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By Yong Pan, Srivatsan Jayaraman Sridharan, Purushotham Tukkaraja

Block cave mining method poses unique ventilation challenges compared to other underground metal mining methods. This research study focuses on assessing the airflow behavior in regulated airflow distribution systems by developing a 1:100 scaled block cave experimental model and a numerical model. This study also investigated gas flow behavior under various airflow conditions. Based on our findings, we observed that reduction in particle size and porosity of caved materials, decrease in cave footprint, and closure of undercut drifts would increase cave airflow resistance. The increased airflow is found beneficial for gas dilution regardless of its source locations, while the regulated airflow distribution system might deteriorate gas dilution situation when the source is located in the extraction drifts.

May 12, 2022

By Jose F. T. Agapito

The mining engineer must be able to predict the structural behavior of the rock around underground openings so that he can answer questions relating to safety and economics. With the present status of rock mechanics knowledge, exact predictions cannot be attained and approximate idealizations are made. As a first approximation, structural design makes use of theory, laboratory testing of rock properties, and available experience from excavations in similar rock formations. However, realistic design can usually be obtained only after in-situ observations and measurements are made. After all the information is collected, judgement and experience play a most important role in the final formulation of the design. This paper describes part of a geotechnical program which was instrumental in obtaining information for the design of large oil shale pillars. The work was carried out during 1971 and 1972 in the experimental mine of the Colony Development Operation. Colony is an oil shale venture formed between Atlantic Richfield Company, Operator, The Oil Shale Corporation, Cleveland-Cliffs Iron Company, and Sohio Petroleum Company to conduct research and development in mining and retorting of oil shale, The property is located in the southern edge of the Piceance Creek Basin in northwestern Colorado, approximately 250 miles west of Denver (Figure 1) . Mining was conducted by the room-and-pillar method in a 60-ft high portion of the Green River Formation at a depth of 600 to 850 ft, Pillar dimensions are approximately 60 ft by 60 ft. The mine site is in the eastern face of the canyon containing the Middle Fork of Parachute Creek, The distance from the mine to the side of the mountain varies from 500 to 1,200 ft, and its height above the stream floor is approximately 700 ft.

Jan 1, 1974

By F. Turatti

Rio Tinto is one of the world's largest mining companies, involved in every stage of metal and mineral production, producing aluminium, copper, diamonds, coal, iron ore, uranium, gold and industrial minerals. Operations are in more than 50 countries in multiple continents and vary in location between large urban centres, regional industrial complexes and remote regions. A risk-based strategy was developed by Rio Tinto to manage its air quality impacts on a global scale. The strategy consists of three objectives ? improving air quality performance, developing industry leading practices and engaging and influencing in air issues. This paper discusses three major successes achieved this approach. Firstly, how air shed resources are managed in constrained air sheds. Secondly, how financial modelling is used to value air quality constraints, and thirdly, how a rigorous and comprehensive e-learning course is used to improve the overall level of air management knowledge of Rio Tinto?s environment managers.

Feb 27, 2013

By D. Blackwell, W. R. Reed, G. Ross, S. Peters, M. Shahan

Dust collectors for roof bolting machines generally use a dry box to collect the roof bolting material. Recently, an underground mining operation converted a dry box dust collector to a wet box dust collector with a unique exception from MSHA for testing purposes.Water is routed to the roof bolter fromthe main water line of the continuous miner. The wet box utilizes a water spray to wet the incoming material. Testing was conducted comparing the two different collector types. Respirable dust concentrations surrounding the roof bolter with the different collection boxes were similar. The main difference in respirable dust concentrations occurred when cleaning the dust boxes. The average respirable dust concentration during cleaning of the wet box was 0.475 mg/ m3, and during the cleaning of the dry box, the average respirable dust concentration was 1.188 mg/m3, a 60% reduction in respirable dust concentration. The quartz content of the roofmaterialwas high, ranging from 28.9 to 52.7%during this study. The results from this study indicate that using the wet box as a collector reduced exposure to respirable dust up to 60% when cleaning the collector boxes.

Aug 26, 2020

By Aleksandar D. Bugarski, Dylan A. Ritter

The results of laboratory characterization of tailpipe emissions for three “clean” engines that meet U.S. EPA Tier 4 final emissions standards were used to assess the viability and effectiveness of repowering existing engines and powering new mobile equipment with those engines as a control strategy for reducing exposure of underground miners to diesel aerosol and criteria gases. The evaluated engines were representative of those that achieve the emission standards through implementation of various in-cylinder emissions control strategies, use of crankcase filtration, and use of three types of exhaust aftertreatment systems: (1) diesel oxidation catalytic converter (DOC), (2) combination of DOC and the full-flow wall flow monolith diesel particulate filter (DPF), or (3) combination of DOC, diesel exhaust fluid (DEF) based selective catalytic reduction (SCR) system, and ammonia slip catalyst (ASC). The study showed that the highest reductions in concentrations of diesel aerosols in underground workings, in terms of both mass and number, could be achieved if the engines, preferably in all power classes, are fitted with viable DPF systems. The use of U.S. EPA Tier 4 final engines equipped with DOC and DOC/SCR/ASC systems could help operators to considerably reduce mass, but not number concentrations of aerosols. The emissions of two of the evaluated engines, one equipped with DOC and the other equipped with DOC/DPF systems, were characterized by substantial secondary NO2 emissions that would limit the viability of those engines for underground mining applications. It appears that the catalyst formulations used in the exhaust aftertreatment systems of the “clean” engines marketed to the underground mining industry need to be formulated to minimize the potential for generation of secondary NO2 emissions. The results indicate that the engines fitted with viable SCR/ASC systems present a low-NO2 alternative. All three “clean” engines were found to have low CO output. Therefore, due to nuances associated with the use of diesel-powered mobile equipment in underground mines, special attention needs to be paid to the selection and potentially optimization of “clean” engines for underground mining applications.

Feb 1, 2025

By RICKARD HANSEN

With vehicles frequently found in underground mines and tyres being a major fuel item, the risk of tyre fires will be severe underground. This study presents an in-depth analysis of tyre fires on mining vehicles to increase the knowledge of the risk, applying data from full-scale fire experiments and CFD simulations. It was found that the wheelhouse of the loader caused an increase in the flame tilt angle of approximately 10%, decreasing the flame impingement and heat flux downstream. The flame temperature of the drilling rig tyre was found to be approximately 7% higher than the loader tyre, increasing the risk of igniting adjacent fuel items. The construction of the wheelhouse/mudguard will contribute to a longer flame length by creating a fuel-rich environment. The CFD simulations predicted higher flame tilt angles for the drilling rig case for higher flow velocities, indicating the influence of a varying wheelhouse/mudguard construction and tyre geometry on the flame tilt angle. The construction of the loader resulted in a flow behaviour, where the short distance to the front mudguard/tyre and the separation of flow directly downstream of the protruding construction led to fire gases being steered past the front mudguard/tyre. In the drilling rig case, the longer distance to the front mudguard/tyre led to fire gases being directed towards the body of the vehicle after passing the area with flow separation. An increased knowledge of the tyre fire risk on mining vehicles and mitigating measures would improve the fire safety in underground mines.

Feb 10, 2022

By Ting Ren, Jon Roberts, Zhongbei Li, Ming Qiao, Jianming Wu

Spontaneous heating of coal continues to present a health and safety hazard in underground coal mines. The influence of seam gas composition on gas flow dynamics and distribution characteristics in the active longwall goaf has not been studied in-depth, and corresponding effective proactive goaf inertization strategies for preventing potential spontaneous heating from occurring have limited investigation. To advance this knowledge, an 80-m-height goaf model was constructed and developed based on specific conditions of an Australian underground coal mine, and onsite gas monitoring data was collated to verify base model results, which allowed for various scenarios of seam gas composition to be simulated and investigated with confidence. This study involved modeling five different gas composition scenarios for the goaf atmosphere, namely, 100% CO2 (case 1), 80% CO2 and 20% CH4 (case 2), 50% CO2 and 50% CH4 (case 3), 20% CO2 and 80% CH4 (case 4), and 100% CH4 (case 5). Simulation results show that O2 is primarily distributed at the middle and upper part of the CO2- dominant goaf model, while it is mainly layered at the floor level of the CH4- dominant goaf model. N2 is superior to CO2 in the goaf inertization for the CO2- dominant goaf model, whereas CO2 performs better than N2 for the CH4- dominant goaf model. The optimal inert gas flowrates for case 1 to case 5 are 1.5, 1.75, 0.75, 0.5, and 1.0 m3/ s, and the oxidation zone area is reduced by 55.76%, 67.21%, 58.04%, 78.17%, and 81.82%, respectively. The simulation results allow for increased insight and understanding of the gas distribution patterns in the active goaf with different seam gas composition and the development of corresponding proactive goaf inertization practices, thus minimizing potential spontaneous-heating-related hazards and improving mining safety.

Sep 26, 2023

By Jorge Alberto Soares Tenório, Denise Crocce Romano Espinosa, Morgana Rosset, Bárbara da Rocha Pereira

High-purity alumina finds application in various electronic industry sectors, with approximately 100 million tons of this compound being produced worldwide. Alumina is acquired through the mining process of bauxite, a rock composed of a mixture of minerals such as gibbsite, kaolinite, hematite, and either anatase or rutile. In 2020, both bauxite and alumina were included in the list of critical raw materials. Due to the demand for high-purity alumina production, the development of a methodology to remove impurities present in the leach liquor from bauxite processing by solvent extraction (SX) followed by precipitation has been widely studied. This work aims to obtain high-purity alumina from bauxite by a solvent extraction process followed by a precipitation step from the sulfur leach liquor obtained by the thorough dissolution of Al and Fe from bauxite. Different parameters were evaluated in the SX step, such as extractant type, pH, temperature, and volume-to-volume ratio. The results indicated that using Alamine 336 as an extractant at pH 0 and room temperature led to an extraction of 90% of Fe and 15% of Al. Aluminum sulfate was completely precipitated as aluminum hydroxide and 55% of Fe using NH4OH. After the calcination procedure, obtaining a 99.9% pure alumina was possible without generating a red mud-similar residue.

Dec 28, 2023

By Valeh Aghazadeh, Shima Barakan, Mina Soleymani, Ehsan Bidari, Morovvat Faridazad

Molybdenite is the most important molybdenum concentrate, which is mainly recovered as a by-product from porphyry copper deposits. Due to the low efficiency of purification processes such as flotation in the reduction of copper content of molybdenum concentrate to a standard level (i.e., less than 0.5 wt.%), further purification by a hydrometallurgical method is required. Although different types of chemical reagents were found to be effective in the leaching of copper minerals from molybdenum concentrate, the mechanisms of these processes remain largely unexplored. In this study, optimal conditions for maximum copper leaching (> 99%) were obtained at the concentration of HCl = 1 M, FeCl3 = 0.5 M, CuCl2 = 0.05 M, CaCl2 = 0.5 M at 75 °C, 500 rpm, and S:L = 1:10 during 60 min. CuCl2 was identified as the most effective leaching reagent for copper dissolution in agreement with Visual MINTEQ model results due to the formation of various types of copper chloride complexes. Furthermore, the electrochemical behaviors of FeCl3, CuCl2, and CaCl2 reagents before and after the leaching process were investigated by the cyclic voltammetry technique. The results of cyclic voltammograms at different scan rates verified the presence of copper chloride complexes, and ferric ions as the oxidizing reagents for better dissolution of copper sulfides. Based on kinetic study results of shrinking core models, both chemical and diffusion reactions controlled the copper leaching process with an obtained activation energy of 33.56 kJ/mol. For recovery of the leached copper, the precipitation process was done by the addition of Na2S at 45 °C, S/Cu = 1, and pH = 9.

Dec 26, 2022

By Amar Prakash, V. M. S. R. Murthy, Ajoy Kumar Singh, Avinash Paul, John Loui Porathur

Weak, layered, and fragile rock mass formation, if not supported properly, is subject to roof failure thereby affecting safety and productivity in underground coal mines. Though Central Mining Research Institute – Indian School of Mines Rock Mass Rating (CMRI-ISM RMR) based well-defined support design guidelines are established, still occurrence of roof failures in underground coal mines is a real matter of concern for mining engineers and researchers. Numerical modeling techniques are successfully used by several researchers by simulating rock mass condition for stability assessment of mine openings. The analysis becomes crucial in case of weak and fragile rock formation. The present research envelops the determination of 31 cases of rock load by CMRI-ISM RMR under different geo-mining conditions followed by the development of modified Rock Mass Rating (RMR), i.e., rock mass rating dynamic ( RMRdyn) by incorporating P-wave velocity as a new parameter. The rock load determined using RMRdyn and numerical models was correlated and found in close agreement. In addition, the deviation in rock load determined by all the three approaches, i.e., CMRI-ISM RMR, numerical modeling, and RMRdyn, was compared with the actual field data. The percentage deviation obtained in RMRdyn and numerical modeling is less compared to CMRI-ISM RMR.

Sep 1, 2023

By John Drew Ridge

Tables showing world trade in metallic mineral raw materials during the years 1953 through 1957 have been prepared for the following twenty-one commodities: alumina, aluminum, bauxite, chromite, copper concentrates, partly refined and fully refined copper metal, iron ore, pig iron, iron and steel (simple shapes), lead concentrates, lead metal, manganese ore, mercury metal, nickel ore, concentrates, and matte, nickel metal, raw pyrites, sintered pyrites, tin concentrates, tin metal, zinc concentrates, and zinc metal. In each instance, the amounts given by the importing country were used except when statistics from the importing nation were lacking, incomplete, or misleading. To show the considerable divergence between importing and exporting country totals for the same years, the complete mercury table is given and, in parallel columns, shows the comparable tonnages of importers and exporters. Tables for the other twenty commodities are presented in summary form. The data of the concentrate tables are used with those of the corresponding metals as a basis for a discussion of trade in concentrates versus trade in metals. The data of all twenty-one tables provide the basis for testing the thirteen rules governing international trade in metal raw materials which I first published in Mining Engineering for July 1955. Because the 1953 through 1957 data are far more complete and considerably more extensive than those on which the 1955 rules were based, it was found possible to deduce five additional rules and to modify three of the original thirteen appreciably. The full text of the eighteen rules is given.

Jan 1, 1960

By Howard S. Avery

The wear resistance of an alloy in heavy mill liner sections may be quite different from that of the same alloy in small balls and other light sections. This fact was established by means of a well standardized laboratory test that was validated for ball mill service. The salient properties of mill liner alloys, including austenitic manganese steels, medium alloy hardenable steels, and abrasion resistance cast irons are described, critically compared, and quantitatively ranked in terms of mill liner service. Where they are tough enough the high-chromium and other martensitic cast irons (e.g. Ni-Hard) promise maximum economy, but their section sensitivity is a limitation. To overcome this an extensive research program studied over a hundred experimental alloys, ranking them for heavy section abrasion resistance by means of the laboratory test. Computer analysis of the results provided a parabolic formula in terms of composition, the apexes of the parabolas providing optimum wear resistance. From the extensive family of parabolas one apex was selected for intensive study in experimental liners, pilot plant production, development of quality controls, and finally full scale production. This is a 19% chromium iron critically alloyed with nickel and molybdenum and hardened by heat treatment. It has excellent resistance to various types of abrasion, but its chief advantage is in heavy mill liner sections, where it has about 25% better abrasion resistance than the best of the quality controlled chilled Ni-Hards. It is also tougher. After production problems were solved, a number of ball and rod mill tests were arranged on a guaranteed performance basis. Two of these, representing about 138,000 pounds of mill liner castings, have recently confirmed in service the superiority that was predicted by the laboratory tests.

Jan 1, 1969

By Robert Moore Lewis

A unit for separating minerals into two prescribed size fractions, designated as a Lewis Hydrosizer, was developed at the North Carolina State University Minerals Research Laboratory. Ore samples with different mineral compositions, including coal, were separated effectively with the laboratory continuous unit. Commercial size units are in operation in North Carolina and Mexico, and under construction in Norway. Additional units are being build or are in the planning stage at several companies.

Jan 1, 1983

By R. R. Klimpel

The efficiencies of plant scale comminution processes are often evaluated by various indices that are calculated and/or measured somewhat independent of the performance of any associated downstream froth flotation processes. In order to compare some specific comminution factors such as energy utilization, media consumption, equipment utilization time, etc. comparisons of comminution efficiency independent of flotation behavior are appropriate. However, as more and more detailed plant level information is gathered on the joint and highly interactive nature of comminution and froth flotation, it is becoming increasingly obvious that knowing and using simple efficiency indices are not enough. What is needed are more performance related measures of the efficiencies of the combined size reduction -froth flotation system for effective plant level economic optimization to occur. The purpose of this paper is to present some examples of important interactions that influence the joint efficiencies of size reduction and froth flotation processes.

Jan 1, 1998

By S. A. Richards

Business planning in the coal' industry revolves around the production and quality forecast. It is difficult to accurately estimate costs and revenues until the production forecast is made. At mines where production comes from multiple sections, quality is tied to each section's production. Blending becomes a part of the planning process. In order to respond to rapidly changing business climate, a reliable program is needed to accurately forecast the effects of changes in key parameters affecting the production. This paper discusses an efficient, intuitive, and economical approach to underground coal mine planning program which uses a PC-based relational database as the programming platform to forecast production and quality. The program was developed at a major coal company. The relational nature of the production planning data, the programming algorithm, and the underlying principles are discussed in this paper.

Jan 1, 1994

By Menglong Bian, Xiaotong Dong

Thermal damage is an urgent problem faced by deep mining. High-temperature rock mass, hot water and electromechanical equipment are the sources of the thermal damage. The increase in air temperature in mine tunnel is the result of fluid–solid coupling heat transfer from various heat sources. This paper takes a roadway with hot water and a mine car as the research object. Based on the Fluent, Static Structural and Steady-State Thermal modules in ANSYS, the thermal-fluid–structure coupling analysis in the roadway is carried out. It is found that the hot water has a significant effect on the thermal environment of the mine. Under the experimental parameters, the maximum heat flux density and equivalent elastic strain at the interface between the hot water and the rock are 9789.3 W/m2 and 0.00054532 m/m, respectively. The heat flux distribution in the rock area near the mine car does not change much, and the equivalent elastic strain value in this area is high. After the air is heated in the hot water area, the temperature curve changes gradually and then rises steadily. By changing the inlet air temperature parameter, it is found that the lower the inlet air temperature, the better the cooling effect, and the change of the inlet air temperature can change the air temperature field in the roadway as a whole. By changing the parameter of inlet air speed, it is found that higher wind speed brings better cooling effect, but with the increase in wind speed, the cooling effect of roadway thermal environment is very limited. When the wind speed increases from 5 m/s to 10 m/s, the air temperature of most measuring points drops by more than 2℃; when the wind speed increases from 15 m/s to 20 m/s, the air temperature of most measuring points drops below 0.7℃. After the wind speed reaches a certain value, the cooling effect of ventilation is very limited.

May 5, 2022

By Frederic Souche, Andrew R. Klaetsch, Brian Hann, Nick Goodenow

This paper describes support of excavation (SOE) design and construction for three large diameter shafts excavated through glacial soil and controlled blasting in complex sedimentary rock formations. SOE in soil consists of unreinforced secant pile rings designed to resist lateral pressure in circumferential compression, eliminating costly steel core beam reinforcing. Controlled blasting at the shafts, adits, and tunnels in densely populated neighborhoods requires managing risks to the public, buildings, and utilities. Controlled blasting approaches limited adverse impacts to receptors nearby while achieving adequate production and fragmentation. A site-specific observational approach was used to adjust blasting parameters, limiting the impact on local stakeholders while maintaining daily progress and managing overbreak.

Jun 13, 2023

By G. Bylapudi, A. Spearing, J. Weber, K. Mondal

U.S. National Institute for Occupational Safety and Health (NIOSH) reports state that about 100 million rock anchors are installed annually in U.S. coal mines (Tadolini et al., 2006), and rock-related safety remains an issue. The majority of these coal mines have conditions that make corrosion probable in the longer term. Despite this, very little research has been performed to analyze corrosion and its effects on rock anchors in coal mines. To further evaluate the effects of corrosive conditions in coal mines on rock anchors, three different experiments were conducted during an initial Illinois Clean Coal Institute (ICCI)-funded project from 2008-2009. The results of these experiments were further studied, with additional tests, in the extended ICCI-funded project during 2011-2012. The experiments were destructive testing, electrochemical testing (potentiodynamic polarization tests) and open circuit potential (OCP) testing, conducted in order to study corrosion in environments similar to those found in Illinois coal mines with a focus on major rock anchor types typically installed underground. Destructive test results showed highest reduction in peak strength at higher pH and temperature. From the destructive test results, epoxy-coated and galvanized anchors were observed to be better when compared to uncoated. Electrochemical testing was performed to find the corrosion potential and corrosion rates of ASTM A615 steel grades 40, 60 and 75 in four different solutions of varying sulfur content at ambient temperature. The effect of temperature and pH levels on corrosion potential and corrosion rates of steel grades were also evaluated with additional electrochemical testing, where an increase in temperature with all other constant conditions caused a significant increase in the corrosion penetration rate. OCP data indicated higher corrosion potential values (-mV) for rock anchors in wet areas, when compared to those from the dry areas. OCP test results of the rock anchors from the laboratory corrosion chambers were similar to those measured in the sampled coal mines.

Jan 1, 2013

By C. Hilton

Arch Coal Inc. has implemented and sustained Best Practices at its four western mines through utilizing foremen in ongoing time studies. A prime benefit is the unique opportunity provided to front line supervisors. To date, 48 supervisors have participated in this program. Each quarter a new team is assembled with members from each operation. During three month blocks the supervisors conduct studies at each mine and identify best practices to implement at their own mine. Ongoing Best Practice and Action Item lists are reviewed each study. Mine management edits, prioritizes and monitors the completion of the proposed action items.

Jan 1, 2010

By James H. Allen

The air lift method of pumping water is discussed. A review of several large diameter hole drilling projects that used reverse circulation air lift techniques is presented. Proposals are made for reverse circulation flow rates for slow rates of bit penetration (5 fph) as well as reverse circulation flow rates for faster rates of bit penetration (10 fph). The Ingersoll- Rand air lift equations are modified for rotary drilling operations. By establishing minimum reverse circulation flow rates and utilizing the modified air lift equations, the establishment of minimum circulation equipment sizes and a more definitive requirement for improved bit body design should result.

Jan 1, 1976