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By Larry L. Snyder

A compact 4.87 m (16 ft) diameter tunnel boring machine (TBM) is capable of boring a 12.2 m (40 ft) radius curve while gripping horizontally, or vertically, as may be required for the excavation of turnouts. The machine's 5.0 m (16.5 ft) length and a patented machine structure allows steering while boring without causing harmful eccentric loads. An extremely stiff thrust system, rigid front and rear grippers, and the torsional stiffness of a front end electric cutterhead drive combine to create superior machine stability and boring efficiency. A 2.2 m (7.2 ft) diameter prototype, complete with a soft ground shield attachment, was used successfully on a tunnel project in Scotland.

Jan 1, 1989

By Warren D. MacEvoy

INTRODUCTION Good ventilation bulkheads (stoppings) can be obtained only by conscientiously adhering to four basic principles: carefully selecting the site for the bulkhead, adequately preparing the site, properly constructing and sealing the bulkhead, and checking the results with a smoke tube before leaving the area. If all these guidelines are followed during each ventilation project, a poor job will result only from the use of improper materials and cannot be blamed on carelessness or oversight. SITE SELECTION A perfectly constructed bulkhead in the wrong location can be completely worthless. Conceivably, a bulk-head in the wrong location could cause dangerous ventilation conditions that are difficult to identify and isolate. If the suggestions herein are followed, a considerable amount of work, time, and material may be saved. Perhaps the single most important step is always to select the exact site for a bulkhead before starting construction. Although the latitude in selecting a site may be limited by instructions or operating conditions, it is common to find poor bulkheads built within a few meters (feet) of a site that would have been far superior but was overlooked during the planning process. The ideal site for a bulkhead should have as many of the following features and conditions as possible: 1) To provide a solid bulkhead, the selected site should be in firm and unbroken ground. 2) To minimize the amount of work and material required and to minimize the danger of later damage to the bulkhead, the site should have as small a cross section as possible. 3) The bulkhead site should not be encumbered by interferences such as pipes, wires, ditches, wire roof supports, trash, muck piles, etc. 4) The walls and timbers of the site should be free from oil, grease, or tar that would inhibit adhesion of the sealant used on the bulkhead. 5) Unless special precautions are taken, the site should not have water seepage, standing water on the floor, or water-carrying ditches. 6) To expedite construction of the bulkhead, the site should have reasonable access to transportation, supplies, communication facilities, and compressed-air lines. 7) The site should have a reasonably level floor, allowing direction of the bulkhead door swing to be reversed at a later time if so desired. In a steeply sloping location, it may be possible to open the door in one direction only. SITE PREPARATION Once a suitable site has been selected for the bulk¬head, it must be prepared properly. All site preparation work should be completed before starting any construction work on the stopping itself. Unfavorable site conditions can be identified during the course of thepreliminary site preparation, saving time, effort, and materials that otherwise might be wasted. The follow¬ing preparation steps help assure the construction of a good stopping: 1) If wire mesh has been used at the site, a strip 457 mm (18 in.) wide should be cut and removed from the walls and roof at the selected location. 2) The exposed strip of rock should be barred down thoroughly to provide a smooth surface. 3) All obstructing materials should be removed, including old timbers, pipes, rockbolts, wires, etc. If a conduit must cross the bulkhead area, it should be located or relocated away from the floor, walls, and roof to allow a 6.28-rad (360°) seal around the juncture between the conduit and the bulkhead structure. 4) All loose muck should be cleaned from the site and a trench about 152 mm (6 in.) deep should be dug from wall to wall in the floor. The trench must be wide enough to accommodate the entire bulkhead, including the posts. 5) The rock surfaces of the walls and roof should be cleaned with a wire brush to remove as much loose surface material as possible. Thorough cleaning promotes adhesion of the bulkhead sealant to the surfaces of the walls and roof, thus promoting an airtight seal. 6) It is quite difficult to seal landing mats that cross a bulkhead. If such a crossing cannot be avoided, the bulkhead should be placed between the end and the first hole in the steel so at least one side of the bulk-head can be sealed easily and completely. That may have to be done prior to actual construction if the end is located on the opposite face from the seal coating of the bulkhead. BULKHEAD CONSTRUCTION The three principal considerations in bulkhead con¬struction are the type of bulkhead, materials to be used, and construction method to be employed. For many projects, the bulkheads are specified by the requesting agency, with no latitude for independent choice of the type, materials, or construction method. In such cases, any deviations from the specifications, for any reason, must be approved in advance by the proper department or by the project senior ventilation engineer. Types and Materials When a choice of type, materials, or method is allowed, consideration should be given to factors such as cost, required useful life, proximity to blasting concus¬sions, availability of materials, direction of permissible air leakage, and degree of airtightness required. Other factors to be considered include the amount of time available, accessibility of transportation, potential for interference with operations or production, ambient water conditions, availability of connections to com¬pressed-air lines, etc. Despite the multitude of factors to be considered, most stoppings can be analyzed easily and the proper choices can be made without much difficulty. The four common classes of bulkheads utilized in

Jan 1, 1982

By Noris Del Be1 Belluz

Drilling underground in the Grasberg dewatering drifts has routinely hit water aquifers with high flow rates and pressures. Two types of holes are used. Pilot holes probe ahead of the tunnel development to intersect aquifers ahead of the face. And dewatering holes dewater rock formations that will drain water from the Grasberg pit and allow tunnel development to proceed safely. Recently, static pressures of >8.3 MPa (> 1,200 psi) have been recorded with flows from a 100 mm (4 in.) HQ core hole measured at 5,700 L/min (1,500 gpm). The waterflows can be slightly acidic, necessitating the use of stainless-steel collar gear to resist corrosion. These rates were anticipated and contingencies were planned early on to deal with these conditions. PT Freeport Indonesia (PTFI) established procedures to maintain the safety of the drill crews, to enable coring of the rock, and to maintain the safety of the miners driving the drifts. The collar gear controls the waterflows because these drill holes are a vital source of water for the concentrator.

Jan 1, 1998

By W. Stark

Many developing countries with little or no previous environmental regulation are now promulgating air quality regulations which require facilities to demonstrate compliance with both process parameter based emission limits and ambient air quality standards. For many companies with operations in developing countries, an air quality compliance program at the facility level is lacking and these companies have very little background information to work with in developing a program for assessing and maintaining compliance. This paper will present a methodology for development of a comprehensive air quality compliance program for operations located in developing countries with new environmental regulations. The experiences of the authors in developing an air quality compliance program for a mining operation located in South America will be used as a basis. A program for meeting new air quality requirements can be developed in seven steps. The seven steps are: (1) regulatory review and project scope; (2) design and implementation of a baseline air quality monitoring program; (3) site visit, (4) development of a complete air emission inventory; (5) dispersion modeling; (6) compliance analysis and compliance plan; and (7) project completion.

Jan 1, 1998

By B. J. Arnold, F. F. Aplan

Prior laboratory work has demonstrated that much of the fine ash forming minerals entering a flotation froth are there as a result of water carryover- from the bulk contents of the flotation cell (Arnold and Aplan, 1986a). Using a bank of four 8.5 m3 (300 cu ft) Wemco flotation cells cleaning a well-liberated Lower Kittanning seam coal, test results show that the sulfur and ash content of the froth is directly related to the water content of the froth (or inversely related to the percent solids in the froth). Reagent changes that result in a watery froth produce a higher ash content in the froth. A direct comparison of laboratory and plant results show that the standard laboratory flotation test produces a product higher in sulfur and ash than that produced in the plant. Caution should be exercised when extrapolating laboratory test results to the plant situation. A method of estimating coal flotation product quality in the plant based on laboratory tests is given.

Jan 1, 1991

By Pierre Mousset-Jones

A questionnaire was sent out to three classes of mines to determine the extent of the heat problem in U.S. and Foreign underground mines. The following list shows the replies received from this questionnaire, however not all the known hot mines in the US replied. A complete listing of the results can be seen in Appendix I. 1) US coal mines - 37 replies 2) US non coal mines - 23 replies 3) Foreign non coal mines - 36 replies. At the present time there are approximately eleven non coal and one coal mine in the US experiencing heat problems which require special efforts to maintain an acceptable working place climate. However since the survey was completed some of them have been placed on standby. The Mine Safety & Health Administration (MSHA) does not have any specific regulations relating to heat stress. Informally the American Conference of Governmental Industrial Hygienists guidelines are followed which use wet bulb globe temperature (WBGT) with values ranging from 26.7°C to 31.1°C for a moderate workload, and different rest regimes. An MSHA report (Misaqi 1976) recommended that conditions should not exceed 26.1°C WBGT for men and 24.4°C WBGT for women. However, quite recently the organizations involved with planning two of the proposed nuclear waste repositories in the United States, have opted for the criteria of an air cooling power of 300 w/m2, and a WBGT of 27'C respectively.

Jan 1, 1986

By K. A. Brame, L. G. Austin, R. S. C. Rogers

The breakage parameters of phosphate ore were determined by batch first-ordering grinding studies in a laboratory ball mill according to the Austin, Klimpel, and Luckie procedures. The results were scaled to five larger mills of 0.56, 0.82, 8.36, 4.41, and 5 m in diameter assuming equilibrium ball charges for the full-scale mills. The results were used to predict product size distributions and capacities for batch grinding in the smaller mills and open-circuit grinding in the larger mills. The predicted capacities were in approximate agreement with experimental values except for the 5-m diam mill. The Bond method gave capacity predictions that were 4570 to 150% too high.

Jan 1, 1987

By H. Fayed

Two-phase (water and air) flow in a self-aspirated WEMCO flotation machine has been investigated using computational fluid dynamics (CFD). The geometric model is a replica of a 300 m3 cell. A 72-degree sector containing two blades of the ten-blade rotor has been modeled and periodic boundary conditions are applied in the circumferential direction. Simulation of a sector of the machine allows acceptable resolution of the mean flow field using 4x106 grid points. The flow is modeled by Euler-Euler approach, and transport equations are solved using a commercial software ANSYS-CFX5 [1]. Unsteady simulations have been performed. In a self-aspirated machine, airflow rate is not known a prior; it is an output from the CFD simulation. Uniform mean bubble diameter of 0.7 mm has been specified as an input for the simulation. Air flow rate and power consumption have been monitored with time, and results indicate a stable operation. Air volume fraction contours and velocity field in different regions of the machine are presented and discussed.

Feb 27, 2013

By A. E. Hall, K. R. Mutama

The wind tunnel has been used extensively for mine ventilation research and continues to be a valuable tool. The advent of the powerful personal computer has reduced the use of wind tunnels because several flow problems car be simulated and investigated quickly. This paper describes the recent design and construction of a wind tunnel which is now being used for mine ventilation aerodynamic research and teaching purposes. The wind tunnel has a square cross section measuring 900 by 900 mm and is 8485 mm long from the entrance to where it joins the fan. The tunnel was designed as an open circuit suction type and is attached to a 7.5 kW variable pitch axial flow fan capable of producing over 6 m3/s of airflow. The entire length of the wind tunnel can be used for flow investigations and all activities are visible since the sides are made of plexiglass. Results are presented from the test program to show that even without honeycombs and screens air flow symmetry is achieved.

Jan 1, 1993

By E. W. Geist

This paper is presented from the viewpoint of the mill operator and maintenance supervisor. Its purpose is to highlight the things that have been accomplished by the mill designers to lighten the load for the maintenance superintendent and to reduce the overall costs for the plant operator. The complexity of plant design, the civil and structural engineering problems encountered when the satisfactory maintenance layout is accomplished are appreciated, and the writer is fully aware of the complexities of these problems. However, it is not the purpose of this particular paper to dwell upon these problems, nor to emphasize or de-emphasize the problems of the civil, mechanical and electrical engineers. It is simply that the paper will attempt to review what these people have accomplished in spite of the many technical problems. This paper then is prepared with the operator and maintenance people?s viewpoint. What is their definition of design for maintenance? It is the writer's interpretation that the various design concepts which mean improved maintenance are such items as (I) maintenance areas, (2) laydown space for maintenance materials in specific maintenance jobs, (3) the inclusion of bridge cranes in the plant and specific design of the craneways to accomplish flexibilities for the cranes, and (4) the location of the piece of equipment to allow maintenance people to work around the equipment - - - this specifically includes the orientation of the particular piece of equipment.

Jan 1, 1967

By R. M. G. Machunter

The presence of ultra-fine particles affects the separation performance of wet gravity separation equipment. Several studies have been undertaken to establish the maximum level of these particulates that can be tolerated by spiral separators and it has been found that unless the ultra-fine material is effectively processed, relatively low proportions in the ROM material combined with high feed rates can result in degradation in plant performance and/or excessive water consumption. The maximum level of particulate material in the process water has been determined by examination of separation performance of spiral separators under varying slime loading. This work has been conducted utilizing various feed sources and a robust ‘rule-of-thumb’ has been derived.

Jan 1, 2005

By Y. David

In 1990, the United States became only the second country (after China) to produce more than 900 Mt (1 billion st) of coal in a single year. US production of bituminous and subbituminous coal, lignite and anthracite totaled 933.5 Mt (1.029 billion st) in 1990, 5% more than in 1989. The production gains were largely due to the rebuilding of depleted coal stockpiles by electric utilities and a surge in US coal exports. Domestic coal consumption essentially remained at its 1989 level. A slight increase in electric utility coal consumption was partly offset by a decline in metallurgical coal use. The use of coal in other industries and in the residential-commercial sector remained virtually flat.

Jan 1, 1991

By F. L. Wilke

Truck haulage costs form a major part of the total mining costs in hard rock open pit, mining operations. In order to minimize these costs one has to - determine the optimal truck fleet (type, size and number of trucks), and. simultaneously - determine the optimal organization of running the haulage system, i.e. especially select the optimal dispatching strategy in order to ensure maximal utilization of the trucks, and simultaneously - establish a reliable maintenance and servicing system to guarantee maximal availability.

Jan 1, 1982

By John R. Twining, Michael D. Lawton, Ross A. Jeffree

The Finniss River system in tropical northern Australia has received 'acid-drainage' contaminants from the Rum Jungle uranium/copper mine site over the past 4 decades. Following mine-site remediation that began in 1981-82 the annual contaminant loads of sulfate, Cu, Zn and Mn have declined by factors of 3, 7, 5 and 4, respectively over 1990-93, compared to the 1969-74 pre-remediation loads. Comparison of the frequency distributions of contaminant water concentrations over these pre- and post-remedial periods have shown varying degrees of reduction in the highest levels following mine-site remediation, that are consistent with reductions in their annual-cycle loads. Among the three selected major metal contaminants the reductions in maximum water concentrations are most pronounced for Cu. The demonstrated reductions in the highest water concentrations of all four contaminants are also associated with previously reported ecological improvement in the Finniss River system, compared to the benchmark of environmental detriment established in 1973fl4, prior to the beginning of remediation at the mine site.

Jan 1, 2000

By H. W. Peirce

Arizona is a sun-belt growth-region where 13 tons of industrial (nonmetallic) minerals is being produced annually per capita. In 19B5, non-fuel mineral production reached $1.532 billion and consisted of metallic ($1.277 billion-84%) and nonmetallic ($253.5 million-16%) earth materials. Sand-and-gravel value was second only to copper. over 90% of the value of nonmetallics is represented by combined sand, gravel, cement, and lime. The remaining less than 10% ($25 million) was attributed mainly to stone, specific volcanic products (cinder, perlite, pumice), gypsum, clays, salt, zeolite, and others. Current interest in industrial-mineral development in Arizona is high, especially in the geologically complex Basin and Range region.

Jan 1, 1988

By David X. Zhang

This paper describes the results of using shear flocculation and flotation known as aggregative flotation technique for the enrichment of coal-derived char produced from mild gasification process. Aggregative flotation is a separation process which involves the use of suitable aggregating liquid under the action of high shear forces to render hydrophobic surface of coal-derived char particles to aggregate in an aqueous slurry. The fine carbonaceous particles are aggregated into larger floes while the impurities remain hydrophilic. In subsequent flotation process, the char aggregates are then separated from mineral matters by aeration in the flotation cell. The floatability of char aggregates and removal of mineral matters from chars are studied in a lab scale flotation column cell. The effect of various operating parameters on the aggregative flotation responses is presented. Emulsification of aggregating liquid using high intensity agitation and ultrasonic energy provides excellent aggregating liquid dispersion and increases selectivity for char aggregation. In subsequent flotation process, it results in significantly increasing the flotation rate of char aggregates. The microscopic examinations of bubble attachment to coal-derived char particles under various aggregating liquid dispersion levels were conducted by induction time measurement. The distributions of hydrophobicity of char particles and char aggregates prepared under various aggregating liquid dispersion techniques were measured by film flotation. The char particles prepared under high intensity emulsification attach at significantly faster rates to air bubble and with lower mean critical wetting surface tension than that of char with direct aggregating liquid addition. An interrelationship of increasing in flotation rate/combustible recovery with decreasing in induction time, mean critical wetting surface tension and dispersion of hydrophobicity on the char particles and char aggregates were obtained.

Jan 1, 1992

By Scott G. Britton

This chapter discusses the necessary construction techniques for installing coal mine ventilation devices. Included in the discussion are the major air controlling devices called over- casts, regulators, stoppings, and doors. Under-casts, although a valid device, are used infrequently in coal mining and are not discussed here. Typically, coal mines require a great many ventilation devices to control the air movement. Post-I969 mines have had to design their air systems to comply with the Federal Coal Mine Health and Safety Act (CMHSA) as discussed in Chap. 1. Pre- 1969 mines have had to redesign major portions of their systems to comply with the basic components of the law such as separation of air courses, single unit split ventilation, and minimum air quantities. It is not uncommon, therefore, to find a large mine (2.0 Mt/a) requiring several hundred overcast installations (permanent, as well as repeat construction), plus doors and regulators placed among a thousand or more stoppings. When each of these devices is subject to leakage from installation and weathering defects, the importance of effective construction becomes evident. An historic rule of thumb for average mine ventilation says that about 70% of all the air pressure generated by the mine fan is lost between the portal and the working faces. Of course, this rule is subject to many factors, but the message is clear: there is a tremendous inefficiency in controlling leakage through common air devices. This chapter strives to present a standard approach and design alternatives which can go a long way in reducing this leakage, and hence, ventilation costs. Historically, mine ventilation has progressed from natural, or draft ventilation, to fire-induced ventilation (Fig. l), furnace-fired centrifugal fans and finally, to today's modem mine fans. Underground controlling devices have been in use in the coal mines since the late 1600s, but the CMHSA of 1969 was the real turning point for mine ventilation. Minimum quantities and velocities of fresh air were required for mining, forcing coal operators and engineers to reevaluate and improve their systems. As a consequence, the cost for ventilating air increased. Today, companies face a variety of choices among design alternatives, materials, labor, and costs of ventilating devices for their mines. The best approach for any individual company or mine is determined by (1) the needs of the mine, and (2) the local design parameters. In my discussions of ventilation construction I shall be fairly general in terms of device installation steps, where specifics are warranted for clarification, I will include this information.

Jan 1, 1983

By Frederik P. Agterberg

Mineral exploration consists of the acquisition of data and their interpretation to ascertain the presence or absence of uncertain events. In general, the amount of uncertainty decreases during exploration when targets become increasingly well defined. Decisions on further exploration and whether or not mining should be commenced are based on new information using both objective facts and subjective reasoning. Computers play an important role during all stages of exploration. Three recent books (References 1-3) on decision-making in exploration and mineral-resources evaluation provide additional background supplementing the papers in this volume and articles in scientific journals or other conference proceedings (e.g., References 4 and 5) dealing with the subject. Other new developments to be considered are that microcomputers are becoming increasingly important in the earth sciences (Reference 6), and so are applications of artificial intelligence (Reference 7). Microcomputer- based technology allows rapid communication between field parties and main office. Expert systems are becoming increasingly sophisticated aids for mineral exploration an can now contain objective rules based on statistical theory (Reference 8).

Jan 1, 1989

By V. D. Hanson

When maintenance of a plant or operation is under discussion immediately three "M's", all in short supply, are brought to mind - money, men and markets. This paper will present what currently is being done at our plants and its effect on the 3 "M's". Examination of coal realization figures (F.O.B. Mine) from 1945 to the present reveals the fact that open and free competition can and will meet market conditions. The industry, without benefit of advantages afforded tax and transportation wise to oil and gas, remains the backbone of the energy market of United States. Figure No. 1 shows the realization figures from 1945 through 1962 compared to the hourly earnings. Note that through 1945 to 1948 F.O.B. prices increased $1.93 per ton while hourly earnings increased $.66 per hour. Since 1948 (with the ex¬ception of 1957) F.O.B. prices have declined $.45/ton, while hourly earnings have increased $1.23 per hour. Basically the maintenance men possibly represent the highest increment rate in the overall hourly earning.

Jan 1, 1963

By Ted C. Mathews

Pre-concentration by sorting is as old as the mining industry. Inevitably waste rock is broken with ore. Separation may take place in the stopes by selective mucking and transport, or selective loading and transport of ore and waste by 12-cu, yd. shovels and 100-ton trucks in large open pit operations. Hand sorting of 1" to 16" pieces, formerly widely practiced at underground chutes and prior to or following first stage crushing, has greatly diminished in the United States with its high per hour labor cost, although still widely practiced in other countries and, surprisingly, in some of the most modern mills where inexpensive labor is available. The economics of pre-concentration by sorting is attractive since elimination of waste at any cost less than the total milling cost will show a profit. The size at which sorting should be under- taken is determined by the size at which liberation is secured to yield a product of ore and waste, and greatly influences cost and the point in the flowsheet where sorting can be undertaken. In some instances mining costs can be reduced where an inexpensive sorting system to eliminate waste is combined with a less selective and less costly mining method. This is particularly true in deep mines where hoisting capacity determines the rate of extraction and sorting is performed underground, with waste utilized for fill. Hand sorting, while efficient, is expensive because of low sorting rates. Peale (1) quotes man hour capacity at 1/3 ton per hour on sizes 3/4" to 3" copper ore, and up to 5 tons per hour on rich iron ore sized from 4" to 16".

Jan 1, 1974