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By D. Burkhard, E. Herth

"Geologic structure and properties are the primary influences on ground control at San Juan Mine. Geotechnical properties of the coal seam and near seam strata, the presence of above seam sandstone paleochannels and water, are thought to be the leading contributors to ground control issues. It is the confluence of specific geologic conditions rather than isolated features that most often produce adverse conditions. Altering primary support installation and mining practices are done when unfavorable conditions appear during development. Installation of standing support is most often employed when adverse conditions develop at later dates. REGIONAL GEOLOGIC SETTING San Juan Mine is an underground coal mine located on the western flank of the San Juan Basin in northwest New Mexico. The San Juan Basin is contained within the south eastern region of the Colorado Plateau geographic province. The basin contains multiple coal bearing formations and is also a major producer of coalbed methane gas. San Juan Mine is stratigraphically located within the Fruitland Formation. From a prominent monocline marking the western boundary of the basin, the formation dips gently to the east towards the center of the basin. The primary driver for the deposition of coal bearing formations within the basin was the Cretaceous Inland Seaway. Multiple cycles of transgression and regression driven by sea level rise and tectonic subsidence deposited rock types from marine shale’s to terrestrial sandstones. The Sevier Mountains to the west of the seaway likely provided the sediment supply for the Fruitland Formation. During a major cycle of seaward regression, the Pictured Cliffs Sandstone Formation prograded over the marine Lewis Shale. The coal bearing Fruitland Formation followed, being deposited over the Pictured Cliffs. The Fruitland Formation contains numerous coal seams and is approximately 400 ft. thick at San Juan Mine. Fruitland Formation coal seams are numbered in order of superposition. San Juan mines the Fruitland number 8 seam. Dating has placed the age of the seam at approximately 73 to 75 million years [1]. LOCAL GEOLOGIC SETTING The Fruitland 8 coal seam dips approximately 1-3 degrees towards the E-NE. At San Juan Mine, the seam displays a mild plunging, synclinal structure, the axis roughly bisecting the mine from west to east. The number 8 seam consists of five coal benches and four volcanic ash band partings labeled sequentially based on superposition. The lowest portion of the seam is the 8-1 bench, the 8-2 through 8-5 benches following sequentially to the top of the minable seam. Ash band partings are labelled P1 through P4 from bottom to top respectively. The presence of distinctive partings and benches allows for seam definition and aids in identifying mining horizons."

Jan 1, 2016

By J deVries, A Broodryk, P Kyselica, K McLean

Gwalia gold mine is located close to the town of Leonora in the Goldfields region of Western Australia, some 830 km from Perth. The mine is wholly owned by St Barbara Ltd, an Australian Securities Exchange listed gold producer and explorer. The Gwalia mine is a deep, all-trucking mine and is serviced by a 10 km long decline from surface. Mining is currently 1540 m below surface. Reserves extend to 1820 m below surface and are open at depth. The mine produces in excess of 200 koz of gold per annum.The Leonora area is hot and arid, with a mean annual rainfall of 230 mm and a 95 per cent mean daily maximum temperature of 20.3°C wet-bulb and 35.6°C dry-bulb.The primary ventilation system comprises a 490 kg/s surface exhaust fan, which draws air down a parallel intake system consisting of the decline, and a dedicated fresh-air intake system extending to the bottom of the production zone. Cooling is provided via a surface bulk air cooler serviced by an ammonia refrigeration plant that delivers 150 kg/s of chilled water to the bulk air cooler.The refrigeration plant and bulk air cooler were installed in 2008. The design allows cooling to be increased over time by installing an additional refrigeration plant in a lead lag configuration with the current refrigeration plant when required.Since 2008, expansion and increased depth reached a point where the underground heat load exceeded the installed capacity of the existing 4.0 megawatt rated (MWR) refrigeration plant. In order to maintain the mine design conditions underground, upgrading of the existing refrigeration system was required to bring the cooling capacity to 7.5 MWR.Two expansion options were considered: the addition of an ammonia vapour-compression refrigeration machine similar to the existing one or a lithium bromide absorption refrigeration system using waste heat from the site power station. The original design and layout of equipment on-site meant that either could be used, allowing an assessment of the merits of both when additional cooling was required.The decision was made to install a lithium bromide absorption system on the lead side of the existing ammonia refrigeration plant. This arrangement provides considerable economic benefits, including reductions in site-generated electrical power, generator fuel consumption and carbon dioxide emissions.This paper details the planning, design, installation and commissioning of the absorption chillers.CITATION:Broodryk, A, deVries, J, Kyselica, P and McLean, K, 2015. The design, installation and commissioning of an absorption refrigeration system at Gwalia gold mine in Western Australia, in Proceedings The Australian Mine Ventilation Conference, pp 193–200 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By A. Juganda, Jr. Bogin, S. A. Lolon, J. F. Brune, J. W. Grubb

"A longwall gob is mainly filled with broken rocks from the collapsed roof and becomes a porous medium where explosive methane-air mixtures can accumulate. In bleeder ventilation systems, this mixture can migrate out of the gob into the longwall face and other active areas in the mine during barometric or ventilation-induced pressure changes. When external pressures change, the gob does not perceive this disturbance instantly but with a delay due to air flow resistance in the porous gob material. The delay of gob response to outside pressure changes increases the pressure differential across the gob and may cause an outflow of explosive air mixtures from the gob into the adjacent bleeder entries. With computational fluid dynamics (CFD) modeling, researchers at the Colorado School of Mines have evaluated the impact of gob pressure fluctuations on the outgassing of the explosive gas zones (EGZs), the magnitudes and rates of pressure changes, the volumes as well as the potentials location of outgassing if it occurs. INTRODUCTION The air pressure field in underground mines is controlled by many factors such as operating fan settings, ventilation controls, surface atmospheric conditions, and other local events that can intermittently disturb mine pressure, including blasting, roof falls, or inundations. Mine fan settings are rarely changed. Mine atmospheric pressure fluctuations due to adjustments in ventilation controls occur more often during the mining process. Atmospheric conditions and barometric pressures can generate fluctuations in mine pressure on a large scale. Atmospheric pressures change regularly every day but can fluctuate abruptly and become increasingly hazardous in adverse weather conditions. Investigations conducted in coal mines in the United States, Australia, Poland, and South Africa observed higher methane emissions from the gob during periods of falling atmospheric pressures, which led to mine explosions (McIntosh, 1957; Boyer, 1964; Kissell et al., 1973; Fauconnier, 1992; Belle, 2014; Wasilewski, 2014; Lolon et al., 2015). Falling external pressures are understood to cause potential outflow of explosive mixtures from the gob, while rising pressures may push fresh air into the gob. This phenomenon is widely known as gob breathing. The actual processes that trigger gob breathing are not fully understood, nor are the parameters that contribute to the process. Other major events such as roof falls or fan failures can also change the pressure conditions in the mine. In contrast to atmospheric pressure changes, these events can change mine pressures much more rapidly or immediately. TIME LAG AND GOB BREATHING CONCEPT In a bleeder ventilation system, the pressure in the gob is designed to be lower than that of the headgate entries and the longwall face. Air from the gob and gate entries flows towards the tailgate-bleeder returns. When the external pressures are disturbed, this designed pressure arrangement may change, potentially resulting in increased outflow from or inflow into the gob."

Jan 1, 2017

By M D. Melville, B C. T Macdonald, T D. W

The surface waters in regions with acid sulfate soils (ASS) can contain high concentrations of acidity and dissolved metals. These soils cause problems for agriculture, construction and development. The water can be neutralised through many techniques, however a technique that is low in maintenance and low in cost is most desirable. Due to the vast spread of ASS along AustraliaÆs coastline an expensive and high maintenance solution would not be cost-effective. In this study, a passive treatment system that has been used to neutralise acid rock drainage has been applied to treat ASS water. This system is commonly referred to as an oxic limestone drain (OLD) or an anoxic limestone drain (ALD) depending on the waters dissolved oxygen concentration. The system that has been developed for ASS has a similar closed system to the OLD or ALD, that traps the carbon dioxide which forms when limestone reacts with acidic water. It has been called a closed tank reactor (CTR) and is constructed by placing limestone into an airtight tank. A common problem that will occur when acidic water with a high concentration of dissolved metals reacts with limestone is the formation of metal oxy-hydroxide precipitates. These precipitates can coat or armour the limestone and reduce its reactivity. To minimise the accumulation of precipitates in the CTR, perforated subdrains have been installed. It is anticipated that high water pressure and flow through the subdrains will remove some precipitates. A sump has also been installed at the base of the tank to collect precipitates that settle under gravity. The CTR has been tested for 70 days at a sugar cane farm located at McLeods Creek, NSW. Within this time the sump and subdrains have been used to flush the system. An orange solution was produced during flushing and it is believed to contain iron and aluminium precipitates. The initial performance of the CTR raised pH by at least one unit. Almost all dissolved aluminium was removed and more than half the dissolved iron. The total titratable acidity ranged from 17 - 92 mg/L CaCO3 in the initial month of monitoring. After passing through the CTR the acidity was reduced to zero. The performance of the CTR during the last few days of monitoring decreased. This is believed to be due to a pulse of water with higher acidity and dissolved metal content that lasted a week. In this pulse, the acidity reached 307 mg/L CaCO3 and the total dissolved aluminium reached a maximum of 24 mg/L. Higher concentrations of dissolved metals may have been the cause for lower performance due to increased precipitation and coating on the limestone.

Jan 1, 2003

After some 50 years of worldwide research in relation to coal pillar mechanics and design as well as numerous workshops and technical papers related to these issues there is still some significant disagreement as to the approach one should adopt in the assessment and design of a coal pillar. Of course there are many different types of coal pillars that fulfil a wide range of roles at any particular mine and in this instance it is appropriate to have a 'tailored' approach for each pillar type in relation to the role it fulfils. However where it can become very difficult for the mine operators is when various researchers or consultants use or recommend significantly different approaches for the same type of pillar fulfilling the same role. By 1999 two pillar design techniques had been developed specifically for the Australian underground coal mining industry (ie The University of New South Wales Pillar Design Procedure, UNSW PDP and Analysis of Longwall Tailgate Serviceability, ALTS) and several other pillar design techniques were being practiced by individual consultants. The Australian industry hoped to resolve the issue of what technique to use for each pillar type and role, when it funded UNSW in 2000 to develop a 'Systems Approach to Pillar Design'. The findings of the abovementioned project were published in 2005 and while every attempt was made by UNSW to include the views of various local and overseas researchers and consultants it would be fair to say that a unified approach to pillar design in Australia was not adopted as a result of that project. This is the experience of one country where there has never been one central group solely undertaking such research in relation to pillar design (such as the Chamber of Mines in South Africa). This paper explores the Australian experience in terms of pillar research and what that experience may offer to researchers in Australia and other countries. At the First Australasian Ground Control in Mining Conference (2003) the first 'update' of the ALTS Design Methodology (ie ALTS II) was presented. In subsequent years the ALTS database was continually updated and significantly expanded such that it now includes detailed information in relation to both the tailgate (148 cases) and maingate belt road (58 cases). In addition to tailgate roof support and chain pillar design, the current version of ALTS (referred to as ALTS 2009) includes a maingate belt road roof support design module. This paper is also intended to update and summarise the development and application of the ALTS Design Methodology for longwall gateroad design over the last decade both directly and in the context of coal pillar research conducted in Australia over the last 15 years.

Nov 25, 2010

By Bo Westerberg, Mattias Andersson, Yvonne Rogbeck

"Deep stabilisation has been used in Sweden for decades. The method has been improved to allow it to be used in different types of soils and with new binders. One challenging soil type in Sweden is so-called sulphide soil, a fine-grained soil which contains organic material and iron sulphides. There have been some cases in Sweden of problems when using deep stabilisation in this type of soil, and in one case a slope failure occurred. This paper shows that it is possible to achieve good results with deep stabilisation in sulphide soils. Laboratory and field studies from a test site along the Botniabanan railway line in Sweden are presented. Geotechnical and chemical properties of the natural soil were investigated in the laboratory and one or more of these properties may explain the differences in the stabilising effect of sulphide soils. The strength of the laboratory samples and the columns in the field were tested and compared. It is shown that a satisfactory stabilisation effect can be achieved with the proper choice of binder, amount of binder added, curing time and mixing energy. In sulphide soils, more binder additive is needed than in “ordinary” inorganic clays.1. INTRODUCTIONThe term sulphide soils is used in this paper to refer to the unique types of sulphide soil commonly found in the coastal areas along the north-eastern coastline of Sweden between the cities of Gävle and Haparanda, a distance of about 900 km. Sulphide soils are in general very compressible, susceptible to creep deformation and normally show low undrained shear strength. A sulphide soil may have a negative environmental impact through acidification and chemical action if it is subjected to oxygen, for example during excavation or lowering of the ground water table, Mácsik (1999). In foundation engineering works, efforts are made, for environmental or/and economic reasons, to use the sulphide soil as the foundation instead of excavating it. Deep stabilisation by means of columns is a potential method for use when sulphide soil needs to be improved in order to reduce settlements or/and increase the stability of embankments.Sulphide soils were formed as sediments at river mouths and off the coast in the special environment prevailing at the time of sedimentation, Mácsik (1994). The water in which the sulphide soil was sedimented was brackish/sweet and the environment was typically deficient in oxygen. The environment prevented complete decomposition of the organic material in the sediments. As a result, sulphide soils were formed primarily in the form of a fine-grained composition of clay and silt minerals, iron sulphides and organic matter. Such environments still exist today and new sulphide soil sediments continue to be formed."

Jan 1, 2015

By Meredith Scaggs, Emily Sarver, Lucas Rojas Mendoza

"Early on Jan. 9, 2014, approximately 37,800 L (10,000 gal) of crude 4-methylcyclohexanemethanol (MCHM) leaked from a storage tank sitting on the bank of the Elk River near Charleston, WV (WVDEP, 2014; CSB, 2014). MCHM is a chemical commonly used in preparation of fine coal and is considered nonhazardous in terms of transportation, storage regulations and also toxicity (CDC, 2014a). Freedom Industries Inc., a producer and vendor of specialty chemical products, had acquired the storage facility from Etowah River Terminal, LLC just a few weeks prior in December 2013 (WVDEP, 2014; Freedom, 2005). The direct cause of the spill was ultimately determined to be two small holes in the base of the 76-year-old tank, which were created due to corrosion damage (Bauerlein and McWhirter, 2014).The spill site was located a little more than 1.6 km (1 mile) upstream from the intake of a municipal water treatment facility operated by West Virginia American Water (WVAW), which serves a population of 300,000 across nine counties in central West Virginia (CDC, 2014a). In a matter of hours, the leaked MCHM made its way through the treatment facility and into the water of nearby homes and businesses, where its strong smell was noticed almost immediately. On the evening of the spill, WVAW concluded that its conventional treatment processes, which include carbon filters to remove a variety of contaminants from water, were not capable of fully removing the MCHM and a "Do Not Use" order was issued for all customers (WVAW, 2014a).With little information readily available regarding the potential human health effects of MCHM, the U.S. Centers for Disease Control and Prevention (CDC) quickly issued an advisory ruling that set a maximum screening level of 1 ppm for safe drinking water (CDC, 2014a). Based on this recommendation, the "Do Not Use" order remained in effect for a total of eight days, until Jan. 17, when the WVAW distribution water was confirmed to have MCHM concentrations below the approved level (WVAW, 2014a). However, due to the pungent odor of the chemical, its presence was still recognizable in the WVAW facility and in consumers’ tap water after the order was lifted (Manuel, 2014). Recent studies have shown that the chemical can be detected in water at sub-ppb concentrations, a fact that undoubtedly added to growing public concern (Rosen et al., 2014; Gallagher et al., 2014). In response to numerous complaints and demands, WVAW continued flushing the treatment facility and pipes until Feb. 25 when MCHM levels were measured below 2 ppb (WVAW, 2014b), and eventually replaced the affected filter media (WVAW, 2014c)."

Jan 1, 2014

"How Wall Street Darling Molycorp Undermined the U.S. Economy, Degraded our National Security and Distorted the Global Economic Balance and How These Falsehoods Continue to be Promoted Even Today INTRODUCTION & SUMMARY In 2007 the Molycorp Mountain Pass rare earth mine was resurrected from its desert-grave in California by its then-owner Chevron Mining. Responding to elevated rare earth prices Chevron began processing on-site rare earth concentrates left over from past mining operations that were terminated in 1998i. Chinese demand had sparked what was being described as a commodities super-cycleii. Commodity prices were on the move. Wall Street smelled opportunity. In 2008 Goldman Sachs, Pegasus Partners, Resource Capital Funds, Traxys North America LLC and Carint Group LLC acquired the mining assets from Chevron. In an environment of ever-declining ethical standards and regulatory consequences the private capital group and their investment bankers would bring Molycorp to market. Molycorp, with its high powered investment banking team of Morgan Stanley and J.P. Morganiii, easily dominated the contest. Molycorp promoted itself, largely based on its past operating history and proven reserves, as the best company to challenge China’s monopoly control over the production of rare earths: a group of elements critical to most advanced technologies and U.S. defense systemsiv. Most of Wall Street’s hottest investment sectors were dependent on these materials: alternative energy, green technologies, computing, personal communications, advanced electronics and defense systems. By late 2010 there were dozens of prospective rare earth start-up ‘mining companies’ seeking capital. Eventually the number of prospective rare earth mining companies seeking capital exceeded 400, despite the reality that supply requirements of this market were disproportionally small when compared to other natural resource sectorsv. In the world of finance ‘smart money’ picks the winners. Consequently just twovi projects attracted nearly all of the capital (Molycorp and Lynas). Wall street picked Molycorpvii. This paper will primarily focus on Molycorp. By early 2010 the words “Molycorp” and “Rare Earths” electrified many people in the mining industry, most non-Chinese manufacturing technology companies, U.S. & allied defense contractors, technocrats in the U.S. national security community and eager investors across most of the world’s stock markets. It was the hottest story of the yearviii. The financial, technology and defense press coverage verged on euphoric: heaping fuel on fuel until the highly combustible Molycorp-pyre cast a long shadow over all of its rivalsix. When the IPO match was lit the spectacular flaming pyre sucked all of the oxygen out of the rare earth spacex. Molycorp was ranked the most lucrative IPO of 2010, resulting in record breaking profits to its private investors and massive returns for its early stock holding investors."

Jan 1, 2017

By Takashi Enomoto

"The cement deep mixing (CDM) method has a wide range of applications, both on land and at sea. This paper describes the features of the equipment on CDM vessels engaged in maritime construction in Japan: the DCM No. 3 barge, the DCM No. 6 barge, and the DCM No. 8 barge. The DCM No. 3 barge is a large vessel with a mixing area of 5.7 m2. The design of the elevator of the deep mixing unit on the DCM No.3 barge enables us to conduct deep underground/ sea operations. This enables us to conduct mixing at depths of up to 52.6 m below the seabed and up to 70.5 m from the water surface. Additionally, since the tower is installed on the center of the barge, it has excellent stability. The DCM No. 6 barge and DCM No. 8 barge are mid-sized vessels with a mixing area of 4.6 m2. The DCM No. 6 barge was fitted in 2013 with energy conservation equipment and upgraded to an environment-friendly CDM barge. The energy saving upgrade used electric power, instead of hydraulic power, by inverter controlled alternating current motor for both mixing unit and main hoisting winch. This enables the using on effective use of regenerative power when the deep mixing unit is lowered. A feature of the DCM No. 8 barge is that it has an inclinable tower located at the bow section for elevating the deep cement mixing unit. Since the tower can be greatly inclined, the hull has a lower center of gravity and greater stability when the vessel turns. This also allows the vessel to pass below bridges and simplifies cruise preparations, outfitting and dismantling work.INTRODUCTIONThe cement deep mixing method (CDM method) involves mixing and stirring a cement-based solidifier into soft ground to rapidly bring the ground to the desired firmness. This method is used to suppress ground shear deformation, increase strength, increase slip resistance, and mitigate liquefaction and subsidence. It has been recently used in Japan in the construction of revetments at controlled waste disposal sites, both to boost the strength of the seabed and to prevent the seepage of waste matter and other pollutants. Undertaking CDM construction work at sea requires specially constructed marine construction CDM vessels. Since CDM construction at sea entails many more restrictions on working conditions than construction on land, the vessels themselves sometimes need to be modified. This paper will describe 1) the remodeling of the turrets and mixing machinery for mixing to great depths in deep water (DCM No. 3 barge with eight axes); 2) the upgraded of equipment on board CDM vessels after accounting for environmental considerations (DCM No. 6 barge with four axes); and 3) the use of a inclinable tower (DCM No. 8 barge with four axes)."

Jan 1, 2015

By Skinner. W.

"Introducing cutting-edge development work, which aims to simplify mineral processing flow-sheets, reduce costs and address environmental issues. Over the past four years Innovative Mineral Processing Technologies Pty. Ltd (IMPTEC) Australia have developed a Super-fine Crusher and a Planar Magnetic Separator which offer low cost, wet or dry alternatives to conventional grinding and conventional magnetic separation. Each of these machines has been successfully trialed at pilot scale and are now in the process of transitioning to commercial scale. This paper reports on the progress made in each of these fields. The potential scope for application of super-fine crushing technology as an alternative to grinding is potentially expansive and could include beneficiation of metalliferous ores, precious metal ore processing, hydrometallurgical processing, industrial minerals and coal processing, plastic fillers and ceramics processing as well as processing of cementitious slags and fly-ash. IMPTEC have recently achieved outstanding results at pilot scale with a dry combination of super-fine crushing and planar magnetic separation, which offers an alternative to the wet processing of magnetic iron ores. The dry combination has set new laboratory performance benchmarks when compared with the industry standard wet Davis Tube Tester. The test results have also established a strong evidence base showing that super-fine crushing achieves liberation of value minerals at coarser sizes when compared with grinding. The dry combination of super-fine crushing and planar magnetic separation also addresses environmental issues and completely eliminates grinding. An IMPTEC super-fine crusher is currently undergoing commercial trials, generating ultra-fine products from granulated lead blast furnace slag for use as cement substitutes. The performance of the super-fine crusher on this extreme duty highlights the potential benefits of super-fine crushing over the wide range of industries and applications where conventional grinding is employed.INTRODUCTION Present day mineral processing practices can become anchored in convention, where, inefficient methodologies are recognized and accepted as “best practice” or “industry standard”. Motivated by this challenge, IMPTEC has undertaken the development of radically different and improved methodologies in the fields of fine comminution and magnetic separation. Whilst, crushing is much less energy intensive and generally less capital and maintenance intensive than grinding, the technology has stalled due to the lack of crushing devices, which have the capacity to adapt to fine and ultra-fine duties. Grinding practice advances have been achieved through major increases in machine size and power. However, these advances are also accompanied by major escalations in capital, operating and maintenance costs. The economics of this strategy has become increasingly questionable. A typical example is the viability of low-grade magnetite beneficiation, which can hinge largely on the cost of grinding to fine and ultra-fine liberation sizes."

Jan 1, 2018

By T. Bhambhani, O. Yavuzkan, D. R. Nagaraj

"The recovery of oxide Cu minerals by flotation is a longstanding challenge in the minerals industry, especially for high acid-consuming ores which would not be economical for direct acid leaching. Sulfidization (often using controlled potential sulfidization or CPS) using NaSH (or Na2S) followed by flotation using traditional sulfide collectors is the widely used technique. CPS has certain limitations: a) inability to recover certain oxide Cu minerals because they are refractory to sulfidization, b) high consumption of NaSH (or Na2S), and c) potential health and safety hazards associated with NaSH (and Na2S). Flotation of oxide copper minerals using alkyl hydroxamate (AHX) collector has been studied extensively. Investigations using single minerals and laboratory ore flotation have been conducted in the past to demonstrate the efficacy of alkyl hydroxamates. The technology has been used intermittently in plants. One of the main challenges in plant use has been quantifying the true potential for alkyl hydroxamates for recovery of various oxide Cu species in complex and variable ore systems and identifying the most suitable conditions for optimal use. Quantitative mineralogical analysis using QEMSCAN was used in this study to characterize flotation products lab flotation samples. Analysis of concentrates and tails from hydroxamate flotation and CPS flotation stages demonstrated that certain oxide Cu minerals respond exclusively to alkyl hydroxamates and not to CPS. The hierarchy of interaction of AHX with the various oxide Cu minerals could be inferred from these studies. Finally, these studies also allowed quantification of a group of minerals species, which (erroneously) report as part of the Acid-Soluble Cu [ASCu] but cannot be recovered by flotation, thereby facilitating an estimation of the true recovery potential for alkyl hydroxamate.INTRODUCTIONCopper that is economically recoverable occurs in three major types of ores, which are defined by the modal mineralogy of Cu. For sulfide ores, Cu occurs as sulfide minerals and is satisfactorily recovered by flotation using sulfide collectors. Non-sulfide ores, which contain Cu in the form of oxides, phosphates, carbonates and silicates, described in the industry as “oxide” ores (or ores containing “acid-soluble” Cu or ASCu), are currently treated using hydrometallurgy, which involves leaching with dilute sulfuric acid followed by solvent extraction and electrowinning, unless the ores contain acid consuming gangue minerals such as dolomite. For mixed sulfide-oxide ores (i.e. containing both sulfide and oxide Cu minerals) that do not contain acid consuming gangue minerals, Cu values are easily recovered by flotation of sulfide Cu minerals followed by leaching of oxides (only when a leach plant is available). However, when the ore contains acid consuming gangue minerals flotation is required to recover both sulfide and oxide Cu minerals."

Jan 1, 2018

By R. V. Ramani, S. Shankar

"Available literature on the effect of re-entrainment on overall airborne dust concentration in mine airways or the fundamental mechanisms of coal dust re-entrainment in mine atmosphere is scant (Shankar and Ramani, 1991 ). Therefore, as part of the Respirable Dust Center's ongoing research, the following three-part study was undertaken:• a study of the re-entrainment phenomena of anthracite and bituminous coal dust particles in a wind tunnel under the influence of varying air velocities;• a study of the same in the Lake Lynn Laboratory Mine of the USBM with both air flow and walking by personnel causing re-entrainment; and• the mathematical modeling and computer simulation of the re-entrainment phenomenon.In this paper, results from the re-entrainment studies in the wind tunnel and the Lake Lynn Laboratory mine are presented. Comparing the results from the two studies,it was observed that increasing the air velocity increased the rate of re-entrainment ( Shankar and Ramani, I 994a) and the rate of re-entrainment decreased with the time of exposure of the source dust to the flowing air. In addition, when the source dust was composed of particles of different sizes, the airborne dust concentrations due to re-entrainment were higher than when the source dust was composed of particles of the same size. The contribution of airborne dust concentration due to air flow was negligible compared to the contribution due to walking. IntroductionIn underground coal mines, dust is produced primarily during the process of mining and during such activities as pillar spall, loading, belt transfer and roof fall. The generated dust is entrained and then collects on surfaces through dispersion, diffusion and eventual deposition. Removal forces, such as flowing ventilation air or turbulence caused by walking and moving vehicles, can re-entrain the deposited dust (Hall, 1955). A portion of the re-entrained dust remains airborne and increases the concentration of airborne dust in mine airways.The presence of airborne coal dust in mine airways in large concentrations can be hazardous. Health effects include coal workers' pneumoconiosis (CWP) and silicosis, and it can be a nuisance affecting visibility. In addition, as is common during methane explosions, if the concentration of airborne coal dust becomes significant, there could be a coal-dust explosion (Singer, Cook and Grumer, 1972; Singer, Harris and Grumer, 1974; Edwards and Ford, 1988). Through concerned research efforts over the last decade, significantprogress has been made in reducing the airborne dust concentration in mine atmospheres. However, secondary sources, such as re-entrainment, have not been studied in-depth. It is important to understand the phenomenon of re-entrainment and its potential contribution to the airborne dust concentration in mine airways for further decreasing airborne dust hazards in mines."

Dec 1, 1996

By Scott Lawson

BOB FALCONER: Our next topic leader is Scott Lawson. Scott is manager of human resources for Independence Mining Company, Cripple Creek and Victor Gold Mining Company, Victor, Colorado. Scott has 25 years of human resources management experience in the mining industry, surface and underground, precious and base metals. His topic this morning is "It's the Employee That Counts." SCOTT LAWSON: When reviewing the topic of productivity in a union versus nonunion workplace, we need to look at who, and not what, can make the difference in ensuring the success of a production-oriented operation. It's not explicitly whether the property is unionized or not, but whether the employee team (including the "management group") is working together to accomplish common, shared, and meaningful goals. The bottom line is what action or actions can be taken to develop trust and to strengthen working relationships that challenge and compel employees to willingly share their particular areas of expertise. I want to share a real-life experience that happened to me during the summer of 1961. Perhaps some of you will be able to relate to the following story. I was an 18-year-old fresh out of high school, ready for my first true work adventure. I found summer employment for myself and two friends with the New York Central Railroad in Cleveland, Ohio. Our jobs were as laborers, laying ties and rails, and unloading ballast. We made $2.62 an hour. We were fat cats! My friends and I took on the job with a great deal of vigor, to the dismay of our fellow workers. These workers were unionized by the Railway Workers, which I believe were affiliated with the Teamsters. Talk about being naive, we wrote the book in 1961. When we took the jobs, we did not realize the employees were represented by a union, even though we didn't think they worked too hard. Within our first two weeks of work, we established new daily records for laying virtually twice as many ties as had been standard, and we nearly tripled production by the end of our hall of fame railroad careers. We even took naively to the next level by lining up the ties for our afternoon work shift during our lunch break. In 1961, we thought we were the Mantle, Maris, and Colavito of tie laying. For the younger set in the audience, we would have felt like the McGwire, Griffey Jr., and "The Big Hurt" Thomas of tie laying. A section of the union contract allowed for a 60-day probationary period during which the employee was evaluated and also exempt from joining the union. I will venture to say that, to none of your surprise, on day 60 we were asked to join the union, and on

Jan 1, 1998

By Yuanbo Zhang, Qian Li, Helei Zhang, Heng Yu, Guanghui Li, Tao Jiang

"Large reserves of specularite iron ores have been found all over the world, which is characterized by high total iron grade, low gangues content, as well as low commercial price. However, it has not been widely used in sinter or pellet production due to its inferior sintering and roasting behaviors. It has shown that the proportion of specularite ores was increased as high as 40%~50% and good results was achieveed by using Composite Agglomeration Process (CAP), an innovative agglomeration process invented by Central South University. But the mineralization of specularite is still unknown during composite agglomeration processing. In this paper, the induration characteristic of specularite ore is studied by simulating CAP in laboratory, as well as microstructure analysis of CAP product. The results show that specularite pellet is mainly indurated through recrystallization of Fe2O3, calcium ferrite within high basicity sinters matrix interweaves with the recrystallized Fe2O3 on the surface of the pellet, which forms an integral microstructure, and ensures high strength of CAP product for ironmaking.IntroductionLarge reserves of specularite iron ores have been found all over the world, especially in Minas Gerais of Brazil, Xuanhua city and Anshan city of China, Elba island of Italy, St.Gotthard of Switzerland, Cumberland of Britannic, and so on. The specularite ores have a smooth surface, as well as a good crystallization and dense texture. When specularite is used to produce pellets, the specularite ore grains are difficult to adhere onto green ball due to its poor ballability. Moreover, specularite pellet requires high roasting temperature over 1300°C [1]. When specularite ore is used in sintering, the permeability of sintering bed gets bad and the quality of sinter is diminished. The practice in a few sintering plants finds that the output and strength of sinter decrease with the increase of specularite proportion, and the consumption of coke increases [2-4]. Therefore, the utilization of specularite has been limited. Composite Agglomeration Process (CAP) is an innovative technology invented by Central South University [5-7]. The process has the following merits: making reasonable utilization of different iron ore resources; improving the quality and output of sinters; manufacturing sinters with low basicity; significantly reducing energy consumption, etc[8-9]. It has been shown that large proportion specularite ores, as high as 40%~50% can be used well by CAP [10], but the mineralization of specularite pellet is still unknown during composite agglomeration processing. In this investigation, the induration characteristics of specularite ore pellets is studied by simulating CAP in laboratory, and the phase composition and microstructure of CAP product are also characterized by using microscope and Leica image analyzer (Germany, Leica DM RXp)."

Jan 1, 2011

By D. Kruse, M. Sanaei

"A three dimensional nonlinear finite element model was constructed to simulate and analyze the behavior of large diameter segmentally lined shafts when subjected to seismic waves. To reduce computation time, a less complex shell model was also constructed. Transient excitation was applied to the supported nodes of both models, at the base of the shaft, with a time-function representing the 1994 Northridge earthquake. The models are developed at the end of an original phased construction-stage analysis of the shaft. Displacements, forces and moments are monitored and compared during the analyses steps. During the initial 15 seconds of the earthquake, the top and bottom of the shaft show similar displacements. The maximum horizontal displacement within the shaft is approximately 3.5 inches in the solid model and the shell model results conform to this by a factor of 50%. Keywords: Segmentally Lined Shaft, Soil Structure Interaction, Seismic Analysis, Finite Element Modeling, Ground Modification INTRODUCTION TO SEGMENTALLY LINED SHAFTS Large diameter segmentally lined shafts (SLS) are underground systems, constructed sequentially using precast concrete segments to form a ring which provides both temporary earth support during excavation and permanent structural support. The segments are connected via alignment pins, bolts, packer material and other structural components that ensure the continuity of the SLS. In this analysis, the construction process uses a top-down sequence wherein each soil layer is excavated, damp-proofing is installed and concrete segments are assembled to form each ring. This process is repeated until design depths are achieved completing the shaft. It is known that cylindrical structures sustain lateral (earth) pressure mainly through the mechanism of hoop-stress. As Timoshenko’s ring theory goes, a cylinder shell structure is prone to buckling under external pressure [1]. In typical designs of small diameter shafts and tunnel linings with small diameter to wall thickness ratios, nonlinear buckling analysis (i.e., nonlinear geometric analysis) is not considered, since the buckling capacities for those structures are much higher than typical pressures encountered at their design depths. However, in shafts with large diameter to wall thickness ratios, buckling could become a critical issue. In any given mode, as buckling occurs in a ring, some sections of the structure move inward while alternating sections protrude. Although the presence of the surrounding soil could mitigate the buckling by resisting the movement (Soil structure interaction) seismic loads can cause ground movements and lateral pressures, exceeding the capacity of the structure. It is therefore essential to design the load bearing capacities of the shaft to minimize the possibility of any catastrophic failure due to earthquakes. This study explores the structural response of the SLS when subjected to seismic loads."

Jan 1, 2016

By C Jones

Ridgeway Deeps is a block cave (BC) located down dip of the operating Ridgeway sublevel cave (SLC) mine. The BC is located approximately 210 m vertically below the lowest SLC level and approximately 1100 m below surface. Due to the mine layout containing a number of common pieces of key infrastructure the activities of both were interlinked.When investigating project construction options for the BC, a number of potential risks were identified including a conflict of priorities between operational and project deliverables and the varying safety and work methods between an owner mining approach in the SLC and a potential contractor workforce in the BC. This led to a review of the construction philosophy and the opportunity to utilise the existing SLC workforce as the basis of all activities in the mine. It was identified that a number of synergies existed with the current SLC operators and mine supervision including common work practices and the opportunity to build on the unique SLC skills of the operators and supervisors which could then be used at other Newcrest caving mines.With the commitment to this philosophy of building on the existing SLC crews and supervision the number of employees reporting through the superintendent underground operations grew from 95 to 245. This increase led to a restructuring of the reporting and work requirements of the superintendent, foremen and shift bosses. In order for the foreman and shift bosses to focus on running the larger crew numbers for the full 12 hour shift the mine superintendent became a pseudo human resources manager taking over all non-mine focused activities including overtime allocation and work and behavioural performance management. In simple terms, ensuring there were competent bums on seats when and where required. As the additional workers were recruited to top up the existing employee numbers, their employment history was used to place them in the most suitable roles. For example, those with building industry experience were placed on the civil construction crews and those with a farming background were used as truck drivers, nippers or on the service crews. To cope with the increased number of new starters a number of key personnel were seconded from the crews into the training group to act as on shift trainers. This initially caused a reduction in mine performance as the main operators were reassigned but it proved a valid move as the time for new operators to reach acceptable levels was significantly reduced with safe operating standards being maintained. This paper discusses how the Ridgeway Deeps Project was delivered on time and under budget whilst at the same time retaining its position globally as an operation to be benchmarked against.

Mar 21, 2011

By J. F. Mack, P. R. Michael, J. M. Shapaka, S. J. Self, M. W. Richmond

"On October 11, 2000, an estimated 306 million gallons of water and coal waste slurry drained from an impoundment in Martin County, eastern Kentucky into an adjacent underground mine. Approximately 230 million gallons of the water and slurry discharged from two underground mine portals and affected over 75 miles of streams in Kentucky and West Virginia. In response to this and several other similar events, the U.S. Office of Surface Mining Reclamation and Enforcement (OSMRE) commissioned an oversight study that evaluates how well state and federal regulatory programs established under the Surface Mining Control and Enforcement Act are ensuring that impoundment operators are minimizing the potential for impoundment-basin breakthroughs. The study focuses on slurry impoundments constructed in the hollows of Appalachia where numerous coal seams and steep topography combine to result in a large number of mined seams intersecting and underlying impounding facilities. Factors under consideration include: (1) full accounting of all mineable coal seams intersecting and underlying the impoundment; (2) identification and accurate location of underground mines close enough to the impoundment to potentially affect its stability; (3) assessment of the stability of coal barriers between the impoundment basin and adjacent mines, and stability of roof rock and pillars in mines subjacent to the structure; (4) determination of the flowability of the impounded slurry when expanding or undermining the facility are being considered; and (5) measures undertaken to reduce breakthrough potential when necessary. The oversight study began in 2012 after program-evaluation criteria were defined in an OSMRE technical position paper. The study is scheduled to be completed in 2017. BACKGROUND The Surface Mining Control and Reclamation Act (SMCRA) authorizes the disposal of coal mine waste by constructing a coarse coal mine waste embankment across a valley and pumping the fine coal mine waste (slurry) into the resulting basin (Figure 1). A concern shared by many engineers, geologists, and mine inspectors familiar with coal mine waste slurry impoundments is related to the common occurrence of underground mine workings adjacent to or beneath the impoundment: the potential for slurry “breakthroughs” into mine works and subsequent breakouts into the surface waterways (Figure 2). On October 11, 2000 a combination of coal refuse slurry and water from the Big Branch impoundment in Martin County, Kentucky broke through into an underground mine and subsequently discharged into the receiving streams. The location of the point of breakthrough, pathways of slurry/water flow within the mine workings, and two points where the liquid exited the mine are shown in Figure 3. An estimated 306 million gallons of water and coal refuse slurry drained from the impoundment into the adjacent underground mine. Approximately 230 million gallons subsequently discharged from the underground mine at two portals."

Jan 1, 2015

By W. R. Reed, G. J. Joy, B. Kendall, A. Bailey

"Testing of the roof bolter canopy air curtain (CAC) designed by the U.S. National Institute for Occupational Safety and Health (NIOSH) has gone through many iterations, demonstrating successful dust control performance under controlled laboratory conditions. J.H. Fletcher & Co., an original equipment manufacturer of mining equipment, further developed the concept by incorporating it into the design of its roof bolting machines. In the present work, laboratory testing was conducted, showing dust control efficiencies ranging from 17.2 to 24.5 percent. Subsequent computational fluid dynamics (CFD) analysis revealed limitations in the design, and a potential improvement was analyzed and recommended. As a result, a new CAC design is being developed, incorporating the results of the testing and CFD analysis.IntroductionExposure to respirable coal mine dust can cause coal workers’ pneumo-coniosis (CWP), also known as black lung. If silica is present in the dust, the miner may develop silicosis in addition to CWP. CWP and silicosis are occupational respiratory diseases that are ultimately fatal and have no cure. The only method of prevention is to eliminate exposure to respirable coal mine dust and crystalline silica, or quartz. The occupational exposure limit on a Mining Research Establishment (MRE) basis for respirable coal mine dust had been 2 mg/m3 during each shift that a miner is exposed in the active workings of the mine or in mine facilities. Under recently enacted legislation, this standard was changed in August 2016 to 1.5 mg/m3 for a full working shift (The Office of the Federal Register, 30 CFR 70.100, 2015). When respirable quartz is present, the mine must maintain its average concentration at or below 0.1 mg/m3. If the mine exceeds the 0.1 mg/m3 respirable quartz dust concentration, then the applicable respirable dust standard is reduced, calculated as 10 divided by the percentage of quartz present (The Office of the Federal Register, 30 CFR 70.101, 2015).The sources of exposure to respirable coal mine dust for roof bolting occupations include infrequent maintenance and cleaning of the vacuum dust collection system and operating the bolter downwind — in the return air — of the continuous miner (Good-man and Organiscak, 2003). Recent studies have demonstrated that vacu-um dust collection systems are effective in capturing bolter-generated dust if maintained and operated correctly and if proper face ventilation techniques are used. However, most expo-sure to respirable coal mine dust for a roof bolter occurs when the roof bolter machine is operated downwind of the continuous miner (Potts, Reed and Colinet, 2011; Colinet, Reed and Potts, 2013). Because of this higher exposure downwind of the continuous miner, the roof bolter is often limited to working downwind of the miner only once during a production shift."

Jan 1, 2017

By B. Drew, K. Budna, C. Wenzl, D. Gregurek, A. Spanring

"The metallurgy of nickel and cobalt and of copper is closely interlinked when processing sulfidic Ni-Co ores and Cu-Co ores. The respective furnaces are typically lined with magnesia-chromite refractories, which are exposed to multiple and complex stresses. The selection of the processing route, furnace type and slag system will be dictated by the specific ore type available, this will determine the individual refractory wear mode. This paper evaluates the common refractory wear mechanisms, namely infiltration, spalling and chemical attack by various slag systems, as well as sulfur attack, as observed when processing primary sulfidic ores. All these wear parameters, which are discussed in this paper, lead to a severe degeneration of the brick microstructure and a decreased lining life. Therefore, a detailed investigation and understanding of the wear mechanisms through “post mortem studies” is an important prerequisite for the refractory producer. Based on such research results, combined with specific process knowledge, appropriate brick lining solutions for nickel and cobalt processing furnaces can be recommended.INTRODUCTION The metallurgical production of cobalt and nickel and of copper is closely interlinked to the mineralogy of the respective ores: cobalt is found in African Cu-Co ores as well as in Co-rich nickel ores (laterites and sulfides). Also, Co-bearing secondary raw materials contain the mentioned elements in different contents. In pyrometallurgical processing of sulfidic ores, cobalt is generally recovered as a by-product during the production of copper and nickel, whereas it is normally not recovered separately during the processing of nickel laterites but remains in the FeNi product. Besides various hydrometallurgical production routes, the pyrometallurgical processes involved comprise smelting (i.e., production of a Cu-Ni-Co-Fe matte in electric or flash furnaces), converting and refining (i.e. removal of Fe and S as well as other elements from matte by oxidation). The ongoing trend to use higher oxygen enrichment in process air enables higher intensity processes but also increases the oxidation potential in the vessel. Therefore, during smelting and especially during the oxidative treatment in converting and refining, some amounts of valuable metals are also transferred to the slag in their oxides form. A subsequent slag treatment is then applied for recovering valuable metals from the slag, namely allowing an economic material stream handling and minimizing metal losses. This is often done in a slag reduction furnace. Additionally, copper and nickel are very good collectors for precious metals and platinum group metals (PGMs) - therefore, depending on the content of these metals, an additional refining process is used to recover these valuable metals from the matte or metal phase (Elvers et al., 1997; Davenport et al., 2002; Crundwell et al., 2011)."

Jan 1, 2017

By Shilai Yuan, Huimin Lu, Zhijiang Gao, Panpan Wang

"Solvent refining of silicon through using Si-Al melts is a valid method to remove the impurities from metallurgical grade silicon (MG-Si) melt. The thermodynamic behavior of impurities Fe, Al, Ca, Ti, Cu, C, B and P in MG-Si during the solidification of MG-Si was studied based on the available thermodynamic parameters and experimental data. The morphology of inclusions was investigated by Scanning Electron Microscope (SEM). The chemical composition of inclusions in MG-Si and Al-Si melt was analyzed by EPMA. It is found that the amount of white inclusion reduces and most impurities are solved into the Al-Si melts. After solidification of Si–Al alloy using induction heating and acid leaching, impurities can be effectively removed. The solidification of silicon from the Si–Al melt is found to be more effective for purification than general silicon solidification.IntroductionPhotovoltaic energy is one of promising energy resources in a sustainable society because of its inexhaustibility and cleanliness. Although the production and installation of solar cells have increased significantly during the last decade, the cost of solar cell installation is still high. Multicrystalline silicon has now become the main material in the photovoltaic market because of its low production cost and because of the relative high conversion efficiency of solar cells made from this material, which has been studied for a long time [1-3].Electronic grade (EG) silicon (99.9999999% Si) is commonly used as the raw material to produce SOG-Si (99.9999% Si). Silicon produced from the chemical routes restricts the development of solar cells due to environment threaten, high energy consumption and low productivity. Purification of metallurgical grade silicon (MG-Si) is a low cost, environment friendly method. Although several metallurgical processes such as directional solidification, vacuum refining and electron beam melting [4], have been developed, the cost reduction and refining efficiencies for manufacturing silicon is still have to be further optimized.In the purification process, it is difficult to remove boron and phosphorus by the conventional metal refining method. The refining efficiency depends on the segregation behavior of different elements in solid silicon and the liquid phase. The segregation ratios of all investigated impurities were found to be much smaller than the segregation coefficients between solid and liquid Al-Si melts [5]. For instance, the segregation coefficient of B in Si is 0.8 at the silicon melting point (1687K), whereas it is around 0.2 when silicon is solidified from Si-Al melt at 1273K. For phosphorus the segregation coefficient is 0.06 when silicon is solidified from Si-Al melt at 973K°C, which is much less than 0.35 for recrystallization from liquid silicon. Since the segregation coefficient of boron in silicon is 0.8, it cannot be removed by directional solidification."

Jan 1, 2014