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By Holger Witthaus

Various seam conditions had been examined during longwall production at RAG German hard coal mines. Based on the field data a prediction method was developed considering separation planes as influencing factors for roof falls at the face. The characteristics, orientation, and density of separation are important factors on the occurrence of roof falls. In addition to geological influences, the performance parameters and geometry of support must be considered and optimized for the prediction and prevention of roof falls in a longwall face. Based on detailed macro- and microscopic investigations of e coal seams considering various ranks of carbonization, the origin and characteristics of separation planes are determined and a strata-specific influence on roof fall is interpreted. It was assessed that the coal face fracturing and displacement caused by the stress depend on the floor and roof strata conditions due to activation of the existing separation planes. Field studies are shown giving an idea of influences by advance rates of the longwall face, support delay and hydraulic pressure to the roof control in longwall faces in depth of more than 3000 ft. The analysis includes the application of specific software developed for longwall roof fall prediction as a result of a European research project. The software allows a laminar graphic display of roof fall probability, which is used for recognition of risk areas and risk management.

Jan 1, 2009

By Li Zhang

Air was blown into the molten slag as oxygen resource during the dynamic oxidation. It was found that the oxidation is not only in favour of Ti components into perovskite phase, but also the increase of slag temperature and decrease of slag viscosity during the dynamic oxidation promote the precipitation and growth of perovskite phase, average crystal size of perovskite phase is 48 µm. The experimental result realizes the selective enrichment of Ti components and coarsening of perovskite phase, perovskite phase can be separated by mineral dressing method.

Jan 1, 2009

By H. H. Murray

The largest reserves of palygorskite in the world are located in Anhui and Jiangsu Provinces in East Central China. The deposits are Middle Miocene in age and range from 3 to 6 m in thickness. The deposits are the alteration product of basaltic volcanic ash. The Chinese Geological Survey estimates the palygorskite reserves are in excess of 200 million tons. The elongate particle shape results in unique colloidal properties. Large quantities are exported to Japan, Taiwan, Southeast Asia, New Zealand, Australia, and West and Gulf Coasts of the United States. The markets include agricultural carriers, paint, joint tape compounds, animal feed binders, catalyst support, drilling muds, and suspending agents for chemicals, pharmaceuticals, and medicines. The viscosity is high and the quartz content is generally 5% or less.

Jan 1, 2009

By Andrew Cecala

Miner?s exposure to dust remains a top concern among regulatory agencies, particularly at production facilities with high levels of silica. This respirable dust is present in almost all operations and is a direct cause of the deadly disease silicosis. Silica is one of the most abundant minerals on Earth and is a threat at all operations, especial-ly granite and sand and gravel facilities. The National Institute for Occupational Safety and Health continues to analyze silica?s threat. The institute?s research indicates that heavy-equipment operators have an increased risk to dust exposure, especially when drilling or breaking rock, even when working from an enclosed cab. However, there are methods to reduce an operator?s exposure further, according to recent NIOSH research, which is detailed in its report, Improving Air Quality in Enclosed Caps with Uni-Directional Filtration/ Pressurization System. NIOSH indicates that when surface mining equipment is new, the operator?s dust exposure is normally at accept-able levels. As the equipment ages and components such as gaskets and seals deteriorate, the level of protection can degrade to a point where it is no longer acceptable. However, the institute indicates that at least two critical factors necessary for an effective system.

Jan 1, 2009

By Eric Rehwoldt, Walt Rabe, Jesús Gómez, Tim Myers

"An expansion plan for Washington Dulles International Airport is currently underway to prepare for growth at this northern Virginia facility in the future. While Dulles currently serves more than 20 million passengers a year, when the Master Plan for the Airport is fulfilled, it will be capable of handling approximately 55 million passengers a year. The current Capital Construction Program underway at Dulles will take the Airport one step closer to its full potential.As planned, work includes a new Airport Traffic Control Tower, expansion to existing concourses, a fourth runway, additional parking, and other improvements. One of the most interesting features of this project is the construction of a two-track passenger train system (Automated People Mover, or APM) linking the main terminal and concourses, which will largely replace the Mobile Lounge transportation system, thus greatly reducing surface traffic. Construction of the APM system involves deep excavations along the tunnels and at the transfer stations. This poses special challenges because the settlement-sensitive terminal, original Airport Traffic Control Tower, and concourse buildings, as well as other facilities, exist near the proposed below-ground stations. The site is also underlain by a tight grid of underground utilities that include jet fuel, gas and central communication lines, in addition to more mundane electric, sewer and water mains.One of the most interesting features of this project was the extensive and skillful utilization of micropiles for support of existing structures adjacent to the excavations. Without the use of micropiles, the cost and difficulty of the excavations would likely have been much more. Several important lessons were learned about the use of micropiles, which advance that technology.Throughout the project site, bedrock was generally encountered at 25-ft depths or more. The rock consists of micaceous and highly calcareous siltstone rock. This rock is typical of the sedimentary component of the Culpeper Basin, a Triassic Age geologic feature extending from south central Virginia to western Maryland. The siltstone beds dip gently to the west at about 10 to 20 degrees. Joint planes typically dip 60 degrees to vertical. The rock underlies a sequence of fill materials and residual soils of varying thickness."

Jan 1, 2009

We are moving into an era where we experience the consequences of the skills crisis û namely many resource models have been generated by inexperienced people under pressure to deliver high quality resource estimates in unsupported environments, often without technical mentors. These resource models form the basis of our decision to pursue actual mining. This begs the question: how valid are the resource models that form the basis of our mining decisions? This paper presents various model validation tools such as comparison of input and output statistics, swath plots, sectional or bench comparisons between drill holes and models as well as a variety of other approaches. Each model validation tool currently used in industry is examined:how the tool generates results,what assumptions exist,what constitutes a pass/fail in the test, and what interpretations to consider when using the validation tool. Each validation toolÆs suitability and the inherent flaws in the underlying assumptions are also discussed. These are supported with examples of good versus bad validations. Our principles based reporting codes provide flexibility in how models are generated and what approaches and/or parameters are used to generate resource estimates. This flexibility works well when used by experienced practitioners. However, our reporting codes assume a level of experience not always available in the current skills crisis. This paper seeks to provide minimum model validation prerequisites for model acceptance and suitability, regardless of the resource analystÆs experience. As we move forward, our immediate challenge is to ensure our baseline resource models are material, transparent and competent.

Jan 1, 2009

By R. Franfield

This paper describes a situation that many drilling and blasting contractors have found themselves in – a client?s fear of the use of explosives. In the summer of 2007 Blasting Services Ltd was asked to undertake some drilling and blasting work in an abandoned quarry that was being restored for a housing development. Previous quarrying operations had left a series of overhangs that were considered unsafe and required removing. The site contractor considered that the best and safest way to carry out this work was by drilling and blasting. Blasting Services Ltd, with the technical assistance of Exchem Explosives, designed a drilling and blasting regime to accomplish this work with a series of trim blasts. The design took into account the close proximity of a structure in very poor condition and the imposed vibration limit of 6.0 mm/s (0.24 i.p.s.). The faces were profiled, holes drilled and explosives ordered. A few days before the first blast was due to be carried out the client decided that the poor condition of the nearby structure meant that the use of explosives could not be permitted. This decision was made despite the blast design indicating that the vibration level would be well below the 6.0 mm/s (0.24 i.p.s.) limit.

Jan 1, 2009

By B. K. Belle

The beginning of 21st century has heralded the global strategic importance, as evidenced by increase in energy prices and energy generation-emission-utilization dilemmas. In January 2008, the South African energy supplier, ESKOM had tabled the concept of power conservation and acknowledged the energy crisis until 2016. The concept is required of all energy users to reduce their electricity consumption, intensify energy efficiency and cautiously proceed with new projects. The generation of energy results in by-products called ?green house gases? (GHGs). To make a positive response to climate change and their effect on the environment, every energy user must ensure efficient energy use through technical and administrative means referred to generally as energy savings. This paper identifies mine ventilation engineering, in particular the electricity consumed by main fan units, as an area of potential energy savings. For a major mining company, electricity consumed by main ventilation fans alone can be in the order of 120 MW. Although a known fan engineering technique but scantly applied technology identified as the Hermit Crab can be seen as a ?quick win? project, due to its success in other industries such as cement and steel. The ?Hermit Crab? technique® involves upgrading or replacement of an impeller - whatever its origin - with a design impeller to suit the actual ventilation requirements, resulting in increased fan efficiencies. The cash flow benefits associated with a case study and its rollout of this technology have been calculated. For a 10% increase in main fan efficiency, would have a net present benefit of US$ 16.08m over 10 years. With the inclusion of carbon credits, this benefit rises to US$ 29.40m in total. Application of other available technologies, viz., composite materials, ventilation-on-demand and variable speed drives are discussed.

Jan 1, 2009

By Daniel Su

This paper describes recent ground control challenges encountered at the longwall recovery areas of one of Bailey Mine?s two longwall faces and the proactive measures taken by CONSOL management and engineering to mitigate them. The challenges derived primarily from the following causes: (1) irregular roof coal and draw slate thickness, (2) presence of thick sandstone at the recovery area and extremely weak rocks below the sandstone, (3) close proximity to a regional anticline, (4) low shield set pressure and tip load, and (5) ineffective primary roof support that led to progressive failure of the headgate roof. The presence of the anticline contributed to extensive fracturing of the sandstone. Excessive pot-out in advance of the shields frequently occurred near mid-face due to the presence of thick draw slate and irregular roof coal near the recovery area. This, in turn, resulted in face heights that exceeded the maximum reach of the shields. Subsequently, during longwall meshing, when the advance rate slowed considerably, fractured sandstone would often break loose, causing the shields to yield, thereby reducing the height and inhibiting shearer movement. To improve the headgate and face conditions within the longwall recovery area, several actions were taken, including: (1) assessing site-specific roof geology by conducting in-mine roof coring around the recovery areas and by mapping immediate draw slate and roof coal thicknesses within surrounding entries, (2) increasing pump pressure and thus shield set pressures (3) diligently monitoring shield set pressures and longwall extraction horizon, (4) installing additional cable bolts and roof screening to prevent progressive failure of the immediate headgate roof, (5) fully-grouting supplemental cable bolts to improve headgate support stiffness, and (6) gluing the headgate roof within the recovery areas with polyurethane. As a result of these collective efforts, longwall recovery delays at Bailey Mine were reduced from 21 days in 2006 to nearly zero in 2009.

Jan 1, 2009

The Copperbelt areas of Zambia and the Democratic Republic of Congo (DRC) have recently been seeing the development of a significant number of new projects. Due to the current economic climate, some of these projects have been delayed but the region remains an important resource for copper and cobalt for future years. Many of these projects will utilize an agitation leach followed by solvent extraction and electrowinning to recover both copper and cobalt. The flowsheet route for copper is fairly well established while the processing options for cobalt vary considerably depending on the final product (metal or salt) the operator wishes to make. The mineralogy of ores in the area is typically associated with high gangue acid consumption during the leaching process. This has resulted in acid availability to the area being constrained and acid prices have risen accordingly. Agitation leach circuits, typically, have a tight water balance which needs to be maintained and a bleed of process liquor needs to be continuously removed from the circuit in order to maintain this balance. This bleed, typically, contains fairly high levels of acid and requires neutralization prior to tailings disposal or secondary metal recovery. It is, therefore, desirable to minimize the acid concentration in this bleed stream in order to decrease total acid requirements and neutralization costs for the process plant. An in depth case study by Cognis and Bateman Engineering evaluated three different flowsheets with the aim of determining relative operating costs between the three alternatives, together with differences in plant capital cost requirements.

Jan 1, 2009

By A. V. Wilke

The metallurgical balance is a tool usually applied in the mining industry. The final result is used for different objectives. All the existing software for the calculation of the metallurgical balance fits the numbers in such way that a logical correspondence between the input and output materials exist. Nevertheless, the accuracy of the metallurgical balance strongly depends on the quality of the input data. Division El Teniente of Codelco Chile has been optimizing the metallurgical balance system the last 14 years. As well, it has participated in the development of corporate norms to optimize the operations of sampling and weighting systems. As a consequence, the precision and the accuracy of the metallurgical balance have been improved in a significant way. Also the understanding of process variability was enhanced. The improvements have allowed Codelco to discover and minimize hidden losses and to better support top management decisions. The present paper describes the main aspect of the continuous improvement process.

Jan 1, 2009

By Roy H. Grau

Increased awareness of a healthy work environment is common to all industries and the stone industry is no exception. The presence of operating diesel equipment, welding, stone production blasting, and silica dust in a working environment all contribute to air quality issues in underground stone mines. Particularly recognized is the exposure of workers to diesel particulate matter (DPM). Recent regulations call for a DPM standard of 160TC ug/m3 (TC = Total Carbon). The National Institute for Occupational Safety and Health (NIOSH) has conducted research to improve the ventilation of these mines and consequently reduce the exposure of workers to harmful airborne contaminants. The results have shown that the ventilation of underground stone mines can be significantly enhanced using improved ventilation controls and techniques. Large-opening stone mines present specialized ventilation challenges because their entries are much larger than in other types of mines. Most stone mines have entries about 40 feet wide and up to 30 feet high, with bench areas that may extend even higher. These large entries present the positive opportunity to move large air quantities at relatively low mine fan pressures resulting in lower fan horsepower and reduced operating costs. However, the difficulty in ventilating large-opening mines is that even with large air volumes, the air velocity is often less than 100 feet/minute. Higher ventilation velocities more quickly dilute and remove contaminants from the face areas. Higher ventilation airflow velocities can be achieved by effective ventilation planning and proper choice of ventilation fans.

Jan 1, 2009

By J. Barrett

State-of-the-art wireless communication and location-tracking technologies will dramatically change the face of mine worker safety. The MineTracer System developed by a Liberty Lake Washington company is a broad capability wireless sensor network based on a new breed of technologies known as wireless mesh systems. In this paper, R&D Manager Jim Barrett summarizes the balance of engineering tradeoffs that result in a system that (1) performs well, (2) is survivable against many types of mine accidents, (3) operates for many hours post-accident on battery power, (4) meets stringent MSHA requirements for intrinsic safety, and (5) is economically affordable for the mines.

Jan 1, 2009

By Sean Gallagher

Bolting large sheets of wire mesh screen (WMS) to the roof of underground mines prevents injuries due to rock falls. However, WMS can be heavy and awkward to lift and transport, and may result in significant spinal loading. Accordingly, six male subjects (mean age =45.8 years + 7.5 SD) were recruited to lift WMS in a laboratory investigation of the biomechanical demands. Biomechanical modeling was used to estimate external moments about L5-S1 for sixteen lifting tasks, using two sizes of WMS. Full-size WMS involved a two-person lift, while half-size WMS involved a one-person lift. Lifts were performed under 168 cm and 213 cm vertical space. Restriction in vertical space increased the maximum L5-S1 extensor moment from 254 to 274 Nm and right lateral bending moment from 195 to 251 Nm. Lifting full sheets of screen (as opposed to half sheets) resulted in an average 33 Nm increase in L5-S1 extensor moment. The L5-S1 extensor moment was increased by an average of 44 Nm (18%) when lifting screens positioned flat on the floor compared to an upright position. Relevance to industry: Large flexible materials are commonly lifted in industrial work environments, and may involve the efforts of two or more workers. The current study examines the low back loading associated with lifting large flexible screens and presents recommendations to reduce spine loading.

Jan 1, 2009

By Frederick C. Rhyner

The United States government sponsored the construction of a new vehicular bridge over the Diyala River in Bubriz, Iraq. This paper describes the geotechnical engineering for design and construction of drilled shaft foundations for this bridge. An Iraqi geotechnical engineering firm made borings and laboratory tests while analysis and design recommendations were provided in the United States. Despite the severe challenges of engineering in a war zone, excellent cooperation was the key to a successful effort. Three drilled shafts designs were necessary to accommodate the different subsurface conditions: a) medium-compact to compact sands, b) stiff to hard clays and c) mixed soil profile. The alpha and beta methods were used to estimate capacities for a conservative design, recognizing that quality control during construction might be less than what is normally provided in the United States. Iraq has a high seismic risk and LPILE was used to estimate the drilled shaft response during earthquake loading conditions. Settlement estimates were made using FHWA methods. Construction was carried out entirely by local Iraqi firms, despite the challenges of working in an active conflict area.

Jan 1, 2009

By Amanda Elioff

Success of the Gold Line Eastside Ex-tension rail tunnels in Los Angeles, CA has prompted the Los Angeles County Metropolitan Transportation Authority?s (Metro) planning new rail lines to include underground alternatives. The Westside Extension Transit Corridor alternatives include up to 27 km (17 miles) of subway to be constructed in soft ground. The routes will require construction in Los Angeles? ?potential methane zone,? which was not considered for subway construction until recently. Slurry face tunnel boring machines (TBM) will likely be specified.

Jan 1, 2009

Mineral sands are different to almost any other commodity; however, it shares similarities with other commodity types, such as the importance of quality constraints of iron ore and coal or the importance of physical properties of diamonds. The mineral sands industry consists of two principal product streams; titanium dioxide minerals û in the form of rutile, ilmenite and leucoxene, and zircon. The principal valuable heavy minerals (VHM) include ilmenite, leucoxene, rutile and zircon. Variations of other titanium minerals occur between the end members of ilmenite and rutile, including pseudo rutile and anatase. Most mineral sands deposits are found in unconsolidated fossil shorelines several hundreds of metres to tens of kilometres and occasionally hundreds of kilometres inland from the present coastline. Mineral sands orebodies essentially fall into two categories based on the mode of deposition: alluvial or aeolian. Alluvial deposits are further split into marine beach placers (or strandlines) and lacustrine heavy mineral (HM) accumulations. Exploration for mineral sands involves the positive identification of key criteria leading to the focus of exploratory surface sampling, augering and drilling. Assaying is primarily focused around determining the percentage of HM contained within a given sample. Other results of interest include clay fines, sand and oversize. Metallurgical/mineralogical assessment is often undertaken via laboratory scale bench tests that replicate the wet concentration and dry mill processing routes. The most critical component in resource assessment for mineral sands is about quantifying HM grade, then mineralogical assemblage and then quality of those mineral species. This will determine whether a mineral sand final product is marketable or not. Mining of mineral sands is conducted either wet or dry. Wet methods are generally preferred for large tonnage, unconsolidated and low clay orebodies. Where ground conditions are hard and orebodies are small, high grade and discontinuous, dry mining techniques are generally employed. Concentration of mineral sands from the primary ore is carried out in two sections; wet, utilising sizing and gravity differentiation between HM, VHM, clay and quartz, and dry, exploiting the magnetic, electrostatic and to a lesser extent specific gravity (SG) properties of the minerals of interest. Mineral sands exploration, mining and processing faces the same operating challenges as the rest of the resource sector. Added to this are the issues that are unique to mineral sands and to which the industry devotes considerable resources to developing solutions.

Jan 1, 2009

By J. Wiese

Recently the operating philosophy at concentrators processing platinum bearing ores has started to move from a recovery dominated system to one in which the production of high grade concentrates at the expense of some recovery would provide greater benefits in the further upgrading of the platinum group minerals (PGM). The low grades usually obtained are associated with the presence of naturally floatable talcaceous gangue minerals in all PGM ores. Polysaccharide depressants such as guar gum and carboxymethyl cellulose (CMC) are used to improve the grades of the concentrates. Recent testwork has shown that the use of high depressant concentrations can prevent any naturally floatable gangue from reporting to the concentrate. The only gangue present in the concentrates would be due to its entrainment in the froth. Under these conditions much higher grades can be achieved. The sulphide minerals themselves, however, become susceptible to depression at high depressant concentrations. This work examines how the recovery of sulphide minerals in two Merensky ores was affected by the type and concentration of the collector in the presence of high depressant concentration (500 g/t) and that the response of the sulphide minerals was also dependent on the type of depressant used (guar or CMC).

Jan 1, 2009

By J Lea, P Hatherly, J L. Edwards

Coal exploration has traditionally involved the acquisition of data to enable a resource to be quantified and qualified to the extent that its economic potential can be determined. This process commonly relied on: drilling to determine the depth and thickness of coal seams, broad characterisation of the overburden and interburden, and to provide cores for coal quality analyses; basic wireline logging to cross-check the depth and thickness of coal seams and provide some indication of rock mass strength; and basic surface geophysics and remote sensing to identify major geological structures. In recent years, the adoption of the JORC Code as a basis for the reporting of resources and reserves has placed a greater emphasis on the need for detailed, reproducible data sets that not only satisfy the traditional requirements of mine planners, but also satisfy the governance requirements of corporate and financial institutions. Similarly, the development of sophisticated numerical modelling techniques for use in both open cut and underground mine design, has seen a greater demand for precise geotechnical data, in situ stress characterisation and hydrological information as routine input to the design process. These requirements, coupled with the prevailing trend toward high capital, relatively inflexible mining techniques less tolerant of geological surprises, and the need for consideration of environmental issues such as groundwater impacts and surface subsidence, requires that modern exploration programs be multifaceted, and designed to commence capturing data relevant to ædownstream issuesÆ even during the initial phases of exploration planning.

Jan 1, 2009

By A Tawadrous, P D. Katsabanis, S Kim

A series of small scale tests, have been performed to establish the effect of powder factor and initiation timing on the grindability of rocks. The blasts were performed in high quality granite blocks, which were cut from stone prepared by dimensional stone quarry operations. Three different types of granite, Barre, Stanstead and Laurentian, were tested. The charge consisted of detonating cord placed in five holes with water as a coupling medium, or concentrated charges of equal mass of high exolosive, fully stemmed or air decked. Powder factor was varied from 0.39 to 1.17 kg/m3. Charges were detonated simultaneously or with a small delay and in some experiments, detonation waves collided in the middle of each borehole. All fragments were collected and screened, and drop weight impact tests were performed on selected size fractions, using different levels of impact energy, to calculate the resistance of the rock to impact breakage. The work index of some of the blasted samples was measured using standard Bond mill grindability tests. The experiments generally showed increased softening of the rock with powder factor, manifested by the increasing initial slope of the relationship between t10 and impact energy. The rate of change of the initial slope decreased with increasing powder factor. Changes in the work index were small and consistent in trend with the results of the single fragment impact characterization tests. Charge configuration, timing as well as in-hole collisions of detonation waves affected the initial fragmentation but had little effect on the impact breakage of the samples.

Jan 1, 2009