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By R. Mier

The metals and minerals mining industry has evolved dramatically from the earliest objects ever made out of native copper circa 9,000 BC to the modern developments we see today. To better appreciate past developments and to get a sense of where the industry is heading, a brief overview of mayor industry highlights over the last 100 years will be presented, followed by a discussion on potential global scenarios and by a review on mayor industry trends.

Feb 27, 2013

By Paul Lynch

"Since being reported to the 2012 UMI in Shanghai, the Cook Islands has been steadily developing for the commencement of it Seabed Minerals sector in its large Exclusive Economic Zone which contain a vast and unique Manganese Nodule resource, estimated at 10 billion tonnes1. At the 2013 UMI in Brazil, it was reported that the Seabed Minerals Act had commenced and all the necessary complex Technical aspects of this developmental work was being undertaken. At the 2014 UMI in Portugal, full details of the final developments leading to the opening of the Tender of Exploration Blocks in the Cook Islands EEZ will be presented in a brief but comprehensive method, using Poster displays, Powerpoint and active Website interaction. This will show the drafted Regulations, prepared on best international standards, to address both Licencing and Environmental requirements, to give clarity and security to the Resources Owner, industry and stakeholders. This work in being coordinated by the Cook Islands Seabed Minerals Authority, with the valuable collaboration of many international, regional and national stakeholders, including the Cook Islands NGOs, Marine Resources, Marine Park and National Environment Service."

Sep 1, 2014

By M. K. Eryadin, I. Yildirim, R. Asmatulu

Novel dewatering aids were tested on various coal samples from the U.S. and Canada in laboratory and pilot-scale filtration experiments. The reagents substantially improved the dewatering kinetics and reduced the cake moistures. The cake moistures were typically reduced from 20-30% by weight to 8-14% range in vacuum filtration. When the reagents were used in conjunction with a pressure filter, higher degrees of moisture reductions were achieved. In the present work, the novel dewatering aids were tested using different types of pilot-scale vacuum filters. The results were consistent with those obtained in laboratory experiments.

Jan 1, 2003

By A. Vien

Over the past several years, Svedala has developed a continuous charge monitor (CCM) for tumbling mills. It consists of a strain gauge embedded into a rubber lifter and associated electronics. This paper describes the results of a research program to evaluate the technical and economical merits of such a device on a SAG mill. The evaluation includes validation through discrete element modelling and comparison to measured static volumetric load. Inclusion of the measurement into a control strategy and its potential for condition monitoring is discussed.

Jan 1, 2001

Arsenic (As) removal behavior from Changgoon mine tailings was investigated using Acidithiobacillus ferrooxidans (A. ferrooxidans) in well-controlled batch reactors by varying pulp density (0.5?4%, pH=1.8, temp=30oC), reaction initial pH (1.8?2.2, pulp density=0.5%, temp=30oC), and temperature (25?35oC, pulp density=0.5%, pH=1.8). The initial concentration of As in the mine tailings used for bioleaching tests was about 30000 ppm, and the size range of tailings used in this study was 63?74 µm. The reaction speed and initial cell concentration were fixed to 150 rpm and 107 cells/mL, respectively. To complement leaching experiments, pH, oxidation/reduction potential (ORP), and amount of ferrous/ferric ions in leachate were analyzed. Scanning electron microscopy and x-ray diffraction analyses were also conducted for the samples before and after leaching to see if any morphological and compositional changes in tailings took place during leaching process. The As leaching efficiency increased with decreasing pulp density, decreasing pH, and increasing temperature in the presence of A. ferrooxidans. Specifically, no significant change in As removal rate was observed when pulp density d 2% while the removal rate dramatically decreased at pulp density of 4%. Regarding pH effect, As removal rate was much more enhanced at lower pHs (i.e., 1.8 and 2.0) compared to pH 2.2. Increasing temperature was observed to tend to enhance As removal rate, showing about 20% enhanced leaching rate under 35oC compared to 25oC and 30oC at the elapsed time of 5 days. The results for As removal behavior at different conditions (i.e., pH, temperature, pulp density) were consistent with the change in pH, ORP, and ferric ion concentration in leachate, showing greater removal rate at the condition with lower pH, and higher ORP and ferric ion concentration in leachate. Furthermore, decreasing removal efficiency was likely in part due to the extent of the formation of by-product (i.e., jarosite) of ferric ions.

Feb 27, 2013

By R. J. F. Goodfellow

Many underground projects now include preparation of a Risk Register through planning and design as a tool for project and risk management. There is still significant discussion within the industry as to whether and how to best present the Risk Register through the bidding process and the construction phase of a project. While the ITIG Code of Practice for Risk Management of Tunnel Works recommends this approach of continuity in risk management procedures, it is silent on the specifics of how this should be achieved. This paper will explore the perceived benefits and disbenefit of including the project Risk Register with bid documents; format and content that should be transferred and lessons learned using the case history of bidding and early construction phase of the Bi-County Water Tunnel in Montgomery County, MD

By V. Svalbonas, M. Fresko

The present versions of the Welding Codes, such as BS7608, have long been known to be compatible with hand computations of membrane and bending stress, rather than detailed finite element solutions. However, in the last five years, in the mining industry, this incompatibility has been largely ignored, and the code interpretations have been pushed into the realms of ground welds, residual stresses, and even flaw growth. Such techniques have to be recognized as extrapolations not necessarily sanctioned by the original code documents. The safety of such extrapolations, as they are related to grinding mill fatigue design, is investigated herein.

Jan 1, 2002

By Tom Martin

Mega projects present unique challenges with regard to estimating costs. With such projects, which may span decades, these challenges often begin as soon as a project is conceived. The importance of having a sound, resource based estimate avail-able early in the process cannot be overstated because it provides the basis for ongoing project decisions. For the final phase of providing an updated cost estimate, often while bidding by contractors is underway, the Engineer?s Estimate (EE) must incorporate present market conditions; account for possible volatile material price swings; be based on actual labor and fringe costs; rely on meaningful productivity rates; and accommodate any recent technology advances while identifying and allowing for risk factors. This paper explains the benefits associated with consultants adopting a contractor?s estimating approach when preparing the Engineer?s Estimate on mega projects like the various tunneling projects in New York City.

By A. B. Cecala

Enclosed cabs have been used on surface mining equipment for many years to protect equipment operators from health and safety hazards. The surface mining and quarrying process is a highly mechanized process that generates large quantities of respirable dust. Due to economic factors, more older mining equipment is being used today than in years past. With this older equipment, it is common to observe deterioration of many components on the enclosed cabs which greatly reduce their protection effectiveness. NIOSH has performed a number of different field studies, as well as a comprehensive laboratory study evaluating various factors and parameters regarding enclosed cabs. NIOSH has recently completed a cooperative research effort with Sy-Klone International and Vulcan Materials Company to evaluate the effectiveness of a newly designed uni-directional filtration and pressurization system that brings all the clean filtered air in at the roof of the cab and extracts all recirculated air near the floor. This design provides the highest air quality to the equipment operator. Testing on this new system showed an almost 10-fold reduction in respirable dust inside the enclosed cab. The uni-directional design is easy to incorporate and should be considered for all new and retrofit systems in surface mining equipment.

Jan 1, 2009

By J. F. Lupo

Heap and valley leach operations rely on solution collection piping placed within the heap to enhance both solution recovery and to assist overall solution management. The most common piping used in leaching operations is solid or perforated High Density Polyethylene (HDPE) pipe and Corrugated Polyethylene pipe (CPE). These pipes are widely used because of their low cost, ease of installation, durability, and flexibility. The typical recommended maximum design depth of burial for HDPE and CPE pipes is on the order of 30 meters (100 feet). However, ore heap heights at many facilities exceed 30 meters and some are now approaching 180 meters (600 feet) in height. At very high ore heap heights, the stability and performance of HDPE and CPE pipes becomes a critical issue for leaching facility design and operation. Failure of solution collection piping can lead to poor solution recovery, high hydraulic heads on the liner system, and in some cases, unstable ore slopes due to high solution pressures near slopes. This paper presents a review of methods that have traditionally been used to evaluate pipe stability under high normal loads. A common shortcoming of these methods is the inability to account for beneficial effects of ore arching around pipes and the time-dependent creep (stress relief) behavior of polyethylene (PE) materials. A new analytical approach is developed and presented which includes the effects of ore arching around pipes and creep of PE materials. The results of the new approach show that PE pipes will deform under high heap loads, but can remain stable and functional. Pipe stability is shown to be dependent on the type of pipe backfill and initial backfill compaction. The new approach represents a useful tool for designing applications for PE pipe under high normal loads.

Jan 1, 2001

By Tim Hurley

On Friday, May 27, 1983 at about 6 p.m., an avalanche occurred at the Revenue-Virginius Mine. Six mine personnel and two contract diamond drillers were trapped when the avalanche covered and blocked the portal, the only access into the mine. The San Juan Mountain Range in southwestern Colorado is an old volcanic caldera. It has dikes and other intrusions, many of which are mineralized with sulfide ores rich in silver, gold, lead, zinc and copper. Several peaks rise above 4,260 m (14,000 ft) and the district has been the location of avalanches dating back to prehistoric times. This is evidenced by the numerous snow-slide chutes that are infamous enough to be named on topographic maps.

Jan 1, 2006

By T. Payne

Underground heat issues are mainly focused on the detrimental effects to a workers health. However, working in hot, humid conditions has other negative effects. Studies have shown that safety, productivity, workforce morale and operating cost are also worsened in these conditions. The human body has several mechanisms for rejecting heat and remaining cool. However, once the air temperature exceeds about 34°C, the only effective mechanism is by evaporation of sweat from the skin. This is assisted by acclimatisation which is the human body?s enhanced ability to combat extended exposure to heat. The body has to remain well hydrated when working in heat as even small degrees of dehydration cause significant decreases in the ability to work in heat. There are two ways in which heat load can be reduced: Through use of refrigeration/vent/cooling to reduce thermal stress on workers; Reduce the contribution that heat sources have to underground heat load (e.g. reduce idle time, fleet size, etc). Some of the sources of underground heat have the potential to be more manageable than others. Geothermal heat and heat from autocompression will be found in all mining situations in varying degrees depending on geothermal gradient and surface temperature, however, the use of equipment and blasting may be streamlined to reduce the underground heat load. It is through a combination of the available options that most mines will successfully control their heat related problems. Mt Isa, which has been a focus for heat related study in Australia, has successfully implemented protocols for working in heat. Through combining these with the installation of a surface bulk air cooling plant, Mt Isa has consistently reduced the incidence of heat illness. This is likely to be the most cost effective method of reducing heat load for deep mines in Australia. Shallower mines which may only occasionally encounter hot conditions should consider more portable cooling options. This study will review the heat issues in underground Australian metalliferous mines.

Jan 1, 2009

In the dimension stone industry, workers in processing shops may be exposed to harmful levels of respirable silica dust when conducting the different tasks in stone preparation, which include cutting, grinding, polishing, and thermaling. To protect workers from this health hazard, operators sometimes ventilate processing shops using fan-powered dust collectors to capture and filter dust. To investigate this issue, NIOSH, Pittsburgh Research Laboratory, in cooperation with a dimension stone operation, upgraded an off-the-shelf dust collector the operator was utilizing in a polishing/cutting shop. Initial dust surveys showed that the unit was under-designed for the amount of dust being generated in the shop. The objective of the research was to cost-effectively increase the air cleaning volume and improve dust capture efficiency of the unit with a larger motor and blower. The unit?s original stock 0.56 kw motor and blower was replaced with a 2.24 kw motor and matching blower to increase airflow. The unit was evaluated both in the laboratory and the shop before and after the retrofit to determine the improvement of the upgrade. The study showed that the 2.24 kw upgrade improved the performance over the original 0.56 kw motor resulting in more dust being cleaned from the ambient air in the shop. The 2.24 kw unit cleaned 19% more air and captured 32% more respirable dust than the 0.56 kw unit.

Jan 1, 2009

By Dean Workman

Located in downtown New York City, this project necessitated an innovative conveyor design for successful muck removal. This paper will discuss the technical challenges and engineering solutions of the muck transport system which consists of every commonly recognized version of a belt conveyor. The elaborate system includes a TBM conveyor integral to the back-up system, a wall-mounted extensible conveyor, a crown-mounted transfer conveyor, a floor-mounted fixed-length conveyor, a pocket-belt vertical conveyor, three cascading overland conveyors, and one radial stacker. The most challenging design element was an over-land conveyor featuring a box truss for muck transportation over Northern Boulevard while simultaneously going under the Queens Plaza railroad viaduct. An overview of the project is provided along with the following topics: developing final plans from the proposal concept, interfacing with existing works, communication with the joint venture, and complying with local regulations.

Jan 1, 2008

By Steven M. Puricelli

In recent times, smelter off gases treatment plants have become more efficient and environmentally friendly. Where in the past it was acceptable to process only high strength, treatable furnace gases, new smelters must now treat primary gases and abate dust and SO2 from secondary gases: Processing smelter gases can present some interesting challenges. Some equipment can see varying concentrations of sulfuric acid, up to the boiling point, with a periodic table of contaminates thrown in for good measure. Treating weaker secondary gases have, in the past, been cost prohibitive. Nowadays, new technology, like physical absorption or catalytic carbon, show promise for economically treating low strength secondary gases. Modem smelters do a much better job of treating the SO2 laden gases generated by the smelting process but significant challenges remain.

Jan 1, 1998

By J. K. Lemley

The human element in large measure dictates success in contracting relationships. Because of our professional backgrounds, we view contracts primarily as either engineers, contractors or owners. A beneficial contractual environment--one in which decisions, risks and benefits are shared--demands equal consideration of all three points of view. Most of the older cities in the United States, for example, suffer from bad contracts--generalized, patched-together documents that represent an accumulation of modifications originally written to compensate for specific situations that have occurred over the years. Because such documents lack coherence, they often present conflicting instructions which lead to defensive, ultimately destructive attitudes among the parties involved in the day-to-day administration of the project. Good contract development begins with a strong central philosophy to which the details of the contract can be related. First, the owner should establish a comprehensive philosophy in which risks between the parties are identified. Following this, a specific contract document can be written to satisfy this established philosophy. The contrast between two opposed contractual situations, NYC Water Tunnel Number Three and the Seabrook Nuclear Power Plant Cooling Water Tunnels, illustrates how comprehensive, well-written contracts--contracts which share both risks and benefits--provide the basis for achieving quality construction that will reward engineer, contractor and owner.

Jan 1, 1983

By J. Peterson, P. G. McKneight, R. W. Riggle

"In today’s tough mining environment, the key difference between surviving and thriving is how effectively miners optimize their mining operations. This paper explores the compounding effects material fragmentation has on mining costs and productivity. Starting with Drilling & Blasting and moving through Loading, Hauling and Crushing, we will illustrate the opportunities to improve operating costs and thus reduce the Total Cost of Ownership (TCO) of the total mining system. Material size and volume requirements are defined by the needs of the mill or plant, and drive the rest of the mining operation from the bench through the primary crusher. At the start of the cycle, where the rock mass is drilled and blasted, the degree of fragmentation and the muck pile configuration is determined, as are the effects on cost and productivity of all subsequent operations. The cost of managing oversize material, including secondary handling, overloading, reduced diggability, higher load factors, extra pass loading, increased wear factors and reduced throughput rates are all opportunities for improvement. INTRODUCTION Having visited many mine sites, customers are asking about the end to end mining value stream from loading to the crusher and how to measure the cumulative effects on each part of the mining value chain. All too often improvements with the drilling and blasting may impact fragmentation but do not improve the diggability so the net change on cycle times or fill ratios is perceived to be negative at the point of loading but they may have a measured improvement going through the primary crusher. This makes it imperative to measure performance at each segment of the overall cycle and not just to the crusher but thru it. The mine material process originates with solid rock, in-situ, and progresses to the output of the primary crusher. Once the material has passed the primary crusher the fragmentation size will be fairly consistent and promote consistent throughput of the plant or mill. In late 2015 a team was conducting a reassessment visit to a mining site where we had conducted the original assessment the previous year. Though many recommendations had been implemented some had been so recent they had not resulted in the expected improvements. Several of our discussions kept returning to the impact fragmentation has to both the individual components of the mining cycle but also the effects compounded throughout the end to end process. Let’s move on to the big picture before we zoom in on any specific operation. To get from native solid rock in the ground to a concentrate or a saleable rock product we have the same steps from one end of the chain to the other. We start with a good geological understanding of the rock type, characteristics and structure to design a program to drill and blast the rock. The height of the bench is relevant to the annual production requirements and the specific digging equipment models best sized to make that production possible. The equipment selection influences the bench height which has a minimum and maximum hole diameter to maintain a safe blasting operation. The diameter of hole burden and spacing all contribute to a good distribution of explosives in the rock mass that maximize the fragmentation and preconditioning of the rock when blasted. The timing and sequencing of hole initiation will yield a fragmentation ratio and diggability factor. Fragmentation size adjustments will change the meters drilled per cube and the explosives consumption will change accordingly. Drill cost is measured by meter drilled so a direct relationship exists between cost and fragmentation sized achieved."

Jan 1, 2017

By L. "Andy" Anderson, Stephen N. Short, James E. Friant

Since the introduction of "boxhole" drilling in South Africa in 1973, the concept of a blind raise, drilled upward from below, has become an accepted mining practice. A combination machine, capable of constructing raises to a mining level below, or blind raising upward from a single setup position adds a further dimension in versatility. A machine with these dual operating modes was designated by The Robbins Company as the 53R and was introduced into the Western Deep Level Mines, South Africa in 1984. The unit is powerful (200 hp) and compact (18,000 lbs., in a 10 ft x 4 ft 5 inch x 4 ft 6 inch package). This paper describes the design considerations for the new machine, provides field data from early trials, and looks briefly at its overall market and potential.

Jan 1, 1985

By R. D. Peterson

As underground mine operations expand, the ventilation systems supporting them become complex. Complexity increases with periodic ventilation changes. New diagonal connections require a rebalance of resistance to maintain airflow in affected splits in the system. Incidents of mine fires and explosions have occurred in U.S. coal mines when diagonal connections resulting from ventilation changes have resulted in changing airflow directions. MSHA regulations prohibit the reversal of airflow and poor ventilation practice in general, but regulations cannot stipulate or recommend proactive preventative measures because every situation is different. This paper discusses the phenomenon of diagonal branches and recommends practical precautionary measures that can be taken to prevent airflow reversal in planned ventilation changes.

Jan 1, 2012

By Z. Duan

A novel concept involving the deployment of chemical stabilization has the potential to eliminate the need of slurry impoundments and significantly reduce the release of trace elements from the high surface area fine coal waste. The process involves mixing the fine waste generated from the underflow of a thickener operation with chemical stabilization agents to tie up the water and to create a solid waste material that can be discharged directly. Portland cement, sodium silicate, F type flyash, C type flyash and hydraulic lime were evaluated as stabilizing agents. A detailed experimental study has been conducted to identify the conditions that provide the maximum compressive strength within a short curing time. Results to date show the ability to achieve compressive strengths adequate for equipment to maneuver on using a Portland cement concentration of around 10% by weight. Quick-setting concrete was not found to enhance stabilization time and compressive strength.

Jan 1, 2012