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By Tapan Goswami, Lloyd Hain, Geoff Brent

For many years Ramp 24 at Ensham mine in Queensland, Australia has suffered substantial coal loss and damage due to the fragile nature of the coal and problematic geological conditions, which have proved very challenging. In the past various blasting techniques were applied in attempts to improve coal recovery. One approach was to use a shallow throw (cast) blast followed by a separate post-strip blast underneath. Another method was the introduction of the practice known as “baby decking” with the addition of a large buffer of material in front of the coal. However, despite increasing mining costs, none of these techniques adequately reduced coal edge loss and damage.

Jan 1, 2008

By Carla Lupi, Alessandro Pescetelli

"Spent lead battery recycling still shows few weak points in the achievement of a 100% recycling of different waste matters and by- products arising from the recycling process. Some of said problems are dealing with aqueous streams outgoing the recycling plant, and more particularly, a) the waste waters discarded from the breaking and separation unit, b) purification of the spent electrolyte drained from waste batteries and upgrade to a quality compatible with full re-use by the batteries’ manufacturers, c) purification of the mother liquors discarded in the sodium sulfate crystallization process so to produce a salt of commercial grade. All of the above listed problems have been satisfactorily overcome applying an electrochemical process that, through different process conditions and parameters, is able to remove the harmful impurities that hinder the successful commercialization of such by products, or, at least, that can avoid heavy and expensive treatment plant and operation.IntroductionAlmost 100% of commercial lead and lead alloys produced by secondary lead plants is recycled to the new lead accumulators manufacture. The other by-products and residues produced through the lead recycling process may be classified into two groups:a) matters reusable in the new accumulators production processb) matters produced as a result of various reagents and additives used in the recycling process, to be sold to different market sectorsQuality and saleability of by-products are significant points for the economics of the secondary lead plant operation, because, if said by-products are not saleable, they are just wastes, so offsetting potential revenues, and, at the same time, adding a heavy burden to operating cost, like disposal cost [1]. When looking at a typical, modern lead scrap batteries recovery cycle, it is quite evident that we are still rather far from dealing with a waste-less technology (fig.1).The group a) includes 3 by-products produced through the breaking process: among those matters the polypropylene only usually reaches a standard quality suitable for sale to lead manufacturing sector or to other sectors as well. The other two by-products, electrolyte and separators, do not still reach, through a viable and effective regeneration process, a quality standard sufficient for their re-use in the lead batteries sector ."

Jan 1, 2008

By E. R. Spencer

National Institute for Occupational Safety and Health (NIOSH) researchers conducted an investigation to quantify sound levels and to determine the amount of sound reduction provided by engineering noise controls installed in a talc processing plant. Baseline sound level and sound intensity measurements were performed at the plant and the measurement locations were recorded for comparison to post-control measurements. Follow-up measurements were then made at the same locations after the initial noise controls were installed. The plant subsequently decided to implement additional noise controls and the researchers returned to conduct measurements for a final analysis of all noise controls. The most significant results showed a sound level reduction in the main mill area from a range of 93-104 dB(A) down to 90-94 dB(A), and a total sound power level reduction of 21 dB(A) for air classifying mill 3.

Jan 1, 2008

By Andrew J. Ciancia

The construction of the Pennsylvania Station in Manhattan, the Beaux-Arts masterpiece, was completed in 1910. In financial ruin, the Pennsylvania Railroad Company sold the station in the 1960?s and the new Madison Square Garden and the Penn Plaza complex were constructed at the site. The demolition of Pennsylvania Station brought public awareness and outcry to protect historic structures and the Landmarks Preservation Commission (LPC) was subsequently established in 1965. In the 1960?s relatively little engineering data was available on the performance of historic structures during adjacent construction and thus, no published criteria were established by the LPC on allowable movements and vibrations. During the late 1970?s a commercial tower was planned adjacent to the landmark Fraunces Tavern Block (FTB) in lower Manhattan. Through negotiations between the LPC and the developer, Dr. M. I. Esrig and the author were retained to monitor the historic block during foundation construction. The monitoring data and building performance compiled from the project formed the basis of the published 1981 ASCE technical paper by Esrig and Ciancia entitled ?The Avoidance of Damage to Historic Structures Resulting from Adjacent Construction?. Based on the ASCE paper, the NYC Department of Buildings adopted Technical Policy and Procedure Notice #10/88 entitled ?Procedures for the Avoidance of Damage to Historic Structures Resulting from Adjacent Construction When Subject to Controlled Inspection by Section 27-724 and for Any Existing Structure Designated by the Commissioner?, June 1988. This paper describes the author?s recent experience during the installation of deep foundations within, or adjacent to, three Manhattan landmark structures. Discussions are provided on the foundation construction, monitoring programs and performances of the three structures.

Jan 1, 2008

By Cissé Kane, Klaus Hieronymi, Mathias Schluep, Gerry Newson, Susanne Dittke

"E-waste is currently the fastest growing waste stream in South Africa as well as in many other African countries. Informal collectors, dismantlers and recyclers based in Africa play an increasingly larger role in the processing of e-waste under generally unacceptable social and environmental conditions. In direct response to this trend, and as part of Hewlett Packard’s international Extended Producer Responsibility, the project “e-Waste Management in Africa” was started in 2007 in cooperation with the Global Digital Solidarity Fund (DSF) and the Swiss Federal Laboratories for Materials Testing and Research (Empa). This project is investigating the e-Waste situation in various African Countries, including South Africa, while actively supporting the development of practical, socially just and environmentally acceptable local e-waste management solutions. To this end, the project has been funding the development of a pilot project in Cape Town, South Africa since February 2008, supporting the start-up of a low tech/highly labour intensive material dismantling and recovery facility (MRF) for the pre-processing of e-waste. The aim is to test the feasibility of an integrated value adding local e-Waste management system, designed to maximize the potential of refurbishment, repair, re-use, dismantling and recycling of equipment, with environmentally responsible disposal as a last resort only. The project also seeks to incorporate the current informal e-waste processing activities, by transforming them into sustainable and environmentally sound operations. The MRF acts as a nucleus, raising awareness, and providing training and education to previously disadvantaged individuals as a means of creating opportunities for entrepreneurship in the technical maintenance, dismantling and waste-to-art project sectors."

Jan 1, 2008

By Hemraj Dangi, S. Murali, Bhisham Yadav, Mohini Saxena, P. Asokan

"Demonstration studies were carried on the use of fly ash as soil modifier and supplier of micronutrients to improve the agricultural productivity based on the process optimised at lab scale at Advanced Materials & Processes Research Institute, Bhopal. The field trials were conducted in Uttar Pradesh (North India) Orissa (South Eastern India) and Madhya Pradesh (Central India) under different soil and crop conditions. 100-650 tonnes of fly ash per hectare were applied depending upon the soil and fly ash characteristics. Both short and long term studies on impact of fly ash on soil and food quality were conducted. With the fly ash application, the edible yield of tomato, cabbage, potato, wheat, pea, onion, paddy, sunflower, maize etc., were increased from 12 - 46% as compared to the control soil where no fly ash was used. The crop response to various elements mainly heavy metals grown in soil and fly ash applied soil was found comparable to that of control, which are within the permissible limits and meet the food quality standards. The results of impact of fly ash on biotic and abiotic properties of soil, along with the quantity and quality of agricultural produces generated under pilot scale demonstrations in three different parts of India are discussed in this paper. The outcome of this work could act as guiding force for confidence building and to maximise the use of fly ash, generated from thermal power plants worldwide as one of the major mineral waste for agriculture purposes.IntroductionThe advantages of application of fly ash in terms of improvement of soil properties and crop yields have been published by various researchers in India and abroad. Attention is also given about the possible negative and beneficial impact of pond ash in agriculture due to presence of heavy elements, radioactive nuclides and plant nutrients in fly ash. It is evident from the analysis of Indian fly ash that the presence of heavy elements and radionuclides levels are comparable with normal soil. The positive impact that has been reported is with regard to germination, yield and crop growth. The significant impacts are: long term effect of heavy and toxic elements content of fly ash on soil and up take of these elements by plant. Pilot scale demonstration studies have been completed with varying soil crop-combination under different agro-climatic conditions showed considerable improvement in the productivity of cereals, oil seeds and vegetables."

Jan 1, 2008

By Samson Adeosun, Sanmbo Balogun, David Esezobor

"Iron and steel making processes give rise to large amounts of usable and unusable materials, the latter generally being termed wastes. It is sometimes difficult to distinguish between re-usable by-products and wastes which cannot be sold or land-filled. Much depends on circumstances such as the local market for the material. This can itself vary from time to time with by-products which cannot be used or sold becoming wastes and vice versa. This paper defines the concept of “waste-free technology”, discusses its development in the steel industry and highlights the benefits of the technology to the manufacturing sector and the environment. The paper also articulates how the “waste-free” technology could be applied in the proposed Ajaokuta integrated steel plant in Nigeria.IntroductionIn the past, nature was considered an inexhaustible store. Its resources were consequently exploited and waste products therefrom were discarded. Today, attitudes have not changed appreciably even as raw materials cost rise by the year to pose a series of socio-economic problems, which, among others, may include the rational and optimum utilization of resources, environmental protection and reduction of waste formation. Consequently, industrialists now face unexpected regulatory pressure in areas of pollution prevention, waste minimization and hazardous waste disposal.Iron and steel making processes give rise to significant amounts of usable and un-usable materials, the latter generally being termed waste. It is sometimes difficult to distinguish between re-usable by-products and wastes which cannot be sold or land-filled. Much depends on circumstances such as the local market for the material. This can itself vary from time to time with by-products which cannot be used or sold becoming wastes and vice versa. In this paper, the term waste refers to those materials that are either irrationally utilized or, land-filled and part of the byproducts that are not utilized. It includes that part of used materials which is not incorporated into the products manufactured during a process stage and which in contrast to reuseable materials, is considered not suitable for any further use, owing to technical or economic factors. In general, these materials are inorganic and parts of them are either utilized or passed to the other processes; the other part should be disposed of using well-established waste disposal practices to avoid any environmental threat.Thus, creative methods must be developed to modify the manufacturing processes to reduce emissions and process wastes by fully utilizing all resources. One method of eliminating the negative effect of waste formation is the use of purification and cleaning structures (pollution control system, PCS). These are, however, quite expensive."

Jan 1, 2008

By James M. Lockwood

"Eureka Technology has developed and patented a technology for the recycling of EAFD. Through this process all constituents of the material become salable commodities or are returned to the steel making process. In transforming the EAFD ""waste"" stream into a ""process"" stream the Steelmaker eliminates potential liabilities and the uncertain future of current processes while further reinforcing its role as a recycler. This is a cost-effective and energy efficient technology that combines hydrometallurgic and electrolytic processes resulting in the recovery of salable metals. For instance, unlike pyrometallurgic processes, zinc is recovered in metallic form and no elements are volatilized. This on-site operation also eliminates expensive transportation costs. In summary this technology reduces the cost of dealing with EAFD by recycling material currently being landfilled.IntroductionWorld crude steel production reached a new record level in 2007 - 1.34 billion tons of which 31% was produced by EAF steel makers [1]. This resulted in the generation of over 6 million tons of EAFD. This steel byproduct contains significant amounts of lead, cadmium and other hazardous metals. In the United States the Environmental Protection Agency (EPA) has designated EAFD a hazardous waste (EPA waste code K061). With over 50% of steel production in the US coming from EAF steel making this byproduct represents the single largest source of solid hazardous waste generated."

Jan 1, 2008

By J. Borlée, J. P. Birat

"ULCOS is a large European program launched by a consortium of 48 partners led by arcelor and a core group of steel producers, which was started in 2004 with the support of the European Commission (RFCS and 6FP programs) to search for breakthrough process routes that could, in the future, when fully developed, demonstrate the potential of large cuts in CO2 emissions for the production of steel from iron ore.The timescale for commercial implementation is the post-Kyoto period, i.e. 15 to 20 years from today.The present paper presents the progress made in the first 2 years of this 5 year program.Several concepts are being investigated in parallel: re-engineering of the blast furnace to incorporate CCS in the core of the process, smelting reduction with CCS capabilities, massive use of natural with more CO2-lean technologies than today, hydrogen steelmaking and electrolysis of iron ore. Biomass also offers very attractive perspectives, while raising major challenges.None of these new steelmaking routes are ""no regret"", which means that the European Steel Industry has already incorporated extensive energy saving steps in its present process technology and is working as close to thermodynamics limits as is cinematically and economically feasible, and that decreasing GHG emissions further means introducing breakthrough technologies that add significant costs to the operation of the Steel Mills.They will also require much research and development before they can be proven and implemented commercially.IntroductionThe ULCOS program (Ultra Low CO2 Steelmaking) is a large research program of the European Steel Industry and its industrial and research partners launched in September 2004 to investigate steelmaking technologies that have the potential of reducing the CO2 emission of the Industry by a large amount, typically in the order of 50%. It is supported in the European Community by the 6th Framework and the RFCS programs through 3 complementary European projects [1,2].The present paper summarizes the work carried out in the phase 1 of ULCOS and in framing the program of phase 2."

Jan 1, 2008

By I. Yu. Melekestseva

Two types of hydrothermal massive sulfide fields were discovered in the Mid-Atlantic ridge (MAR) in the last twenty years. The first type associates with basalts and includes the TAG, Snakepit, Broken Spur, Lucky Strike and Krasnov hydrothermal fields. The second type is related to ultramafic rocks and represented by the Logatchev, Rainbow and Ashadze hydrothermal fields. In 2007 a new, probably, the largest cluster of hydrothermal massive sulfide field on the MAR (Fig. 1), related both to basaltic and ultramafic rocks, was discovered at 13°31'N of the MAR (Beltenev et al., 2007). [ ]

Jan 1, 2008

By Rick Deschamps

A reoccurring problem with support of excavations in urban areas involves the placement of external support components like anchors or nails in right-a-ways, subway and utility setbacks, in areas occupied by adjacent structures, and within the property of non cooperative neighbors. Such a situation occurred for a project in Arlington, Virginia, which ultimately resulted in the preliminary design of a large footing supported cantilever retaining wall that was extremely costly and impractical to build. An innovative design alternate consisting of a series of vertical concrete elements (VCEs) supported by post tensioned tiedowns was proposed to the General Contractor and accepted by the owner. The VCEs were designed to serve as the main structural elements for both the temporary support of excavation system and the permanent wall. The VCE?s were constructed using single bite diaphragm wall panels oriented perpendicular to the excavation face including a rebar cage and tremie concrete. Threaded inserts were placed within the rebar cage to attach the cast in place exterior wall. Overall stability and lateral movement of the VCEs were controlled by high capacity vertical anchors embedded within the VCE. A detailed instrumentation program was installed to monitor the movements of the VCEs with relation to the excavation depth. The paper present the project case history by discussing the design concepts of the VCE, the construction approaches used to install them, the construction challenges encountered, and the performance of the unique system.

Jan 1, 2008

Research cruises dedicated to seafloor hydrothermal activity along the Kermadec arc first began with the Sonne-135 expedition in 1998. This was followed by the worldÆs first systematic survey for venting along an arc during the 1999 NZAPLUME I expedition. Since then, cruises dedicated to mapping plumes along the Kermadec arc include NZAPLUME II (2002), NZAPLUME III (2004) and ROVARK (2007). In addition, the manned submersible cruises SWEEP Vents (2004) and NZASRoF (2005) utilised the Shinaki 6500 and Pisces V, respectively, to sample in detail select hydrothermalsystems for mineralised samples, rocks and vent fluids. The ROVARK (2007) cruise was the first to deploy an autonomous underwater vehicle (ABE) along the arc which surveyed Brothers volcano at a far greater resolution than had been done previously by ships on the sea surface. While these expeditions have largely been led by GNS Science, together with its collaborators from National Oceanic and Atmospheric Administration, Pacific Marine Environmental Laboratory (NOAA/PMEL), significant contributions have been made by other groups from various nations, exemplifying the global interest in seafloor hydrothermal activity associated with intraoceanic arcs. This is an ASTRACT only. A full-length paper was not prepared for this presentation.

Jan 1, 2008

By Hiren J. Shah

Across much of New York City, the geology of glacially deposited soils follows a common sequence. Outwash sands generally overlie varved silts and clays, which lie above a basal till deposit underlain by the bedrock. Pile foundations at projects with such typical stratigraphy generally develop their axial capacities by extending below the fine-grained deposits into the till or the bedrock. Contrastingly, at a project site on the Brooklyn waterfront, high capacity piles were efficiently and economically installed by driving them into the relatively shallow glacial drift and till deposits which lay above thick fine-grained compressible glacial lake deposits. An unusual aspect about the foundation design at the Brooklyn project site is that, relatively short and high capacity piles were driven into the shallow glacial drift and till deposits, overlying the thick fine-grained glacial lake deposits. In order for this unusual foundation scheme to be feasible and economical, the piles needed to achieve their driving criteria in the upper strata. Consolidation settlements in the lower stiff and over-consolidated glacial lake deposits below the pile tips had to be relatively small. The paper discusses the unusual stratigraphy in this area of Brooklyn in greater detail with geologic profiles and engineering characteristics of the glacial strata. It also discusses the design aspects of the pile foundations, settlement estimates, a pile drive test program during design, results of the static load test program during construction, and production pile installation results.

Jan 1, 2008

By Brian L. Quick

Problem: The National Institute for Occupational Safety and Health's [NIOSH] National Occupational Research Agenda (DHHS Publication No. 96 115) reports that approximately 50% of miners will experience hearing loss by age 50, compared to only 9% of the general population. The present investigation examines three antecedents believed to be associated with miner's use of hearing protection. Method: A posttest delayed posttest control group field research design was employed to assess antecedents toward wearing hearing protection. Results: Following the initial posttest, miners' attitudes and subjective norms were antecedents to intentions to wear hearing protection devices. Also, intentions toward wearing hearing protection predicted hearing protection behaviors. Approximately six weeks later, miners' attitudes and perceived behavioral control were each significant predictors of intentions to wear hearing protection and again, intentions were positively associated with hearing protection behaviors. Impact on Industry: Our results indicate that appeals to normative influences may be the most effective antecedent to employ when persuading coal miners to wear hearing protection. However, messages designed to impact attitudes and perceived behavioral control were also effective.

Jan 1, 2008

By A. Longval, Q. Jiao, T. Shannon

In 2000, Xstrata Zinc (former Falconbridge Ltd.) Brunswick Smelter commissioned a modified lead blast furnace. Since then, efforts have been made to improve its operation in order to achieve optimal operation in terms of coke consumption, lead loss to slag, and improved environmental and hygiene conditions. This paper will review the important step changes in operational philosophy, undertaken since 2004, for the control of the blast rate, oxygen enrichment in blast, slag chemistry and charge level. Furthermore, a review of the improvements made in secondary materials consumed at the blast furnace will be made. This paper will also discuss the significant reduction of the frequency of accretion removal as a result of improved furnace operation.

Jan 1, 2008

Two years ago I was sitting in a big lecture theatre at the School of Mines in Kalgoorlie at the annual New LeadersÆ Conference listening to a guy tell us all how much he loved his job, travelling the country ælegallyÆ blowing stuff up à and getting paid to do it. I would have paid to see and do the things he spoke of à now IÆm that guy. From finishing a mining engineering degree at the University of Ballarat, through the job hunt, to firing environmental blasts in Tassie and designing and implementing construction blasts in the middle of the Gold Coast. My name is Rohan Stevens and IÆm a blast-o-holic. While the æjob huntÆ we all embark on toward the end of our degrees is a stressful time, itÆs also very exciting in the current climate. There are a number of things I have learnt through both my hunt for the job that best suited me and working for the worldÆs largest explosives manufacturer. If at least you donÆt benefit from my learnings IÆm certain you will enjoy hearing about (and viewing) some of the work I have had the opportunity to be involved with over the last 18 months with Orica Mining Services.

Jan 1, 2008

By G. G. Richards, D. J. Rioux, R. L. Stephens

Teck Cominco Metals Ltd. operates an integrated zinc-lead complex at Trail, British Columbia, Canada. The year 2007 marks ten years of operation of KIVCETTM flash smelting technology for the treatment of zinc plant residues and lead concentrates. Since start-up in 1997, the furnace throughput has been increased to exceed its design rate and other metallurgical performance targets while continuing to meet its environmental objectives. This was achieved through resolution of key mechanical issues, improved understanding to stabilize the reaction shaft operation and control furnace accretions, significantly reduced boiler corrosion by molten chloride salts through the extensive application of weld overlay, a suite of projects to improve furnace integrity, and some debottlenecking of the surrounding unit operations in the lead smelter. The combination of increased feed rate and improved on-line time allowed the KIVCETTM furnace to set a new quarterly feed throughput record of 129,300 tonnes in the first quarter of 2008.

Jan 1, 2008

The Ernest Henry Mine is an open pit copper-gold mining operation located in north-west Queensland, Australia. It is owned and operated by Xstrata Copper with a current concentrator throughput of approximately ten million tonnes per annum. The pit will cease mining towards the end of 2010. Extensive surface diamond drilling has confirmed an extension of the orebody to depths of 1000 m below surface. A prefeasibility study was commissioned in late 2006 to investigate underground mining options with the preferred mining method being an inclined sublevel cave. In February 2008 mining of a decline commenced in conjunction with a feasibility study to further investigate the project. Work from the prefeasibility study indicates that an underground crusher, conveyor and hoisting shaft could be utilised to crush and transport broken ore from the sublevel cave workings to the concentrator. The study suggests that a production rate of five million tonnes per annum could be achieved and sustained for up to ten years. Ventilation designs and requirements will form a large section of the feasibility study. This paper will detail investigations of preliminary ventilation network designs of the proposed sublevel cave. Work has been completed using both Ventsim and VumA ventilation simulation packages. Ventsim was used to provide preliminary estimations and suggest alternatives for: surface fan duties;airflow characteristics (direction, velocity, pressure and quantity); andventilation network design in key mine areas. With mining activities reaching depths in excess of 1000 m below surface an analysis of heat conditions should be conducted. The VumA software package was used to model the thermal properties of the ventilation system. This model will provide a basis for the preliminary decisions on refrigeration requirements for the mine.

Jan 1, 2008

By M. Holmes, R. Molnar, E. Norton, K. Baxter, J. Riordan

The Boleo Copper-Cobalt-Zinc-Manganese Project of Baja Mining Corp. is situated adjacent to Santa Rosalia on the Baja Peninsula of Mexico. The El Boleo ore is a mixed oxide-sulfide deposit with major values in copper, cobalt, zinc and manganese. The metallurgical process designed to treat the El Boleo orebody involves a sulfuric acid leach in seawater using oxidative and then reductive leaching to maximize metal extraction. The leach solution is separated from the barren solids via counter current washing through a series of high rate thickeners. Copper is recovered using conventional SX-EW processing as cathode. Zinc and cobalt are extracted from the copper SX raffinate after iron and aluminum precipitation. The CSIRO DSX solvent system (Versatic® 10 and LIX® 63 mixture) are used in this extraction. Manganese remains in the DSX raffinate and is recovered by soda ash addition as a high quality manganese carbonate precipitate. Zinc and cobalt are acid stripped from the loaded DSX solvent. Zinc is then re-extracted away from cobalt using Cyanex® 272 extractant and stripped into a highly concentrated strip liquor (+100 g/L Zn) and directed to either a spray dryer or a granulator for production of zinc sulfate monohydrate. The zinc solvent extraction raffinate, containing cobalt, advances to another SX circuit using Cyanex® 272, for the recovery of cobalt as cobalt cathode. In this paper, the detailed results from bench and integrated pilot plant testing for zinc recovery from the El Boleo ore will be described. The results of this testing are currently being used to engineer the commercial plant at El Boleo.

Jan 1, 2008

By Dennis R. Dolinar

The National Institute for Occupational Safety and Health?s Pittsburgh Research Laboratory conducted a full-scale test of a composite polyurethane-aggregate seal in a hydrostatic chamber at the Lake Lynn Experimental Mine. This composite seal consisted of a polyurethane and limestone aggregate core that was formed between two concrete block walls. In the hydro-static chamber test, water is used to pressurize the seal. During the test, the maximum average water pressure the seal was able to withstand was 18.9 psi. Further, the seal began to yield at an average water pressure of only 17 psi. At the time of the test, the minimum seal design requirement was 20 psi under 30 CFR4 75.335 (2005). Therefore, based on this test, the seal did not meet the regulatory minimum design requirement. Uniaxial compressive tests conducted on samples from the polyurethane-aggregate core revealed that both the compressive strength and the elastic modulus of the material were much less than that for polyurethane only with a density of 10.0?12.0 lb/ft3. The significant reduction in the strength and stiffness of the polyurethane-aggregate mixture results from the formation of a soft polyurethane foam around each piece of aggregate. The formation of the soft foam seems to be caused by residual moisture from the aggregate. The moisture also caused the density of the polyurethane in the polyurethane-aggregate mixture to be less than the design requirements. The lower density of the polyurethane in the mixture, along with the formation of zones of pure polyurethane only, resulted in the overall seal density being less than the design requirements. During seal construction, steps were taken to control the moisture, but were not successful. An analysis of the seal failure showed that the calculated shear stresses at failure and the estimated shear strength of the polyurethane-aggregate mixture are fairly close. This suggests that the strength properties of the polyurethane-aggregate mixture along with a weak zone of poorly bonded aggregate controlled the maximum pressure the seal could withstand. At the time of the seal testing, the minimum design requirement was 20 psi, as specified at 30 CFR 75.335 (2005). New emergency temporary standards for seal designs were promulgated on May 22, 2007, with a minimum requirement of 50 psi under specified conditions. However, it will be shown that the evaluation of the polyurethane seal performance as designed to meet the older 20-psi criterion can be relevant to the design requirements under the new standards.

Jan 1, 2008