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By T Roberts, S Talu

Steel wire weld mesh is a common industry standard surface support used in underground mining, traditionally installed with mining drills during the bolting cycle. As underground mining depth and stress increase, mining methods and their sequences at these depths place challenges on conventional surface support options. These challenges have provided a need for high capacity surface support options that improve development efficiency, reduce the need for secondary ground support installation and is easily installed with current mining equipment. A 5m2 mesh testing machine was built, suspending a 9500kg concrete slab, designed with multiple hold down points to test varying bolting patterns. Mesh load and displacement is accurately measured using a data acquisition system which pushes against the restrained mesh module with an available 200kN load and 1200mm displacement capacity. A testing program comparing conventional surface support, straps and combinations of both were tested for baseline results. New module designs incorporating existing mesh types and new design concepts were manufactured to allow for single pass installation during a bolting cycle. Nine mesh types, mesh/strap combinations and new mesh module designs were compared using the same test method. Based on these results, two high capacity mesh module types are produced. This paper will detail the test program, load and displacement results and underground mesh module performance, describing the two high capacity mesh modules function within the development cycle and manual handling. CITATION:Roberts, T, Talu, S and Wang, Y, 2018. Design and testing of high capacity surface support, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 303–322 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By L. R. Moore

The World Health Organization (WHO) considers contamination from oxyanions, such as selenium and arsenic, a global concern. While their elemental forms are toxic, the aqueous oxyanions are more so. These aqueous forms, which exist at a higher oxidation state, are the most common forms released during mining processes. Many technologies are capable of meeting the governmental discharge criteria for oxyanionic contaminants, but may possess limitations due to redox chemistry as well as the water matrices. An innovative technology was developed that can successfully reduce such aqueous forms generated during mining processes to a level below the discharge criteria. This paper discusses how an understanding of the sensitivities of this novel adsorbent towards these variations in water matrices and redox chemistry can be used to optimize its application.

Feb 27, 2013

By Z. Yu

The effect of particle size on coal dewatering has been well recognized However, there are no systematic studies on ultrafine coal dewatering. The results discussed last year revealed the effect of flocculant type and coal wettability on the filtration of ultrafine coal In this paper, the differences in dewatering between -25 µ m ultrafine and -500 µ m fine coal with addition of flocculants, surfactants and oil-emulsions in vacuum filtration are further investigated Significant differences were observed in the reduction of the cake moisture. The utilized emulsions were found to be very powerful and promising filtration aids for both ultrafine and fine fractions of hydrophobic and hydrophilic coal

Jan 1, 1995

By R. P. Vinson

The Bureau of Mines examined the effects of high humidity and water droplets on the GCA Corp. real-time aerosol monitor (RAM--l). which uses a lO4mm cyclone preseparator. Tests were conducted both in a laboratory and in a full-scale model mine entry. The laboratory tests were conducted in a test chamber saturated with moisture and water droplets. Under these extreme conditions. the RAM-I responded by indicating dust concentrations of 1-1/2 to 2 mg/m3? although the air was dust free. Within the first 2 h of each test. water accumulated in the cyclone and affected the cyclone particle separation characteristics. resulting in readings of 3 to 4 mg/m3. In addition. condensation formed inside the RAM-I case and affected the liquid crystal display (LCD). However. the full-scale mine entry tests revealed that the RAM-I can function ac-ceptably in an atmosphere of water vapor and water droplets similar to the most severe conditions found in an underground mine.

Jan 1, 1984

By Thomas M. Ware

"MR. Chairman, our Honourable Minister, Mayor Cole, it is a pleasure for me to come here, and join with you in one of the largest industrial shows ever held in Saskatchewan.It is an honour to be asked to keynote your meeting, to help mark an early chapter of this new industry for Saskatchewan. God has placed in our hands a new resource for His man on earth. This store of potash, 350 million years in the making, offers a vital resource to help man support his advanced intellect for thousands of years. It is a gift so large we must all wonder at its purpose and our responsibilities in serving our fellow man with it.We who are here to plan and implement the development of this essential mineral resource enjoy a great -privilege; and we share a great responsibility -to see that the billions of tons of potash which have waited beneath these prairies for millions of years are widely and wisely used to nourish the earth through future millenniums.To know the true value of potash, to be able to bring forth this re-source from over 3,000 feet deep in the earth, to establish markets and develop its potential worldwide is all part of our great heritage from generations past. So I think it is fitting on this occasion that we reflect for a moment on this heritage, to help us assess the responsibilities of its future development."

Jan 1, 1966

Times are changing for the mining industry. Civil society is demanding that miners pay more attention to the ways they impact on, and engage with, communities around their mines. Miners, in turn, are being forced to adapt and learn new social skills for which they were not originally trained. They are doing so in the middle of a broad resources boom, which is adding short-term operating challenges at the same time as miners need to be developing thoughtful solutions to longer term community issues. This paper examines a number of the issues that now loom on the horizon of mining companies. These include: human resources challenges and the crisis in minerals education; continuing community and social expectations of the resources industry and the impacts they will have, for example, on product stewardship, greenhouse gas emissions and the use of increasingly precious water resources; and current impediments to mineral exploration spending.It is concluded that the greatest challenge for the minerals industry is to develop a stronger cadre of local leaders and for the larger global miners to empower their local management to take on stronger public leadership responsibilities. There is a need for executive leadership to remember both the longer term and shorter term cyclical nature of the mining industry in developing solutions to community problems. Above all there is a compelling case for mining industry leaders to be more actively engaged with the wider community in the resolution of these issues.

Jan 1, 2005

By J. C. Stankus

How to quantitatively identify the loads on a square/arch set is a complicated issue in designing the square/arch set in an intersection/entry. From an engineering perspective, understanding the nature and support mechanism of standing support such as a square/arch set can not only help design the support structure to maintain the roof stability, but save the steel materials and costs of manufacturing, labor, and delivery. Based on the design practices in recent years and successful applications in slope bottom intersections, the authors are confident that the concept of interaction and confinement effect between the steel square/arch set and surrounding rocks is critical in designing a proper steel structure to support an intersection/entry. This paper will detail the design concept and its applications in several underground slope bottom intersection designs, reaching the goals of improving roof stability and reducing costs.

Feb 23, 2014

By David M. Koogler

If you are contemplating starting a small coal mining operation there is a good possi¬bility that you can not afford it. If you, have already started, you may be on the road to bankruptcy. If you are a small but well established operator you may be trading dollars, or even dissipating your capital, equipment and other assets. A bleak outlook? Yes! Meant to be discouraging? No! Just a reminder that, with todays costs of doing business, high interest rates, rapidly increasing costs and decreasing sales prices, a small businessman/miner had best watch closely or he will be mired in something worse than a soft bottom - namely a cash and credit shortage, and in too many instances In recent times, bankruptcy. We will not dwell on what happens once you are that far gone, though I could cite a good example. But, let us look at what should be done to avoid such a catastrophe.

Jan 1, 1981

By E. G. Noble

The potential for using heterotrophic microorganisms to solubilize manganese from low-grade domestic ores is being assessed at the Reno Research. center, U.S. Bureau of Mines. More than 90 pct of the manganese has been extracted from a variety of oxide ores in shake-flask tests using molasses as a source of .. nutrients for the microorganisms. It has also been demonstrated that high recoveries of manganese can be obtained from a domestic wad ore using column bioleaching. 'l'he isolation and identification of organisms responsible for manganese extraction is discussed, as are the mechanisms responsible for manganese solubilization.

Jan 1, 1991

By Webster S. Anderson

Bureau of Mines planer mining tests on the phosphate bed of the Douglas mine, near Drummond, Mont., indicated that a competent bed with a Mohs' scale hardness of 3 to 4 cannot be mined economically with the planer. Although planer mining was feasible where the bed was fractured enough for a 4-inch depth of cut to be consistently maintained, the depth of cut in the competent beds at the Douglas mine did not exceed 0.5 inch. Average production rates were 0.15 ton per minute and 9 tons per man-shift.

Jan 1, 1966

By Y. C. Guan

In an attempt to replace the traditional cyanide process of extracting gold, a new technology using ammoniacal solutions has been developed. In this study, the electrochemical behavior of gold in ammoniacal solutions at temperatures above 100°C has been investigated. An electrochemical cell in an autoclave has been introduced to carry out this study. The system consists of a gold working electrode, a platinum counter electrode, and an external saturated calomel electrode (SCE) which is connected to the autoclave system through a Birch wood plug. Techniques used in this study included potentiodynamic polarization, galvanostatic polarization, cyclic voltammetry, and Tafel polarization. The electrochemical reaction mechanisms governing the dissolution process are presented.

Jan 1, 1996

By Ashley Tews

In 2005, we automated a forklift-based Hot Metal Carrier to be capable of typical metal transfer operations around a smelter. The project was highly successful and the vehicle has demonstrated hundreds of hours of live autonomous operations to thousands of people from industry and the public. As a result of the exposure and success of the project, we have expanded its focus to demonstrate how various technology components can be utilised to gain benefits in other areas of industrial operations. These include asset tracking, vehicle usage analysis, pedestrian detection and infrastructure profiling. Each of these components was derived from the core autonomous vehicle technology suite and has shown a high potential for improving safety and efficiency of vehicle-related operations, and improved diagnostic processes for measuring deformations of bakes and furnaces. The autonomous vehicle project and its extended technologies are described in this paper.

Aug 1, 2013

By R. MacRosty

The demand to increase production levels in smelting furnaces has driven the increase in the power levels. Consequently, greater cooling capacity of the furnace shell has been necessary, resulting in the widespread use of water-cooled elements to protect the refractory linings. Since water ingress into the furnace is an explosion hazard, monitoring and maintenance of the water-cooled elements is of key importance. Some of Hatch's recent research and development efforts have been focused on methods to provide an increased level of monitoring of water-cooled furnace elements; this paper focuses on two technologies developed for this purpose. The first involves the installation of a fibre optic temperature sensor in a water-cooled tapblock. The sensor is capable of providing high accuracy temperature measurements with a fine spatial resolution throughout the tapblock. Hatch has already developed a diagnostic system that uses multivariate statistical analysis to interpret the large quantities of data generated by the sensor. A second technology under development is concerned with enhancing the operating integrity and safety through detection of leaks in the water circuits. A successful leak detection strategy requires minimal maintenance and the ability to detect minute leaks. An instrument that meets these criteria has been investigated and is currently under development. This paper focuses on the technology and results from the test work that has been completed to date.

Jan 1, 2007

By Peter K. Eriksson

Nanofiltration is very efficient in separating heavy metals from water solutions, even if they contain strong acids. Desalination System, Inc., has many years of experience in this area, and this paper deals with three different such cases. The first case deals with concentrating the heavy metals in the pregnant leach solution from a copper dump leaching site with a surplus water problem. The increased copper concentration in the pregnant leach solution increases the capacity of the following copper extraction stage. The nanofIltration permeate is polished with a biomass adsorption column to remove the small amounts of remaining heavy metals, before being discharged. This method eliminates sludge handling and disposal, which are quite costly with the alternative precipitation process. In the second case, a complicated precipitation method was used to remove heavy metals from the waste stream of a specialty metals manufacturer. Nanofiltration was installed to increase the metals concentration four times, which greatly simplified the precipitation process. The chemical consumption and sludge production decreased by more than 80 percent, and the labor cost decreased by 66 percent. In the third case, nanofiltration was used to purify waste sulfuric acid solutions containing heavy metals, to meet the specifications for technical grade acid. Sulfuric acid concentrations above 30 weight percent were successfully purified in a multiple pass membrane system.

Jan 1, 1996

By F. N. Kissell

U.A. Mine Safety and Health Administration (MSHA) coal dust compliance data sometimes shows high silica levels at roof bolters. However, it is unclear whether this silica normally originates from the bolter itself or from other dust sources upwind of the bolter research studies to answer this question at individual mines have been conducted. However, operational practices vary from mine to mine thus, the information gleaned from any one study cannot be accurately extrapolated to describe silica dust sources in most mines. In this paper, three decades of bolter dust research are reviewed the results showed that, while inadequate maintenance on the bolter dust collection system can result in excessive dust, more likely reasons for high silica levels are inadequate ventilation of the mine entries being bolted and dust traveling downwind from the continuous miner to the bolter. Scrubbers on continuous miners may not be removing as much silica dust as expected. Mining Engineering, 2011, Vol. 63, No. 10, pp. 78-82. Official publication of the Society for Mining, Metallurgy and exploration, Inc.

Jan 1, 2011

By Sureshan K. Moothedath

This paper provides a mechanistic representation for floc formation, growth and degradation and presents results from an experimental study of batch flocculation in which step changes were made in the impeller speed, flocculant addition, and slurry concentration. A discussion of the experimental results is included in terms of the mechanisms of floc formation and size-change.

Jan 1, 1993

By C. Alexandru Sonoc

Donnan Dialysis uses ion exchange membranes to extract and separate cations. The driving force is provided by differences in chemical potential, rather than by electric fields or pressure. A Donnan Dialysis based process to recover lithium, nickel, cobalt, manganese, and organic acid lixiviant from recycled lithium ion battery cathodes is under development. In this paper we present a model of Donnan Dialysis and results of simulations of the aforementioned process. The simulations show that 170 m2 of membranes can process 1000 L of leachate ([Li+] = 0.285 M, [Co2+] = [Ni2+] = [Mn2+] = 0.095 M, pH 2) in two days and recover 94.1% of the lithium (as lithium carbonate), 99.4% of the transition metals (as mixed sulphates ready for solvent extraction), and all of the organic acid using 423 mol of H2SO4 and 268 mol of KHCO3.

Real-time data collection and plant historians are becoming common place in mining and processing plants. This vast quantity of data must be turned into easily accessible and actionable information for all levels of the organisation.Queensland Nickel use a combination of Microsoft and SAP business intelligence tools to collect, cleanse, aggregate and present plant information to the appropriate people for supporting decision making in the business. SAP Business Objects, for visualisation, and SAP MII, for integration, allows complex and accurate metrics to be delivered as real-time dashboards. Designing a rigid data management architecture to segregate the data collection, integration and logic and visualisation into distinct logical layers, allows for rapid report development and greatly assists with IT maintenance, while also minimising the complexity of any customised programming. This type of architecture ensures a common data source for all business reports, ensuring one version of the truth. The past few years at Queensland Nickel have seen process and maintenance engineers spending considerably less time collecting and integrating data and spending more time analysing what is happening in the plant. Real-time reports and dashboards have been developed around the business needs rather than around the data. Two years ago Queensland Nickel introduced an employee bonus scheme based upon meeting monthly performance targets; an easy to use dashboard that allows everyone, from operators through to management, to monitor these metrics day-to-day.

Sep 26, 2011

By A. Rödfalk, P. Bloemer, J. P. Nilsson, N. Brogden

"Reliable and accurate metal transfer information during silicon tapping from an EAF is invaluable for decision-making and process optimization, while obtaining such information safely is a necessity.Elkem Thamshavn Norway, a producer of metallurgical-grade silicon, identified inherent safety problems with gauging fill levels in ladles using dip bars while molten metal was continuously pouring from a rotating EAF. Operator safety was a paramount concern, and an alternative automatic method of controlling the tapped fill level needed to be found.It was also considered that further benefits could be achieved such as monitoring the tapping flow from the EAF in order to identify any clogging, as well as the potential to use the live feed from such a system to assist decision-making regarding work around the taphole area.Agellis Group AB, Sweden, a company with over 30 years of experience in gauging molten metal levels in the metals industry, was able to design a solution for Elkem Thamshavn that would provide the required real-time process data while enhancing operator safety.This paper shows how the Agellis AB EMLI-L system was successfully installed at Elkem Thamshavn’s EAF continuous tapping area, how ladle fill levels were constantly monitored, and how full ladles were replaced by empty ones without the need for operators to be in the tapping area to take level readings. The results were used to compare the accuracy and reliability of Elkem Thamshavn’s current measuring methods with that of the EMLI-L system. The paper also covers how problems such as how to connect, run, and protect cables in and around the EAF tapping area, as well as connector and cabling survivability during the three day refractory pre-bake period, were solved. Finally, the paper discusses the potential production improvements, maintenance requirements, and data integration attainable through the installation of the system, as well as the major safety improvements that have been achieved."

Jan 1, 2014

By M. J. King

The Chino Smelter embarked on a program to reduce smelter emissions. Fugitive sulfur dioxide and particulate emissions were reduced by (i) removing the flash furnace settling chamber and (ii) installing a baghouse, to treat converter secondary emissions. Neutralization plant capacity was increased, to accommodate increased flow from the flash furnace off-gas cleaning system and to reduce costs.

Jan 1, 1998