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By D. S. Kieffer

Ground characterized by hard boulders embedded in soft matrix represents one of the most challenging conditions for TBMs, as the cutterhead must cope with the non-optimal conditions of cutting hard blocks while simultaneously excavating through soft, soil-like matrix material. Dowden and Robinson (2001) and Hunt and Mazhar (2004) summarize several case histories relating to the problems of advancing a TBM through boulder-laden ground and provide guidance with respect to appropriate site investigations and baselining strategies. Some rock types constituting boulder-laden ground include: ?Sedimentary Rocks?cemented alluvial channel deposits, colluvium/talus, landslide debris, and glacial till. ?Igneous Rocks?agglomerates, lahars, and pyroclastic deposits. ?Metamorphic Rocks?tectonic mélange and cataclastic fault zones. ?Decomposed Rocks?corestone bearing saprolites. Disc cutters are commonly utilized to cut the hardblocks; however, as compared to the understanding of disc cutter behavior in hard continuous rocks, little is known regarding fundamental cutting mechanisms in highly heterogeneous bouldery ground conditions. To advance this understanding, a suite of full scale tests have been performed using a linear cutting machine at the Colorado School of Mines (CSM). This paper summarizes the observed cutting mechanisms and their practical implications for TBM excavations through boulder-laden ground.

Jan 1, 2008

By Richard Adsero

The Australian Bureau of Statistics and the United States Bureau of Labor Statistics publish data for a range of industries, allowing a measure of performance to be quantified, called multifactor productivity (MFP), and allowing performance between industries to be compared on a consistent basis. At the time of writing, the last released data was for 2011-2012. For Australia, the plot of mining industry productivity and a basket of the 12 most significant industries in Australia?s economy (including mining) are shown in Fig. 1. For the United States, mining and petroleum and all manufacturing productivity are also displayed in Fig. 1. The trends are as follows: ? The MFP in the Australian mining sector rose 36 percent from 1986-1987 to 2000-2001. There was a 47-percent decline in MFP from 2000-2001 to 2011-2012 (Australian Bureau of Statistics, 2011). ? The MFP in the United States mining sector rose 17 percent from 1986-1987 to 2004-2005. There was a 7-percent decline in MFP 2004-2005 to 2010-2011, (Topp et al., 2008).

Sep 1, 2013

By Stuart F. McTavish

Mechanically suitable grinding mills became available to the mining industry in 1908. Since then, mill operators have been searching for the best material and design with which to line the mills. These liner systems had to fulfill several criteria. Most important, they had to last long enough in an operating mill to protect its structure from the abrasive wear of the ore and the grinding media. In addition, they had to be capable of efficiently transferring the energy from the mill to the mill charge in order to facilitate the grinding process. And these liners had to be easy to install and remove. The first liners used were generally made of cast white iron, Hadfield manganese, unalloyed high-carbon steel and composites of steel and concrete or cemented in flint blocks or natural stone. In the early 1920s, pieces of solid rubber truck tires were used as emergency repairs for broken cast metal liners. Thus was rubber first introduced as a mill liner material. The first patent for rubber mill liners was awarded in 1921 to James Denny and Rolla Watson, both of the Coniagas Mine in Cobalt, Ontario, and to Dale Barnum of the Comstock Lode in Virginia City, NV. This original design was covered under US Patent No. 1470597. It had a fabric backed rubber that was bonded to the shell of the mill.

Jan 1, 1990

By Peter Bigwood

Whether drilling through tough clay or breaking rock, or facing the most severe conditions including mixed face ground, perched water and running and flowing sands, working under-ground certainly comes with no shortage of challenges. In an environment where the unknown is faced on a daily basis, tunneling contractors must be able to rely on their equipment to get the job done properly. Not only that, their equipment must comply with two of the highest priorities: safety and efficiency. In addition to being the number one concern, a proven safety record provides additional benefits to a company. A safe work environment serves as a key component to company growth, including the ability to remain competitive in bidding and maintaining higher-level, more challenging projects.

Jan 1, 2012

By S. J. Boone, A. Poschmann, C. Pound, A. Pace

San Diego’s Stadium Conglomerate consists of poorly cemented cobbles, gravel, sand, silt and clay. Conventional laboratory and in-situ testing is not suitable for characterizing its engineering properties. Although the formation is often considered a “rock” its behavior is more readily modeled using soil mechanics. Static and seismic design of a tunnel for the Mission Valley East light rail extension required that the stress-strain characteristics of the ground be identified over a broad strain range. Geophysical methods and field plate load testing were used to develop a full non-linear stress-strain model of the expected ground behavior. Quantification of the coarse material distribution was also required for selection of tunneling methods and construction considerations.

Jan 1, 2001

By Paul H. Johnson

Resource Engineering and Development, Inc. is desigining and building a portable 150 to 225 tpd, flotation-cyanide leach plant with unitized, skid-mounted components. This plant design, with its portability, low capital investment, and high recovery of silver and gold from many partially oxidized ores, is well suited to treat many small, highgrade deposits, old waste dumps, and old mill tailing piles. A description is given of flotation and/or cyanide leach tests run on 18 partially oxidized, newly mined ores; waste dump materials; placer slimes; and old mill tailings.

Jan 1, 1981

Membrane technology has been available for over 36 years, but has been used sparingly in the general mining industry. However, recent developments in polymer chemistry, spiral wound element construction, pretreatment equipment and techniques and an expanded understanding of membrane fouling and cleaning techniques have dramatically improved the reliability and robustness of membrane based systems in the mining industry. Harrison Western has expanded the use of this “new” technology to enhance the use of membrane technologies to separate metals from large volume heap leach mining solutions containing copper, zinc, and iron, gold or silver. Moreover, membrane technologies are ideally suited to fractionations that add value to processing fluids from refineries like separating metals from acids or concentrating acids and producing high quality process fluids. Finally, wastewater from Acid Mine Drainage (AMD) or, as in the case of the Newmont Yanacocha Mine in Peru, the treatment of excess barren leach solution created during the rainy season, can be cost effectively processed to meet World Bank Standards for surface discharge. Polymeric membranes, specifically thin-film composites, have been developed that will purify, fractionate or concentrate gold, silver, copper, zinc or nickel. Recent applications have been developed for spiral wound modules that operate across the pH spectrum from 0 to 14. Systems using membranes have been constructed that operate on feed streams from 140° C to 300 centipoise. Opportunities exist to apply membrane technology to concentrate gold, silver, copper, zinc or nickel using thin film composite membranes. Engineered membrane types can operate across the spectrum from low pH (<2) acid applications to high pH > 10 cyanide applications. Incorporating HW EMS™ membrane technologies into current mining operations could allow one to increase production because the membrane technology would be used to pre-concentrate heap leach solutions, and therefore, increase utilization of existing extraction and refinery capabilities.

Jan 1, 2007

The Pogo Mine, near Delta Junction, Alaska is a 2500 TPD gold operation employing processes including grinding, gravity, rougher flotation, leach, CIP, and E/W. An OCS(Optimizing Control System) expert control system has been implemented on rougher flotation in early 2008. The OCS system communicates with the Plant DCS(Distributed Control System) through OPC(OLE for Process Control) communication. The initial strategy was to control the flotation cell froth level set points to achieve target froth velocities. This strategy was enhanced by controlling both level and air flow setpoints. The flotation cell air and level are adjusted to reach cell pulling rates (froth velocities). The pulling rate setpoints for each cell are determined based on downstream capacity (concentrate surge tank level). The effect of pH and upstream disturbances is also taken into account in adjusting the air and level setpoints. Feed forward compensation is employed down the flotation row to minimize disturbances.

Jan 1, 2009

By Peter Campi, Harry R. Asche, Ian P. Callow, Edmund G. Taylor, P. Scott Smith

The US$1,850 million EastLink project is a 39km tollway and includes twin 3-lane,1.5km long, undrained driven tunnels. The hard rock tunnels are being built to avoid passing the motorway through the Mullum Mullum Valley and so to help preserve the unique flora and fauna in the area. This paper describes several of the key issues in the tunnel design and construction, including: the integration of the temporary support design with the Contractor’s tunnel excavation and support procedures, including sharing of responsibility between the Designer and Contractor for support type selection and the production of a project specific rock mass classification system to enable more objective determination of ground conditions. detailed hydrogeological assessments during the design and construction phases to allow confirmation of design loads for the tunnel lining design and the various suite of waterproofing tools in order to meet the project inflow requirements. development of a pre-cast invert solution to the main tunnel secondary lining to enable faster lining construction and to minimize risks to the tunnel membrane associated with fixing reinforcement and construction traffic.

Jan 1, 2007

By William H. Langer

Large amounts of limestone fines co-produced during the processing of crushed lime-stone may be useful in the sequestration of carbon dioxide (CO2). Accelerated weathering of limestone (AWL) is proposed as a low-tech method to capture and sequester CO2 from fossil fuel-fired power plants and other point sources such as cement manufacturing. AWL reactants are readily available, inexpensive and environmentally benign. Waste CO2 is hydrated with water to produce carbonic acid. This reacts with and is neutralized by limestone fines, thus converting CO2 gas to dissolved calcium bicarbonate. AWL waste products can be disposed of in the ocean. Feasibility requires access to an inexpensive source of limestone and to seawater, thus limiting AWL facilities to within about 10 km (6 miles) of the coastline. The majority of U.S. coastal power-generating facilities are within economical transport distance of limestone resources. AWL presents opportunities for collaborative efforts among the crushed stone industry, electrical utilities, cement manufacturers and research scientists. There is a concern that CO2 generated from human activities is contributing to climatic and environmental changes. Approximately one-third of anthropogenic CO2 emissions come from burning fossil fuels to generate electricity. Each power plant is capable of emitting several million tons of CO2 annually. A variety of other industrial processes, such as cement manufacture, oil refining, and iron and steel production, also emit large amounts of CO2. The level of atmospheric CO2 can be reduced by capturing CO2 from point-source emissions and storing or sequestering it in isolation from the atmosphere (U.S. Department of Energy, 2003). In 1999, G.H. Rau and K. Caldeira proposed a geochemistry-based method that is referred to as accelerated weathering of limestone (AWL) in a paper titled ?Accelerating carbonate dissolution to sequester carbon dioxide in the ocean ? geochemical implications.?

Jan 1, 2009

By J. C. Schneider, G. Van Weert

Hydrochem Developments Ltd. has developed and put into full scale operation a novel type of vertical flotation column incorporating a multiplicity of mechanically agitated stages. Characteristics of this flotation column include a low height to diameter ratio, high upgrading factors and the possibility of modifying geometry and operation to specific flotation requirements. A commercial unit is currently handling up to 100 tpd rougher concentrate at Dickenson Mines Limited, Balmertown, Ontario. Design parameters and plant performance will be discussed.

Jan 1, 1988

By Roy C. Fedotoff, Jon Hurt, Gregg Sherry, Gilbert Tang

The 1,380 m (4,200 ft) long New Crystal Springs Bypass (Polhemus)Tunnel (NCSBT) will replace the existing Crystal Springs Bypass Pipeline. This tunnel project is part of the SFPUC’s $4.3 billion capital improvement program to repair and seismically upgrade their aging pipelines, tunnels, reservoirs and dams that provide drinking water to more than 2.4 million customers in the San Francisco Bay Area. This paper describes the development of the tunnel alignment and design, and the complex ground conditions of the Franciscan Mélange. Of particular interest is the challenge of tunneling with a possible downhill grade of 3%, a rigorous environmental process and incorporating the lessons learned from 1960s construction of the adjoining Crystal Springs Bypass Tunnel.

Jan 1, 2007

A series of flotation experiments were carried out in a 2.25-dm3 laboratory-scale Rushton turbine cell using hydrophobic quartz particles. Flotation was performed at a constant mean bubble diameter over a range of superficial gas velocities and impeller rotational speeds. The overall flotation rate constant increased linearly with increasing superficial gas velocity (and hence bubble surface area flux). The rate constant also increased linearly with increasing energy dissipation, until a maximum value was reached. A further increase in energy dissipation had little effect on the rate constant. The dependency of the rate constant on energy dissipation is a reflection of the size range and hydrophobicity of the particles used in this study. The flotation rate constant increased with increasing particle size, except at the highest energy dissipation value examined, for which the flotation rate of the larger particles reached a plateau and, in some cases, decreased. Good agreement was obtained between the experimental results and those predicted by a fundamental flotation model using experimentally measured values for mean energy dissipation and the Sauter mean bubble diameter. The bubble velocity was adjusted to obtain the best fit to the experimental data. The inferred bubble velocity, based on the flotation model, was found to increase with increasing superficial gas velocity (and bubble surface area flux) and was found to decrease with increasing impeller rotational speed. While the inferred bubble velocities were significantly lower than experimentally measured bubble velocities, and, except at low superficial gas velocity values, significantly higher than the bubble swarm velocity calculated from gas holdup measurements, similar trends with impeller rotational speed and superficial gas velocity were observed in all cases.

Jan 1, 2007

By S. C. Tadolini

Roof support systems have evolved from standing posts and timbers to a generation termed ?big nails? where steel bars are inserted into boreholes and anchored with expansion shells and/or resin cartridges. These systems have been effective but are limited to mining height. Additionally, the properties of steel do not resists shear forces or have the flexibility being required in difficult ground conditions. The next generation of roof support systems is coupling the best parts of the ?big nail? and resin grouted cable bolt systems. This paper will present the advanced technical solutions of the next generation of cable systems that includes an indented high-capacity PC-strand used with a variety of fixtures. Case histories of support applications will be presented.

Jan 1, 2012

By Xinming Chen, Huazhe Jiao, Qi Zhang, Yunfei Wang, Liuhua Yang

The effect of initial damage generated by weakly cemented interlayer surfaces on the physico-mechanical properties of layered cemented tailings backfill (LCTB) is considered for the interlayer inclination structure generated by multiple layered backfills in large-scale mining voids. Utilizing the theory of damage mechanics, the damage evolution and constitutive model of LCTB with interlayer inclination is constructed by considering the coupling of interlayer inclination effect and loading. Based on Mitchell’s mechanical model, we analyze the damage mechanism of the inclined cementation surface of LCTB, and derive the expression for the strength of LCTB considering interlayer inclination. The mechanical properties test of LCTB with different inclinations was carried out, and the results showed that the damage model of LCTB established was highly consistent with the experimental curves, which verified the correctness of the model. The initial inclination damage leads to the decrease of adhesive cohesion of cemented surface, and with the increase of inclination, the separation of layered surface, aggravation of misalignment, layered cemented surface is more prone to shear damage, and the mechanical properties of cemented tailings backfill in the lower part of layered surface are not effectively played, which reduces the overall performance of the material.

Nov 23, 2023

By J. D. Morgan

Demand for nonfuel minerals depends on the overall state of the economy, which steadily improved each quarter in 1984. New housing starts rose to 1.8 million units. Automakers turned out about 15% more cars (7.8 million) and 30% more trucks (3.1 million) than in 1983. Nevertheless, many domestic mineral operations experienced difficulties in 1984. This resulted from import competition greater use of newer engineered materials, emphasis on multi-unit housing and downsizing of motor vehicles. About 15% of our energy was imported. This in cluded $36 billion worth of crude oil and $22 billion in refined products This added significantly to the overall merchandise trade deficit of $12; billion. On the bright side for mining, coal production rose 14% to 810 Mt (890 mil lion st). Three-fourths o: the coal was burned to generate electricity and more than half of our electricity was derived from coal-burning plants. With the exception of a few large-bulk, low-value raw minerals, most minerals move relatively freely in world trade. The strong dollar encouraged imports and made exporting more difficult. Consequently, our nonfuel minerals trade deficit rose 60% to $19 billion, reflecting imports of $39 billion and exports of $20 billion. There were increased pressures from some major segments of the minerals industry for some form of import protection. But President Reagan said, "Our goal is a system of free and fair trade in goods, services, and capital. We will work toward this goal through both bilateral and multilateral trading agreements." The US minerals industry consists of domestic mines, concentrators, smelters, refineries, mineral manufacturing plants, and recyclers. It also includes many wholly- or partially-owned operations in many parts of the world, providing employment and income for US citizens and others as well. Compared with 1983, the value of US raw nonfuel mineral output rose 8%, to $23 billion. The $253 billion worth of goods processed from this crude mineral output was a 14% increase. Major Metals Raw steel production - a major indicator of both material use and mineral production-rose 10%, to 84 Mt (93 million st). This stimulated a 36% rise in domestic iron ore production, to 52 Mt (57 million st), about 98% pelletized. Iron ore imports rose 44%, to 14 Mt (15 million st). Despite the increase of steel production, output remained well below levels of just a few years ago. For example, 1984 production was still 23% less than in 1981. Raw steelmaking capacity remained steady at 122 Mt (135 million st). The industry continued to cite steel imports as a major reason for low domestic capacity. In December, pacts with seven leading steel exporting nations were announced. This is an effort to reduce import penetration to about 18.5% of the domestic market. Domestic producers of bulk ferroalloys of chromium, manganese, and silicon operated at about 50% capacity. The US mined no manganese or chromium. Only a small quantity of ferronickel was produced from domestic laterite mining in Oregon. Molybdenum production, at 45 kt (49,500 st), rose threefold. Mine shipments of tungsten, another mineral tied to steel

Jan 5, 1985

By A. K. Majumder

The multi-gravity separator (MGS) is a novel piece of equipment for the separation of fine and ultra-fine minerals. However, the published literature does not demonstrate its use in the separation of coal fines. Therefore, an attempt was made to study the effects of different process variables on the performance of an MGS for the beneficiation of coal fines. The results obtained from this study revealed that among the parameters studied, drum rotation and feed solids concentration play dominating roles in controlling the yield and ash content of the clean coal. Mathematical modeling equations that correlate the variables studied and the yield and ash contents of the clean coal were developed to predict the performance of an MGS under different operating and design conditions. The entire exercise revealed that the MGS could produce a clean coal with an ash content of 14.67% and a yield of 71.23% from a feed coal having an ash content of 24.61%.

Jan 1, 2007

By Manuel Pérez-Tello, María M. Salazar-Campoy, Óscar Rodríguez-Hoyos

A common problem during the operation of the Kaldo furnace is the formation of accretions and blockage of the injection lance due to splashing. This typically occurs during the processing of anodic slimes for the production of doré. In this work, a 1:7 scale model of the Kaldo furnace currently in operation at Metalúrgica de Cobre, Mexico, was built in transparent acrylic plastic. Water and colored oil were used to represent the doré and slag, respectively. The model was used to determine the maximum penetration distance of the injection lance under a variety of experimental conditions at room temperature. Input variables included two types of oil, rotation speed, inclination angle, and the fraction of the vessel volume occupied by the liquids (φ). A mathematical correlation for the dimensionless maximum penetration distance of the injection lance d ∗ as a function of φ, the Froude number of the liquids in the vessel (Fr), the Reynolds number of the gas jet (Re), and the oil-to-water kinematic viscosity ratio (η)was developed. Reasonable agreement between the calculated and experimental values was obtained. Digital images showed that splashing was caused by the turbulent gas jet impinging upon the free surface of the liquids, whereas the cascade effect was negligible. The results of this work have been useful to improve the operation of an industrial Kaldo reactor.

By Manuel Pérez-Tello, María M. Salazar-Campoy, Óscar Rodríguez-Hoyos

A common problem during the operation of the Kaldo furnace is the formation of accretions and blockage of the injection lance due to splashing. This typically occurs during the processing of anodic slimes for the production of doré. In this work, a 1:7 scale model of the Kaldo furnace currently in operation at Metalúrgica de Cobre, Mexico, was built in transparent acrylic plastic. Water and colored oil were used to represent the doré and slag, respectively. The model was used to determine the maximum penetration distance of the injection lance under a variety of experimental conditions at room temperature. Input variables included two types of oil, rotation speed, inclination angle, and the fraction of the vessel volume occupied by the liquids (φ). A mathematical correlation for the dimensionless maximum penetration distance of the injection lance d ∗ as a function of φ, the Froude number of the liquids in the vessel (Fr), the Reynolds number of the gas jet (Re), and the oil-to-water kinematic viscosity ratio (η)was developed. Reasonable agreement between the calculated and experimental values was obtained. Digital images showed that splashing was caused by the turbulent gas jet impinging upon the free surface of the liquids, whereas the cascade effect was negligible. The results of this work have been useful to improve the operation of an industrial Kaldo reactor.

By Christopher J. Bise

INTRODUCTION Traditionally, the purpose of mine ventilation has been defined as diluting, rendering harmless, and sweeping away hazardous gases which may accumulate in the mine workings. In addition, the ventilation sys- tem must keep the mine air as close as possible to the composition of the outside air in order to provide a healthy environment for mineworkers and to prolong the useful life of mine equipment. When plans are being developed for opening a new mine, sound engineering dictates that a calculated estimate be made of both the maximum air quantity requirement and the accept- able mine pressure (head) loss related to the under- ground layout and projections. For efficient mine ventilation, the two problem areas that demand constant attention are (1) the control of fugitive air (through short circuiting or leakage) and (2) the provision of ample airway capacity. Fugitive air is that quantity of air which enters the mine but short-circuits the mine ventilation system through improperly constructed stoppings, doors, overcasts, etc.; it represents an investment in power consumption (to move the air by the fan) while providing little, if any, return on the investment. Typically, efficient mines are those that can deliver 50% of the air handled by their fans to the working faces. Paying close attention to a new mine&apos;s ventilation system at the outset can provide numerous benefits during the later stages of mine development. It has often been noted that the main cause of trouble in many mine ventilation systems can be found within a radius of 2500 ft from the fan installation. Ample airway capacity is essential to maintain the mine&apos;s head loss within manageable limits. Similar to an industrial ventilation setting, the mine&apos;s headings are the ductwork for the handling of air. The difference between normal industrial ventilation and mine ventilation is apparent when more capacity is needed; a plant can install new or larger ductwork, but it is difficult for a mine to install new entries or enlarge existing entries. Air velocities are usually maintained under 800 fpm to limit the stirring up of dust in the intakes. With this in mind, it is usually simple to estimate the number of entries required in the ventilation system. The problem that often arises, though, is when the system&apos;s capacity is overestimated and the required head loss to achieve the desired quantity is excessive. Experience has shown that problems are often encountered when the mine&apos;s condition requires much more than three inches of water gage to ventilate the mine on a day-to-day basis. Thus, if proper attention is not paid to these parameters in the preplanning and initial development of a new mine, it may take an extremely high water gage to achieve the ultimate quantity. This chapter will not delve deeply into the theory of mine ventilation; many other books have been writ- ten on that subject. Instead, the following sections will point out the important considerations that should take place before the development of a mine ventilation system, as they relate to normal industry practice. FUNDAMENTALS OF AIRFLOW Volume Versus Water Gage The common method of measuring ventilation pressure is in terms of inches of water gage (wg); one inch of water corresponds to a pressure of 5.2 psf (pounds per square foot). Further, airflow follows a square-law relationship between volumes and pressures where, as shown in the previous section, a doubling of quantity requires a quadrupling of pressure. Table 1 shows how heads and quantities are related. Using Table 1, it is readily apparent that, for the same mining conditions, an increase in pressure from one inch wg to three inches wg results in only 34,640 cfm when the initial quantity is 20,000 cfm. Pressure Losses Pressure losses in mine ventilation systems are caused by friction between the heading walls and the air stream and by shock losses due to abrupt changes of the air stream caused by obstructions. The common pressure-loss formula for mine ventilation is: [ ] where H is the pressure loss in inches of water gage, K is the coefficient of friction, L is the length of the airway in feet, 0 is the airway perimeter in feet, V is the air velocity in feet per minute, and A is the cross-sectional area of the airway in square feet. Table 2 lists the US Bureau of Mines schedule of friction factors (K) for mine airways. Recent research indicates that the values of K are slightly less for coal mines than those presented in the USBM Schedule, and Table 3 should be consulted in this instance. It should be

Jan 1, 1986