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By Thomas Camus

"STATE OF THE ART The current situation of ground prediction in TBM is of great concern for tunnelling contractors, and the subject has been quite widely addressed over recent years, for instance by the French Eupalinos 2000 programme, which tested a variety of technological approaches. A number of interesting projects were executed, such as the SOUND and OnSITE projects, part of the German Geotechnologien programme: these projects are focused on seismics, while other techniques such as radar are not considered. Little information and even less industrial applications have been released apart from lab simulations and numerical modelling. A number of field tests in different configurations have been carried out for compression waves, but the results were often not reliable or convincing, and therefore little has been reported in open literature. The advances seem somewhat promising as far as hard rock tunnels are concerned, but ignore the problem raised by concrete lined tunnels such as those bored by a TBM in soft ground. In such tunnels, sending and receiving seismic waves reliably through the lining (and the grouting behind) is quite illusory. A careful analysis of the seismic prediction research results show that the main problem is the source which is poorly controlled and poorly coupled (for instance in concrete lined tunnels, or in approaches that use the TBM cutter head vibrations as a source). Generating waves perpendicular to the tunnel axis is also a problem: aligning with the tunnel axis makes more sense. Radar (Ground Penetrating Radar - GPR) has been used in geotechnical surveys for decades, and also for tunnel inspection. Attempts have been made at using it on a TBM (for example in Japan by Taisei) but mainly using off-the-shelf GPRs, which are not adapted to work in the specific environment of a TBM (because of its huge mass of metal, to start with). Very few results have been published, probably due to the somewhat disappointing performance of such implementations. At present, no TBM has a GPR incorporated in its cutter head that is able to predict ground characteristics while drilling. Another characteristic and drawback of most current methods is that they require dedicated periods of time during which other tunnel construction activities must be stopped. Due to the duration of such operations this leads to performing ground prediction on a weekly basis only, and therefore to a requirement for an investigation range of 100 metres approximately (in order to cover the TBM advance over the coming week). This is not achievable with boreholes made from the TBM, even less if a reasonable accuracy is required, as is usually the case."

Jan 1, 2016

By Martin Brueggemann

In 1993, the El Paso Smelter began operation of the first commercial CONTOP copper smelting furnace. The CONTOP process was chosen for the plant modernization due to its low capital cost and the ease that it could be incorporated into a 100 year old existing smelter. After four years of operation, CONTOP has proved itself to be a reliable copper smelting technology. This paper will discuss a brief start-up history, current operation, and future modifications and improvements.

Jan 1, 1998

By R. Hendrickson

In the 1940's a top blown water-cooled oxygen lance was developed to inject oxygen into liquid iron. This process, the LD or BOF process technique, today is used in 65% of the world's steel production, and represents the largest oxygen market for temperature enhancement in steel and non-ferrous smelting applications. There are three major approaches to the use of oxygen in metallurgical processes: (1) general enrichment of the air supplied to burners or tuyeres, (2) under-flame enrichment or injection, and (3) the use of an auxiliary oxy-fuel burner as a heat source. With each of these techniques there are technical and economic trade-offs.

Jan 1, 1990

By S. Seetharaman

A mathematical model has been developed to evaluate the viscosities of melts at high temperatures. The viscous flow in liquid is described by the equation, {n = Aexp(AG*/RT)} based on the absolute reaction rate theory. The Gibbs energy of activation,{ AG* } is considered to be a function of the temperature as well as the composition of the melt. The model has been applied successfully to various metallic and slag systems from unary to quaternary. On the basis of this model, a relationship has been suggested to relate the Gibbs activation energy of viscosity to the Gibbs energy of mixing in binary metallic melts. The viscosities predicted from available thermodynamic data in the case of a number of binary metallic systems using this correlation show satisfactory agreement with the reported experimental values.

Jan 1, 1994

By Terry B. Linde, William M. Dowall

The recently completed In-Pit Crushing and Conveying Project at Phelps Dodge's Morenci Mine is rated among the world's leading materials handling projects. The operation involves the crushing and transport of more than 109,000 tonnes per day of copper ore, utilizing regenerative conveyors capable of providing over 5.5 megawatts (7,000 hp) of equivalent electrical energy. This paper describes the key aspects of the project and includes: Original project objectives; System design criteria; System description; Optimization studies; Major design features; Equipment description; and System commissioning.

Jan 1, 1993

By P. A. Cornejo

Blastings always generates induced vibrations through seismic wave, these are lost energy from the blasting and therefore causing the disturbance of slopes and structures near the blast source. Most of the components of an open pit mine have to reach a physical stability, especially during its closure process. Aiming to develop a vibration prediction model using the historical records from an open pit mine located on Peru, this research has two main focuses depending on the distance from the blast source to the structure: to protect the final slopes and to protect the villagers houses. Both are based on the Devine model of the Square Root Scaled Distance (SRSD) to predict the Peak Particle Velocity (PPV). The Mid field model, where is found mainly final slopes from the pit, limited by the failure criteria of McKenzie based on the geo mechanical properties of the rock mass. The Far field model ranges distances where are located the most community households, limited by the German rule DIN 4150 for highly sensitive structures. Both scenarios resulted on a distribution abacus to limit the weight of used explosives to get the best operational advantage and structure safety.

Mar 2, 2022

By David La Rosa, Matthew Craft, Lee Julian

Rules of thumb are ubiquitous in blasting. Typically presented as ratios, they assist with the initial assumptions of blast design and provide guidance for best practice. Examples include the blast hole diameter as a function of bench height, and stemming length as a function of hole diameter. The most common rules of thumb were developed in mid-20th century and it is important for a blaster to know if the rules of thumb are still reliable.

Feb 6, 2023

By Stephen Mansfield, Johannes Schoeman

In August 2006 a technical alliance was formed between Orica Mining Services and Century Mine to provide blasting solutions. The alliance is in the form of a Rock to Specification (R2S™) service, one of Orica’s Blast Based Services (BBS™). The ultimate goal was to facilitate the rapid expansion of material movement from 26 to 41M m3 (34 to 53M yd3) per annum while maintaining a reliable ore supply to the mill.

Jan 1, 2010

By Q. G. Liu

New solid-state electrochemical sensors 1;.1sing Li2SO4-Ag2SO4 electrolytes have been developed to measure SO2 and/or SO3 in gas mixtures. Silver embedded in part of the electrolyte is used as the reference electrode. Although single-phase electrolyte sensors yield accurate results for one to two days, a two-phase electrolyte cell exhibits excellent long-term chemical stability. For example, stable and accurate potent iometric responses have been obtained over a six mo.nth period. The. advantages of the two-phase electrolyte ( 23 mol% Ay 2SO4 ) cell include excellent mechanical strength on temperature cycling and an insensitivity to compositional variations in the electrolyte and to temperature fluctuations. Experimental tests have shown excell.ent results in SO2-air. mixtures with the SO2 concentration ranging from 3 to 10,000 ppm (vol). However, the SO2 concentration range was limited by a lack of standard gas mixtures, and our sensor cells can be used to measure S02 concentrations significantly less than or larger than our experimental range. Results also indicate that the presence of significant concentrations of CO2 and H2O in the gas mixture has no effect on the sensor response. Thus the two-phase electrolyte ( 23 mol% Ag2S04) sensor has exceptional selectivity, reliability and long-term chemical and mechanical stability.

Jan 1, 1985

By Christopher Mark

"Many problems in rock mechanics are limited by our imperfect knowledge of the material properties and failure mechanics of rock masses. Mining problems are somewhat unique, however, in that plenty of real world experience is generally available and can be turned into valuable experimental data. Every pillar that is developed, or stope that is mined, represents a full-scale test of a rock mechanics design. By harvesting these data, and then using the appropriate statistical techniques to interpret them, mining engineers have developed powerful design techniques that are widely used around the world. Successful empirical methods are readily accepted because they are simple, transparent, practical, and firmly tethered to reality.The author has been intimately associated with empirical design for his entire career. But where his past papers have described the application of individual techniques to specific problems, the focus of this paper is the process used to develop a successful empirical method. A six-stage process is described:1. Identification of the problem, and of the end users of the final product2. Development of a conceptual rock mechanics model, and identification of the key parameters in that model3. Identification of measures for each of the key parameters, and the development of new measures (such as rating scales) where necessary4. Data sources and data collection5. Statistical analysis6. Packaging of the final productEach of these stages has its own potential rewards and pitfalls, which will be illustrated by incidents from the author’s own experience. The ultimate goal of this paper is to provide a new and deeper appreciation for empirical techniques, as well as some guidelines and opportunities for future developers."

Jan 1, 2015

Just as geophysics, in the form of 3D seismic and wireline logging, plays a key role in petroleum reservoir management, so too will geophysics play an important role in mining of coal, metals, and minerals in the 21 st century. The commercial and social imperatives driving greater use of geophysics are reduced costs, increased revenues, and enhanced safety. In short, superior utilisation of capital and management of risks. In relatively undeformed sedimentary environments it is possible to adapt petroleum-style 3D reflection seismic to image mines. This has been demonstrated most impressively in the Witwatersrand. Anglo-American, for example, completed a $1 million 3D seismic survey at Western Deeps in order to site a new $300 million shaft with confidence. Likewise, 3D seismic has gained rapid acceptance at Australian coal mines in recent years. Encouraged by these successes, metalliferous mining companies are supporting research in Canada and Australia, as well as South Africa, to adapt 3D seismic for more highly structured, metamorphic terranes. Because the mining industry is far more diverse than the petroleum industry in terms of commodities and geological environments, 3D seismic is not always cost-effective. A plethora of other geophysical techniques can be applied, many of which are employed in mineral exploration. Mine applications of geophysics differ from traditional exploration applications in two main ways: time scales and length scales are shorter, and boreholes are more plentiful. Borehole geophysical techniques therefore play a more significant role, both for logging and imaging. Logging systems detail the variations of in situ physical properties down the borehole at scales measured in centimetres, while geophysical imaging techniques can map features located tens or even hundreds of metres from the sensors. While geologists tend to think of boreholes in terms of chips and core, geophysicists perceive them first and foremost as access paths for instruments. Borehole logging has been employed at iron and coal mines for decades, mainly to accurately define ore boundaries in delineation holes. In base metal mines, Outokumpu implemented logging widely for orebody delineation in percussion holes in the 1980s. The benefit was a direct cost-saving, arising from substitution of core drilling with percussion drilling plus borehole logging. The practice has since spread to other companies. INCO, for example, defines nickel boundaries in blast holes at Sudbury using conductivity logs. The benefits are in the form of reduced dilution and enhanced ore recovery, flowing from a more accurate mine model. Density, natural gamma radiation, magnetic susceptibility, and conductivity are the principal metalliferous mine logging parameters because they can be recorded in both dry and water-filled holes. Sonic velocity is the premier geotechnical logging parameter, given its sensitivity to rock strength, stress, porosity, and degree of fracturing. Sonic is recorded routinely in exploration and geotechnical holes at coal mines. With the advent of slimline dipmeter, full waveform sonic, and optical and acoustic scanner tools, the role of borehole logging in geotechnical evaluations is expanding. Monitoring of strain and micro-seismic activity enhances safety during mine production. While qualitative interpretation of logs is adequate for stratigraphic identification or definition of boundaries, a wealth of quantitative information, eg density, can be derived from properly calibrated, repeatable geophysical logs. Moreover, geophysical logs can sometimes serve as surrogates for geochemical assays, and not only for magnetite and uranium. At OutokumpuÆs Kemi chromite mine, for example, gamma-gamma logging provides the basis for grade control. By reducing reliance on assaying, three benefits can be realised: reduced reliance on core drilling; lower core handling and assaying costs; and shorter turn-around times. Conventional downhole EM and borehole magnetics are used for near-mine exploration, and for ground sterilisation. Inco has enjoyed considerable success with borehole UTEM in the Sudbury Basin, for example, and Geopeko has applied three-component borehole magnetics successfully in the Tennant Creek area. Electrical techniques such as applied potential and magnetometric resistivity (MMR) are also finding application at mines. For higher resolution, borehole seismic, radio imaging, and radar have been invoked, with varying degrees of success, to delineate orebodies and map structures, or to geotechnically characterise the rock mass and identify hazards. Success mapping nickel sulphide shoots with borehole radar has been reported by WMC at Kambalda. There are no universal geophysical panaceas, and each mine imposes different geological, logistical, and economic constraints. Geophysics will not always be cost-effective. However, the greatest single impediment to expanded use of geophysics at mines has been the low level of awareness of geophysics on the part of most mine geologists, engineers, and managers and, equally, the limited understanding of mine geology and engineering exhibited by the majority of geophysicists. This myopia will be remembered as a 20th century affliction! Blue Sky areas for mine geophysics in the next ten years include integration of geophysical data acquisition with drilling, enhanced grade estimation and rock mass characterisation, and the incorporation of geophysical information into mine models using geostatistical techniques. All these advances will be predicated on an expansion of petrophysical knowledge.

Jan 1, 2000

By James J. Olson

Most of the projects summarized in this paper are funded under the Bureau's Advancing Metal-Nonmetal Mining Technology program and are part of the in situ mining subprogram coordinated at the Twin Cities Mining Research Center. The borehole mining equipment development, are funded under the Bureau's Advancing Coal Mining Technology program, is essential to accelerated progress in the in situ mining subprogram, and some background information on this concept is included. The initial in situ research projects started in 1971-72 evaluated some of the critical blast design parameters for in situ copper leaching. The present program totals about $1 million per year and includes in-house research projects, cooperative (cost-sharing) projects with the mining industry, and research and development contracts. Two different extraction schemes are under investigation: inplace leaching and borehole (or slurry) mining. The principal commodity targets for the Bureau's improved in situ mining technologies include copper, uranium, coal, and potash. The principal purpose of this paper is to inform the mining industry of the in situ mining research recently completed or being conducted by the Bureau of Mines. In addition the Bureau encourages companies to comment on the program accomplishments as well as offer suggestions on top priority research needs for improving the in situ mining methods described in this paper.

Jan 1, 1977

By Jorge Misle, Daniel Silva

"This paper addresses the need for advanced control technologies and strategies in the mining industry, its potential and actual impact on mining processes and the best practices for their implementation, operation, and long term sustainability. It is well known that advanced process control (APC) can be a very good source for incremental process improvement for the mining industry, yielding to higher production rates or helping maintain consistent production rates despite ore changes. The application and integration of new technology, process knowledge and innovation are key elements in building such a supporting structure. More specifically, and this cannot be emphasized enough, the correct application and assembly of control tools, the in-time presentation of key data to decision makers and the development of relevant statistics and KPI’s (key performance indicators) can and will make a difference not only in terms of production, but also in plant stability, availability and production costs. In deploying such ideas and aiming at the long-term goal of "Operational Excellence", Minera Los Pelambres (MLP) has developed a number of successful control strategies, best practices and technologies, which are not only the application of state-of-the-art automation and computing tools, but rather the assembly of the above presented structuring factors. This work discusses some of the key tools and ideas implemented for SAG & Ball milling and Flotation areas, their performance results and the roadmap taken for the integration of process knowledge and control tools. Also, cases studies are presented and discussed further to not only show the main areas of improvement, but also to highlight the benefits of such strategy that for the most part, deviate from the traditional mining industry control approach. Also, a word is given on the need for innovating in the design of control strategies and leveraging best practices and process knowledge that ultimately, will contribute to long-term reliable operations, improved mineral processing and, although unmeasured, lead to a superior overall performance and productivity of all mining personnel involved."

Jan 1, 2014

By Donald H. McLaughlin

THE activity and enthusiasm of pioneers still prevail among workers in applied geophysics1.- Within the year, new devices have .been tried out, instruments and technique have been improved and the methods of application to commercial problems have been increased in many ingenious ways. There is still great need for more skillful interpretation of results in terms of geology, but oil the whole geophysical prospecting is making encouraging progress toward finding its proper place and function in engineering and geological practice. Spectacular successes continue to be reported, particularly .from the Gulf Coast, where the race for salt domes has not slackened, and encouraging results have been giined elsewhere in the mapping of structures in the search for oil. In the mining field, however, it can hardly be claimed that the same measure of success has been obtained, for brilliant efforts worthy of wide recognition have been overshadowed to some eatent by the unfortunate outcome of surveys undertaken unwisely without recognition of the limitations of the work. Consequently, hopes were aroused that could not be fulfilled, and it must be admitted in an impartial survey that there are a few regions, chiefly in the far north, where the standing of geophysical prospecting is somewhat doubtful and where the course of public opinion regarding it shows a certain similarity to the history of the market during the past few months. Reliable work, however, is steadily going 011 and it can confidently be expected that the methods will eventually be regarded in many regions as an essential part of the technique of securing geologic data needed for intelligent exploration.

Jan 1, 1930

By A. Heriba

Cyanide is highly toxic to humans and other organisms. Concentrations of RCN as low as 0.05 ppm can be lethal to fish (Scott and Ingle', 1981). In wet climates and in colder climates where natural degradation is slow, it is becoming mandatory to destroy cyanides in effluents before they can be discharged. The disposal of spent gold ore as tailings from cyanide heap leach processing facilities is a matter of concern to the public, the mining industry, and regulatory agencies. South Dakota mining laws and regulations require that spent ore be neutralized to a suitable level with respect to cyanide before disposal (Durkin, 1990). To safeguard the environment and protect ground-water and surface-water supplies adequately, a reliable test is needed to determine the amount of cyanide in the solid spent ore.

Jan 1, 1993

By Chris Laughton, Bernhard Spoerr

"Tunnel inspections are increasingly needed to ensure that aging infrastructure does not fail in service. To this end the time between inspections is being reduced, the thoroughness of each inspection is being increased to provide for a more detailed assessment of conditions and inventory defects. The conventional Tunnel Report, containing hand-drawn maps and/or photos, and a log describing observed defects and areas of deterioration, is being increasingly replaced by LiDAR generated 3-D surface maps. The data collection process that traditionally supports development of a Tunnel Report is labor-intensive, taking crew-days of engineering effort, and requires partial or full stoppage of tunnel operations. In an urban setting, such multi-day interruptions in service are difficult to countenance for a near-capacity tunnel operation. Under time pressures, the detail and accuracy of the manual inspection process will inevitably be compromised, resulting in a high cost, low quality product. As the tunnel inspection window decreases the argument for incorporating laser scanning in to the inspection process is increased dramatically... The 3D scan technology allows detailed and accurate data to be collected within the tight time frames demanded by the owners and operators of critical infrastructure. Not only does the use of laser scanners improve the 3D accuracy of the data collected, it also, enhances the efficiency and safety of the inspection process, reduces data collection and processing costs and enhances the reliability of results over time. The paper will also demonstrate the value of adding photogrammetric data to the 3D Model to show surface defect discoloration. The accurate and detailed data collected by a combination of LiDAR and photogrammetric techniques provide superior data needed to inform critical asset management decisions related to maintenance, repair and replacement."

Jan 1, 2016

By J. Shen

Direct methanol fuel cells have been the subject of considerable research in the last decade. Performance levels realized in cells, stacks, and systems show that this technology is a promising power source for a wide range of portable applications. A direct methanol fuel cell (DMFC) operates directly on a methanol fuel stream typically supplied as a methanol/water vapour or as an aqueous methanol solution in liquid feed DMFCs. The fuel streams in DMFCs are usually recirculated in order to remove carbon dioxide and to re-use the diluent and any unreacted fuel in the depleted fuel stream exiting the DMFC. The concentration of methanol in the fuel circulation loop is an important operating parameter because it determines the electrical performance and efficiency of the direct methanol fuel cell system. The methanol concentration in the circulating fuel stream is usually measured continuously with a suitable sensor, and fresh methanol is admitted in accordance with the signal from the sensor. There are many factors to consider in developing a methanol sensor suitable for DMFCs. These factors include sensitivity, cost, size, simplicity, reliability, longevity, concentration range, and dynamic response. In particular, reliability and low cost should be addressed. Methanol concentration sensors measure methanol concentration by means of detecting the variations of physical/chemical properties of the solution. In this work, methanol concentration sensors based on electrochemistry, electric-capacitance measurement, infrared sensing, ultrasound sensing, and other techniques are reviewed to discuss their advantages and disadvantages.

Jan 1, 2005

By William Bergeson

"BACKGROUND As of December 2015, there are roughly 475 road tunnels within the United States according to the most recent national tunnel inventory data compiled by the Federal Highway Administration (FHWA); whereas, there are more than 615,000 highway bridges on public roads. The FHWA estimates that tunnels represent nearly 100 miles of Interstates, State routes, and local routes. Tunnels are part of the national transportation infrastructure and represent a significant financial investment for the owner and, hence, the tax payers. Tunnels, that are not properly maintained, usually require more extensive repairs and consume more resources. Tunnels must provide safe, reliable, and effective transportation even as these structures age and deteriorate. Furthermore, tunnels generally remain in service for extended periods of time due to their very high construction costs. For example, many tunnels were constructed decades ago during two historic periods of highway system expansion; the first period correlated with the era of public works programs linked to the Great Depression of the 1930-40s; and the second period of expansion occurred with the building of the interstate highway system in the 1950-60s. As such, these tunnels are fast approaching 60 to 80 years old. Congress enacted the Moving Ahead for Progress in the 21st Century Act (MAP-21), which was signed by the President on July 6, 2012. This legislation followed a fatal tunnel incident on July 10, 2006 and a National Transportation Safety Board (NTSB) report1 that noted the importance of conducting regular tunnel inspections. MAP-21 authorized the Federal Highway Administration (FHWA) to develop a mandatory inspection program for all tunnels on all public roadways (Bergeson and Ernst 2015): To help safeguard tunnel users and to ensure reliable levels of service, the FHWA developed the National Tunnel Inspection Program (NTIP), which is comprised of the National Tunnel Inspection Standards (NTIS), the Tunnel Operations Maintenance Inspection and Evaluation (TOMIE) Manual, the Specifications for National Tunnel Inventory (SNTI), and the Manual for Bridge Evaluation (MBE). The data collected from the program will be stored in a National Tunnel Inventory (NTI) database. A comprehensive and refresher training program was also developed to help qualify and certify key tunnel inspection personnel to include the program manager and team leader."

Jan 1, 2016

By Blair R. Benner

This paper describes the installation and operation of a Texas Nuclear on-line silica analyzer (NOLA) coupled with a Leeds and Northrup Microtrac particle-size monitor (Microtrac) at U.S. Steel's Minntac taconite concentrator. An automatic sampling system provides the NOLA with samples of final concentrate. After the sample is analyzed for silica by the NOLA, it is pumped to the Microtrac for size and surface area measurement. A sample is analyzed every six minutes, providing the control room with the silica concentration, the percent passing 270, 400, and 500 mesh, and an equivalent Blaine surface area number. When fed a slurry of final concentrate containing between 20 and 70% solids and 5 to 6% silica, the NOLA analysis is within ±0.2% of the wet chemistry silica. The agreement between the Microtrac output and standard screen analyses is ±1.2% at 270 mesh; ±1.5% at 400 mesh, and ±2% at 500 mesh. The poorer disagreement at the finer sizes is mainly due to inaccuracies in screening at 400 and 500 mesh. The agreement between Microtrac surface area a d laboratory Blaine surface area is about 9 ±80 cm 2/g. These instruments provide rapid and reliable feedback information to the concentrator and feed forward information to the agglomerator.

Jan 1, 1984

By John J. Ginty

The objective of the work reported herein was to evaluate state-of-the-art repeaters used in wireless communications to determine their suitability for use in extending the range of portable and mobile communications in underground mine applications. The scope of the work included wireless repeaters in the frequency range from LF (500 kilohertz) up to the one giga-hertz range. These repeaters included not only single-channel repeaters, that is F1/F1 repeaters for short range simplex party line communications, but in addition, F1/F2 type repeaters currently commercially available in the HF, VHF and UHF bands.

Jan 1, 1975