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By Joel Lööw, Jan Johansson, Lena Abrahamsson

Industry 4.0 offers new possibilities to combine increased productivity with stimulating workplaces in a good work environment. Used correctly, digitalization can create attractive jobs in safe control room environments, which provide space for the employee’s full expertise and creativity. This is true also for the mining industry. But, to succeed, it is important to analyze the development from a worker’s perspective. What will happen to their work? What skills will be needed in the mine of tomorrow? We must also consider the risks, such as privacy issues, increased stress, and work-life boundaries. These questions must be understood if we are to create workplaces that can attract a young and diverse workforce to tomorrow’s mining industry. In this article, we try to illustrate what the new technology can mean for the individual miners. We formulate the notion of Mining 4.0 (Industry 4.0 in the mining industry), where we try to create an image of how the future might look from a miner’s perspective and how mining companies may navigate their way to a future that works for all miners. To illustrate the range of possible outcomes, we formulate two scenarios: one utopian and one dystopic. At the end of our article, we bring forward six recommendations that can be considered a beginning of a road map for the human side of Mining 4.0.

By Joel Lööw, Jan Johansson, Lena Abrahamsson

Industry 4.0 offers new possibilities to combine increased productivity with stimulating workplaces in a good work environment. Used correctly, digitalization can create attractive jobs in safe control room environments, which provide space for the employee’s full expertise and creativity. This is true also for the mining industry. But, to succeed, it is important to analyze the development from a worker’s perspective. What will happen to their work? What skills will be needed in the mine of tomorrow? We must also consider the risks, such as privacy issues, increased stress, and work-life boundaries. These questions must be understood if we are to create workplaces that can attract a young and diverse workforce to tomorrow’s mining industry. In this article, we try to illustrate what the new technology can mean for the individual miners. We formulate the notion of Mining 4.0 (Industry 4.0 in the mining industry), where we try to create an image of how the future might look from a miner’s perspective and how mining companies may navigate their way to a future that works for all miners. To illustrate the range of possible outcomes, we formulate two scenarios: one utopian and one dystopic. At the end of our article, we bring forward six recommendations that can be considered a beginning of a road map for the human side of Mining 4.0.

By Frank Pepe, Nestor Garavelli

The 2023 Rapid Excavation and Tunneling Conference (RETC) will be held in Boston, MA and will include the presentation of 133 papers divided into 20 technical sessions during the 3 day conference that were selected from over 200+ papers that were submitted to the committee. The selected papers are included within this book to provide a comprehensive recap of the conference while also providing a source of reference for contractors and engineers in the future. The selected papers will include contributions from all divisions of the tunneling industry plus risk management and best contract practices. Boston is known to the tunneling industry for its complex and difficult tunneling history, specifically of recent memory the Central Artery/Tunnel Project also know as the “Big Dig” of the 1980s and early 1990s. The selection of Boston as a host city was fitting from a historical perspective and as avenue for the city to present its upcoming tunnel projects. RETC began in 1972 with the idea of sharing ideas, design and project construction experience, and new technology, between contractors, designers, owners and suppliers. The ability to provide a single location every other year for all facets of the tunneling industry to gather and discuss the aforementioned was and still is viewed as a way to help the tunnel industry grow. The lessons learned from completed projects, the advancement of technology which could be implemented into design and the presentation of new projects by owners/designers and contractors allows for the limits and complexity of upcoming projects to be expanded beyond our current capabilities. Our industry has never been as busy as it currently is, and we are seeing more future projects coming out for solicitation across all business sectors. With the good fortune that all of us have been blessed with one of the biggest challenges that we have been faced with is the shortage of future management on all levels for our projects including the labor force. We all want our industry to continue to grow and succeed, our most important assets are the people that we employ. Investing in the education and continued training of our work forces to be up to date with the latest technology and methods is the key to our success. This also includes develop, recruiting and mentoring of young students graduating college to join our industry so that we can all continue to grow. We hope that all those attending the conference will have the ability to attend as many sessions as possible and to expand their network within our industry. As in past years, scholarship students will be in attendance and we encourage all to offer these students an opportunity to visit jobs, attend learning sessions or future internships to expand their interest in our industry that needs an injection of young engineers to contribute and lead our future Rapid Excavation and Tunneling Conferences. The program chairs wish to thank the session chairs, co-chairs, authors, and other members of the RETC Executive Committee for their dedication to this conference. Last but certainly not least, we give special thanks to the SME staff for their hard work and enthusiastic support in making this conference possible.

Dec 1, 2023

By Larissa Koroznikova, Steve Durkin, Bradley Drake, Michael Tuck

This paper presents the results from the investigation of the application of thermal fragmentation in Australian hard rock underground narrow-vein mining. Two geologically similar samples from an underground narrow-vein hard rock gold mine were collected to obtain a measure of the technology’s ability to recover ore by the creation of large thermal openings to assess the applicability of the thermal method. Particle size distribution showed a higher generation of fine product, − 2 mm, by thermal fragmentation compared with selective blasting by 31%. The Bond work index for thermal ore (12.62 kWh/t) is half to that of the blasted ore value (25.32 kWh/t). The average grindability obtained for the thermal ore sample was greater than the blasted sample by a factor of 2.44, a higher value indicating a decrease in the energy required to grind. The thermal fragmentation method generates product with higher dissolution of gold in cyanide, by 14% for the − 9.5 + 2 mm size fraction samples. Additionally, the thermal fragmentation results in higher production of − 9.5 + 2 mm material by 15 % compared with selective blasting.

By Larissa Koroznikova, Steve Durkin, Bradley Drake, Michael Tuck

This paper presents the results from the investigation of the application of thermal fragmentation in Australian hard rock underground narrow-vein mining. Two geologically similar samples from an underground narrow-vein hard rock gold mine were collected to obtain a measure of the technology’s ability to recover ore by the creation of large thermal openings to assess the applicability of the thermal method. Particle size distribution showed a higher generation of fine product, − 2 mm, by thermal fragmentation compared with selective blasting by 31%. The Bond work index for thermal ore (12.62 kWh/t) is half to that of the blasted ore value (25.32 kWh/t). The average grindability obtained for the thermal ore sample was greater than the blasted sample by a factor of 2.44, a higher value indicating a decrease in the energy required to grind. The thermal fragmentation method generates product with higher dissolution of gold in cyanide, by 14% for the − 9.5 + 2 mm size fraction samples. Additionally, the thermal fragmentation results in higher production of − 9.5 + 2 mm material by 15 % compared with selective blasting.

By Cem Şensöğüt, Özer Ören, Yaşar Kasap

The mining sector, which has an important place in terms of raw material and energy supply, is referred as a sector with one of the highest fatal accidents in comparison with other sectors. In this century, where occupational health and safety awareness has increased, it is important to review the past accident statistics and to determine the current deficiencies by using the information in the inventory. In this study, the Malmquist total factor productivity index (MPI) has been utilized to investigate the changes in the work accidents occurring in the Western Lignite Corporation (Turkey), where underground and surface production methods are applied, and to determine the measures to be taken. According to the results obtained, both the decrease in production amount and the increase in the number of accidents caused inefficiencies during the period in concern due to the expected 10-year economic life of the mechanized system operating in the underground production panel that came to an end in 2007 and the flooding took place in early 2017. Compared with the underground operations, it has been determined that production can be carried out at the appropriate scale despite the heavy working conditions encountered due to the changing climatic conditions and the progress of production in the surface operations.

By G. H. Sedahmed, S. A. Nosier, M. H. Abdel-Aziz, A. A. Mubarak, M. A. El-Naggar, E. G. Abdel-Aziz

The performance of a rotating fixed bed reactor in recovering copper from industrial waste solutions by cementation is studied under various conditions. The rotating fixed bed is made of stacked woven steel screens to take advantage of two features of screens: the ability to present large area per unit volume and their ability to promote high turbulence. Variables studied are initial CuSO4 concentration, bed rotation speed, mesh number of the screens and bed thickness. The presence of baffles was found to increase the rate of cementation. The data were correlated by a dimensionless mass transfer correlation suitable for the design and operation of large scale cementation reactors.

By G. H. Sedahmed, S. A. Nosier, M. H. Abdel-Aziz, A. A. Mubarak, M. A. El-Naggar, E. G. Abdel-Aziz

The performance of a rotating fixed bed reactor in recovering copper from industrial waste solutions by cementation is studied under various conditions. The rotating fixed bed is made of stacked woven steel screens to take advantage of two features of screens: the ability to present large area per unit volume and their ability to promote high turbulence. Variables studied are initial CuSO4 concentration, bed rotation speed, mesh number of the screens and bed thickness. The presence of baffles was found to increase the rate of cementation. The data were correlated by a dimensionless mass transfer correlation suitable for the design and operation of large scale cementation reactors.

By K. E. Yassin, A. Yehia, M. Amar

Phosphate fines (size ≤ 45 μm), from the Red Sea Region, Egypt, were subjected to beneficiation process to recover the phosphorite grains from such fines. The sample is characterized by low P2O5 content (18.78%) associated with gangue minerals such as silica (22.77% SiO2) and carbonate (2.01% MgO) indicating its low grade. Phosphate pre-concentrate was prepared by gravity separation, using Falcon, where 63.37% of the phosphate, with 24.94% P2O5, 1.46% MgO, and 10.54% SiO2, was firstly recovered reducing the mass flow to the subsequent beneficiation process. However, the gravity tailing was the feed for the reverse phosphate flotation using bench scale column flotation where oleic acid was used as a carbonate gangue collector and amylase enzyme as a phosphate depressant. Under the appropriate flotation conditions (0.1% amylase, 5·10−4 mol/dm3 oleic acid, and temp. 30 °C), phospho-concentrate assaying 0.61% MgO, 13.14% SiO2, and 27.85% P2O5 with a P2O5 recovery of 55.45%, was finally obtained without the use of expensive depressants, e.g., phosphoric acid or sodium silicate. A tentative flow sheet for the whole process was postulated.

By P. Zhang

The use of phosphate depressants in the cationic flotation of silica from francolite in the Florida phosphate industry is rarely practiced. The occasional use of gelatinized starch derivatives and pH adjustments to assure a slightly alkaline flotation feed slurry pH have been used in some processing plants to improve selectivity. This paper presents a preliminary laboratory comparison of several potential phosphate depressants for use with the flotation of siliceous phosphates. It was found that starch is ideal for floating fine (-35 mesh) silica from phosphate, while sodium tripolyphosphate may be the best for coarser (+35 mesh) feeds.

Jan 1, 2009

By J. R. Patts, A. B. Cecala, E. J. Haas

Exposure to respirable crystalline silica (RCS) remains a serious health hazard to the US mining workforce who are potentially exposed as various ore bodies are drilled, blasted, hauled by truck, crushed, screened, and transported to their destinations. The current Mine Safety and Health Administration (MSHA) permissible exposure limit (PEL) for RCS remains at approximately 100 μg/m3 , but it is noteworthy that the Occupational Safety and Health Administration (OSHA) has lowered its PEL to 50 μg/ m3 (with enforcement dates staggered through 2022 for various sectors), and the National Institute for Occupational Safety and Health (NIOSH) has held a 50 μg/m3 recommended standard since 1976. To examine a method for reducing RCS exposure using a NIOSH-developed video exposure monitoring (VEM) technology (referred to as Helmet-CAM), video and respirable dust concentration data were collected on eighty miners across seven unique mining sites. The data was then collated and partitioned using a thresholding scheme to determine exposures that were in excess of ten times the mean exposure for that worker. Focusing on these short duration, high magnitude exposures can provide insight to implement controls and interventions that can dramatically lower the employee’s overall average exposure. In 19 of the 80 cases analyzed, it was found that exposure could be significantly lowered by 20% or more by reducing exposures that occur during just 10 min of work per 8-hour shift. This approach provides a method to quickly analyze and determine which activities are creating the greatest health concerns. In most cases, once identified, focused control technologies or behavioral modifications can be applied to those tasks.

By J. R. Patts, A. B. Cecala, E. J. Haas

Exposure to respirable crystalline silica (RCS) remains a serious health hazard to the US mining workforce who are potentially exposed as various ore bodies are drilled, blasted, hauled by truck, crushed, screened, and transported to their destinations. The current Mine Safety and Health Administration (MSHA) permissible exposure limit (PEL) for RCS remains at approximately 100 μg/m3 , but it is noteworthy that the Occupational Safety and Health Administration (OSHA) has lowered its PEL to 50 μg/ m3 (with enforcement dates staggered through 2022 for various sectors), and the National Institute for Occupational Safety and Health (NIOSH) has held a 50 μg/m3 recommended standard since 1976. To examine a method for reducing RCS exposure using a NIOSH-developed video exposure monitoring (VEM) technology (referred to as Helmet-CAM), video and respirable dust concentration data were collected on eighty miners across seven unique mining sites. The data was then collated and partitioned using a thresholding scheme to determine exposures that were in excess of ten times the mean exposure for that worker. Focusing on these short duration, high magnitude exposures can provide insight to implement controls and interventions that can dramatically lower the employee’s overall average exposure. In 19 of the 80 cases analyzed, it was found that exposure could be significantly lowered by 20% or more by reducing exposures that occur during just 10 min of work per 8-hour shift. This approach provides a method to quickly analyze and determine which activities are creating the greatest health concerns. In most cases, once identified, focused control technologies or behavioral modifications can be applied to those tasks.

By Rambabu Pothina, Rajive Ganguli

The economics of a mineral processing circuit is dependent on the numerous sensors that are critical to optimization and control systems. The sheer volume of sensors results in mines not being able to keep the sensors calibrated. When a sensor goes off calibration, it results in errors which can severely impact plant economics. Normally, these errors are not detected until the error grows and becomes a large (“gross”) error. Undetected errors are not remedied until the next calibration, which on average are a year apart Beamex (2019) [1] across all industries. Classical statistical methods that depend on linear relationships between input and response variables are typically used to find gross errors, but are not effective for highly non-linear and non-stationary operations in mining and mineral processing industries. Calibration of sensors is time-consuming and generally requires physical intervention that results in equipment downtimes causing production losses. Therefore, in situ detection methods are warranted that do not require physical removal of sensors to compare with standard measurements or well-calibrated sensors. Data-mining based techniques and algorithms have high success rate in tackling such problems. This paper presents results from a groundbreaking multi-year big data research project whose goal was to develop data-mining-based original techniques in a multi-sensor environment to identify when sensors start to stray, rather than wait for errors to grow. The carbon stripping (gold) circuit in the Pogo Mine of Alaska was selected for this project. Maintaining strip vessel temperatures at optimum levels is crucial for maximizing gold recoveries at Pogo, and hence the focus was on the temperature sensors of the two strip vessels. An automated algorithm to detect errors in strip vessel temperature sensors was developed that exploited data from multiple sensors in the strip circuit. This algorithm was able to detect with a high success rate when bias errors of magnitude as low as ± 2% were artificially induced into strip vessel temperature data streams. The detection times of about 1 month were much less than the industry average calibration frequency of 1 year. Thus, the algorithm helps detect errors early, without stopping the circuit. The algorithm alarms can serve as triggers when calibrations are done. Experimental methodology along with results, limitations of algorithms, and future research are also presented in this paper.

By Rambabu Pothina, Rajive Ganguli

The economics of a mineral processing circuit is dependent on the numerous sensors that are critical to optimization and control systems. The sheer volume of sensors results in mines not being able to keep the sensors calibrated. When a sensor goes off calibration, it results in errors which can severely impact plant economics. Normally, these errors are not detected until the error grows and becomes a large (“gross”) error. Undetected errors are not remedied until the next calibration, which on average are a year apart Beamex (2019) [1] across all industries. Classical statistical methods that depend on linear relationships between input and response variables are typically used to find gross errors, but are not effective for highly non-linear and non-stationary operations in mining and mineral processing industries. Calibration of sensors is time-consuming and generally requires physical intervention that results in equipment downtimes causing production losses. Therefore, in situ detection methods are warranted that do not require physical removal of sensors to compare with standard measurements or well-calibrated sensors. Data-mining based techniques and algorithms have high success rate in tackling such problems. This paper presents results from a groundbreaking multi-year big data research project whose goal was to develop data-mining-based original techniques in a multi-sensor environment to identify when sensors start to stray, rather than wait for errors to grow. The carbon stripping (gold) circuit in the Pogo Mine of Alaska was selected for this project. Maintaining strip vessel temperatures at optimum levels is crucial for maximizing gold recoveries at Pogo, and hence the focus was on the temperature sensors of the two strip vessels. An automated algorithm to detect errors in strip vessel temperature sensors was developed that exploited data from multiple sensors in the strip circuit. This algorithm was able to detect with a high success rate when bias errors of magnitude as low as ± 2% were artificially induced into strip vessel temperature data streams. The detection times of about 1 month were much less than the industry average calibration frequency of 1 year. Thus, the algorithm helps detect errors early, without stopping the circuit. The algorithm alarms can serve as triggers when calibrations are done. Experimental methodology along with results, limitations of algorithms, and future research are also presented in this paper.

By Tom Dettweiler, Robina Sharpe, Wright. Michael

The International Seabed Authority and a number of countries have or are in the process of developing environmental impact assessment guidelines and legislation for seafloor mineral development. The formal decision to grant a project an environmental permit is based on an environmental and social impact assessment (ESIA), culminating in an environmental impact statement (EIS). The EIS needs to be supported by sufficient data upon which an assessment of impacts can be made and mitigation measures developed. Given the remote locations of many seafloor prospects, collection of sufficient environmental data to inform an EIS is often a difficult, expensive and lengthy process.

Sep 1, 2014

By Irving D. Cohen

In order to overcome our reliance upon foreign energy sources for both crude supply and finished products, we must realize the goals proposed by Project Independence. In general this involves expanding production of existing and new oil, gas, and coal resources, utilizing and improving nuclear technology and the developing of new energy sources such as solar, geothermal, oil shale, tidal, wind and stimulation techniques. There is a continuing debate, both in the scientific community and the consuming public as to the potentiality of nuclear power generation being cost effective and environmentally and safety conscious. The development of new sources of energy does not occur overnight; it is rather a continuing effort in time and money to achieve the goal of providing energy to an ever increasing demand. The public has been accustomed to the availability of energy whenever and wherever it was needed. The era of "energy gluttony" has begun to fade into the realm of "energy awareness". Unfortunately, it required the action of another country to bring the picture that has been discussed many times in the past by energy suppliers into correct focus. Nevertheless, the public responded by conservation efforts to reduce energy wastefulness. Still, the demand for foreign importation of energy supplies is on the rise. What is our recourse? The largest known unexploited energy resource available in the United States is our coal resources. Moreover, the Department of the Interior has noted that 63 counties in Montana, Wyoming, and the Dakotas hold 60% of the nation's least expensive strip minable coal. This western coal is the most abundant and least costly Fossil Fuel in the United States. It is acknowledged that western coal is an important input in meeting the energy needs of our nation.

Jan 1, 1976

By Robert C. Freas

While on the surface limestone marketing may appear mundane, it has continued to provide a series of challenges beyond the realm normally envisioned with this industry. This paper presents a case history of a mature and well-established quarry company that has attempted to keep pace with an ever-changing economy. It examines the impact of socio- economic and technological factors on the company's marketing efforts, and looks at the role of both short and long range planning. The realities which have had to be faced and how product requirements have been kept in balance with production restrictions are also discussed.

Jan 1, 1981

By G. Tiess, S. Mujiyanto

Indonesia is a fast growing democratic developing country comprising more than 17,000 islands, founding member of ASEAN and a member of the G-20 major economies. It is one of the most highly mineralised countries in the world, the mining sector playing a pivotal role in the country's economy. In 2001, the Decentralization Law No. 22/1999 came into force and caused a transfer of authority and responsibility from central to regional and local administrative governments. The new Mining Law of 2009 substituted its 40 year old predecessor, but lacked detailed regulations for its implementation. These were only issued in 2010, which lead to a period of great uncertainty for investors in the mining industry. The new legislation intends to foster domestic economic development, which may be interpreted as protectionist policy. For the development of a sustainable mineral resources policy, further endeavours will have to be made.

Jan 1, 2011

By B. Burke, R. Colquhoun, K. Thomas, R. Walton, D. Fentie

The new Roasting Facility at Barrick’s Goldstrike Mine in Nevada, U.S.A. was developed to process 12,000 tons per day of refractory gold ore. The process consists of crushing, dry grinding, roasting, extensive gas purification, calcine quenching and leaching in the presence of activated carbon. The new plant is integrated into the existing Goldstrike facility, treating ore from both open pit and underground sources. The process design, procurement, construction and commissioning of the Roaster facility was performed successfully over a 3½ year period with peaks of 400 engineering personnel and 950 construction personnel supporting the project. The US$330,000,000 project was completed ahead of schedule and under budget. The commissioning was well planned and proceeded smoothly through a rapid start-up to achieve all primary goals within three months of the start of processing of ore.

Jan 1, 2001

By Will Jansen

When Enron rocked the United States with its Titanic-sized financial accounting scandal, miners and metallurgists were probably too busy on the mine sites in remote locations to wonder about its ripple effect. But then Enron sank, Arthur Andersen tanked and the list of scandals, costing billions of dollars, continued to ripple. Followed by the Public Company Accounting Reform and Investor Protection Act of 2002 (Sarbanes-Oxley), the recent credit crunch and weak economy, the currents from Enron?s collapse eventually washed right into the mine and the mill. These events placed intense scrutiny on metals production accounting processes as traditional semi-qualitative metal accounting practices provided insufficient credibility and transparency. ?There is growing intolerance of organizations that are unsure about the location of thousands of tonnes of ore, which will typically lose 10 to 15% of their notional value on the way to the concentrator,? Rob Morrison wrote in the opening chapter to An Introduction to Metal Accounting and Balancing. ?If the measurement and forecasts also contain qualitative (fudge) factors, a very real suspicion might emerge about just how much metal might disappear (by theft or misplacement) before detection becomes likely.? Metallurgical accounting, put simply, is the tracking and reporting of the quantity and quality (tonnage and grade, usually) of materials entering or leaving each stage from source to product for a specified accounting period. Lacking an accounting standard, metals accounting in precious metal operations has been performed in an ad-hoc, informal manner, leading to numerous errors and unidentified potentially significant inefficiencies and financial losses. As a result, mining companies are beginning to examine the quality of their metals accounting systems since they form the basis of mining company?s financial accounts and reports. As part of an effort to create that accounting standard in the mineral industry, University of Queensland?s Julius Kruttschnitt Mineral Research Centre published the textbook An Introduction to Metal Accounting and Balancing in 2009. While development of a textbook and standard are significant steps forward, the challenge in the precious metals industry is in the application of some of these suggested practices. Though improving process transparency and precious metals accounting reporting accuracy is a key driver for change from the financial side, perhaps even more important is the potential benefit to operational performance that comes with better measurement, accounting and reconciliation systems. Loss of precious metals, processing of waste and inefficient mining and processing systems are all problems that are faced in an operation on a daily basis that can help be resolved through improvements in metal accounting and reconciliation. The financial consequences of such operational inefficiencies and bad decisions based on poor information are arguably greater than consequences of fraudulent accounting. Large discrepancies between mine and mill measurement systems that measure the quantity and quality of valuable material currently exist. Some of these are expected because of statistical variation, but inherent random measurement variation is sometimes an insufficient explanation. Though the mill can usually make much better production estimates through their measurement systems (that is, less variation), this knowledge rarely benefits the mine. 3 Moreover, even if the mine does a reasonably good job of estimating expected production at the grade control level (in situ), issues such as blast movement, poor mining practice and inefficient ore/waste classification make for a disconnect between the in situ estimates of the mine and the estimates from the concentrator. This inhibits effective evaluation of the reserve and grade control models using concentrator estimates. Linking the two ends, mining and concentration, is a neglected area sorely in need of an overhaul. Hence the need for improved mine to mill reconciliation ? the area of comparing, balancing and adjusting production estimates between mine and mill for consistency in reporting.

Jan 1, 2009