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By R. Flattery, Z. Agioutantis

Coal and rock pillar design is critical not only for mineral extraction but also for the safety of the mine operators. Pillar strength can be estimated through numerous empirical formulas that are available in the literature, which are typically based on a statistical analysis of case study data. The limitation of most of these equations is that they only considered the width to height ratio and in situ rock or coal strength for pillars in horizontal seams. The adoption of such equations to estimate pillar strength in inclined seams may overestimate the pillar strength and ultimately lead to a poor pillar design. This paper will discuss different techniques that can be used to estimate pillar strength in inclined seams as well as present preliminary modeling results for stress redistribution around inclined pillars. Factors in the parametric analysis include pillar shapes, geometry, and seam inclination.

Mar 2, 2022

By Y. Wang, G. Xu, N. A. Amoah, A. Kumar

Mining-induced coal dust causes various respiratory diseases to mine workers, such as coal workers’ pneumoconiosis (CWP). Current available underground monitors are expensive, heavy and only measure mass concentration. These disadvantages limit them for regulatory sample monitoring purposes only while personal exposure levels for most miners remain unknown, risking miners to potential overexposures. Low-cost light scattering PM sensors offer a potential solution to this problem with capability of high spatio-temporal resolution PM characterization. However, these sensors require careful calibration before they can be applied in mining environments. There is basically no comprehensive study in the literature using a standard protocol assessing these sensors for coal dust monitoring. With the aim of calibrating the PMS5003 sensors for coal dust monitoring, we design the calibration method and system to calibrate these low-cost PM sensors coal dust monitoring. Working principles of present coal dust monitor and low-cost sensors are presented in detail. The linear regression calibration model which is used for the sensor calibration is further described. Sensor calibration and evaluation protocols are comprehensively compared and discussed. This investigation reveals the feasibility of low-cost sensors for real-time personal coal dust monitoring in underground coal mines.

Mar 2, 2022

By T. McNulty

The author was privileged to find employment as a uranium mill chemist for The Anaconda Company while working his way through school in the mid-1950s. He then served Anaconda in various technical and management positions until 1980. This paper describes the prevalent technologies employed by uranium producers, briefly describes various mines and mills in the U. S., and memorializes a few of the thousands of men and women who contributed to the U. S. Uranium Boom. Following isolation of uranium as an element by M. H. Klaproth in 1789, uses of uranium were confined primarily to pigments, glass coloring agents, and ceramic glazes. In 1896, Antoine Becquerel found that uranium is radioactive, releasing particles and energy as it decays. In 1898, Pierre and Marie Curie isolated radium from uranium and learned that it can be an effective treatment for some types of cancer. In 1939, it was discovered that the isotope U235 is fissionable1 . Up to this point, nearly all uranium production was from pitchblende concentrates made in Bohemia, Canada, and the Belgian Congo. In 1938, only about 5 percent (23.85 short tons) of global output was produced from ores of the carnotite mineral that were being mined in the U.S. By the early-1950s, physicists in many countries had begun to recognize the potential for nuclear chain reactions. Ernest Rutherford (UK), Frederick Soddy (UK), and Leo Szilard (US) explained transmutation of elements and formulated the principle of “atom splitting”. In 1934, Marie Curie’s daughter, Irène, and her husband, Frédéric Joliot, identified uranium as the most viable source for this new form of energy. The basic fission process was unraveled by German scientists in December 1938. After Hitler’s army seized the uranium deposits in Czechoslovakia, many feared that Germany would build the first nuclear weapon.

Mar 2, 2022

By J. R. Klaehn, M. Shi, T. E. Lister, L. A. Diaz, J. S. McNally

Since 2019, approximately two dozen international battery recycling companies have been operating at the commercial or pilot scale [1]. However, current process capacity does not exceed 100,000 tons of end-of-life (EOL) lithium-ion batteries (LIB) per year, and the current recycling rate is only about 5% in North America [2-3]. Recycling metals from EOL LIBs is not only essential to waste minimization and environmental stewardship, but also a source of critical materials, which can contribute towards supply chain stabilization. LIB recycling can be roughly divided into three categories: direct recycling, pyrometallurgy, and hydrometallurgy. Direct recycling seeks to retain as much of the manufactured effort with minimum chemical processing [4]. The evolution of battery designs and chemical compositions are challenges to this approach [5-6]. Pyrometallurgical processes are robust and flexible allowing a broad spectrum of batteries with minimum pre-processing requirements. Some of the matrix issues are solved through combustion of some constituents. Smelting is strongly tied to fossil energy and air emissions are a concern. In addition, pyrometallurgical processes are not stand alone, as hydrometallurgical refining normally required to separate and recover the metals of interest (Co, Ni, and Cu) from the produced alloy and Li from the slag [7]. Hydrometallurgical processes can be highly selective and efficient in recovering high purity materials [8]. In general, hydrometallurgical processes are considered cleaner and less costly than high temperature processes [4,9-10]. Extensive chemical consumption and waste generation significantly increase the operating costs and overall environmental impact of the hydrometallurgical processes [11]. Leaching of metals from LIBs is dominated by the mixture of sulfuric acid (1 to 4 M H2SO4) and hydrogen peroxide (1 to 15 wt.% H2O2) [10]. Although organic acids have been tested as lower environmental impact alternatives, the reported pulp density operations are low < 60 g/L [10-11]. For the H2SO4/H2O2 leachates, high leaching efficiencies >90% are reported for Co, Ni, Mn, and Li from cathode materials at temperatures over 40 ⁰C and pulp densities between 30 to 200 g/L [9-10]. H2O2 acts as reducing agent to convert Co+3 and Mn+4 into their soluble forms, Co+2 and Mn+2 [12]. Despite the claims of H2O2 being a clean reducing agent [13], production of H2O2 has significant environmental impacts as determined by life-cycle analyses [13-14]. Moreover, the costs and risks associated with H2O2 transportation and storage cannot be ignored [15].

Mar 2, 2022

By P. Zhang, D. W. H. Su, M. Van Dyke, H. Dougherty

To provide critical scientific data and engineering guidelines to federal and state regulatory agencies as well as the coal and gas industries, the National Institute for Occupational Safety and Health (NIOSH) initiated a Gas Well Stability Research Program in 2016. This paper summarizes the critical scientific data acquisition, interpretation, and modeling by NIOSH regarding the stability of unconventional shale gas wells influenced by longwall mining. Currently, NIOSH is the only organization in the U.S. conducting such fundamental and impactoriented research, which receives input and collaborations from MSHA, PADEP, WVDMS, OHDNR, the coal industry, and the gas industry. Results from the NIOSH field instrumentation programs—which include surface, subsurface, and underground instrumentation—and the parallel three-dimensional numerical modeling programs indicate that, under shallow and medium covers, the measured horizontal displacements within the abutment pillar are one order of magnitude higher than those measured under deep cover. Casing couplers are found to play an important role in longwall-induced casing deformations. Cementing alternatives are found to have significant impact on longwall-induced casing stresses and deformations. Measured 60-arm caliper logging results are in good agreement with three-dimensional computer simulation results. Engineering guidelines on longwall-induced deformations, casing and cementing alternatives, gas well setback distances, as well as risk assessment strategy are proposed.

Mar 2, 2022

By R. Owens, C. Roos, B. Hill, S. Rosenthal

It is common practice, and even legally required in many jurisdictions, to design two-lane haul roads in open pit mines to three and a half times the widest dimension of the haul trucks operating on the road. In open pit gold mines with high strip ratios, the road width has a significant impact on the economics of a design. It is possible to minimize the flattening of the highwall if the road width is reduced, assuming the width used is not needed to flatten the slopes for geotechnical purposes. With the use of autonomous haulage and pullouts, it may be possible to operate safely and efficiently on a reduced road width of two times the width of the hauling equipment.

Mar 2, 2022

By K. S. Fraser, R. Frischmuth

High temperature pressure oxidation (>190°C) is a wellrecognized and versatile metallurgical oxidative pre-treatment process commonly used to liberate gold from refractory sulfide ores and concentrates. The pressure oxidation of refractory gold ores was first commercially applied in 1985, at Homestake Mining Company’s McLaughlin mine in the United States. Since that time numerous refractory gold and other high temperature pressure oxidation facilities have been built throughout the world. The design of each facility was met with unique challenges and opportunities which have led to an array of plant configurations, pressure oxidation autoclave sizes, and sulfide oxidation capacities. This paper presents a historical review of high temperature pressure oxidation operations and current projects in execution with a focus on the autoclave vessel design, circuit configuration, and unit sulfide oxidation capacity as a basis for characterization and comparison.

Mar 2, 2022

By T. Emery, D. Sweet, J. Bourgeois, M. Gomez, B. Seymour, J. Feiler

For traditional underhand cut-and-fill mining operations, it can be challenging to design a suitable cemented paste backfill (CPB) mix that can meet the necessary strength requirements and yet maintain its ductility. In deep underground metal mines, the CPB must achieve a high enough strength to be competent under high stress conditions while also remaining ductile enough to withstand high strain from squeezing ground as underhand mining continues under backfilled stopes. To eliminate ground falls that result in injuries and fatalities, researchers from the Spokane Mining Research Division (SMRD) of the National Institute for Occupational Safety and Health (NIOSH) have partnered with Aerix Industries, a producer of concrete additives, to study the effects of foaming agents on the strength and ductility of CPB. This laboratory study examines the impact of various amounts of foam additive on the strength and ductility of CPB mix designs, using binder and tailings provided by Hecla Limited from the Lucky Friday Mine

Mar 2, 2022

By L. Yuan, C. Brown, N. Rayyan, J. Soles, T. H. Dubaniewicz

As lithium-ion batteries (LIBs) become more prevalent in the mining industry, new hazards of battery fire and explosion are emerging. Efforts must be taken to ensure that workers are safe from these new hazards, such as batteries undergoing thermal runaway in underground areas that may have explosive methane-air mixtures. Researchers at the National Institute for Occupational Safety and Health (NIOSH) investigated overpressures generated within a sealed battery enclosure filled with an explosive methane-air mixture and a single cell lithium-ion battery driven into thermal runaway using an accelerating rate calorimeter (ARC). For both iron phosphate (LFP) and nickel manganese cobalt (NMC) lithium-ion cells, the explosion overpressures remained unchanged with varying percentages of methane concentration in the atmosphere surrounding the cell. It’s likely that the gases released from the battery undergoing thermal runaway caused an inert atmosphere within the sealed canister. The results from this study will help mining equipment manufacturers develop proper measures to keep miners safe while working with lithium-ion batteries in underground gassy mines

Mar 2, 2022

By J. Loeb, R. Ramanathan, P. Cameron

All mining operations, including iron ore, maintain a focus of continuous improvement and asset optimisation in their operations. As all the operations in the Mine-to-Mill value chain are inter-dependent, available technologies that address efficiencies across the value chain are once again in the spotlight as companies are driven to improve productivity and maximise mine site profits to increase return on capital invested. Core to continuous improvement is the need to understand the baseline and the impact of changes to the process. In this paper, we discuss some of the key attributes in the mine to mill process, including their influence on productivity and cost, the need for direct measurement and areas where they should be applied. Many initiatives can be considered to improve mine to mill processes. Mining operations are planned and executed based on designs and models to achieve the operation’s objectives. However, there are many variables in the different parts of the value chain, such as blasting, material handling, crushing and screening. Measurement of the key attributes establishes the baseline for Mine to Mill (or Pit to Plant) performance which is necessary to understand the impact of any proposed improvements to the process design and execution and to monitor the outcomes on an ongoing basis to sustain the improvements that have been implemented. We have focused this paper on two types of measurement – blast movement and particle size of materials through the mine to mill process. Several innovative technologies are already available to measure these attributes and assist operations improve productivity and mine site profits.

Mar 2, 2022

By M. Guzman, S. B. Thais, M. F. Obispo, M. R. Arribasplata

One of the greatest environmental issues related to the development of the mining activity is the generation of Acid Mine Drainage (AMD). Many methods have been developed for AMD treatment, being wetlands a good option for heavy metal removal. In this sense, the implementation of artificial wetlands for the treatment of mining effluents would seem to be an environmentally friendly alternative. In this paper, we present the results on the elimination of heavy metals (Cu, Zn, Pb and Fe) using two Peruvian native species such as Schoenoplectus californicus (C.A. Mey.) and Phragmites australis (Cav.) Trin. Ex Steud. The results show that Schoenoplectus californicus preferentially removes copper (82 and 90%), lead (88 and 92%) and iron (28 and 69%), whereas Phragmites australis removes copper (68 and 87%) and zinc (53 and 95%). Likewise, it is observed that the Schoenoplectus californicus mainly retains the ions in its root, copper (89%), zinc (84%) and iron (76%). While the Phragmites australis accumulates iron (62%) and copper (74%) in the steam and root part respectively

Mar 2, 2022

By K. Johnson, B. Schiffer

Demonstrating aquifer restoration is an essential component of regulatory approval needed to mine uranium, copper, and other minerals by in-situ recovery (ISR). A PHREEQC geochemical model provided a useful means of forecasting the time for restoration and predicting future groundwater quality following low pH mining at Strata Energy’s Ross ISR Project in northeast Wyoming. The model simulated groundwater quality at three phases of the process: at the end of mining; during restoration; and post- restoration. The model utilized the one-dimensional reactive transport and dual porosity features of PHREEQC. Mineral surface ion-exchange, dissolution/precipitation reactions, and adsorption processes were simulated to estimate water quality as the pH was shifted from circumneutral to acidic during mining and back to neutral during restoration. The model results showed that cost-effective management of mine water could meet regulatory requirements. Additionally, the model was used to interpret results from a field trial and inform operational decisions. The predictive approach and geochemical understanding developed have application in assessing aquifer restoration for other ISR projects.

Mar 2, 2022

By R. Yang

This paper presents a kinematic approach for blast modeling with examples of blast models that were developed previously. A kinematic approach was applied successfully in developing blasting models that can simulate all blast design parameters for field applications. Several applied blasting models have been developed and applied widely in the world. A kinematic approach to blast modeling refers to using measurements of kinematic quantities such as the velocity, strain, or displacement and well-established assumptions to model blasting phenomena, rather than being restricted to use first principal of physics, such as, the stress- and material-constitutive relations. The kinematic quantities are easy to measure in the field. Due to the complexity and inhomogeneity of rock mass properties, using first principles of physics, many parameters of rock and explosive properties must be involved, which are hard or impossible to quantify. This creates a major impediment when trying to simulate the total process of blasting based upon first principles of physics. The 3D kinematic model for muckpile formation was developed and applied to open pit blasts. The multiple blasthole fragmentation model developed during recent years has been applied successfully to many mine sites around the globe. These models are typical examples of blast modeling using the kinematic approach, which enables the models to catch major trends of the blasting process and explicitly simulate full blast design parameters and complex geometries. Blast modeling using the kinematic approach results in easy model calibration and validation against field measurements and effective applications to practical problems. Using kinematic models of the muckpile formation and the multiple blasthole fragmentation model, this paper demonstrates the merits of the kinematic approach for blast modeling. New developments of the models were also presented in the paper, which illustrate the potential of the kinematic modelling approach.

Mar 2, 2022

By S. K. Palm

The commercial life of a mineral product can be long, but like hitech electronic and software products that soar in sales one day to become obsolete and forgotten a few months or years, mineral products have a life cycle. They are invented, commercialized and eventually decline and disappear from commerce. Diatomite and perlite are produced from mined minerals, but almost none of the products in these industries spring from the earth in finished form. Straight calcined diatomite was invented over 100 years ago and flux calcined diatomite just a few years later. The expansion properties of perlite were discovered and first exploited about 75 years ago. Some applications for diatomite have disappeared or currently face competition from newer products. Dry cleaning was once the second-largest application for diatomite but disappeared over 30 years ago. Both the beer and wine filtration markets for diatomite face increased competition from membrane filters. A pipeline of new, proprietary products is critical to the future of the industry.

Mar 2, 2022

By S. Makni, F. Wang, A. Rosa, B. Klein, C. Saud, R. McIvor, A. Kumar, C. Gagnon, D. Gong

In response to the Natural Resources Canada “Crush It Challenge”, Corem partnered with the University of British Columbia and led a project to develop and demonstrate the use of high-pressure grinding to replace the workhorse of the industry, wet ball milling, with high-pressure grinding. Two plant case studies, a small tonnage gold recovery operation, and a large tonnage copper recovery operation, were carried out. Plant circuit performances were compared to pilot plants operated on the same circuit feed set up to represent the novel equipment and flowsheet that was developed to produce separation circuit feed. Numerous obstacles to industrial implementation of highpressure grinding in this role which were recognized at the outset of the work were successfully addressed. In both cases, comminution equipment energy savings alone, and final stage total circuit energy savings, exceeded 60% and 50%, respectively. Downstream mineral separation performance was the same or better.

Mar 2, 2022

By J. Kretschmann, T. Rudolph, L. Michael, P. Goerke-Mallet

The mining value chain plays an important role in our societal development. Even in a circular economy, mining and raw materials are in great demand, and so are skilled engineers. In Germany, many students decide to pursue STEM studies in the tertiary degree. Nevertheless, the OECD reports low completion rates in obtaining the degree of studies [1]. Generally, the dropout rates in STEM education are high [2]. Many students have difficulties with basic subjects such as science and mathematics, in which they lack knowledge they should have acquired in school [2]. With the German STE(A)M project PepperMINT (https://peppermint.thga.de/), the Technische Hochschule Georg Agricola (THGA) offers a digital and open educational platform, as a dynamic, massive open, online course (MOOC) for students and prospective engineers. The project is funded by the RAG-Stiftung (RAG-Foundation; No. 20-0004). Using adaptable MOOC classes and applied examples from the wide-ranging cycle of mining activities, we motivate students to engage in STEM studies. Our adaptive and application-oriented content demonstrates the diversity of jobs and career paths in the mining industry. The integrations of applied examples and research activities of the Technische Hochschule Georg Agricola can increase the curiosity and motivation of learners. In mathematics, mine-surveiying technologies and geomonitoring methods (see figure 1) can be used to teach trigonometry. Additionally the concept of the free open online classes enables students in high school to get insights into the field of engineering before they decide the subject of their studies. For freshmen who already decided to pursue a STEM degree, the PepperMINT courses can help to identify and close knowledge gaps and to align different levels of knowledge within a heterogeneous student body. Empowering students in STEM education and integrating examples from mining research can help us train the mining engineers of the future.

Mar 2, 2022

By M. B. Haggerty, R. J. Sheets, F. Abbasy

To address coal refuse tailings storage needs for a mine operation in western Canada, a feasible solution was to convert excavated open pits into tailings cells. A slope stability investigation and design study were completed to determine the necessary width and slope geometry for in-situ native plugs as the impoundment embankment. The native plugs separate the previous open pit from the current active open pit. This configuration allows for the deposition of refuse tailings in the previous pit while allowing mining to safely continue “downstream” of the temporary impoundment. As mining progresses, each subsequent pit will be filled with refuse tailings; thereby, buttressing the upstream slope of the previous native plug. Although these cells are excavated, and the timeframe for downstream exposure is relatively limited, the native plugs are classified as dams and must be designed to meet applicable safety of dam standards since they impound water and tails above mining personnel in the subsequent open pit. The presentation and paper will discuss the investigation and analysis conducted to develop the geotechnical and hydrogeological design recommendations.

Mar 2, 2022

By W. A. Mathews

We report on the progress of an automated mineralogical deportment of fluorine (F) in two portions of the Grasberg District for the development of metallurgical amelioration protocols for Cu sulfide concentrates. Fluorine detection limits in automated SEM technologies range from 1% (TIMA) to about 9% (QEMSCAN), however substitution in hydrophobic minerals or those reporting to concentrate is typically much lower (

Mar 2, 2022

By B. H. Kim, S. J. Schatzel, K. M. Ajayi, G. S. Esterhuizen, D. W. H. Su, Z. Khademian

The stability of shale gas wells drilled through current and future coal reserves can be compromised by ground deformations due to nearby longwall mining. Depending on the longwall-induced rockmass permeability, the high-pressure explosive gas from the damaged well may reach mine workings and overwhelm the mine ventilation systems. This study uses geomechanical models to estimate the rockmass permeability induced by mining. A two-panel longwall model of a deep, 341-m-cover mining site in southwestern Pennsylvania is constructed in 3DEC to explicitly model the rockmass by a Discrete Fracture Network (DFN) technique. Stress-induced fracture apertures and permeabilities are calculated across the model and are validated against permeability measurements. A Fracture Flow Code (FFC) is developed to use these results to predict potential inflow to the mine should a gas well breach occur. One hundred DFN realizations are simulated, and the results show that for a gas pressure of 2.4 MPa, the average of the predicted inflow rates to this deep-cover mine is 0.03 m3 /s, significantly lower than the average inflow of 0.92 m3 /s for a shallow-cover mine (145 m deep) studied in the previous work (Khademian, et al. 2021). The result can help assess the potential hazards of a shale gas well breach for mine safety and evaluate the ventilation requirements to mitigate the risk

Mar 2, 2022

By C. R. DeGennaro, M. R. Girman, J. Bickson, J. P. Homer, C. C. Jobes

Between 2005 and 2021, a NIOSH internal review showed that haul trucks were involved in 54 incidents at surface mines in the United States. Haul truck collision warning and avoidance systems (CXS) can assist in preventing accidents at surface mines. CXS use technologies to detect people or objects and alarm to alert haul truck operators. Robust testing can help ensure that they detect objects without excessive false positive alarms. Testing and validation would increase confidence in and encourage implementation of a CXS. Researchers from the National Institute for Occupational Safety and Health (NIOSH) reviewed documents related to the evaluation and validation of CXS with two objectives: (1) to identify methods and parameters used to evaluate detection performance and (2) to identify gaps in CXS test methods and in detection performance. Stakeholders can use the findings from this research to guide implementation of CXS to improve safety at surface mines.

Mar 2, 2022