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By Mohamed Gamal, Bill Zietlow

"In oil fields that have been depleted with conventional surface oil wells but still contain significant reserves, an extraction alternative that has been constructed recently consists of a drilling gallery below the oil-bearing formation at the bottom of a 1,200-ft deep shaft where upward sloping wells are being drilled to allow oil collection by gravity. The gallery is 92-ft diameter with a flat ceiling supported by rock bolts and shotcrete structurally connected to the shaft liner, which doubles as a large tension support element. A special excavation sequence was implemented for the gallery to maximize arching in the stress above the large diameter gallery. The gallery was located in competent sandstone, constructed with sequential excavation methods, and designed with a 3D finite element model. Special consideration was given to optimizing the gallery location to take advantage of the geology for construction and support while giving good positioning to the well drilling equipment. BACKGROUND Brierley Associates was contracted to provide both design and construction management services for an approximately 1,165-ft deep, 18-ft excavated diameter vertical shaft that opens to a 92-ft diameter flat roof gallery. The geotechnical data for the site was based on information available from literature and from data obtained during core drilling and from in-situ testing in a 1250-ft deep borehole. Wire line coring was conducted using a HQ, 10-ft long core barrel with a mud-rotary drilling method through sedimentary bedrock. The geometry of the shaft and the bottom gallery is shown in Figure 1(a). GEOLOGIC SETTING AND STRUCTURAL GEOLOGY The stratigraphy at the site includes a series of interbedded marine limestone, shale, claystone, siltstone, sandstone, and chert units. Limestone and shale are the predominant lithologies in the upper approximately 675 ft, while the lower portion contains five distinct sandstone units and more abundant shale, claystone, siltstone, and coal than the upper zone. A cherty sandstone at a depth of 1,130 below ground surface (bgs) was encountered. At a depth of about 1,000 ft to 1,116 ft bgs, a non-marine sandstone unit was encountered. This sandstone is the hydrocarbon bearing layer. Joints and fractures observed in the limestone had dips ranging from 0 to 90 deg. from horizontal with joint and fracture surfaces that ranged from planar to irregular and smooth to rough. Several, near vertical shear planes with slickensides were observed with surfaces that were generally smooth and planar. RQD values for the limestone ranged from 0 to 100 percent but in general were good to excellent."

Jan 1, 2016

By Gregory M. Rumbaugh, Todd R. Kostecki, Christopher Mark

From 2015 to 2021, five massive pillar collapses occurred at four underground stone mines in the eastern USA. These events resulted in powerful airblasts that damaged mine infrastructure and mobile equipment, seriously injured miners, and disrupted underground travelways. Each of these pillar collapses propagated through the overlying strata, causing a subsidence sinkhole on the surface. Pillar collapses are particularly hazardous for miners because they can occur with little warning and can affect miners that are far from the pillar collapse area. The following case studies show that certain factors may increase the likelihood of a pillar collapse. For instance, each of the 5 events involved at least 12 benched pillars with width-to-height ratios (w/h) of 0.8 or less. This study elaborates on these factors and proposes a framework to assist mine operators where they identify similar hazards.

Jul 24, 2023

By P. Stanley Jacobsen, Hemant B. Gala, Richard E. Hucko

Coal is the nation's most abundant fossil energy resource. However, its use is limited because of the nature and amount of associated impurities, such as mineral matter, sulfur, trace elements, and moisture. The moderate-to high- sulfur content of many U.S. coals is of particular concern as current and newer, potentially more stringent, regulations require reduction in sulfur oxide emissions. Release of particulates, NOx, and other pollutants during the coal-use cycle is also of concern. The current practice of controlling sulfur oxide emissions in the major steps of the coal- use cycle is limited mainly to coal preparation by physical beneficiation and, to a smaller extent, to post-utilization cleanup (flue gas desulfurization). Approximately two-thirds of the coal from states east of the Mississippi river is physically cleaned, whereas only 15% to 20% of the operating boilers in the utility industry are equipped with scrubbers to desulfurize the flue gas (Henzel, 1988). Physical beneficiation methods can be very effective in removing mineral matter, including pyritic sulfur, from coal. These processes take advantage of the differences in physical proper- ties between coal and mineral matter to achieve the separation. In a typical physical cleaning operation, raw coal is crushed to about a 50-mm (2-inch) top size. It is then screened into coarse, intermediate, and fine sizes. Crushing the coal liberates some of the ash-forming minerals, including a portion of the sulfur that is not chemically bound to the coal. The per- centage of impurities freed from the coal matrix generally increases as the coal particle size decreases. The coarse- and intermediate-sized coals are typically subjected to a cleaning pro- cess based on differences in specific gravity between coal particles and the associated impurities. Such cleaning processes used include jigs, dense-medium baths, cyclone systems, and concentrating tables. The fine-sized (typically less than 0.5-mm) coal, if beneficiated, is typically cleaned using a froth flotation technique based on the differences in surface proper- ties between coal and its associated impurities. At fine sizes, greater cleaning potential exists because a greater portion of the impurities is released from the coal matrix. However, this potential is not fully realized owing to inefficiencies in separating fine particles using state- of-the-art flotation technology. Overall, current commercial coal preparation processes are estimated to remove up to 60% of the ash and 10% to 30% of the sulfur, depending on the coal characteristics, with product weight recoveries rang- ing from about 60% to 90% and thermal recoveries of about 85% to 98% (Versar, 1985; Science Applications International Corporation, 1987; Hoffman- Muntner Corporation, 1978). For many U.S. coals, grinding to sizes finer than those used in current coal preparation plants is required to liberate most of the physically bound impurities from the coal matrix. As noted, conventional coal-cleaning methods are not very effective at these fine sizes. Accordingly, the expanded use of domestic coal requires the development of advanced coal cleaning technologies that can provide economic performance while reducing environmental impacts. Program Goals and Objectives The overall goal of the U.S. Department of Energy (D0E)'s Coal Preparation Program is to provide the scientific and engineering knowledge base that industry can utilize to produce economically competitive and environmentally acceptable clean-coal products for introduction as market conditions warrant. The coal preparation process(es) should remove undesirable components from coal and improve its handling characteristics, thus making the product coal technically, as well as economically, viable as a competitor with petroleum-derived fuels and natural gas, and with alternative environmental control technologies. The coal preparation process must be applicable to a wide variety of bituminous and low-rank coals. The cleaning process should reduce the variability among clean-coal products from various raw coals, thus significantly increasing the range of potential end uses for each raw coal. To the extent that deeply cleaned coal products have greatly reduced levels of

Jan 1, 1988

By Drew Bazil, David Smith, Matteo Ferrucci, David Pittman

The Gateway program will provide additional rail capacity between New Jersey and Manhattan. This paper describes how a 70-foot-deep section of cut and cover tunnel was designed to directly support future high-rise towers. The tunnel will link previously completed tunnel sections under Hudson Yards to future tunnels under the Hudson River. The design aims to minimize constraints on future overbuild and future tunnels, while maximizing constructability within a small worksite. The tunnel will pass under the High Line elevated walkway, next to an active rail yard, and close to a subway tunnel. The design was developed by a tri-venture of WSP, STV and AECOM. WSP led the design of major underground works; STV designed utility relocations and the underpinning concept for the High Line; and AECOM designed temporary in-tunnel systems. Construction is expected to start in 2023.

Jun 13, 2023

By Philani Larrance Ngwenyama, Ronald CW Webber-Youngman

Through-the-Earth (TTE) communication systems were developed to provide post-accident communication in underground mines. Unlike primary tracking systems, they do not require any major infrastructure installations underground. Instead, they use the Earth’s overburden as the medium or channel for the transmission of electromagnetic waves between surface and underground. Under ideal conditions, TTE communication systems should be able to provide full-duplex, two-way voice, text and data communication. However, this will depend on the design and optimization of the different types of TTE communication systems (that is, antenna and electrodes), and understanding of the rock properties and their influence on the transmission of signals. This can help simulate and model the transmission efficiencies and predict the possible range and data rates. Being able to optimize the performances of these systems can enhance rescue missions, improving the chances of saving trapped miners, and ultimately reduce fatality rates across the mining industry.

Feb 1, 2025

By Jaye Pickarts, Bret Boster, Jack McPartland

Pegasus Minera de Chile, Ltda. is completing three phases of metallurgical evaluation on the Pullalli project to develop a preliminary process flowsheet. A project feasibility study is in progress. The feasibility study includes a proposed process flowsheet designed based on results from the multiple stages of metallurgical evaluation. Phases I and II of metallurgical evaluation included laboratory scale heap leach and milling cyanidation testwork on multiple drill core composites and bulk ore samples from the Pullalli Project. Phase Ill included pilot scale milling/cyanidation testwork on Pullalli drill core composites. The proposed flowsheet includes selective mining and separate processing of low grade and high grade ores. Low grade ore will be crushed and heap leached. High grade ore will be milled leached for 12 hours in an agitated cyanidation circuit. After 12 hours of leaching, sands and slimes will be separated and the sands will be washed using a counter current cyclone (CCC) circuit. Partially leached and washed sands will be added to the crushed low grade ore for heap leaching treatment and permanent placement. Partially leached slimes will be thickened in a high capacity thickener and will be processed in a CIP circuit. Leached slimes will be placed in a tailings impoundment.

Jan 1, 1996

By B. A. Hancock

New permit discharge standards instituted at Hecla Limited?s Lucky Friday Mine required installation of water treatment plants to manage water quality at two outfalls to the South Fork of the Coeur d?Alene River. The 002 Outfall Water Treatment Plant (WTP) is a clarification-filtration plant for treating the combined mill and underground discharge water flows. Process optimization efforts were a significant challenge until the negative impact the exploration diamond drilling products had on the clarification process was identified and resolved. The products were being wasted directly to the mine water discharge system which was pumped to the surface WTP. Anionic soluble oil and polyacrylamide based products were causing TSS particle hydrophobicity and dispersion that greatly affected coagulation and flocculation response, resulting in excessive chemical usage and treatment control issues. This paper details how problems associated with the drill products negatively impacted the 002 WTP and how system changes, alternative product usage and treatment at the source resulted in more consistent plant performance.

Jan 1, 2011

By Janice M. Zinck, W. F. Griffith

Four different high density sludge-type processes, Cominco HDS, Geco HDS, Tetra HDS Process and the Staged- neutralization process were studied for their effectiveness in treating a low strength Zn-Fe rich acidic drainage solution. Each proms was run continuously for at least two weeks after obtaining steady state conditions. The final effluent quality, lime consumption, sludge density, settleability, filterability, viscosity, neutralization potential, metal leachability, operating and capital costs were measured and evaluated for each process.

Jan 1, 2000

By H. D. Lelono, M. Walden, G. Johnson

3D modelling can be used throughout the mine lifecycle and has proven to be a powerful tool for consultants and mining companies. One of the most significant benefits of 3D models is their ability to enhance collaboration, communication, and understanding between the mine owner, design engineers, and other relevant stakeholders that have a shared interest in responsible mining and site management. Tailings and mine waste management is an interdisciplinary effort that requires effective coordination and communication between a wide range of consultants, operators, and stakeholders alike. The increased emphasis on Environmental, Social, and Corporate Governance (ESG) highlights the importance for mine operators to engage and communicate with all parties involved in the planning, permitting, operation, and closure of mine sites. 3D models are valuable tools that can be used for development of geotechnical conceptual models, allowing for improved design and monitoring of Tailings Storage Facilities (TSFs). A clear conceptual understanding of a TSFs subsurface geology and foundation characterization is essential for proper tailings management, design, and planning. Visualization with 3D modelling can simplify the interpretation of the, oftentimes intricate, mine sight subsurface settings and allows for quick and effective geotechnical conceptualization. 3D models can be used to identify data gaps, optimize field investigations, and streamline the development of numerical stability or groundwater models. They can help communicate the complex nature of subsurface and TSF interactions in a clear, concise, and accurate manner to both technical and nontechnical stakeholders. This paper discusses some of the benefits of 3D modelling in relation to geotechnical analysis for tailings management and provides methodologies for how to improve upon some methodologies that are considered industry standards.

Feb 1, 2023

By Francesco Chiappalone, Franco Gasperin, Fabrizio Fara

This document describes the challenging task of mining through tiebacks using a 21'-8" diameter Tunnel Boring Machine (TBM) as part of the Ship Canal Water Quality Project. The mining operation involves navigating through 17 tie-backs that are evenly spaced at 8-foot intervals, with many intersecting the full face of the cutterhead. Detailed analysis and review of TBM parameters specific to this area have been conducted to ensure operational efficiency and safety. Hyperbaric interventions have been planned and coordinated, encompassing pre-mining preparations, continuous monitoring and adjustments during the mining process, as well as post-mining measures. The document highlights the complexity and importance of strategic planning and execution to successfully overcome the tie-back intersections during the mining operation.

Jun 23, 2024

By M. Albrecht

In the mining industry and particularly in the processing plants, we use some large and unusual equipment. Understanding what it is and what it does is important to good operations, but how do you teach a new employee. When I started out in this field, the information on the processing equipment was easy to come by. Equipment manufacturers readily supplied it; their salesmen, often engineers themselves, knew how important the availability of this information was. Old engineers used their notebooks to train the new engineers. Over time this has changed. Equipment manufacturers have changed hands or gone out of business, and often the older engineers are gone. As a start in reversing this, this presentation will be an introduction to sizing, selecting, and operation of some of this equipment, in particular gravity separating equipment. Major portions of this have been excerpted from A Mining Engineers Notebook: Mineral processing (2).

Feb 23, 2014

By James Carroll, Lance Heyer

This paper describes the shaft design and construction for a 72-inch microtunnel under 14 active railroad tracks in Avondale, Louisiana. Initial shaft design for a deeper tunnel alignment considered secant piles with a jet grout plug. Final design for a shallower tunnel alignment included contractor input with support consisting of braced sheet piles with a jet grout plug. The authors further elaborate on jet grout implementation in very soft organic clay soils and the practical limitations of jet grouting. This paper emphasizes how all project participants worked together to utilize value engineering and alternative delivery on a unique tunneling project with a focus on temporary shaft support.

Jun 23, 2024

By W. Pawlos, A. Bakalarz, M. Duchnowska

This paper presents the results of an investigation into the influence of hydrodynamics on a preflotation process for the copper sulfide ore from the Fore-Sudetic Monocline deposits in Poland in a flotation machine. The main aim of the preflotation stage for Polish copper ore is to remove the easy-to-float organic matter — organic carbon — that causes serious problems in metallurgical processes. The organic matter is connected with the presence of shale ore. This paper describes the preflotation experiments conducted to investigate the effect of various stirrer speeds. The upgrading selectivity of copper and organic carbon were analyzed and compared. The results show that the effectiveness of separation between organic carbon and copper decreases with increased stirrer speed in the laboratory flotation machine. The more intensive the mixing of the flotation suspension, the lower the selectivity of the preflotation experiment. Lower stirrer speed probably provides lower mechanical entrainment and flotation of copper minerals.

By C. RAMADINI, F. NURJAMAN, A. SHOFI, B. SUHARNO

Nickel demand is increasing along with the rising need for stainless steel and other alloy steel/iron. The small addition of nickel in such materials can improve impact strength, ductility and corrosion resistance. Nickel is generally obtained from nickel sulfide ores (nickel associated with sulfur) and nickel laterite ores (nickel associated with iron and magnesium silicate). Almost 60 percent of nickel is now produced from sulfide ores, despite its existence in sulfide ores being less than in laterite ores. However, the depletion of sulfide ore reserves makes the mastery of nickel laterite ore processing of important and immediate concern. Selective reduction followed by magnetic separation has been in development in lateritic nickel ore processing to overcome the issues of high energy consumption and pollution associated with conventional pyrometallurgy methods such as blast furnace and rotary kiln electric arc furnace (RKEF).

By Michael S. Moats, John Bailey Fletcher

The performance of grinding media can be misrepresented in marked ball wear tests due to galvanic interactions between dissimilar media. The possible galvanic interaction of media materials during marked ball wear tests has not been adequately explored. Corrosion rates and potentials of modern high carbon steel and high chromium white iron grinding media materials were measured using electrochemical testing as a function of pH and chloride content in a simulated mill water. The results replicate previous research with the high chromium white iron sample being more noble (higher corrosion potential) and corrosion resistant (small corrosion current) than high carbon steel. Using the experimental data and corrosion theory, the effects of galvanic coupling on corrosion rates were calculated to examine what could happen during a marked ball wear test or when a mixed media charge is present. This analysis indicates that high carbon steel can cathodically protect high chromium white iron leading to significant decreases in the corrosion rate (up to 99%) of this material during marked ball wear tests. The magnitude of the protection is a function of the pH of the mill water.

Dec 21, 2022

By Dan Brunner, Scott Thomson, Ben Lyddall, Duncan Thomson

Geosensing is used in oilfield drilling in conjunction with geophysical tools to support characterization of rock properties, geology, and reservoir conditions. This technology is now available to the mining industry and has been successfully applied to underground in-seam directional drilling in Australian coal mines for geologic exploration and methane drainage. The system utilizes a range of drill rig and wellhead mounted sensors which, combined with analytical software, produce real-time data from which 3D spatial features can be accurately modelled significantly in advance of mining. This innovation greatly expands on the information obtained from current in-seam directional drilling practices and provides for improved characterization of coal seams, including soft and weak zones, locations of geologic discontinuities, and analysis of formation flow. This paper provides a description of the geosensing system and the interpretation of actual data from long in-seam directionally drilled methane drainage boreholes at mines in Australia, and discusses how this system increases the value of directional drilling as an exploration tool for the coal mining sector, and the evaporite and hard-rock mining sectors where directional drilling is also applied.

Feb 1, 2024

By J. H. Rowland, R. A. Thomas, III, C. D. Litton

Atmospheric monitoring systems (AMS) are required when using air from conveyor belt entries to ventilate working sections in U.S. underground coal mines. AMS technology has the potential to increase fire safety mine-wide, but research is needed to determine the detection and response times for fires of a variety of combustible materials. To evaluate the potential of an AMS for fire detection in other areas of a coal mine, a series of full-scale fire experiments were conducted to determine detection and response times from fires of different combustible materials that are found in U.S. underground coal mines, including high- and low-volatility coals, conveyor belts, brattice materials, different types of wood, diesel fuel, and a foam sealant. These experiments were conducted in the Safety Research Coal Mine (SRCM) of the U.S. National Institute for Occupational Safety and Health (NIOSH) located in Pittsburgh, PA, using a commercially available AMS that is typical of current technology. The results showed that through proper selection of sensors and their locations, a mine-wide AMS can provide sufficient early fire warning times and improve the health and safety of miners.

Jan 1, 2016

By Yuanhong Qi, KUN CUI, Tao Fu, XUNFU WANG, Yingyi Zhang, Jie Wang, Junmao Qie

Indonesia is the world’s largest supplier of nickel ore, with its nickel laterite resources mainly distributed in the Moluccas and Sulawesi regions. However, there is scant research on the mineralogical characteristics of nickel laterite deposited in southeast Sulawesi, Indonesia. This study aims to investigate the mineral phase structure, chemical analysis, thermal properties and element distribution characteristics of the middle and lower part of the rotten rock zone located in the southeast Sulawesi ophiolite belt.

By CASSANDRA L. HOEBBEL, PATRICK L. YORIO, Emily J. Haas

This study revealed significantly less favorable perceptions of the existing organizational safety climate among workers in the underground coal-mining sector compared with those in the industrial-minerals and sand, stone and gravel (SSG) sectors. Consequently, it is important to consider pragmatic ways in which health and safety management systems (HSMS) in coal mines can alter processes to improve these perceptions. Given the interdependencies of safety climate factors and HSMS elements, researchers explored mineworker perceptions of the supportiveness of organizational safety climate factors among mineworkers and identified significant differences in perceptions across sectors. In this paper, we suggest that health and safety professionals in underground coal mining and organizations with fewer resources or less mature HSMSs focus on these factors to bolster support for proactive safety performance. Potential barriers to implementing or improving relevant HSMS elements and ideas to help foster more favorable perceptions of organizational safety climate are also discussed.

By JIAQI JIN, Chen-Luh Lin, Amanda N. Erskine, Jan D. Miller, Shijie Wang

The liberation and exposure of valuable mineral grains in ore particles are of significant importance in understanding the efficiency of flotation separations. A flotation feed sample from the Kensington concentrator was scanned by micro Xray computed tomography (micro-XCT), to determine the liberation and exposure of auriferous pyrite grains. The analysis results suggest a satisfying extent of liberation for particle sizes smaller than 212 μm. Theoretical flotation recovery of pyrite for selected particle size fractions was predicted from the three-dimensional liberation and exposure analysis. The plant flotation tail was also characterized by micro-XCT to identify liberated and partially liberated pyrite particles that might not be collected into the concentrate. However, liberation analysis of the tail sample revealed that the majority of liberated pyrite was recovered in the plant flotation circuit. Trainable Weka, a machine learning segmentation approach, was compared with the Watershed thresholding segmentation for the 106 × 45 μm particle size fraction scanned at a voxel size of 1.85 μm. Improved segmentation of small particles was found using the machine learning method.

Mar 1, 2024