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By Luis Llaque, Alain Revilla

Full Potential (FP) es un programa global de Newmont con el objetivo principal de proporcionar una mejora sostenible al flujo de caja sin comprometer el valor presente neto de la vida de la mina (Life of Mine “LOM”). Como sugiere el nombre del programa, el objetivo es que la mina donde se implementa el programa opere junto con su sistema de activo a su "máximo potencial". Como programa global, FP es coordinado por el equipo de FP Corporativo, utilizando las diversas herramientas y metodologías de implementación asociadas con el programa.

Sep 29, 2023

By G Burton, S Fityus, J Li, S Vaughan, D Payne

Daunia and Caval Ridge coal mines, owned and operated by BHP, have been co-disposing rejects and dewatered tailings within spoil dumps from the beginning of their operations in 2013 and 2014, with the purpose of minimising environmental impact and geotechnical risk. Following the recent large failures of tailings dams around the world, BHP Coal, through its Coal Tailings Program, plans to transition other coal mines to deliver “dry” tailings and produce mixed plant rejects (MPR) for inpit co-disposal. This will materially reduce future tailings dam risk exposure. Previous laboratory shear strength testing was conducted on rejects with a maximum particles size of 20 mm, and some concerns were raised that this might not represent the mechanical properties of the actual full particle size distribution (PSD) rejects. BHP was also aware that using different technologies to dewater the tailings, such as belt press filters (BPF) and solid bowl centrifuge (SBC), could produce thickened tailings which could significantly modify the physical behaviours of the MPRs, particularly the bonding between particles. Therefore, laboratory testing on both coarse rejects and mixtures of the coarse rejects and dewatered tailings (MPRs), with full PSDs, was carried out. Testing was performed using the large direct shear machine developed by the Australian Coal Association Research Program (ACARP) project C20019 in 2017, as well as a 300 mm diameter triaxial apparatus at the University of Newcastle (UoN). This paper presents details of the laboratory testing program and results for the rejects from the first studied mine of the BHP Coal Tailings Program. It compares the shear strengths measured at full scale with those tested on modified (scalped or crushed) specimens in the past; and discusses the tailings dewatering technique selection from geotechnical aspects based on the testing results, and finally presents some dump and tip head stability analysis results using the testing results.

Jul 1, 2021

By Richard A. Grieve

A 63.5 metric tons per hour (70 TPH) demonstration coal preparation plant was constructed on the Iowa State University campus, Ames, Iowa, as a part of the Iowa Coal Project funded by the state of Iowa and administered through the Energy and Minerals Resources Re-search Institute. Processing equipment in the plant circuit includes a heavy media separator, concentration tables, separating and dewatering screens, and conveying equipment. Coal samples of size 907 metric tons (1000 tons) with sulfur contents ranging from 2.5 to 8.75% sulfur from seven mines in the state of Iowa have been pro-cessed in the plant. Sulfur reductions have averaged 35%. With ash reduction averaging 45%. Equipment for advanced fine coal beneficiation research is currently being installed in the plant to include a slurry pretreatment circuit, froth flotation, oil agglomeration, pelletization, hydrocyclones, advanced design thickener and disc filtration.

Jan 1, 1978

By Susan Rafalko, Mike Walker, John Sankey, Sherif Aziz, Alex Potter-Weight, Mary Nodine, Frederic Masse

"After several successful projects on the Garden State Parkway and New Jersey Turnpike for support of single-stage MSE (Mechanically Stabilized Earth) walls using rigid inclusions (Controlled Modulus Columns) as an alternate to two-stage MSE walls and surcharge, the Bass River Bridge Widening project presented additional challenges in terms of soil conditions and height of embankment that created opportunities for the design-build ground improvement contractor and its MSE wall-designing partner to enhance their design and construction methods. The specialist contractor decided, in association with the wall system supplier, to perform an independent large scale instrumented test area on the project to demonstrate the ability of the design techniques to model the behavior of the system, as well as the capacity of the rigid inclusions to provide the necessary bearing capacity and settlement control to allow the construction of the highway without any consolidation period. This paper presents a detailed description of the design of the ground improvement system and MSE wall system, as well as the results and conclusions of the monitoring data gathered on the large scale test program. The combination of rigid inclusion ground improvement technologies, such as the CMC system, together with an MSE wall system allows for the rapid and economical construction of high embankment without waiting for a surcharge and consolidation period or the necessity to use a two-stage wall system. In-depth understanding of the design techniques and advantages of this combination will be provided and should be beneficial for any geotechnical engineer or owner looking for innovative solutions to save both time and cost on their projects.1. IntroductionAs development continues on sites with poor ground conditions throughout the world, conventional MSE walls remain a flexible design solution; however, construction of MSE walls in combination with ground improvement is becoming more frequent where extreme differential and/or total settlement prevail due to soft ground conditions. Various techniques have been used in the past in such conditions (e.g. conventional surcharge, staged construction, or two-stage MSE walls), even though these design solutions have typically involved longer waiting times for settlement to occur. As a result, conventional MSE wall design has been combined with a variety of ground improvement techniques consisting of rigid inclusions for an economical and efficient solution with the potential to accelerate construction and limit long term settlement. For the particular subject of this paper, the specialist contractor (Menard) proposed to use CMCs (Controlled Modulus Columns) to support the highest part of the MSE wall. CMCs are grouted displacement rigid inclusions installed in a grid-like pattern using a displacement auger. Before the CMCs are installed, a working platform may first need to be placed to allow equipment to move around the site depending on the ground conditions. Following the CMC ground improvement, an LTP (Load Transfer Platform) is installed prior to the construction of the MSE wall."

Jan 1, 2015

By Bogdan Petkovic, Boban Todorovic

In the early 90's a completely unknown problem was encountered at the converter Department: it was a chronic shortage of the cold copper charge needed for the second operating period. A high temperature operating regime was caused which further provoked a chain of consequences such as a drastic drop of the number of operations in campaigns. The consumption of repair bricks reached the quantity of 8.3955 kg / tonne of anode Cu. In 1994, we won the process of cold material smelting during the "copper" blowing [2]. The number of operations per campaign reached 180-200 again. Also in 1994 we won the process of smelting cold materials to obtain "tin" blowing with the purpose of completing their processing cycle [2]. During the period 1994 – 2007 a total of 107,845 tonnes of cold material were remelted to make copper and 56,794 tonnes were re-smelted to obtain "tin". Upon synthesizing these two processes, a completely new model was achieved in 2005, by Bogdan Petkovic, which entirely utilized all available energy of the Peirce-Smith (PS) converters of the Bor Copper Smelter and now represents the basis of the time cycle. The cold material now enters the converter plant, copper recovery is increased and the method itself is environmentally friendly. 167

Jan 1, 2009

By John Floyd, Maria Rocha, Benjamin Cebrian

Wall control blasting is needed in most metal mining operations in terms of increasing mineral reserves and assuring the safety of the operation. This type of blasting has the goal to achieve a clean, stable rock wall in the shortest distance from a well fragmented, easy to excavate, blasted rock mass. This can be done with a variety of blasting techniques, all of which decrease the explosive energy towards the final wall. Each technique needs to suit the geology: modified production blasting, buffer blasting, pre-split and line drilling of empty holes. Pre-split is the most expensive technique, and allows final steeper bench face angles while modified production blasting is the least expensive but needs wider berms.

Jan 1, 2018

By P. O. Sandstrom

"Atlas Copco is introducing a new patented method for full-face boring. This paper presents the basic principles of the boring action and discusses the present experience regarding performance and costs. The Atlas Copco ""Full-facers"" are designed for hard-rock applications, although they are successfully boring in soft ground without major changes. The unique patented boring principle referred to as the 'Undercutting Method' permits these machines to bore, economically, in harder ground than machines based on the 'crushing principle'. This is mainly due to considerably lower cutting-tool costs, as the tungsten carbide tips only are in contact with one-third of the bored volume. The remaining rock is 'undercut' and peels off from a slight back pressure.The undercutting method also permits boring of non-circular headings and Atlas Copco has already manufactured two machines for rectangular drifts. This concept could revolutionize development work in mines employing trackless equipment."

Jan 1, 1971

By Xing Zhao, Michael A. Sutton, Vikrant Tiwari, Damien Bretall, Xiaomin Deng, William L. Fourney, Uli Leiste

The dynamic response of a thin aluminum plate subjected to both shallow and deeper buried blast loading was studied. Using a combination of high speed stereo-vision and three dimensional digital image correlation (3D-DIC), sequential stereo images acquired every 38.25µs during blast loading were analyzed to determine full-field deformations and plate motions (displacements, velocities and accelerations, effective surface strain and effective surface strain rate). Measurements indicate that the initial sheet deformation was highly localized for both shallow and deeper blast events, with extremely high velocity and acceleration values recorded during the earliest stages of impact loading. Full field strain and strain rate data indicate that well defined strain and strain rate “maxima” are created in the plate, with the potential of affecting the dynamic plate behavior as well as it local failure.

Jan 1, 2010

By M. Hesham El Naggar, Yasser Abdelghany

"ABSTRACT: The axial and lateral monotonic and cyclic behavior of helical pile foundations was investigated and new innovative helical screw systems suitable for seismic loadings were developed and patented. More than one hundred full scale field load tests were conducted on instrumented helical screw piles installed in cohesive soil. The piles included: plain helical screw piles (P-HSP); grouted (G-HSPs); fiber reinforced polymer FRP-G-HSPs; and reinforced grouted RG-HSPs. The RG-HSP piles axial capacity was more than twice that for P-HSP, with minimal reduction after cyclic loading, and their lateral capacity was more than 3 times the P-HSPs capacity. A 3-D finite element model was established. The results of 3-D finite element modeling were used to establish the load transfer mechanism and a design methodology for the considered piles.INTRODUCTION AND LITERATURE REVIEWHelical (screw) anchors have been utilized in tension loading and have gained popularity for bearing load applications. Helical piles represent an overall cost effective alternative to conventional piles for new construction and repair applications. The helical piles speed and ease of installation, less noise during installation added advantage with regards to their efficiency and reliability for underpinning including re-support and reconstruction of distressed and damaged foundations for either stabilization or rehabilitation. The “square shaft” SS175 pile is a segmented deep foundation system with helical steel bearing plates (helices) welded to a central steel shaft. Load is transferred from the shaft to the surrounding soil through these bearing plates. Segments or sections are joined with bolted couplings. Practically installed depth is limited only by soil resistance and economics. A helical bearing plate or helix is one pitch of a screw thread. All helices regardless of their diameter have a standard 75 mm pitch (Figure.1). The performance of single helical anchors and group action were studied experimentally and theoretically by several researchers, the researches focuses on the installation torque and uplift resistance. Some researches focus on the load carrying capacity with little pile response to cyclic loading effects or to instrumented full scale field testing. Helical piles axial compressive or lateral loading still is not well characterized and needs more analyses and their seismic performance was not investigated. For such this research was initiated to investigate the helical piles monotonic and cyclic performances under axial and lateral loadings to consider their usage in different applications in seismic zones. Among the several researchers, Clemence (1983); Mooney et al. (1985) conducted field and laboratory testing; Hoyt (1989), Hoyt et al. (1995), and Ghaly and Clemence (1998) conducted theoretical and experimental testing, Puri and Vijay (1984), Huang et al. (1995), Perko (2000), and Pack (2000) conducted theoretical analyses. Rao and Prasad (1993), Prasad and Rao (1994), conducted experimental testing; Vickars and Clemence (2000) studied the performance of helical piles with grouted shafts."

Jan 1, 2014

By K. Viking

The vibratory characteristics of full-scale sheet piles, vibratory driven into the ground, have so far not been described systematically in detail. This paper concerns the preliminary results of a series of full-scale field tests where both the driveability and induced ground vibrations have been continuously monitored. Furthermore, the results of measured ground vibration levels have been measured at two different sites characterised as having hard and easy driving conditions. In the light of the presented results, the paper briefly discusses how the complexity of a driveability and vibration prediction can be subdivided into three parts, namely, vibrator-, sheet pile-, and soil-related parameters, all of which significantly affect both the driveability and induced ground vibrations.

Jan 1, 2000

By B Mobilio, G B. Sharrock, J L. Lett, I Brunton, T Thornhill

Full-scale marker experiments at Cadia Valley underground operations have been ongoing for over 14 years. Initial marker experiments were undertaken in the Ridgeway sublevel cave (RW) (2002), and subsequently at Ridgeway Deeps (RWD) (2008) and Cadia East PC1 (CEPC1) (2012) block caves. Over 25 000 markers have been installed at the three caving operations to date (approximately 20 000, 3000 and 2500 for RW, RWD and CEPC1 respectively). These experiments aimed to quantify and assess the geometry of the extraction zone, development of the extraction zone over time, variability of flow behaviour and factors affecting flow behaviour in both the near and far field cave column. This paper discusses marker recovery results from the RWD and CEPC1 caves.With respect to the two cave operations, marker recovery in both the near field (markers recovered vertically within 70 m of the extraction level) and far field (markers recovered vertically above 70 m of the extraction level) indicates disturbed flow behaviour where marker recovery is not spatially uniform during material extraction. Two distinct patterns or transient behaviours in the extraction zone are indicated. For RWD (advanced undercut), early material recovery was close to the major apex, and expanded towards the centre of the drawbell as more material was extracted. The inverse was observed for CEPC1 (post undercut), where recovery occurred in the centre of the drawbell initially, and expanded outwards towards the major apex. This trend of recovery for the two operations continued in the far field. In the region above the major apex, recovery was observed for all heights, with no clear height of interaction zone (HIZ) indicated. All of these behaviours significantly deviate from both conventional ellipsoidal flow theory and Laubscher’s (2000) design guidelines. For this reason these new mechanisms are termed the Disturbed Extraction Zone (DEZ).For the CEPC1 marker experiment, electronic markers were utilised to investigate the vector movement of material in the near field. Marker recovery movement vectors in the near field indicate extraction zone widths in the order 30 m, with localised marker recovery outside this region (significant horizontal movement of material potentially due to cave muck pile rilling and blast burden movement). Analysis is ongoing for far field marker vector movement, and will be reported once additional marker recovery has been obtained.CITATION:Brunton, I, Lett, J L, Sharrock, G B, Thornhill, T and Mobilio, B, 2016. Full-scale flow marker experiments at the Ridgeway Deeps and Cadia East cave operations, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 141–150 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Ronnie X. Gu, Xing Zheng, Gem-Yeu Ma

Due to implementation of the rotator construction method from which a smooth shaft was anticipated, a full-scale pile load test (Osterberg Method) was performed at Pier 14 Pile 9 of the main span of the New Benicia-Martinez Bridge to confirm the design parameters of the rock sockets. Two levels of load cells were fabricated in the reinforced cage of the rock socket. Each level consisted of three 670-mm Osterberg load cells with a total testing capacity of more than 50 MN in both directions. In an attempt to separate side friction and end beari ng, a 75 mm thick compressible Styrofoam material was placed at the bottom of the cage. The pile load test was carried out in four stages. The multi-level multi stage pile load test data was interpreted for casing friction, side friction for two rock strata, end bearing, and residual side shear values under repeated loading in opposite directions. The side friction from the casing in soils at Stage 2 is approximately 9 MN. The end bearing at the tip of the rock socket at Stage 3 was calculated to be approximately 17 MN at a displacement of about 75 mm. The residual side shear resistance for the 10 m 50% RQD rock strata was calculated to be 9 MN or approximately 50% of initial values, after being pushed 0.3 mm upward in Stage 1, 71 mm downward in Stage 2, then 55.5 mm upward again in Stage 3, and finally 105.3 mm downward in Stage 4. The test results surprising ly indicate that the side shear resistances from both low RQD intensely weathered rock and higher RQD slightly weathered competent rock are about the same at approximately 19 MN. This pile load test provides very critical information for confirming deep shaft design and analyses.

Jan 1, 2005

By Thomas M. Barczak

The performance characteristics of Mobile Roof Supports (MRS's) were evaluated through full-scale testing in the Strategic Structures Testing Laboratory at the National Institute for Occupational Safety and Health, Pittsburgh Research Center. Safety issues pertaining to the operation and design of these supports for pillar extraction during retreat mining are examined. A unique load frame, called the mine roof simulator, provided a realistic simulation of mining conditions by inducing vertical, horizontal, and lateral loading on the support. The purpose of these experiments was to determine the capabilities and limitations of the supports and to investigate factors that influence the measurement of loading and loading rate. An evaluation of the support design and load conditions that can cause support failure or loss of support capacity are discussed relative to the laboratory tests. In general, lateral loading perpendicular to the longitudinal axis of the canopy is most severe, although horizontal loading in the direction of the long axis of the canopy can also produce critical loading in some cases. The experiments indicate that both setting force and leg pressure measurements are influenced by the staging of the leg cylinders. The implications of these factors on load rate measurement are evaluated. A comparison of MRS capacity and stiffness characteristics is made to conventional timber supports.

Jan 1, 1997

By M R. Hettigner, J Nawrocki, C E. Johnson, P G. Cahill

This study evaluates the effects of both short inter-hole and intra-hole delay times on rock fragmentation and throw. Full-scale test blasts were analyzed at a granite quarry in Talbotton, GA. This analysis provides a representative understanding of timing effects on fragmentation in the field, different from previous lab scale studies that negate the effect of geology. Inter-hole delay times between 0 ms and 25 ms were tested on a series of 4 bench blasts and subsequently examined using photographic fragmentation analysis methods.

Jan 1, 2017

By A Ross, B De Rivaz

The results of full-scale tests on precast segment made at University of Roma are presented. The segments were cast using fibre-reinforced concrete produced without any traditional reinforcement, by using fiber made in high-strength steel and a new type of anchorage.Bending tests were performed in order to check the bearing capacity of the segments under the flexural actions; these occur during de-moulding, handling, storage phases as well as in the in situ condition (due to asymmetric soil pressure). Furthermore, point load tests simulating the TBM thrust were performed, in order to study the construction phase (excavation).The results show that the segment response largely respects the material testing and design advice according to the Fib Model Code 2010. Providing engineers, precast operators and builders confidence in material strengths and design methodology.CITATION:De Rivaz, B and Ross, A, 2014. Full-scale tests on precast tunnel segments made in concrete reinforced with high-strength steel fibres, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 469–476 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By Ambrose Buchanan, Rob Farnfield, Charles Adcock

Beginning on 7th September 1940 the City of London was subjected to 57 consecutive days of bombing in what became known as the ‘London Blitz’. To commemorate the 70th anniversary of this event a television series was commissioned that required the open detonation of World War 2 equivalent bombs close to purpose built structures constructed using period design and materials. The structures were built on a remote test facility in the North of England that is able to fire large quantities of explosive in the air.

Jan 1, 2011

By Sam H. Patterson

Fuller's earth and bentonite are two clay commodities that are interrelated either by mineral composition or use. Because of this interrelation and the sale of both for many different uses, some ambiguity in their classification has resulted. The term "fuller's earth" has no compositional or mineralogical meaning, and it is used more or less as a catchall for any clay or earthy material suitable for certain uses. Most, but not all, of these uses require absorbent properties. Bentonite by geologic definition must have formed from volcanic ash or tuff or the glassy material in volcanic rock; most bentonites consist chiefly of montmorillonite but other clay minerals may be present. In industrial usage the term "bentonite" is applied to any clay consisting chiefly of montmorillonite, irrespective of origin. Georgia and Florida have historically been the leading States in the production of fuller's earth; bentonite has been produced in Alabama on a small scale. The first major use of fuller's earth was in refining of oils. Other materials have replaced fuller's earth for this purpose to a major extent, but many new uses for fuller's earth have been found, and production has increased in recent years. The new uses include absorbent products, insecticide and pesticide carriers, drilling mud, and many others. The bentonite now produced in Alabama is of the "southern," "low selling," or "calcium" type and is used mainly as foundry-sand bond. Most of the fuller's earth mined now is in the Hawthorn Formation of Miocene age; a lesser amount is produced from the Twiggs Clay Member and other beds in the Barnwell Formation of Eocene age. Inactive pits from which fuller's-earth was produced from other formations occur at several localities. The bentonite now mined in Alabama is in beds of Cretaceous age; several years ago bentonite was produced from Eocene beds in this State.

Jan 1, 1972

By R. K. McLimans, C. Knudsen, S. Bernstein, D. Frei

Computer Controlled Scanning Electron Microscopy (CCSEM) is used to analyze indivdual mineral fractions in heavy mineral sands. CCSEM is a fully automated particle analysis technique for the determination of physical and chemical properties of a large number of individual particles. CCSEM enables the precise and accurate determination of the modal abundances of individual mineral fractions (e.g. ilmenite, rutile, zircon, or garnet), their average chemical composition (and compositional variation), as well as their physical properties such as size (e.g. diameter and perimeter length) and shape (aspect ratio and circularity). A unique sample preparation procedure is used to produce representative polished sections from cylinders of raw sand samples such that thousands of grains are present in a polished cross section, but grains are not touching. The combination of this sample preparation technique with CCSEM enables the fully automated analysis of individual grains without the application of de-agglomeration or erosion steps to separate touching particles. Hence, CCSEM yields information representative of the entire area of analyzed grains without systematic bias due to neglect of rim areas by de-agglomeration or erosion steps. Therefore, the resulting data are determined with high accuracy, precision and statistical validity. Because the sample preparation is relatively straightforward, using raw sand samples, and all chemical and physical properties are determined in one analytical session per sample, CCSEM is a powerful cost and time efficient tool for characterizing chemical and physical properties of minerals in heavy mineral sand deposits.

Jan 1, 2005

By B. J. Coetzee, P. W. Sonnendecker

The quality control of a two-stage coal washing process involves several complex components that need to be modelled accurately, to enable autonomous control of the process. The first objective is to develop a method to track the material through the washing process, while ensuring accurate washing prediction models are used. This was achieved through a digital twin model of the Grootegeluk 1 coal processing plant. The model is the amalgamation of manipulating and combining of data-sets from the plant historian, geological wash tables, and mining dispatch servers. This information is then used to control and set the processing medium densities of all 15 modules on the plant, 10 modules in the primary wash and 5 modules in the secondary wash. This controller has been successfully implemented and controlled the plant for 10 days.

Aug 2, 2022

By Daniel Su

Approximately 90% of the primary roof bolts used in CONSOL?s Pittsburgh seam coal mines is 2-piece, 8-foot long, 7/8? (or ¾?), high-strength, resin assisted, mechanical shell tensioned bolt. The remaining 10% is the 2-piece, 8-foot long, 7/8? combination bolt, which employs 4 feet of fast resin to anchor the deformed rebar at the top of the hole. In either system, a 1-3/8? hole is required to accommodate the mechanical shell and the coupler. The cheaper torque-tension rebar system, which is typically fully-grouted with 2-speed resin and which typically provides low bolt tension, is not used in CONSOL?s Pittsburgh seam mines. Rather, it is used in CONSOL?s Central Appalachia mines, where the roof rocks have CMRR rating of 50 or higher. Fully-grouted headed rebars, on the other hand, are used in CONSOL?s room-and-pillar mines. The selection of tensioned versus non-tensioned, fully-grouted bolts for coal mine primary roof support has been debated for the past thirty years. Many researches have been conducted to understand the theoretical bases behind the two systems. This paper describes CONSOL?s experience of using a new fully-grouted, mechanical shell tensioned bolt in the Pittsburgh seam with the development of low insertion force resin.

Jan 1, 2007