacing seems not to be effective, in controlling high goaf gas emissions. A major research project has been undertaken by CSIRO in collaboration with mine sites to address this goaf gas control issue with the aim of developing effective and optimum goaf gas drainage strategies. The project has combined extensive field studies with computational fluid dynamics (CFD) models, to characterise goaf gas flow patterns and develop effective gas control strategies. The research work specifically involved review of gas control issues at field sites, goaf gas monitoring, tracer gas tests, CFD simulations and extensive field trials. Field demonstration studies of the new optimum strategies have been conducted at two collieries in Australia. The project results have shown that the optimum strategies were highly successful, in improving the overall efficiency of goaf gas drainage systems, at both the field sites. Results of the goaf gas flow characterisation studies and field demonstration studies are summarised in this paper.

Jan 1, 2005

By Alan G. Mayton

A prototype end-cab shuttle car (SC) design has been developed to improve protection and address ergonomic concerns of the SC operator in low coal mines. The new design features an end cab transversely mounted to the SC and equipped with a closed-circuit video system. The end cab was retrofitted to a low-coal SC and evaluated in surface trials at the U.S. Bureau of Mines. During surface trials, test operators evaluated the end-cab SC relative to visibility; cab features-space, seating, controls, and operator position; tramming-inby, outby, and turning corners; and dumping. Trials were conducted using 12 test subjects; 6 were experienced SC operators. Results of the trials were promising. Of the experienced operators, the only operator with low-coal experience gave the new design the highest rating. Four experienced operators rated the end-cab design "better" to "much better" than a standard center-driven, side-cab SC for visibility when tramming, protection from roof and rib hazards, and no change in seat position with direction of travel. This report discusses research to modify a used 21SC JOY SC, retrofit the SC with the Bureau-developed end-cab, and evaluate the retrofitted end-cab SC in surface trials.

Jan 1, 1993

By Fuller P. G

The purpose and current practice of cable trusses in underground coal mines is briefly outlined and details of various cable truss designs are presented. The main part of the paper describes the in-situ performance of cable trusses installed as secondary supports in gateroads and recovery roads of longwall coalfaces. The performance analysis is based on the results of in-situ monitoring carried out at a number of sites at two underground coal mines within Australia. Truss performance has been assessed as load developed in relation to roof convergence, face position and time. Additionally, the influence of strata conditions, installation pattern/density, roadway layout and geometry have been taken into account. An analytical model has been developed to predict truss loads. The principal variables are listed and the basis of the model is described. Based upon behaviour observed in the field the model has been progressively upgraded and validated against measured performance. Guidelines on truss performance and factors which influence it are presented and the implications of these to the use of cable trusses is discussed. Possible methods for improving truss performance in certain strata conditions are outlined and some comments are made on the value of cable trussing compared to cable bolting in these Situations.

Jan 1, 1992

The purpose and current practice of cable trusses in underground coal mines is briefly outlined and details of various cable truss designs are presented. The main part of the paper describes the in-situ performance of cable trusses installed as secondary supports in gateroads and recovery roads of longwall coalfaces. The performance analysis is based on the results of in-situ monitoring carried out at a number of sites at two underground coal mines within Australia. Truss performance has been assessed as load developed in relation to roof convergence, face position and time. Additionally, the influence of strata conditions, installation pattern/density, roadway layout and geometry have been taken into account. An analytical model has been developed to predict truss loads. The principal variables are listed and the basis of the model is described. Based upon behaviour observed in the field the model has been progressively upgraded and validated against measured performance. Guidelines on truss performance and factors which influence it are presented and the implications of these to the use of cable trusses is discussed. Possible methods for improving truss performance in certain strata conditions are outlined and some comments are made on the value of cable trussing compared to cable bolting in these situations,

Jan 1, 1992

By S. L. Bell

Most Australian longwall coal mines are currently working coal faces up to nine kilometres from the surface. In the event of a mine emergency walking this sort of distance wearing breathing apparatus becomes very difficult if not impossible. Self-rescue continues to remain the focus of mines rescue in Australian coal mines and this paper describes a vehicle modification which will improve the chances of a miner rescuing himself. Existing mine personnel transport vehicles are not designed to operate in some types of atmospheres that may be present following a mine fire or explosion event. An Australian Coal Association Research program (ACARP) funded research project recently completed in Australia has developed a specification for a vehicle that is able to operate safely in some types of post emergency atmospheres. During the course of this investigation, diesel and electric vehicles were examined prior to making a final decision on vehicle suitability. Based on the fact that there are already some 1500 diesel vehicles in use in underground coal mines in Australia it was decided that modifications to existing diesel engines would be the best option. This presentation will outline the proposed specification for the vehicle and the reasons behind the decisions that were made with respect to the specification.

Jan 1, 2003

By Shailin Lalloo, Allan B. Nesbitt

A fluidised bed was exposed to high gravities by placing it in a centrifuge. The bed expansions were measured and compared with the bed expansions predicted by the Richardson-Zaki model (1954). The Richardson-Zaki model was found to predict effectively the fluidisation behaviour of defined particles in this increased gravity environment.

Jan 1, 2003

By H. E. Exner

This article is a critical review of the influence of surface preparation on crack formation at Vickers indentations in the test used by Palmqvist3-7 to evaluate the toughness of cemented carbides. Experimental results are presented which clearly show that grinding introduces compressive surface stresses into the cobalt phase and thus reduces the crack length. The deformed surface layer is removed by polishing and a stress pattern is approached corresponding to that in the bulk material. Cracks of maximum length are characteristic of this stress state. Deformation stresses can be removed by annealing above 800°C. On the basis of these results , sample preparation for the crack length test can be simplified, the accuracy of measurement is improved, and a simple and significani parameter is found to describe crack resistance of cemented carbides. FOLLOWING suggestions by Ammann and Hinniiber,1'2 Palmqvist3-7 developed a method for testing the toughness of cemented carbides using as a measure the sum of crack lengths at the four corners of a Vickers hardness indentation. This method has several advantages over the bend test commonly used in carbide technology: a) specially formed samples are unnecessary; b) sufficient information can be obtained from one sample; c) the scatter is relatively small; d) the range of actual values for commercial cutting alloys is wide. Thus, this test is both cheaper and more precise than the bend test. Nevertheless, Palmqvist's method is not widely used, mainly for two reasons: a) The relationship between crack length and the technological properties of the material (wear and shock resistance) is not clear. b) The crack length is strongly dependent on surface treatment. It is necessary, therefore, that surface preparation be very precise and reproducible, conditions usually hard to obtain. While any other simple mechanical test has this first drawback, the second became crucial in the application of the crack length method as a practical test. The reasons that this drawback could not be eliminated are, in our opinion, misleading and inconsistent interpretations of the influence of surface preparation on the crack length given in literature. In the following, after a short review of previous experimental results the interpretations given by different authors,4?'-11 cf. Table I, are discussed critically and a consistent explanation is presented on the basis of which improvements of the method of crack length testing are proposed. 1) PREVIOUS EXPERIMENTAL RESULTS In his first attempt to use the cracks at Vickers impressions as a quantitative measure of the toughness of cemented carbides, palmqvist3 calculated the work necessary to initiate cracks by the formula: Sk =k.Pk. [I] where k = numerical constant = 6.49, Sk = critical work to initiate cracks (gf cm), Pk = critical load (load necessary to initiate cracks) HV = Vickers hardness (kp per sq mm). The difficulties involved in experimental determination of the critical load were overcome by the observation that a linear relation holds between the applied load and the sum of the crack lengths at the four corners of the indentation. This linear function, given by Eq. [2] below, was confirmed by Dawihl and Alt-meyer9and by our experiments, see Fig. 1: I = a1.P +a2 [2] where 1 = sum of the crack lengths at a Vickers indentation, P = applied load, al, a2 = parameters dependent on the toughness of the alloy and the surface preparation. The critical load, Pk, is now given by a2, which can be obtained by extrapolating the load vs crack length line to zero crack length, see Fig. 1. This simple relationship, Eq. [2], led Palmqvist1,7 to a parameter which was more reproducible and easier to obtain experimentally than the critical work: the work, S300, put into the sample to produce an average crack length of 300 µm per indentation. This parameter is calculated using the formula: where the load, P3oo, giving a crack length of 300 µm, can be taken from the load-crack length plot, Fig. 1,

Jan 1, 1970

By WILLARD W. CUTLER

This bulletin reviews, in the light of recent experience, the use of production-decline curves in estimating the future production of oil from wells. It deals with the estimation of the reserves of recoverable oil in properties already producing or in those adjacent to them, takes cognizance of the physical laws governing expulsion of oil from oil sands, and shows how the production-decline curve can be made to utilize these laws in estimating reserves and rates of production. The valuation of oil properties should be based on the total amount of oil recoverable from a property by the methods in use, the rate of recovery, the cost of production, and the selling price. Numerous other curves besides those for reserves and rates of production may be formed from the production-decline curve and will present desired information in a convenient time-saving form. These curves also are described. Methods developed before the production-decline curve method was used are briefly discussed in order that the principles on which estimations of oil reserves are based may be made plain. The construction of curves and tables for estimating future production of individual wells and of average wells in most of the important oil districts of the United States is described and operating problems that may be solved by the use of production-decline curves are discussed. The bulletin does not deal with costs, oil prices, or the methods of evaluating oil properties. Many engineers have amply demonstrated the value of the production- decline curve method by forecasting within reasonable limits the production of many thousands of wells and tracts. The value of similar estimates depends however, on (1) the application of trustworthy methods; (2) the care and judgment of the estimator; and (3) the length and reliability of the records and the accuracy of ofher information used in estimating future production. When adequate records and information are available, experience has shown that It qualified engineer can forecast production far more accurately than has been deemed possible, except where the usual conditions governing the expulsion of oil from a sand have been radically changed by applying compressed air or by flooding with water, or, to a less degree, by using vacuum. In general, the production-decline curve method, though there are limits to its accuracy, is far more trustworthy than any other.

Jan 1, 1924