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By Mark Osborne, Ray D. Peterson, C. Edward Eckert

"The theoretical melting energy requirement for a typical hypoeutectic aluminum-silicon alloy is approximately 520 BTU/lb. It has been demonstrated, however, that even a state of the art secondary processing-automated lost foam casting operation can exceed this value by at least an order of magnitude when the actual thermal energy input from melting to solidification is monitored. Metal transfer and holding operations constitutes over 65% of this expenditure. The authors present relative benchmark energy expenditure information by unit operation for an offsite melting/lost foam casting line with a daily throughput in excess of 100,000 lbs. Efficiency improvements through optimization of the current process, and anticipated energy values at the culmination of a U.S. Department of Energy sponsored project to develop, integrate and demonstrate an advanced melting, transportation, and dispensation system will be cited.IntroductionThe size of the U.S. aluminum remelt pool was approximated to be 14.21 billion kg (31.27 billion pounds) by a recent study?, with the engineered castings (foundry) sector accounting for 3.25 billion kg (7.16 billion pounds) or 23% of that total. This study considered overall process yield and all major contributors to scrap. The values cited, therefore, are more meaningful than simply tabulating annual pounds shipped by sector.The foundry sector consists of Sand Castings, PM Castings and Die Castings categories appearing in Figure 1. All other categories comprise the wrought alloy sector. Wrought alloy production enjoys an energetic benefit from both scale and a relatively continuous operation. Many foundry operations, however, operate in batch mode at less than design metal throughput with characteristically longer melt holding periods. Since any detention of molten metal beyond melting represents an overhead use of energy, melt holding (secondary) energy expenditures can appreciably inflate melting energy requirements in the foundry."

Jan 1, 2009

By Peter Reinders, Dirk Hummel

This paper describes a newly developed Surface Remote Blasting System (SURBS) for electronic detonators, which is currently being introduced into surface blasting applications. The rationale for developing the SURBS was to meet key needs of mine operations, such as minimizing the shutdown time and the capability to conveniently initiate blasts in difficult terrain from a safe distance. Increased distance from the blast site, combined with a good overview of the site enables maximum safety during blasting. The system also removes the inconvenience of running long firing cables. The SURBS consists of the field-proven detonator and equipment technology of an existing electronic detonator system, a Surface Remote Blasting Box and a Surface Remote Blaster. The Surface Remote Blaster is the Master unit and controls the Remote Blasting Box via encrypted radio communication using a sophisticated safety technology, which guarantees that the highest safety standards are maintained.

Jan 1, 2005

By T. G. Joseph, M. Bolster, M. Curley

"High tirerim loading on haul trucks operating on rough ground frequently manifests as mechanical separations and rim base cracking caused by cyclic fatigue. This paper provides an understanding of the impact of high loads on rim component life and tire footprint, bulge, and deformation behaviour; and develops a maintenance planning tool to predict strain implications of high g loading for a given rim location. Loading tests and analyses were conducted for a tirerim arrangement under increasing load and internal tire pressure. Graphical models were developed, allowing higher g load extrapolation predictions for specific rim components.KEYWORDS g load, Mining, Model, Prediction, Rim, Strain, Tire bulge, Tire footprint, Ultra-class vehicleRÉSUMÉ L’application d’un chargement élevé sur le système pneu/jante de camions de transport rou¬lant sur des terrains accidentés se manifeste fréquemment par des séparations mécaniques et une fissure à la base de la jante engendrée par une fatigue cyclique. Cet article nous permet de mieux comprendre l’incidence de l’application de charges élevées sur la durée de vie des composantes de la jante ainsi que sur l’empreinte, la hernie et le comportement de déformation des pneus. Il développe également un outil de planification de l’entretien visant à prévoir l’incidence des contraintes en cas d’application d’un chargement g élevé sur un endroit donné de la jante. Des essais et des analyses de la charge ont été effectués pour un agencement pneu/jante soumis à une charge et une pression interne du pneu croissantes. Des modèles graphiques ont été développés, ce qui a permis d’établir des prédictions sur la base d’une extrapolation du chargement g plus élevé appliqué à des composantes spécifiques de la jante.MOTS CLÉS charge g, contrainte, empreinte du pneu, exploitation minière, hernie du pneu, jante, modèle, prédiction, véhicule ultralourdINTRODUCTION The purpose of this paper is to report on a proposed and trialed tire performance test based on data obtained from controlled testing that is used to predict the impact of high g loading on hauler rims and tires with greater accuracy. For example, for many years oil sand mining operations have expressed qualitative beliefs that an impact load of the magnitude experienced by a rim and tire arrangement is not detrimental to a rim as a stiff component; however, mining equipment components are subjected to cyclic loading where failure can result from repeated load/unload activity, truncating the peak region of a stress–strain response and resulting in fatigue failure at a stress value that is less than the peak value. The outcome reported by oil sand haul truck maintenance groups indicates they have realized that most high g impacts—such as those experienced by hauler tires and rims operating on poor ground conditions—can result in failure due to cyclic loading, where higher loads require fewer cycles for failure. This high-level loading and the resulting strain transmitted to the rim is evident in the results of the laboratory testing presented in this paper."

Jan 1, 2019

An accelerated and coordinated program of coal research is believed by many to be a necessary step in assuring coal's proper position in the expanding energy market. The President's Advisory Committee on Energy Supplies and Resources Policy, for example, made the following recommendation: We recognize that coal is a great national asset and endorse a cooperative study to determine what research and development could be undertaken. The coal industry and both Federal and State Governments should participate in this study and its costs. Representatives of the coal industry have agreed that such a study should be initiated. Accordingly, Felix E. Wormser, Assistant Secretary - Mineral Resources, United States Department of the Interior, requested the Bureau of Mines and Bituminous Coal Research, Inc., to conduct a survey of current research on bituminous coal. In addition to this survey, studies were made to determine research projects that would be of value to the coal industry.

Jan 1, 1956

By O. C. Blade

"An important function of the Bureau of Mines is promoting the conservation and more efficient utilization of a natural resource. Petroleum is such a resource, and its utilization depends to a considerable degree upon its characteristics. For this reason the Bureau of Mines, over a period of years, has analyzed many samples of crude petroleum by the Bureau of Mines Hempel method 3/ and published complications of crude-oil analyses. Among such publi¬cations are several reports presenting analyses of crude oils from fields in Oklahoma. The most recent of these relates to samples from southern Oklahoma. 4/ The present paper provides additional analyses of Oklahoma crude oils, largely from areas and formations not heretofore represented in published reports. The analyses of 248 samples from 153 fields are presented individually and collectively in the tables of this report.Crude oil has been produced in Oklahoma in commercial quantities since 1891, and peak production was reached in 1947. The State's cumulative production to January 1, 1944, is, according to the American institute of Mining and Metallurgical Engineers, 5,186,466,000 barrels. 5/ The annual production of crude petroleum in Oklahoma for each year from 1891 to 1943, inclusive, is given in table 1."

May 1, 1945

By A. Rajan

"Drawing upon the experiences of a gold extraction plant startup in the Southern Pacific, this paper will describe the importance of the commissioning phases to the project outcomes to achieve early target production despite an overall time compression to attain full plant production. Some of the highlights of the paper include: impact of roles played by the Owner’s construction and operations representatives during project commissioning, the formation of a capable and competent “Mod Squad,” availability of trained operating personnel, control over work priorities and the scope of work needed to bring the plant to safe initial operations. The commissioning team comprised subject matter experts skilled in process technology supported by “generalists” thoroughly conversant in overall plant operations. The merits of a structured team approach to brainstorm and resolve commissioning challenges as opposed to direction from individual subject matter experts is discussed. IntroductionStartup or commissioning is a unique period in the life of a project. Each stage of a project-exploration, feasibility, design, construction, commissioning, initial operations and continuing operations-requires special talents, know-how, and practices. Each stage makes particular demands of the people involved. Initial operations are no exception.Having experienced the 1997 startup phases of oxide and sulfide facilities for a gold extraction plant at a remote island in the Southern Pacific, I can attest to the many challenges and rewards. Commissioning for both facilities was extremely successful and brought the entire project on line well ahead of the targeted completion dates. Using this specific project as an example, this paper will highlight some of the key features of project commissioning. In this paper, the term “pre-commissioning” denotes all activities that lead to mechanical completion; “commissioning” occurs when feed is introduced; and “initial operations” are defined as the duration when operations accepts the system/facility and takes over."

Jan 1, 2000

By Patrick J. Hannigan

The pile foundation designer typically performs a subsurface exploration program and static pile capacity calculations before selecting a pile foundation type, length, and capacity. During construction, a pile installation criterion must be established to meet these design requirements. This installation criterion usually consists of a minimum penetration resistance or blow count to confirm pile capacity and may also include a minimum embedment requirement. This text will focus on use of wave equation analysis and dynamic measurements to meet design requirements. BEFORE THE WAVE EQUATION Since the mid-1800s, over 450 dynamic formulas for pile driving control have proliferated. In their simplest form, these formulas relate hammer energy to the work of soil resistance, or simply: W ? h = R ? s (1) Where W = ram weight h = ram drop height or stroke R = pile capacity s = pile penetration per blow

Jan 1, 1990

By David O. DeGagné

While mine backfill plants are becoming increasingly more automated and instrumented, especially with paste fill operations, underground backfill distribution systems have hardly changed over the years. While fill properties are appropriately measured in the preparation plants, as backfill enters the mine borehole, the technology for control, data gathering and reporting is somewhat lacking. Mines typically experience problems with borehole and pipeline plugging, pipeline bursting, bulkhead failure and exposed fill sloughing. With adequate instrumentation of the backfill system it is possible to obtain a complete, continuous and detailed picture of the entire filling operation from preparation to post-pour. Good data will, over time, provide the basis for needed improvements of backfill systems and will be essential to safer, more efficient and less costly fill practices. This paper will review the areas of the filling operations where monitoring would prove critical to eliminate failures such as pipelines, bulkheads, fill exposures, stope walls, etc. The types of monitoring systems currently available will be reviewed and potential areas for development will be highlighted.

May 1, 2001

By Noel N. Moebs

This report summarizes a Bureau of Mines study on the use of geotechnology to identify and reduce ground control hazards at slate quarry operations in eastern Pennsylvania. The major ground control hazard is falling rock, attributed to weathered bedding plane faults, which weaken quarry highwalls. It was demonstrated that these faults can be detected outside of the quarry perimeter using surface resistivity measurements. Falls of ice from quarry highwalls constitute a second major hazard, which requires water diversion as a basic control method. In situ stresses seemingly cause only minor problems in slate extraction although they could interact with developed stresses and lead to failure of barriers between quarries. Pull tests showed that rockbolts anchor firmly in slate and should prove effective in securing loose rock.

Jan 1, 1986

By D. Brady

The need for onsite gas monitoring during, or following, a major incident at an underground coal mine has long been recognised. Recommendations from inquiries following Queensland mine disasters have included ?qualified persons and equipment for rapid analysis of gas samples be available in times of emergency? and that ?this may be accomplished by either mobile laboratories or laboratories established in each mining locality.? Following the Moura No. 2 disaster, the Queensland Government allocated funds to Simtars for a mobile laboratory to respond should such a disaster occur again in the future. This vehicle was commissioned in 1997 and has been used at many mine sites under a wide range of scenarios. Simtars, armed with over ten years of operational experience with this mobile laboratory, has taken an active role in the design and construction of a modernised replacement unit. With a twenty point tube bundle system and ultrafast gas chromatograph the result is, arguably, the best equipped mobile gas analysis laboratory for mine emergency response in the world. This paper outlines the features of the new laboratory, its capabilities and the philosophy behind the design and inclusions.

Jan 1, 2012

By Maurice E. Bailey

The purpose of this study is to determine worker acceptance of modified mine equipment at various intervals during a twelve month period. A survey instrument was administered to the workers by two experienced miners in four interviews. All four interviews showed a significant positive response to all modifications, except the small size of the cab of the shuttle car; however, the small size produced significant negative responses with respect to comfort in each of the four interviews. Initially, (interviews one and two), there were significant negative responses with respect to manufacturer receptivity to operator suggestions and program management follow-through on operator suggestions; however, the third and fourth interviews showed no significant negative responses with respect to these items. Likewise, there were significant neutral responses in the first two interviews; however, the third and fourth interviews showed no significant neutral responses with respect to these items.

Jan 1, 1975

By Francis W. Gray

Introduction Extensive undersea coal-mining has developed on both the east and west coasts of Canada, and at this time some four million tons, or 25 per cent of the total output of Canadian coal, representing a pit-mouth value of $14,000,000 per annum, is coming from coal seams lying under the sea. Of the coal now being mined in Nova Scotia, 55 per cent comes from under the sea, and this proportion is likely to increase. The Province of Nova Scotia is at this date receiving in royalties paid upon coal ?removed from undersea areas a sum exceeding $400,000 per annum. The subject is, therefore, one of special interest to the Mining Society of Nova Scotia and the Canadian Institute of Mining & Metallurgy, and while this paper will deal chiefly with undersea coal-mining in Nova Scotia, an attempt has been made to summarize the development of mining practice in the winning of undersea coal in other parts of the world, with the hope that such a recital may assist in the assessment of local problems. The connection between the mining of coal under the sea and an insular or maritime geography is obvious in regard to Great Britain, Japan, Vancouver Island, Australia, and Cape Breton Island, and also in regard to the curious conformation of Chile; the tendency towards growth of a mercantile marine and naval eminence is equally obvious where coal is mined at tidewater. But, there is the further and less favourable significance that the mining of coal under the sea is associated with poverty rather than with abundance of coal reserves.

Jan 1, 1927

The development of research activities at Risdon and the implementing of a policy of instrumentation in plant processes have, in recent years, entailed a considerable increase in research staff and created an urgent need for more space and modern laboratory facilities. The existing laboratories have been in use for 25 years and are now inadequate. New buildings have been authorized.The new buildings will comprise, firstly, a laboratory building of three floors giving a totai .floor space of approximately 11,000 sq.ft., and a pilot plant building as an annexe to the laboratory building, of approximately 4,900 sq.ft. The laboratory building will accommodate from 20 to 22 research workers, and additional plant operatives will be used for the control of processes in the pilot plant building. The new buildings are designed to provide facilities for three principal functions; the investigation and improvementof existing processes, the development of new processes up to the pilot plant stage, and the control and maintenance of instruments.LOCALITY AND ORIENTATION OF BUILDINGSThe site of the buildings is elevated ground on the eastern side of the main plant, near the main entrance and general office building. There will be no obstruction to sunshine at any time of the day, and the laboratory building will command views of wide radius from wooded hills across the River Derwentto the open sea on the south-eastern quarter.The buildings are located to provide space for future extensions. The main laboratory building faces approx...

Jan 1, 1949

By Howard A. Perko, M. Mae Benvenga, Heather H. Trantham

Displacement of soil and groundwater during helical pile installation can produce excess pore water pressures (PWP) in fine-grained soils. Pore water pressure reduces effective stress in the soil immediately adjacent to the helical pile shaft and near the helical piles. Previous studies have shown generation of PWP may affect the capacity to torque ratios of the helical bearing elements. Large diameter helical piles that generate much of their torque and capacity from shaft adhesion are affected by PWP and therefore exhibit significant pile "freeze" after installation. Computer modeling is used herein to evaluate PWP immediately adjacent to helical pile shafts during installation in various soil types. The models show the degree and distance from the shaft that is influenced by PWP during installation and the amount of time required for the PWP to dissipate. Pile freeze has been measured on several project sites by re‐torque measurements. These re-torque data are compared with computer modeling and correlations between saturated hydraulic conductivity and dissipation time are presented and discussed. INTRODUCTION Helical piles are full-displacement piles, meaning installation does not produce drill spoil. Soil is displaced laterally as the pile progresses into the ground. This displacement of soil causes an increase in PWP, which reduces adhesion between the pile and the soil. For helical piles with small-diameter shafts, adhesion contributes little to the overall capacity and torque of the pile, so PWP changes are not typically considered in determining pile capacity. In modern construction, the use of larger diameter helical piles has become very common. For large-diameter helical piles, changes in PWP immediately adjacent the shaft can be quite large during installation. Increased pore water pressure and reduced adhesion can have a temporary effect on pile capacity and installation torque.

Jan 1, 2018

By John E. Lens

How much trouble can narrow vertical fissures in bedrock cause on a shallow bedrock site? Enough trouble so end-bearing H-piles range between 8 and 100 feet long in a single pile cap and tiebacks range from 40 to over 100 feet long within a 10 foot wall span. Sloped bedrock surfaces also complicated the tieback installation as the drill casing followed the sloped rock surface while drilling and caused unanticipated bending (and sometimes breaking) of the drill string. Warned via pre-construction rock probes and cores reaching over 80 feet deep at the Winooski, Vermont project site, the design and construction team expected anomalies in pile driving and tieback drilling due to fissures in the bedrock filled with soil and weathered-rock. The degree of abruptness in the variability in the rock surface, and its impact on pile driving and tieback drilling were less predictable. Close monitoring of pile and tieback installation, redesign of pile caps, and lengthened tiebacks overcame these anomalous fissures. This paper shares the lessons learned for overcoming these geologic challenges to benefit designers, contractors bidding the work, and ultimately, the owner, with lower contingencies.

Jan 1, 2006

By S. Z. Pethö, H. Yilmaz

South Deep Mine is currently undertaking numerous voidfilling projects using low strength aerated cement products. Representative samples from one such site, were taken and tested for the load deformation behaviour under uniaxial loading conditions. The process of sample collection, laboratory preparation and testing are explained in detail. The results of testing were analyzed and the critical aspects pointed out as a design consideration to be implemented as part of the quality control and assurance program. Design aspects and underground application of the aerated cement product are discussed for the particular site on 58 level SV1. A simple instrumentation has been designed and installed to enable monitoring of any future movements in this area. A quality control and assurance process has been formulated enabling all aspects of the support installation in this excavation to be signed off.

Jan 1, 2003

By Jacques J. Eksteen

Any effort to improve the metallurgical control of industrial furnaces employed in the primary extraction of high carbon ferroalloys are bound to fail unless the variability of the melt is not fully accounted for. A number of sampling campaigns were performed on both 3phase AC submerged arc and single phase DC open arc furnaces at different smelter sites in South Africa where High Carbon Ferrochrome is produced. It was found that the heterogeneity between multiple samples during a single taps were much higher that for heterogeneity found within a sample. Moreover, this heterogeneity (as quantified by the relative standard deviation per tap) varied with the operating conditions of the furnace, the element monitored and the type of furnace. A relationship was found between the relative standard deviation of certain elements and the degree of subcooling of the melt.

Jan 1, 2006

By S Dunham

A cross-discipline approach combining geology, metallurgy and mine planning, geometallurgy is seen as the next logical advance in improving the design and operation of mining businesses. This rapidly evolving field is focused on realising the value that has often been lost in the chasms between the aforementioned technical silos. When successful, the geometallurgical approach promises the ability to tailor mining and mineral processing development and operational options more closely to the characteristics of the resource with resulting lower costs (both capital and operating), improved recoveries and fewer project failures.As with any technological (or managerial) change, there will be side effects from the success of the geometallurgical approach that will impact areas beyond obvious linkages between geology and processing. Some of these effects have the potential to be beneficial to the resource industry and society in general. Beyond the basic geometallurgical promise of closer alignment between processing design/strategy and the multivariate 3D spatial characteristics of the mineralisation, this paper discusses the broader implications and ramifications of the emergent geometallurgical approach: enhancing exploration and discovery; improving project development success; achieving sustainability in an industry working with non-renewable resources; in a world of increasingly hard won license to operate, improving the management of potentially harmful by-products and waste materials (with knock on effects for proactive management of closure issues); smarter approaches to energy management and thus optimisation of projects with respect to carbon footprint; and potential to re-value assets and thus realise a strategic advantage in the area of acquisitions, divestments, mergers and take overs. The authors strongly believe that companies that actively engage with the above issues (and ensure that technical efforts in the area of geometallurgy are not isolated from the larger value chain activities of the firm) will be able to exploit the opportunities that consequentially arise. These early adopters will gain first mover advantages. Firms taking the broad view of geometallurgy will have an opportunity to maximise stakeholder value and win greater success than their less insightful competitors.

Sep 5, 2011

By LeRoy D. Loy

The disposal of excess overburden from surface mining can be accomplished by use of a reclamation technique entitled head-of-hollow or valley fill. This report attempts to assess current valley fill regulations and practices, identifies inherent benefits and deficiencies, and develops concepts to enhance fill technology.

Jan 1, 1978

By J. Adkins

This document presents a description of the results of a project aimed at producing a broad description of current mining training programs and an evaluation of their effectiveness with respect to reducing mine injuries. Aggregate training and injury data were used to evaluate the overall training effort at 300 mines as well as specific efforts in twelve categories of training course objectives. From such evaluations, recommendations were derived with particular emphasis being placed on identifying program characteristics that tend to be associated with effective training. Recommendations were also formulated with reference to role changes in industry and government interaction with respect to training programs, new or additional training programs, changes in the types of course materials and training methodologies, and recommendations concerning new areas for investigation.

Jan 1, 1976