Search Documents

By Jim Salley, Mohammad Saleem, Indra Banerjee, Kevin Sapp

"On underground construction projects, effective Quality Management is essential for ensuring facility durability, life cycle performance and low maintainability. Furthermore, follow on contracts also rely on an effective quality management system for interface congruency. An effective Quality Management System (QMS) is also essential in mitigating risks and meeting schedule and budget performance objectives. For the past 15 years Central Puget Sound Regional Transit Authority’s Link Light Rail extension has successfully completed over 10 miles of twin bore tunneling and associated underground features including cross passages, deep sump structures and shafts. After the completion of each segment, lessons learned have successfully been implemented to improve the quality of delivered projects. This paper presents the Sound Transit QMS with regard to a number of project elements of tunnel construction projects, with specific focus on quality performance of slurry wall construction, TBM tunnel excavation assessment, segment production and segmental lining installation, and other associated construction features. A collaborated total QMS will be presented in this paper that will serve as a guide for successful implementation of Quality Assurance and Quality Control processes. INTRODUCTION Implementation of a robust Quality Management System reduces defects, errors and omissions, identifies and addresses nonconformance in a timely manner and increases stakeholder confidence in the project. In fact and effective QMS helps ensure that optimal project outcomes are realized both in terms of project delivery and life cycle performance. The two key components of QMS are quality control and quality assurance. Quality Control (QC) is the procedure implemented to achieve a certain level of quality and ensure that products, processes and services meet specific requirements. Quality Assurance (QA) activities are carried out to evaluate the effectiveness of the quality control measures and ensure that the QC process is working. A team obligation that recognizes that quality is built into every aspect of a project is the basic concept of a successful QMS."

Jan 1, 2016

By V. ?. Chanturiya, G. P. Dvoychenkova, ?. Ye. Kovalchuk

"Several mineralogical investigations have revealed the composition of modified kimberlites and the mud generated during treatment of diamonds, which contains up to 50% clay minerals (e.g., talc, talcsaponite, chlorite-saponite, Na-saponite) and X-ray amorphous phase. We investigated the composition of the natural diamond surface in relation to the diagnosed minerals and established the sequence and conditions for mineral formation on the crystal surface under kimberlite processing conditions. This article suggests a method to destroy and further dissolve minerals on the crystal surfaces using water system electrolysis products, which makes it possible to restore the diamond hydrophobic properties. The application of chemically treated water in the foam separation cycle under the conditions of high recovery of diamonds made it possible to increase the content of the factory concentrate by 8.0%.INTRODUCTIONThe high content of the modified minerals in the kimberlite ore results in the formation of hydrophilic slicks on the surface of the crystals which decreases the diamond’s hydrophobic properties and increases the losses thereof in the process of grease and foam separation to 20-30% (Kurenkov, 1957; Chanturiya et al., 1998, 1999, 2005; Duikarev et al., 2000).The previous researches have revealed the fact that the prospective way of solving the problem of intensity of mineral impurities formation on the surface of the crystals and the increase of concentration parameters is reached due to application of physical and chemical stimulation techniques on the solid and liquid pulp (Stricland-Constable, 1971; “Improvement of the technology…”, 2006; Makarskii, Adodin & Tarasova, 2011; Chanturiya, Dvoychenkova & Trofimova, 2012). However, the main task of investigations to stipulate the objective achievement is the studying and justification of the reasons of the diamond surfaces covering by the mineral slicks"

Jan 1, 2016

By John Greenhalgh, Benoit De Rivaz

"1.INTRODUCTIONThis paper is based on the Lee Tunnel project, which is part of the Thames Water’s Tideway Project.The client Thames Water has employed a Joint Venture of Morgan Sindall/Vinci Grand Projets and Bachy Soletanche to undertake the design and construction of the project under the management of CH2M Hill at a value in excess of £635 million ($990 million). The 3 main elements of the tunnel project are the permanent lining to the shafts, the precast segmental lining, and the secondary tunnel lining. All 3 are reinforced with different types of Dramix steel wire fibers and each element will be described in this paper. This paper will explain the basic structural design of FRC (Fiber reinforced concrete) based on the post cracking residual strength and will describe all the steps of this project, the testing program realized to support innovative design and the main technical learning point. 2.BASIC CONCEPT OF STRUCTURAL DESIGN OF FRCStructural design of FRC elements is based on the post-cracking residual strength provided by fiberreinforcement. Other cases, like early age crack-control or fire resistance, are considered non-structural use of FRC. For structural use, a minimum mechanical performance of FRC must be guaranteed. Fibers can be used to improve the behavior at SLS (Service Limit State) since they can reduce crack spacing and crack width, thereby improving durability and they can be used to improve the behavior at ULS (Ultimate Limit State) where they can partially or totally substitute conventional reinforcement in most conditions. In the design process, the definition of the performance expected from the material is a key factor and the mix-design of the material has to be optimized for the required structural performance.2.1 Testing Method In order to ascertain the structural requirements requested for the FRC segments, preliminary testing on samples will be required and the effectiveness of the proposed solution will also be assured by the testing of full scale specimens. Structural design of FRC elements is based on the post-cracking residual strength provided by fiber reinforcement. For structural use, a minimum mechanical performance of FRC must be guaranteed. Nominal values of the material properties can be determined by performing a 3-point bending test on a notched beam according to EN14651 (figure 1) or by performing the ASTM C1609 beam test:"

Jan 1, 2016

By D. F. Doerr, E. Blalock, D. R. Bush, K. D. Cohen

"INTRODUCTION The design, development, fabrication, and test of cryogenic breathing apparatus is part of a much larger effort funded by the National Institute for Occupational Safety and Health (NIOSH) and managed through a Space Act Agreement with the National Aeronautics and Space Administration (NASA) at the Kennedy Space Center (KSC) in Florida. This effort is designed to create cryogenically based life support equipment that is responsive to the needs of miners as required by the Miner Act of 2006. Our goal was to design and build a liquid air based self-contained breathing apparatus (SCBA) that lasted 2 hours and would be used for the egress of miners during a mining accident and be refillable while worn. Therefore, the current report describes tests of an Advanced Cryogenic Breathing Apparatus (termed the ACryoBA) designed to provide miners egressing an emergency situation with a two-hour open-circuit SCBA. The ACryoBA utilizes low pressure cryogenic liquid air instead of high pressure compressed air commonly used in most commercially available SCBA. The ACryoBA can also be self-filled from strategically placed Cryogenic Air Supply and Fill Stations (CryoASFS) initially, and thereafter on the egress route approximately every 1 hour and 30 minutes with a 30 minute air reserve. The ACryoBA evolved originally from a one hour Liquid Air Pack (LAP) developed in the 1980’s for Space Shuttle Rescue forces allowing for longer duration and cool air (Figure 1). It was used successfully for many years, through the end of the Space Shuttle Program. The first attempt at a mine egress pack was the Cryogenic Breathing Apparatus (Figure 2). It was to have a low profile, two hours of breathing, attitude independence, and a simple rapid refill while in use. The CryoBA met the two hour criteria, but with difficulty due to excessive heat leakage caused by the dual 4 liter Dewar design. Much of the stored air was lost as it vaporized faster than it could be used. However, the pack was successful in demonstrating both attitude independence and a simple rapid refill capability. The ACryoBA project was designed to continue the progression and address the deficiencies in the CryoBA. The ACryoBA pack was designed to last 2 hours. It minimizes the heat leakage with a single Dewar and thereby requires less liquid air. The single Dewar design also minimizes weight, making it much more manageable by the user (Figure 3). The ACryoBA complies with 42 CFR part 84 NIOSH certification test requirements. One critical requirement for the ACryoBA is operation in positions other than vertical for periods up to 1/4 (i.e. 30 minutes) of the rated service life of 2 hours; this was accomplished by use of new technology called the “attitude independent pickup” which is abbreviated “AIP.” The AIP, developed by BCS Life Support LLC (patent #8,899,226), has a tube going from the top flange down through the center of the Dewar. At the end it has a flexible bellows and a weighted end. Due to the flexible nature of the bellows, the pickup at the end is free to rotate and follow the liquid level around within +/- 90o of vertical."

Jan 1, 2016

By L. Widdifield, R. Riggle

"In today’s challenging mining environment the “Big Picture” (Caterpillar, 2013) approach to mining is often neglected. With haulage costs approaching up to 45 % of the overall mining costs, all too often the load-haul-dump- return cycle is not investigated in its completeness. This paper will discuss the aspects of taking the time to observe an operation from the “Big Picture” approach. In today’s mining business miners, engineers, trainers, supervisors, and managers have ever increasing roles and responsibilities as never seen before in the past decade. The endless human resource, safety, environmental, cost control issues and performance initiatives, detracts from precious time that may have been dedicated to examining the day to day operation. Having examined numerous mining operations over the past several years, one common denominator is lack of time to properly observe operating practices in the field and recognize both positive and negative observations. The old fashioned vocation of observing the operation to assess the haulage, loading and maintenance processes to adjust, maximize or enhance operations have sometimes vanished. Four areas to be discussed in this paper: (1) Look at the “Big Picture”(Caterpillar, 2013), (2) Use common sense, (3) Areas identified for biggest improvements in the operations, (4) Observation of small details for big impacts to lower cost per ton and increased production. The objective of this paper is to provide low cost recommendations to lower cost per ton and increase production. INTRODUCTION Whether miners claim to have been around and experienced it all or the “rookie” on the mine site, miners are expected to execute the mine plan at the lowest cost possible. So why is it so difficult to execute this task? Shouldn’t supervisors just have to man the equipment, tell operators to have a safe day and tally up the numbers at the end of the shift? And let the technology system do the rest? So what could go wrong? Lots. Mining companies seek help from consultants, training departments, performance reporting systems and an arsenal of resources. Armed with all this information, the supervisors just hop in the pick-up and tell the shovel operator to speed up. Sounds simple enough. When the improvements don’t happen, what could have gone wrong? It comes down to people, the simple things that were not executed over the months previously and as a result today the mines performance is not where it should be. A mine is built by people. Managers who have the vision to develop the ore body in a manner that follows sound engineering practices. The infrastructure to mill the ore and support the equipment needed to move the material. Along the way equipment is procured and operators trained to run the gear. Engineers and geologists set up the design, the material movement, and haulage routes. Sounds easy to this point. So, why mine after mine is there this constant struggle to move more with less and get the costs down? Understanding how to make “Great Miners” out of these people is critical to lowering your cost per ton."

Jan 1, 2016

By P. Sebola, S. Rasmeni, K. Seripe, D. Chetty

"South Africa’s Northern Cape Province hosts semi-precious and gemstone occurrences that are sporadically mined on a small scale by local communities. Tiger’s eye, a gemstone known for its chatoyancy properties, is found in important deposits located near the town of Prieska, where is it intermittently mined. Challenges faced by small-scale and informal mining include mining without proper permits, risky mining practice in dangerous terrain, and illegal export of raw material without concerted effort at domestic beneficiation. As part of a study aimed at job creation and social upliftment in the region, tiger’s eye deposits in the Prieska area were assessed to assist small-scale miners to understand tiger’s eye grades and their distribution. This will allow not only more efficient and safer mining of these deposits, but also beneficiation of the raw product into tumbled stones, cabochons, jewellery, and other small artefacts for sale. A hub established in Prieska by Mintek trains locals in the beneficiation of tiger’s eye. Supply to the hub must make use of a consistent grading system, which is discussed in this paper. Together with proper mine licensing, such an approach will develop mining and beneficiation skills, and create and sustain employment for the local community. IntroductionTiger’s eye is a semi-precious stone known for its chatoyancy property, which is caused by parallel, silicified asbestos fibres that impart a silky lustre to specimens. Deposits of tiger’s eye in the surrounds of the town of Prieska, Northern Cape Province, formed the focus of a study aimed at small-scale mining and beneficiation of this commodity. The Prieska tiger’s eye deposits are located along the N10 route to Upington (Figure 1). Tiger’s eye is unevenly distributed and occurs as lenses of various sizes, interbedded in gently folded metasedimentary rocks of mostly banded iron formation (BIF). The tiger’s eye occurrence in the Northern Cape Province, especially in the Prieska area, has not been extensively researched. There is thus limited information available in the public domain. The lack of knowledge on tiger’s eye distribution has resulted in local small-scale miners adopting a trial-and-error method of mining. Basic geological mapping and field evaluation of the deposit, coupled with professional judgement, are important aspects of any small-scale mining operation and can contribute significantly to the formulation of various acceptable and equally viable mining methods and practices."

Jan 1, 2016

By D. Ibarra, J. Jacob, A. G. Guezennec, P. d’Hugues, A. Archane

The lack of adequate gas mass transfer is a rate limiting step in many bacterial leaching processes. Oxygen often becomes a limiting factor because of its low solubility compared to the high demand induced by sulfide oxidation. One way of increasing the solubility of oxygen in water or in media solution is by increasing the driving force, i.e. raising the oxygen partial pressure in the gas stream supplied to the leach pulp. The use of oxygen is a well-known practice in high-temperature bioleaching reactors (above 70°C) whereas air is usually preferred in medium and low-temperature operations in order to avoid too high dissolved oxygen concentrations which could impact negatively the bacterial activity. The purpose of this study was to investigate the use of oxygen-enriched gas in bioleaching reactors at 40°C in order to improve the gas transfer in the system when operating at high solid load (20% and more). Bioleaching experiments were performed on a sulfide-rich tailing waste (pyrite 60%, copper 0.8%, cobalt 0.06 %, gold 1 g/t) using the “BRGM-KCC” bacterial consortia. The reactor used for the tests was designed on the basis of a new bioleaching reactor concept developed by Air Liquide, Milton Roy Mixing and the BRGM which uses floating agitators to inject gases and to mix and to suspend solids in the bioleaching solution. Two types of tests were carried out: with air injection and with oxygen enriched gas mix injection. The aim of this work was to confirm the capacity of bacteria to grow and to dissolve pyrite in this type of bioreactors in oxygenrich atmosphere, and to compare sulfides dissolution rates during both types of bioleaching tests. The results obtained show that the use of oxygen enriched gas mix does not decrease bioleaching performances compared to air injection. High metal extraction yields were achieved (above 80%). No deleterious effect due to oxygen use was observed on the bacteria despite the high level of dissolved oxygen reached in oxygen tests (up to 14 mg.L-1).

Jan 1, 2016

By Thomas L. Barkley

"In early 2015 the Seed Waveform method was used to measure the Geologic response of the MesabiIron Formation to explosives energy input. This single charge wave form was then used to design acritical first blast at a newly developed Taconite mine. This initial blast had several irregular restrictions on design and performance. It had a very unusual “Frying Pan” shape, the regulatory agency required that no fly rock land in State owned waters less than 200 feet (61 m) away, there was no open face to blast to. Design criteria included the need to detonate the blast with two sinking cuts, and have the sinking cuts meet through a narrow neck between the cuts. All these had to be met using a 16 inch (406mm) diameter hole."

Jan 1, 2016

By B. K. Gorain

"The Air-Metabisulfite (AMBS) process has been developed to treat complex copper, molybdenum and precious metals (gold, silver) bearing ores using brackish and sea water. This process was able to produce significantly better copper concentrate grades and higher recovery than possible using conventional lime and/or cyanide based processes for certain complex ores with high sulphide gangue minerals. The AMBS technology in now used commercially following a rigorous evaluation process emanating from laboratory curiosity to plant applications. In addition, many projects have embraced this technology at a feasibility level involving various complex ore bodies.This paper presents a summary of the findings from testing the AMBS technology on various ores types. Experiences gained from this successful development from bench to piloting and then to plant applications are also presented in this paper.INTRODUCTIONProcessing of sulphide copper, molybdenum and precious metal ores typically involves flotation of copper bearing minerals while depressing non-sulphide and other non-copper sulphide minerals such as pyrite, pyrrhotite and sometimes arsenopyrite. Though in many precious metal ores, the values are in these sulphide minerals as well. The conventional method employed in the industry to produce a saleable copper concentrate requires depression of these non-copper sulphide minerals using an alkaline pH above 9.5, though 10.5 to 11.5 is more common. Alkalinity is controlled by the addition of a pH modifier. Lime is normally employed as a pH modifier due to its relatively low cost; however, the costs associated with adding lime can be significant and the effectiveness of lime as a depressant could be drastically reduced when the process water supplied to the flotation circuit contains high level of dissolved salts. In some cases, a small amount of cyanide is used along with lime to depress non-copper sulphide minerals especially when its proportion to copper sulphide minerals in the ore is higher than three."

Jan 1, 2016

"Controlling dust generation and keeping it below permissible limits at the working face of a room and pillar mine is a challenge for mine operators. With the recent changes in the respirable-dust regulation, it has become increasingly difficult. The current most effective practice of dust control at a continuous miner face in an underground mine is the use of a flooded-bed scrubber. A study carried out by the National Institute for Occupational Safety and Health (NIOSH) stated that a flooded-bed scrubber, under its optimum condition, can achieve cleaning efficiencies between 58 and 90 percent. The performance of such a system can be maintenance intensive. Other industries face similar dust control issues. The University of Kentucky partnered with Toyota Motor Manufacturing for the development of a novel wet scrubber for capturing paint overspray, with capture efficiencies in excess of 98 percent and minimal maintenance. The aim of this study is to assess the ability of this novel wet scrubber to capture respirable dust in an underground coal mine. This paper presents the conceptual design and the computational fluid dynamics (CFD) modeling of this novel wet scrubber. It discusses the results of the CFD simulation performed on the novel wet dust scrubber. INTRODUCTION Dust generation from underground coal mining is an inescapable phenomenon. No matter the practices employed, it inevitably occurs. Elevated concentrations of coal dust are potential health and safety hazards. Although dust in an underground coal mine cannot be completely avoided, its influence can be mitigated through good engineering practices. The effect of dust on the health of mining personnel has had a significant impact. The prolonged exposure of airborne respirable dust (< 5 µm) can cause coal workers’ pneumoconiosis (CWP), silicosis, emphysema, and chronic bronchitis, collectively known as black lung (U.S. Department of Labor, 2014). According to the National Institute for Occupational Safety and Health, black lung has killed more than 10,000 miners between 1995 and 2004 (NIOSH, 2008). In addition to being a health issue, coal dust is also a safety issue to the underground coal miners. The generated dust, if not captured, is dispersed into the mine air through the ventilating air and deposited downwind on the return entries’ surfaces. In the event of a methane explosion, the coal dust, if insufficiently diluted with rock dust, triggers a coal dust explosion which is much more severe than a methane explosion and causes more damage (Kenneth et al, 2006). The Jim Walters No. 5 Mine and the Upper Big Branch Mine disasters which together killed 42 people and resulted in damage worth millions of dollars in property are the examples of coal dust explosions (U.S. Department of Labor, 2001 & 2010)."

Jan 1, 2016

By D. Michaud, C. Bazin, S. Lévesque, L. Pérez-Barnuevo, H. Longuepée

In recent years, with the emergence of Geometallurgy, a great effort has been made to characterize ore resources as early and accurately as possible, to allow better design and a more efficient operation of mineral processing circuits. In this context, core logging plays an important role, since drill cores provide the first insight into the ore characteristics. However, to satisfy geometallurgical requirements, traditional core logging does not suffice. New tools and methodologies need to be developed for the automation of core logging and the acquisition of mineralogical data better related to mineral processing performances. In this paper, a methodology for the geometallurgical characterization of drill cores is proposed, based on the drill core textural patterns. Textural pattern is defined here as the macroscopic spatial arrangement of minerals. The Mont-Wright iron ore deposit (Quebec, Canada) is used as a case study. The first part of this work aimed at analyzing the potential link between the iron ores textural patterns observed in drill cores and their response to ore processing, namely comminution and concentration. Preliminary results show similar performances in terms of energy consumption and heavy liquid separation for samples showing the same textural pattern. In the second part, this work seeks to develop a methodology for the automated identification of drill core textural patterns by the application of digital image analysis and discriminant function analysis. The results obtained show that this methodology is able to discriminate between the textural patterns identified at Mont-Wright with a good rate of success. Therefore, this work lays the foundation for the development of a new drill core characterization tool, which would allow for the early prediction of the iron ore behaviour during mineral processing through the identification of drill core textural patterns.

Jan 1, 2016

By Karel Rössler, Petr Vítek

"The Ejpovice tunnels in Czech Republic were built by EPBM in soft Clyashale, and in weathered profile with low soil overburden. The segmented liner at the cross-passage openings required support, which would not interfere with the EPBM clearance envelope during the scheduled pull back of the EPBM through both tunnel tubes. For that reason support frames or radial bolting could not be used. Steel rods inserted into the neighboring segments during the ring assembly, and later grouted were tested and realized as an innovative solution. The paper presents practical experience gained with the segmented liner support during cross-passages construction. INTRODUCTION An innovative solution using the grouted dowels was developed and realized for sixteen cross-passage openings of the twin Ejpovice Tunnels, whose construction was part of the railway track Rokycany – Plzen modernization. The following paper described practical experience gained with the innovative support of cross-passage openings, which was realized by short steel dowels grouted within the segments of the EPBM segmented liner. The paper is a continuation of the paper published in WTC 2015, which described the design aspects of the grouted dowels support, while the following paper concentrated on the production, and the performance of the dowel support observed during the breakout for the cross-passages openings. The connection by grouted dowels was patented by Metrostav, a.s. Company THE EJPOVICE TUNNELS CONSTRUCTION The Ejpovice tunnels construction started in 2013. The start of the high speed train operation through the tunnels was planned for 2018. The project was funded by the state government with the support of European Union funds of up to 70%.The tunnels were excavated with one EPBM (Earth Pressure Balanced Machine) with the external diameter of 9.89 m. The segmental liner inner diameter was 8.7 m, and thickness of 0.4 m. First, the South tunnel tube was excavated from the East portal, then the EPBM was pulled back through the South tunnel, and the excavation was started from the same portal for the North tube. After the South tube was freed from the EPBM excavation operations the cross-passage construction started. Due to the short time schedule, in the North tube the cross-passage construction started while the tunnel was still under construction. Therefore, the cross-passage construction was performed concurrently with the segments transportation, and with the EPBM pull-back through the tunnel. There were 8 cross-passages along the tunnels with a maximum distance of about 500 m, Fig.1."

Jan 1, 2016

By Z. Sample

"INTRODUCTION This past year commodity prices continued their dip with increased volatility causing market values to slide another 16% putting increased pressure on even the largest companies to improve their free cash flow.[1] Without a recovery in commodity prices in sight, companies must find a sustainable method to improve returns in the current economic climate. In an effort to improve plant sustainability, the mineral processing industry is investing in advanced automation technologies and innovative processing methods that are both more reliable and more efficient than ever before. One such breakthrough technology is Heap Leaching (HL). This method of extraction has certain advantages over traditional metallurgical methods making previously unsustainable operations economically feasible. While HL is already seeing use in the gold and copper industries among others, recent developments may allow for the use of HL to process primary sulfide ores which make up about 80% of today’s ores.[2] For this reason, this emerging technology is poised for exciting growth. Unfortunately, as with any process change, the implementation of HL projects requires significant training on both the control system as well as the underlying process, and further, due to the complex nature of the HL process, this can be a particularly difficult task. DEMOGRAPHIC TIME BOMB Even before the implementation of these new technologies, the availability of the skilled workforce has already become a significant problem for the mining and mineral processing industries. From a survey of 912 mining professionals, Stratum International found that a mere 0.4% of senior level candidates were between the ages of 25 and 34 and a similar proportion aged over 75 years.[3] This indicates that there is both a deficiency of young skilled workers and a skilled workforce that is retiring earlier than the previous generation. Combined with data published by the US Department of Labor stating that the median age of the mining workforce is approaching 50 years old, research suggests that up to 50% of skilled mining and mineral process professionals are expected to retire in the next 5 years, leaving with their irreplaceable knowledge and experience.[4] While it is projected that the labor pool will be sufficient to fill open positions, the real question is if this young workforce will have necessary skill sets and experiences. In addition to a rapidly aging workforce and an inexperienced labor pool, a study done by the Oil and Gas Journal showed that it takes about 7 years, on average, for new workers to achieve a level of competency that permits them to assess risks and appropriately make decisions.[5] Not only is this figure is in direct conflict with the typical tenure of 5 years in one position meaning that the thinly spread skilled labor will be required to become senior staff before they are able to achieve competency in their current role, this also means that these millennials are not given the opportunity to become competent in their role before the retirement of the more experienced workforce."

Jan 1, 2016

By A. Jolly, A. R. Kumar, T. Novak

"Coal dust in an underground mining environment has always been a health and safety issue, especially with longwall faces. Efforts to integrate a flooded bed scrubber within a longwall shearer are underway at the University of Kentucky (UK) in order to reduce worker exposure. Small scale physical modeling, along with numerical modeling and full-scale experimentation, are engineering tools being used by the authors for simulating operating conditions underground. Recent advances in affordable 3D printers offer a means for fabricating accurate, scale models for obtaining timely insights prior to building large, expensive test setups. Comparing scale-model results with those of numerical modeling, such as computational fluid dynamics (CFD), lends guidance and confidence in a proposed design. This paper discusses the small scale physical modeling of a longwall shearer with an incorporated flooded-bed dust scrubber in its operating environment. A tracer gas was used in the model in lieu of dust to measure dust-capture efficiency. Results obtained from the physical model are presented and compared with those of CFD model. The small scale model and the CFD results demonstrate good agreement. Dust capture results show the usefulness of the approach in advance of actual design implementation. INTRODUCTION Dust generation is an undesirable, but innate, byproduct of all mining processes. It is particularly problematic in underground coal mining, where coal dust poses potential hazards from two fronts – health and safety. Coal workers’ pneumoconiosis (CWP), commonly referred to as black lung, is a chronic lung disease that results from the long-term overexposure to respirable coal dust. Although the prevalence of CWP has steadily and significantly declined over the three decades following the Federal Coal Mine Health and Safety Act of 1969, a study by the National Institute for Occupational Safety and Health (NIOSH, 2008) indicates that significant health hazards associated with respirable dust still exist within the coal mining industry. In addition to being a health hazard, coal dust can also create a potentially catastrophic safety hazard. Dust that is not captured or removed at its source is suspended and transported throughout a mine by the ventilation airstream. This float dust is subsequently deposited on all mine surfaces along its travel path. Without adequate application of rock dust to these surfaces, forces from a localized methane ignition can reintroduce settled coal dust into the airstream creating an explosive mixture. Therefore, capturing and removing coal dust at its source mitigates the probability of two major hazards that continue to plague the mining industry."

Jan 1, 2016

By D. K. Sarkar, J. Perron, J. D. Brassard

"Nearly perfect spherical shaped water drops rolling-off from the surface of lotus leaf is one of the beauties of nature. This kind of surface is called superhydrophobic, since the water does not like it. Physically, a superhydrophobic surface provides a contact angle (CA) of water over 150°. The combinations of both mico-nanostructure topography as well as low surface energy are essential to have such high CA on a surface. Nano-micro structured superhydrophobic surfaces have been developed in different methods. (i) Monodispersed fluorinated silica nanoparticles have been synthetized via Stöber Sol-Gel process and deposited on various surfaces, such as aluminium or glass, to obtain transparent superhydrophobic thin films. (ii) Similarly, zinc stearate nanocomposite coating has been fabricated by spray process on the same substrates. These thin films are found mechanically robust with drag reduction of coefficient 16% lower than as-received surfaces. (iii) By electrodepositing pure zinc on steel surfaces and further coating it with diluted room-temperature vulcanized silicone rubber, the surface become superhydrophobic. This superhydrophobic surface protects the steel against corrosion by increasing the polarization resistance from 1.5 k? on steel to 44.4 k?. This coating also reduced the ice adhesion on the steel surface 6.3 times as compared to bare steel substrates. Globally, these superhydrophobic surfaces have tremendous applications against corrosion reductions, drag reductions and ice adhesion reductions.INTRODUCTIONSuperhydrophobic coatings are increasingly attractive to the industry and academia due to their unique self-cleaning properties as a result of their water repelling characteristics. Fabrication of superhydrophobic coating is an inspiration from nature as water is seen to repel on many natural surfaces such as those of the lotus leaves, butterfly wings, water striders’ legs, and so on (Gao & Jiang, 2004; J. Huang, Wang & Wang, 2006; Neinhuis & Barthlott, 1997; Zheng, Gao & Jiang, 2007). This non-wetting phenomenon is well understood on lotus leaves, shown on the Figure 1 (a), and it is considered as the basis of the studies of superhydrophobicity. The existence of this binary structure on the surface of the lotus leaves allows a large amount of air entrapment and consequently reduces the contact area of water on it and the presence of low surface energy waxy components with reduced affinity to water together leads to the superhydrophobic properties. The phenomenon is shown on Figure 1 (b). Cassie and Baxter (Cassie & Baxter, 1944) as well as Wenzel (Wenzel, 1936) proposed two mathematical models to explain the wetting phenomena on rough surfaces that leads to superhydrophobic properties. By definition, superhydrophobic surfaces are characterized by a water contact angle value = 150° with the rolling off of water drops from the surfaces (Sarkar & Saleema, 2010). Superhydrophobic surfaces find tremendous importance in the technological world where it can applied in domains such as anti-corrosion, anti-biofouling, electrowetting, icephobic and even in drag reductions (Bushnell & Moore, 1991; Cao, Jones, Sikka, Wu & Gao, 2009; Carlborg & van der Wijngaart, 2010; Carré & Mittal, 2009; Y. Huang, Sarkar & Chen, 2010a; R. Karmouch, Coude, Abel & Ross, 2009). However, the most important challenge faced by industries is their feasibility large scale in an effective an economical manner."

Jan 1, 2016

By Douglas Tesarik, Mark K. Larson, Habte Abraham, Heather E. Lawson

Dynamic failures, or "bumps", remain an imperative safety concern in underground coal mining, despite significant advancements in engineering controls. While many factors have been empirically linked to the occurrence of dynamic failure events, identifying a consistent, repeatable set of criteria within a field setting has proven elusive; conditions generally associated with dynamic failure might produce an event at one site, but not another. Conversely and more troubling, dynamic failure could occur where relatively few of these factors exist. The presence of spatially discrete, stiff roof units, such as paleo channels, are one such feature that has been linked to the occurrence of dynamic failure events. However, an empirical stratigraphic review investigating the relative frequency of discrete units in bumping versus non-bumping deposits indicates that no significant difference exists based on this criterion alone, and that instead an apparent relationship exists between reportable bump history and the overall character of the host rock with respect to stiffness. Due to the complexity of the bump problem, however, these results are not conclusive, as they do not take into account any variable other than the presence or absence of stiff members in the roof lithology; To weight the relative impact of changes in a single variable, such as the thickness or location of sandstone members, it must be examined in isolation-i.e. in a setting where all other variables are held constant. Numerical modelling provides this setting, and the effects of variability in a stiff discrete member in a hypothetical longwall mining scenario are investigated within the context of three stratigraphic "types'', as determined by the ratio of stiff to compliant stratigraphic members; Compliant, Intermediate and Stiff A modelling experiment examines changes in rupture potential in stiff roof units for each stratigraphic type as discrete unit thickness and location are manipulated through a range of values. Results suggest that the stiff-to-compliant ratio of the host rock has an impact on the relative stress-inducing effects of discrete stiff members. In other words, it is necessary to consider both the thickness and the distance to the seam, within the context of the host rock, to accurately anticipate areas of elevated rupture induced hazard; acknowledging the presence of a discrete unit within the overburden in general terms is an insufficient indicator of risk. Through modelling of anticipated changes in the placement and dimensions of discrete units within their stratigraphic setting, elevated rupture-induced bump hazard can be anticipated on a case by case basis. Were similar modelling studies conducted at mine sites in tandem with tracking of problematic discrete stiff units, areas of elevated rupture risk could be anticipated in advance of mining. Developing this predictive capability beyond identifying rupture potential in discrete roof members is essential to the eventual elimination of dynamic failure related worker injuries and fatalities. As stress is a necessary component in the occurrence of dynamic failure events, this finding helps to refine our understanding of the role of individual stiff, strong roof members in bumping phenomena, and suggests that a more holistic view of overburden lithology, combined with site-specific numerical modelling, may be necessary to achieve greater miner safety.

Jan 1, 2016

By Robert E. Schock, Eric J. Risberg

"Less than 20,000 years ago, the last of the glaciers retreated from the Chicago region. They left behind sheets of glacial clay till underlain by dense, over-consolidated till (“hardpan”) below which is the limestone bedrock, found about 100 ft (30.5 m) below street level. The most notable feature in this profile is the unusually soft clay till that has historically been called “Chicago Blue Clay.”But the founding fathers of Chicago really didn’t care about what was under the ground. They recognized the importance of the city’s location as a potential trade and transportation hub. With access to the East through the Great Lakes and access to the West through the Mississippi River system, the viability of the city was evident. Chicago’s population grew rapidly. The city continued to grow through the Civil War years, but was dealt a devastating blow in 1871 by the Great Chicago Fire, leaving the city in ruins. The Birth of the SkyscraperAfter the cleanup of the Great Fire came the first real building boom in Chicago’s history. During this era, buildings were generally founded on shallow footings bearing on sand or clay. Many multistory buildings were constructed between 1880 and 1890 on spread footings. The first tall buildings were constructed with load bearing masonry walls. These early tall buildings suffered significant settlement as the soft clay underwent consolidation.The Home Insurance Building, built in 1885, was 12-stories tall and is generally acknowledged to be the first “skyscraper” in the U.S. It was the first building constructed with an iron skeleton frame instead of load bearing masonry walls. Spread footings were used under the interior columns in an effort to better distribute the loads, but the building still experienced large settlements.Construction began for the Monadnock Building in 1891. The 17-story building was built using load bearing walls 7 ft (2.1 m) thick, supported on rail-grillage footing foundations. When completed in 1893, the Monadnock Building boasted the title “World’s Largest Office Building.” The total building settlement over the past 125 years has been measured at over 20 in (0.51 m). The engineering community in the late 19th century observed settlement, but did not yet understand the process of consolidation of the soft clay beneath the city. During this time, many of the new buildings required structural repairs during and after construction; the problem was especially acute in buildings where highrise towers joined lower podium structures."

Jan 1, 2016

By I. Sedat Buyuksagis, Jamal Rostami, Ali Naeimipour

"Improving the safety of underground openings and optimizing ground support systems requires reliable ground characterization. This includes understanding the joints, discontinuities, and rock strength. Joint information can be obtained from borehole cameras, but measuring in-situ rock strength is very difficult. Use of borehole probes can be an ideal and efficient way to meet this requirement. This paper discusses the development of the Rock Strength Borehole Probe (RSBP) and presents the preliminary laboratory/field test. This device can be an accurate, flexible, quick, non-disruptive, and cost-effective alternative to estimate the rock strength inside boreholes in underground mines and tunnels. In addition, the scratch testing procedure in the laboratory by means of a newly developed miniature linear cutting machine is explained. Based on the results of these tests, two equations are developed to estimate the uniaxial compressive strength (UCS) and Brazilian tensile strength (BTS) of the sedimentary/metamorphic rocks. These equations, are based on testing 27 different sedimentary, igneous, and metamorphic rocks by full-scale scratch tests, including the cutting tests by a miniature disc. The results show a good correlation between the normal force and the compressive strength of sedimentary rock if the depth of the scratch is known. No significant correlation was observed for igneous rocks, due to the impacts of grain size.INTRODUCTIONEstimated rock mass properties are essential input for geomechanical studies and stability analysis for any structure constructed in or with rock. The availability of geological information is the crucial component of rock mass classification. One of the important parameters in evaluating rock mass properties is the intact rock strength. This parameter is usually measured by testing the core samples, obtained from exploration boreholes. These samples are subsequently tested in geomechanics laboratories. The test results offer limited information about the rock at the few boring locations despite all the efforts and costs. In addition, these results may not necessarily be representative of the behavior of the rock in the field as the test cannot provide the insitu condition of the ground."

Jan 1, 2016

By Dongfeng Yun, Zhu Liu, Wendong Cheng, Zhendong Fan, Dongfang Wang, Yuanhao Zhang

"For the purpose of studying the strata behavior due to multislicing top coal caving longwall mining along-the-strike direction in steeply dipping extra thick coal seams, the shield support pressures of the upper and lower slices of Panel 37220 in Dongxia coal mine were monitored using the KJ513 dynamic monitoring system. The set up rooms adopted the ""horizontal line-arc segmentinclined line"" form and used different types of shield supports. The results showed that the strata pressure of upper slice Panel 37220- 1 changed slightly along the strike direction, while along the dip direction it exhibited strong to weak pressure from bottom to top. The first weighting interval oflower slice Panel 37220-2 was about 60.Sm, and the average periodic weighting interval were about 22.6m. The strata behavior of Panel 37330-2 exhibited a spatiotemporal characteristic in that periodic weighting occurred first in the middle-upper part, followed by the middle and upper parts, arc segment, and finally the lower part. During the periodic weighting, the weighting interval and intensity also exhibited strong space characteristics. The average dynamic load coefficient was 1.48 and the maximum lateral pressure of the side shield was 900Kn1000kN.INTRODUCTIONThe steeply dipping coal seams account for about 20% of proven reserves and 10% of output in China (Wu, et al, 2014). About 50% of coal mines in the western China have steeply dipping seams, and are mainly distributed in Sichuan, Gansu, and Chongqing. When the steeply dipping seam employs longwall mining along the strike direction is employed, the waste rocks fill the gob nonhomogeneously along the dip direction, the deformation and caving of surrounding rocks exhibit obvious asymmetry and spatio-temporal characteristics with particular and complex strata behavior. In recent years, many research on strata behavior due to multi-slicing top coal caving longwall mining along-the-strike direction in steeply dipping extra thick coal seams have been performed with significant results (Shi, 1999; Wu, Xie, and Ren, 2010; Wu, Xie, Wang, and Ren, 2010). However, there has been a complete lack of research on monitoring the strata behavior due to multi-slicing top coal caving longwall mining in steeply dipping extra thick coal seam. Therefore, the strata behavior of multi-slicing panels 37220-1 and 37220-2 was systematically investigated in this research."

Jan 1, 2016

By C. Heckman, M. S. Moats, A. Luyima, W. Cui

"Nucleation and growth of copper on 316L stainless steel from synthetic acidified copper sulfate was studied in the absence and presence of chloride ions and/or organic additives – HydroStar® 4208, DXG-F7® and Cyquest® N-900 – using a potentiostatic technique. The current–time data obtained at 0.16V versus the SHE were analyzed using nucleation and growth models. Scanning electron microscope (SEM) images of deposits produced at 300 A/m2 show that the addition of 20 mg/L chloride ions increased the size and reduced the number of copper nuclei. Potentiostatic current–time data from the electrolyte without organic additives, and confirmed by SEM images, indicate progressive nucleation with two-dimensional growth under diffusion control. None of the organic additives studied at a concentration of 2.5 mg/L with 20 mg/L chloride changed the nucleation and growth mechanism, but the additives increased the number and reduced the size of copper nuclei, leading to more uniform coverage of the stainless steel substrate.IntroductionElectrowinning of copper is an important process in the manufacture of high-purity copper metal. Approximately 20 percent of the world’s refined copper is produced from acidified copper sulfate solutions by electrowinning (Schlesinger, Sole and Davenport, 2011). In many plants, copper is electrodeposited on AISI 316L stainless steel substrates for a period of 6-7 days, after which the copper is stripped from the blanks. Even though the deposition time for a commercial copper electrowinning circuit is around one week, it is critically important to control the nucleation, growth and nature of the initial deposit (Sun and O’Keefe, 1992).Deposit morphology and structure are influenced by the real current density at the electrode surface. The real current density across the cathode surface is made uniform by proper design of the electrowinning cell and electrodes and careful operational practice. Even with good design and control, some current maldistribution occurs. The outcome of severe current maldistribution is poor deposits that affect product quality and/or increase energy consumption. To combat current maldistribution and create a larger operating window in terms of current density, temperature and copper concentration, small amounts of organic smoothing agents – traditionally, guar products – are added to copper electrowinning electrolytes. Moreover, these additives inhibit the growth of copper nodules and lead to improved deposit quality by producing bright, smooth and dense cathodes.Recently, the use of polysaccharides, such as HydroStar 4208 and DXG-F7, and polyacrylamides, such as Cyquest N-900, has been reported in commercial electrowinning tankhouses as replacements for guar (Ashford, Clayton and Sandoval, 2012; Robinson et al., 2013; Sandoval, Morales and Bernu, 2010). However, little information has been published on the effect of these new organic additives, especially regarding the nucleation and growth mechanisms of copper electrodeposits in their presence."

Jan 1, 2016