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By A. Miller, M. McNinch, R. Jacksha

Each year, hundreds of mine workers are involved in machinery-related accidents. Many of these accidents involve inadequate or improper use of lockout/tagout (LOTO) procedures. To mitigate the occurrence of these accidents, new safety methods are needed to monitor access to hazardous areas around operating machinery, improve documentation/monitoring of maintenance that requires shutdown of the machinery, and prevent unexpected startup or movement during machine maintenance activities. The U.S. National Institute for Occupational Safety and Health (NIOSH) is currently researching the application of Internet of Things (IoT) technologies to provide intelligent machine monitoring as part of a comprehensive LOTO program. This paper introduces NIOSH’s two-phase implementation of an IoT-based intelligent machine monitoring system.

By Shawn P. Coughlin, Michael A. Schimmenti, Juan Leonardo Tello del Pino

"The Sistema de Potabilización Área Norte project (Northern Area Purification System) was a major expansion of the potable water system in Buenos Aires Province, Argentina. The aim of the project was to transport and purify raw water from the Paraná River to provide potable water for five communities in the northern part of the province, benefitting up to two million people. The project was constructed by a joint venture (JV) of four South American contractors and consisted of the following key components:• Treatment plant: A 16-ha (39-acre) area was cleared for the construction of a treatment plant to purify 900,000 m3/day (1.2 million cu ft/d) of raw water from the Paraná River and distribute it to the surrounding communities.• Bored tunnel: Nearly 15 km (9 miles) of 3.6 m (12 ft) inner diameter tunnel, ranging from 18 to 22 m (59 ft to 72 ft) below grade, was bored with two earth pressure balance (EPB) tunnel boring machines (TBM) to draw the raw water from the river. The TBMs started from a central launch shaft and proceeded in opposite directions. Cristina advanced northbound to the Paraná River Intake System, and Liliana advanced southbound to the new treatment plant.• Access and ventilation shafts: Five access shafts and eight ventilation shafts were installed along the length of the tunnel. The access shafts were designed to provide entry points for inspection and maintenance of the final tunnel. The five shafts consisted of one central launch shaft in the middle of the tunnel alignment, one retrieval shaft at each end of the tunnel (intake and treatment plant, respectively) and two intermediate shafts. The intermediate shafts were installed before the TBM passed, with a final liner to be installedafterward."

Sep 1, 2016

By W. Miles

Introduction From a historical perspective, bentonite is the common rock term for various uses and applications. Its name originates from water-based muds near Fort Benton used for lubrication of wagon wheels during the 19th century migration to western territories (which are presently part of the United States) when the pioneers ran out of axle grease. From a clay mineralogy perspective, bentonite is composed primarily of montmorillonite, an expandable magnesium aluminum silicate clay mineral. When magnesium occupies an octahedral structural site that usually contains an aluminum atom, a negative charge is created. In order to neutralize negative charges, cations are drawn to the interlayer surfaces between clay mineral sheet structures. Modern applications for bentonite depend on the sodium or calcium cation populations and other characteristics of the clay mineral. When sodium is the dominant cation, the material is also called sodium bentonite, also known as swelling bentonite, western bentonite or Wyoming bentonite. When calcium or magnesium is the dominant cation, the material is called calcium bentonite, also known as nonswelling bentonite or southern bentonite. Swelling bentonite is recognized for its rapid hydration of interlayer sodium and subsequent dramatic expansion up to more than 20 times its original volume. Low shear can then disperse the hydrated sodium bentonite to form suspensions that increase viscosity and suspend solids. However, when shear is subsequently eliminated a sodium bentonite slurry gels. Characteristically, nonswelling calcium bentonite has relatively poor hydration properties and thus low expansion of the clay mineral. When subjected to low shear, calcium bentonite exhibits very little viscosity and poor suspension. Additionally, when shear is subsequently eliminated no more than minimal gelling takes place. The domestic and export markets related to both swelling and nonswelling bentonite are discussed below.

Jan 1, 2007

By Jamal Rostami, Omid Frough, Wei Hu

Characterizing the abrasiveness of soil/rock and the allowable wear of hard-facing products in various conditions is a critical factor in selection of the best material for certain applications related to drilling and excavation in mining and construction industries. The Soil Abrasion Index test machine at Colorado School of Mines (CSM) is one of the recently developed unique systems capable of testing soil/crushed rock abrasion under various conditions, such as dry, wet, and saturated settings. It is also capable of testing the performance of various types of hard-facing materials in a given geo-material. This paper studies the wear properties of different hard-facing materials in various crushed rocks from a surface mining operation in the iron range region of the USA. The hard-facing materials include regular and hardened steels and six different specialized hard facings, based on chromium carbide. The soil/rock include a standard sand and two rock samples from the surface mine. Fourteen abrasion tests were conducted, where the weight loss of each hard-facing material was measured over timespans up to 1 h of testing. The results show the distinct performance differences between the steels with 17 HRC and 43 HRC hardness and the hard-facing products for this application. The results show the possibility to evaluate the abrasiveness of different rocks at a mine or construction site and the performance of various hard facings in similar working conditions. This is a practical solution for selection of the cutting tool or reinforcement of bucket lips and truck beds for comparison of relative wear life between different wear-resistant materials.

By Jamal Rostami, Omid Frough, Wei Hu

Characterizing the abrasiveness of soil/rock and the allowable wear of hard-facing products in various conditions is a critical factor in selection of the best material for certain applications related to drilling and excavation in mining and construction industries. The Soil Abrasion Index test machine at Colorado School of Mines (CSM) is one of the recently developed unique systems capable of testing soil/crushed rock abrasion under various conditions, such as dry, wet, and saturated settings. It is also capable of testing the performance of various types of hard-facing materials in a given geo-material. This paper studies the wear properties of different hard-facing materials in various crushed rocks from a surface mining operation in the iron range region of the USA. The hard-facing materials include regular and hardened steels and six different specialized hard facings, based on chromium carbide. The soil/rock include a standard sand and two rock samples from the surface mine. Fourteen abrasion tests were conducted, where the weight loss of each hard-facing material was measured over timespans up to 1 h of testing. The results show the distinct performance differences between the steels with 17 HRC and 43 HRC hardness and the hard-facing products for this application. The results show the possibility to evaluate the abrasiveness of different rocks at a mine or construction site and the performance of various hard facings in similar working conditions. This is a practical solution for selection of the cutting tool or reinforcement of bucket lips and truck beds for comparison of relative wear life between different wear-resistant materials.

By John Hanna

Over the years the coal industry in Alabama has generated about 150 million tons of fine waste coal, increasing at a rate of 2 million tons/year, during mining and cleaning operations. Reclamation of the fine-size wastes containing 20-60% by weight clean coal provides, free of charge, mined and crushed feedstocks for coal recovery and eliminates a major source of acid water pollution. Tests were made on the impounded wastes and current plant discharges to recover the coal fraction by sizing, gravity and flotation techniques. Gravity separation of the plus 100 mesh material produced commercial grade coal averaging 8.2% ash, 0.8% sulfur and 13,350 Btu/lb. However, the coal recovery was relatively low at 50-65%. Froth flotation using mechanical and froth column methods gave similar coal products at much higher coal recovery of 87-93%. The coal produced analyzed 10% ash and 1.1% sulfur.

Jan 1, 1991

By M. H. Rauschkolb, J. A. Cremeens

Geotechnical solutions were developed for closure of two historic, remote underground mines in the deserts of southern California. Closure criteria included access closure, minimal site impact, and optimum use of native materials. The closure designs and construction activities incorporated techniques for protecting sensitive biota, particularly bats and desert tortoise. The types of mine openings that were closed include adits, declines, shafts, daylighted stopes, and dugout dwellings. The desert locations permitted implementation of cost-effective closure techniques that relied upon the use of native materials. The strategies and techniques developed for these desert closures are adaptable to other climates.

Jan 1, 2002

By Joern Katzer

It is vitally important to any tunnel project to have an accurate and reliable survey control network inside the tunnel for layouts, as-built surveys, and to provide guidance to the tunnel boring machine (TBM). However, the concepts and methodology to provide such a survey network are sometimes not well understood. For example, the first anticipated survey task that takes place during the bidding process is often ignored, which is to provide a comprehensive survey network preanalysis for the surface network and tunnel traverse based on survey statistics that will be used to make informed decisions on the survey requirements and methodology. Instead, these steps are often only vaguely based on previous results and prior tunneling experience. But each tunnel is different, and a solution that worked for one tunnel project might be unsuitable for another. The purpose of this paper is to provide tunnel project engineers, managers and surveyors with the general concepts for tunnel survey methodologies and examines several statistical tools for a basic horizontal and vertical tunnel survey preanalysis. These survey statistics tools provide useful estimates of the expected lateral and vertical tunnel traverse accuracies, but are not a replacement for a comprehensive tunnel network preanalysis. The proposed formulas do not take centering errors into account, are using average distances for each traverse leg, and assume that the survey data is free of outliers in the measurements. It is very important that the estimated instrument accuracy is based on true values that are reflective of measurement precisions that are actually achievable inside the tunnel to provide accurate results.

Dec 1, 2022

By H. Wesley Peirce

Arizona embraces portions of two major western-U.S. physiographic-geologic provinces and a smaller, local one. These exert fundamental control over the geologic framework and associated earth-material resources and potential. The Mogollon Rim diagonally crosses the State and separates the Colorado Plateau Province to the northeast from the Transition Zone and Basin and Range Province to the southwest. More than 90 percent of the population, production of nonfuel minerals, agricultural land, and water resources are in the Basin and Range part of the State. In 1981 Arizona was ranked number one in the Nation with respect to the value ($2.56 billion) of nonfuel-mineral production. About 8.2 percent of this amount ($212.9 million) can be attributed to nonmetallic (industrial) materials. Although a diversity of nonmetallic substances is produced and some are exported, the bulk is utilized within the State and is directly related to market growth. Since 1950 there has been a fourfold increase in Arizona's population, a concomitant twelvefold jump in sand-gravel production (tons), and a twentyfold increase in "stone" production. New industries developed during this time include cement, salt (and storage of liquid petroleum gas products in solution cavities in salt), zeolite, hydrofrac sand, vitrified clay pipe, crushed marble products (teed additive, pool sand, roofing granules, etc.), and "rock" wool. Most of these newer industries serve out-of-State as well as in-State markets. In 1981 at least 225 industrial mineral or rock deposits were being worked to produce about 10 tons of material per Arizona resident per year. In 1980 the relative values of basic industrial minerals produced in the State, by major group, were cement and lime (51.6 percent); gravel (26.5 percent); sand (11.8 percent); stone (4.6 percent); and others (5.5 percent). Detailed knowledge of the nonmetallic rock-and-mineral content of most Arizona ranges and basins is lacking. Exploration opportunities in this sun-belt growth region appear encouraging.

Jan 1, 1987

By Dean Brox

Tunnel boring machines (TBMs) have been used for the construction of various tunnels for mining projects for the purpose of access, conveyance of ore and waste, drainage, exploration, water supply and water diversion. Several mining projects have seen the successful and economic beneficial use of TBMs, and there is an increasing awareness of the benefits of TBMs for mining projects. Key technical considerations for the use of TBMs for the construction of tunnels for mining projects include geological issues (rock type, rock alteration, rock strength, rock abrasivity, durability, ground water inflows), depth of cover and the potential for overstressing/rockbursts, site access and terrain, portal locations, TBM constraints, minimum tunnel size, tunnel support requirements, contractor and labor experience, and project schedule demands. TBMs offer key project schedule benefits with high rates of progress, which is a unique economic advantage recognized for mining projects where timing is of the essence in order to advance mining development and achieve early startup for operations. A thorough evaluation of the anticipated ground conditions should be performed as part of the decision to adopt a TBM for a mining project. Minimum specifications for TBMs are necessary in order to prevent the incorrect type of TBM from being used. Appropriate geotechnical investigations are necessary in order to provide key information on the anticipated subsurface conditions for careful planning and design of the proposed tunnel alignment. The overall site and geological conditions associated with some projects may suggest that it is not appropriate to use TBMs for some mining projects due to a perceived higher risk.

Jan 1, 2013

By Dean Brox

Tunnel boring machines (TBMs) have been used for the construction of various tunnels for mining projects for the purpose of access, conveyance of ore and waste, drainage, exploration, water supply and water diversion. Several mining projects have seen the successful and economic beneficial use of TBMs, and there is an increasing awareness of the benefits of TBMs for mining projects. Key technical considerations for the use of TBMs for the construction of tunnels for mining projects include geological issues (rock type, rock alteration, rock strength, rock abrasivity, durability, ground water in flows), depth of cover and the potential for overstressing/rockbursts, site access and terrain, portal locations, TBM constraints, minimum tunnel size, tunnel support requirements, contractor and labor experience, and project schedule demands. TBMs offer key project schedule benefits with high rates of progress, which is a unique economic advantage recognized for mining projects where timing is of the essence in order to advance mining development and achieve early startup for operations. A thorough evaluation of the anticipated ground conditions should be performed as part of the decision to adopt a TBM for a mining project. Minimum specifications for TBMs are necessary in order to prevent the incorrect type of TBM from being used. Appropriate geotechnical investigations are necessary in order to provide key information on the anticipated subsurface conditions for careful planning and design of the proposed tunnel alignment. The overall site and geological conditions associated with some projects may suggest that it is not appropriate to use TBMs for some mining projects due to a perceived higher risk. Key words: TBM, Tunnel boring machines, Tunneling in mining

Feb 1, 2014

By W. Miola

The MSHA prescribed method for the determination of quartz in airborne respirable dust samples from underground coal mines is the P-7 method, a combination of low temperature radio-frequency ashing (LTA) and infrared analysis (lR). There is no prescribed procedure for quartz analysis in bulk samples of coal and host rock. Dispersive Infrared (IR), Fourier-transform Infrared (FTIR), and X-Ray Diffraction (XRD) methods are most commonly used for quartz analysis in powders. Several aspects of the experimental procedures such as the analysis sample preparation from bulk samples, ashing techniques, scanning procedures, peak measurement location, calibration techniques, sample amounts, size consist, and data interpretation affect differently the results from each of the methods. Significant differences in analysis results from X-ray diffraction (XRD) and infrared spectroscopy (IR) on the same samples are reported. All these studies point to the need for reliable quartz analysis methods. In a recent research, a procedure for preparing bulk coal and host rock samples for quantitative quartz analysis was developed. Further the results from X-ray diffractometry and infrared spectroscopy for quartz content on identical samples were compared. Calibrations with pure and mixed standards were used to assess the influence of particle size distribution, matrix, and calibration on analysis results. In this paper, several issues with the measurement of quartz in the samples of coal, host rock, and airborne respirable dust from mines are outlined and quantified.

Jan 1, 1994

By I. B. Tulu, M. M. Sears

In 2015, 40 longwall mines provided nearly 60 percent of U.S. underground coal production. During this time, about 80 percent of ground-fall-related fatalities occurred in areas where the mine roof was supported. In an attempt to better understand the status quo of current longwall support practices in the United States, during a period between 2010 and 2017, researchers from the U.S. National Institute for Occupational Safety and Health (NIOSH) visited a sample of 25 longwall mines representing nearly 50 percent of the currently active longwall mines operating in all of the major U.S. longwall producing regions. The data presented here indicate that the types and amount of roof support being installed in modern U.S. longwall mines have reduced ground-fall accident and injury rates to levels never seen before. However, the complete elimination of unintended roof falls in U.S. longwall mines has remained elusive. The data in this paper can be used by mine operators and engineers to determine where their chosen type and density of roof support occur on the spectrum of observations contained in this database. Additionally, this data can be used to enhance, supplement and support additional research on longwall gateroad support systems. 

By O. Ditsele

Coal plays an important role in the energy needs of the World. Given its wide abundance and low cost, coal use is bound to increase with the growing energy demand. Despite its importance, there are growing concerns over coal?s environmental burdens, especially its contribution to greenhouse gas emissions. To ensure sustainable extraction and use of coal, opportunities for minimizing potential impacts from coal have to be identified and exploited. Whilst extensive work has been done on life cycle assessment of coal use, especially in electricity generation which uses the bulk of coal produced, there has been limited work focusing specifically on coal mining. This study aims to estimate the cradle-to-gate life cycle climate change impacts of coal from a surface coal mine in the United States. The study employs general principles of ISO standards for LCA.

Jan 1, 2010

By W. H. Strickland

The research reported here characterizes ultrasonic ranging sensors for autonomous navigation on underground mine mobile equipment. Because ultrasonic rangers are inexpensive, have no moving parts, have no lenses to clean, are small and unobtrusive, and can measure distances in dusty environments, they are especially sui ted to underground mi ne environments. The investigation began with laboratory tests of field of view, angle of incidence, intersensor variation, and ranging accuracy of individual rangers and a ring array of 24 sensors. The results showed the sensors have good accuracy and low variability. Additional experiments at AHAX' s Henderson mine Showed the sensors could accurately and reliably measure rib features, convex and concave corners, and drift intersections. The results showed that when used and analyzed properly, the sensor data may be used reliably for underground mobile equipment navigation.

Jan 1, 1990

By Francisco J. Sotillo

Using new ecological-natural-organic depressant for gangue and pyrite with antibacterial properties (control of acid mine drainage) with new improved xanthate collectors using rheology additive not chemical reacting with xanthate resulted in better sulfide flotation. Rougher-scavenger lead flotation tests were conducted increasing the concentrate grade from 7.07% Pb to 13.44% Pb, enhancing selectivity. Lead recovery increased from 64.08% to 79.38% and 80.40% using only the new depressant, and improved xanthate Z-11 and Z-4, respectively. The results demonstrated that the new depressant was selective and efficient, and the new improved xanthates stronger more selective collectors.

Feb 22, 2026

By Charles B. Manula

This paper describes the development of a mathematical model for simulating the behavior of a longwall coal production system. The longwall simulator is a design simulator incorporating both deterministic and stochastic methods to calculate: (a) the size and density of support; (b) the cutting force, power requirements and haulage speed for the loader-shearer; (c) the conveyor size, speed and power requirements; and (d) delay generation at head and tail-gates and the longwall face.

Jan 1, 1978

By Leonardo Rosas Sánchez, Darío Ángel Bulla

"The two track road sector between Cisneros-Loboguerrero (having a length of 14 km and 11 short unidirectional tunnels) is a new highway still on construction located along the existing Highway Buga – Buenaventura (Colombia). Due to the steep topography, difficult geological/geotechnical conditions, the traditional portal construction approach was impossible to be implemented in eleven (11) of the twenty two (22) portals. In this specific project, the skewed portal approach was developed as the optimal and more effective solution. The construction time and costs of portals were reduced in 21 months and 75%, respectively. At the same time, the natural equilibrium of the slopes was maintained, thus, facilitating adequate safety factors along the useful life of the project. This document pretends to show a detailed design experience (and the construction of the entry portal of tunnel 11 (left)). INTRODUCTION The Cisneros-Loboguerrero project is a 14 km length dual lane highway, connecting productive zones with the Pacific Ocean along the current Bogota-Buenaventura highway as shown in Figure 1. The project is located at the northern side of the Dagua River Valley. The preliminary design suggested constructing portals under challenging topographical conditions, i.e., slope cuts having heights between 50 to 100 m (some having slopes > 100%) requiring complex developments and having very high risks.The entry portal of tunnel 11 (left) was the first portal successfully built by implementing the skewed portal approach. Later, this approach was used as a model for the construction of the other ten (10) portal having similar topographic and geotechnical conditions. The development of this new alternative provided a considerable reduction on the construction time of portals, thus relieving a critical path in this project."

Jan 1, 2016

By Jürgen. F. Brune, CLAIRE STREBINGER, ADITYA JUGANDA, Gregory E. Bogin Jr

The abstract highlights the risk of methane gas explosions in underground coal mines and the potential of computational fluid dynamics (CFD) modeling to simulate such events and assess their impact on mine ventilation. The study focuses on developing CFD models for large-scale explosions in longwall mines, specifically simulating methane gas explosions resulting from face ignition during coal cutting. The research demonstrates the integration of a combustion model into a longwall mine ventilation model and shows how the availability of explosive gas mixtures significantly affects flame propagation and explosion pressure.

Mar 27, 2022

By Martha Gross, Amanda Wachenfeld, Brian Keaney, Jean-Michel Charpentier, Frank Perrone

The Hampton Roads Bridge-Tunnel (HRBT) Expansion widens the existing four-lane bridgetunnel corridor to eight lanes through construction of two parallel tunnels, interstate widening, and bridge expansions. As part of the design-build contract, a supplemental geotechnical investigation was completed to support the design. The investigation for the subaqueous tunnel segment consisted of over 48,400 linear feet of drilling and 7,100 laboratory tests. This paper discusses the challenges of planning and executing a large-scale geotechnical investigation for underground works in a marine environment and the use of big data for effectively managing, interpreting, and transmitting data to the design-builder consistently throughout the investigation.

Jun 23, 2024