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By Jun Enriquez

Kennecott Utah Copper aims to extend anode furnace campaigns to more than three years. As part of that goal improvements are sought on anode-furnace tuyere-area refractory performance. Kennecott and Praxair developed high pressure nitrogen refining for the Oxidation Stage which shortened anode furnace fire refining cycles by up to two hours per cycle. Future developments include optimizing the Reduction Stage’s steam-gas reforming and achieving coherent jet tuyereless refining.

By R. Karl Zipf

Multiple seam mining interactions caused by full extraction mining, whether due to undermining or overmining, frequently involve tensile failure of the affected mine roof. The adverse ground control conditions may prevent mining for both safety and economic reasons. Prior researchers have identified the geometric, geologic and mining factors controlling multiple seam mining interactions. This numerical study examines the mechanics of these interactions using a modeling procedure that 1) incorporates the essential constitutive behavior of the rock such as strain-softening of the intact rock and shear and tensile failure along bedding planes and 2) captures the geologic variability of the rock especially the layering of weak and strong rocks and weak bedding planes. Specifically, the numerical study considered the effect of vertical stress, interburden thickness, and the immediate roof quality of the affected seam in both undermining and overmining situations. The models show that for overburden-to-interburden thickness (OB/IB) ratios of less than 5, interactions do not occur, and that for OB/IB more than 50, extreme interaction is a certainty. In between, the possibility of an interaction was found to depend on gob width-to-interburden thickness ratio, site specific geology and horizontal stress to rock strength ratio in addition to the OB/IB ratio. The models also showed that horizontal stress was profoundly altered well above or below a full extraction area and that these changes are likely to influence the success or failure of multiple seam mining. The role of horizontal stress in multiple seam mining interactions has received little attention in prior investigations. Four factors control the mechanics of multiple seam mining interactions: 1. vertical stress concentration 2. horizontal stress concentration 3. stress re-direction 4. bedding plane slip bands A combination of vertical and horizontal stress increase and high stress gradients in the vicinity of full extraction areas re-orients principal stresses into a very unfavorable direction. This seemingly small stress re-orientation has a profound adverse effect on bedded rock.

By Elaine T. Cullen

Miners, like many skilled blue-collar workers, are not traditional learners. They have not always been successful in classroom-type settings, preferring to learn on the job in a hands-on environment. U.S. law requires that miners have a minimum of 8 hours of safety training annually, plus 40 hours for underground miners and 24 hours for surface miners when they enter the industry. However, miners rarely view this training time positively. In fact, it has been called “safety jail” by many, who regard it as a time to get a little extra sleep While mining has become far safer in the past 100 years, it is still a dangerous occupation. The Office for Mine Safety and Health Research, a part of the National Institute for Occupational Safety and Health (NIOSH), has funded a project for the past 4 years to address this challenge. The purpose of the research was to find a way to develop effective safety training for these people. Miners are born story tellers. They share “near miss” stories, stories about master miners they have known, and stories about how things used to be. These stories not only pass along information about what will happen if a miner fails to respect the mining environment, they also instruct listeners in the culture of mining and the values that it embraces. Stories, it seems, are a way to get safety messages across to miners, especially inexperienced ones, and using older, wiser miners in these stories is an obvious choice. This paper will discuss how a series of training videos was developed, how “master miners” and story lines were chosen, and how the resulting videos have been received in the mining industry.

By J. S. Stachulak, G. H. Schnakenberg

The objective of the Diesel Emissions Evaluation Program (DEEP)-sponsored project at Inco's Stobie mine was to conduct a long term field evaluation of diesel particulate filter (DPF) systems available to the underground mining industry. Some of the major issues studied were criteria for selecting the filter media, means of DPF regeneration, efficiency of DPF systems and the occurrence of unwanted secondary emissions, and reliability and durability of DPF systems. Nine state-of-the-art diesel particulate matter (DPM) filtration systems have been retrofitted to heavy-duty and light-duty vehicles and have been subjected to extensive long-term in-mine evaluation. Periodic efficiency tests were conducted at various stages of the study (2001, 2002 and 2004) to establish in-use efficiencies and durability of the tested DPF systems. The results were used to assess the effects of the filter systems on the concentrations of particulate matter, nitric oxide, nitrogen dioxide and carbon monoxide in the vehicle exhaust. The variety of filtration systems and regeneration concepts used in this study offered the opportunity to investigate their advantages and disadvantages. This paper also offers a review of selected experiences with the installation and operation of the DPF systems on underground mining vehicles at the Inco Stobie Mine.

By H. T. Kennedy, S. G. Dardaganian, J. L. Clanton

This paper presents equilibrium ratios measured on oil and gas samples taken from the Kelly-Snyder field at the reservoir temperature of 128°F. From these data smoothed curves were constructed for the reservoir fluid up to the bubble-point, 1,874 psia. A material balance calculation, based on the use of equilibrium ratios instead of the usual solubility and shrinkage meayr~rements is made on the field and compared to the con\.entional method. DETERMINATION OF EQUILIBRIUM RATIOS The equilibrium ratios, or K values were obtained by recombining separator samples of oil and gas taken when the reservoir was above its bubble point, and thus represented the reservoir fluid before any change had occurred due to the evolution of gas. The well sampled had a gas-oil ratio of 617 cu ft of high pressure sepalator gas per barrel of separator oil. and a bottom-hole temperature of 128°F. Samples were brought to equilibrium by agitating for 24 hours in a thermostat, maintained at the proper temperature within 0.2ºF, mercury being added when necessary to maintain the pressure constant. Samples of oil and gas were then taken by constant pressure displacement, and analyzed by low temperature frac-tionation. Equilibrium ratios were determined at 128°F and 500, 800, 1,000 and 1,400 psig. At the latter pressure, there were indications that the gas samples were contaminated with small quantities of oil, and only data taken at the first three pressures were included in Fig. I. This figure has been extended to higher and lower pressures by the use of the Fluor charts for 3,000 psi convergence pressure, on which the experimental points fit well. MATERIAL BALANCE EQUATIONS The possible errors involved in conventional material balance equations have been analyzed by Muskat1. Where the errors occur in field measurements, or in obtaining effective averages from variables such as gas-oil ratio and pressure, they will evidently be involved in any attempt to estimate the content of the reservoir. On the other hand, substantial errors may be introduced in conventional material balance calculations by: (1) the neglect of the amount of oil dissolved in gas at high pressures and temperatures in the reservoir, but which condenses under separator conditions; (2) the assumption that the separation of oil and gas in the reservoir may be duplicated by a differential liberation in the

By Fulvio Tonon

And Rabcewicz said ?tunnels should be driven full face whenever possible.? ADECO, which stands for ?Analysis of Controlled Deformations in tunnels,? now allows us to fulfll Rabcewicz?s dream in any stress-strain condition. In order to achieve that dream and its consequent control over cost and schedule, however, NATM must be abandoned for the ADECO. The paper presents the basic concepts in the ADECO approach to design, construction and monitoring of tunnels together with some case histories, including: full face excavation for Cassia tunnel (width of 22 m, height of 14 m) in sands and silts under 5 m cover below an archeological area in Rome, Italy; Tartaguille tunnel (face area > 100 m2) advanced full face in highly swelling and squeezing ground under 100 m cover where NATM led to catastrophic failure, France; and 80 km of tunnels (face area > 100 m2) advanced full face in highly squeezing/swelling ground under 500 m cover for the high-speed railway line between Bologne and Florence, Italy (turnkey contract).

By Richard Akerman, Frederick Prime Jr

[THE attention now being paid both in this country and Europe the greatest economy in the working of the blast furnace, and the eagerness with which all thoughtful men in the iron business look for any new information which will tend to throw light on this subject, is a quite sufficient excuse for presenting this paper to the American Institute of Mining Engineers.] I. It must be borne in mind that when two bodies unite to form a chemical compound, heat is almost always evolved. In order to

By Charles P. Williams

The successful production of zinc white or oxide on a commercial scale in this country dates from the issue of the patent of Samuel Wetherill, for the preparation of the material (November, 1855), and

By Oswald J. Heinrich

THE origin of spontaneous combustion in collieries is, of course, chiefly due to bad system in laying out the pits, unclean workings, insufficient ventilation, and neglect in damming off works after they are exhausted of the main coal. This is particularly indispensable in the Richmond field, because it is difficult and dangerous here, on account of the inferior roof, to remove the last vestiges of coal ; and we are compelled also to retain all the slates and bands, as far as possible, in the pit, to help fill up, although such material is liable to fire. This, however, can be prevented to a great extent, as mentioned below. I am satisfied that the only system of working this thick coal is by cross-cutting (Querbau, ouvrage & travers) or working in benches, as practiced in France (Creusot, Rive de Gier, St. Etienne), in Silesia (Kiinigsgrube), which I have used as far as it is practicable in an old pit, almost torn to pieces by former workings. Modifications may, of course, be needed, even in the same pit, on account of irregularities in the seam. I am also satisfied for economical reasons (on account of the heavy cost for timbering) that pits here ought to be worked upwards, even if it requires a longer period of time to win the coal, and a greater outlay of capital to commence with. The various saddle-shaped " troubles " making natural minor basins in the main basin aid in the execution of this plan. A pit worked once ought to be worked out clean, given up, and dammed off forever. If sections of proper height are assumed, according to the required amount of production for a certain period of time, they ought to be worked out and filled in as much as possible, dammed off, and ultimately allowed to fill up with water, in order to protect the upper works in future from fire in the gob below. This I consider indispensable, because we may not be able profitably to fill in all the ground. To do so we have to use the waste of the mine, although it is liable to fire in time. In using this stuff, it ought to be surrounded by walls of rock not liable to take fire, laid firmly in clay, the gob being in the middle, and firmly covered and packed with clay on top. In

By John Marsden

Despite the recent pullback in metal and mineral prices, and the associated market adjustments, the mining industry is still facing a serious issue with the declining availability of graduate expertise. This is due to a combination of an aging workforce, retirements and retrenchments, coupled with a lack of suitably qualified graduates entering the workforce. The issue has certainly improved since 2004 when the industry picked up the rates of hiring graduate engineers and mining/mineral school enrollments picked up in response. This hiring effort has helped to cover the ?gap? years from about 1985-2000, when industry demand for graduates was particularly poor. However, the recent market pullback is likely to set back this progress, as recruitment and hiring wavers as a result of cost cutting measures and economic uncertainty. A key issue for the mining industry is how to ensure the survival and growth of relevant ?core? degree programs. Such programs include mining, metallurgical, mineral processing and geological engineering. The mining industry needs a healthy, high-level education program to ensure an adequate supply of appropriately qualified graduates for the mining industry. Two-thirds of the professionals entering the minerals industry who graduated within the past 40 years graduated prior to 1985. Since 1985, we have been living off the legacy of graduation classes from the mid-1970s and early 1980s. It is estimated that we have been producing graduates at approximately 40 to 50 percent of the sustaining rate since about 1985. Further growth in the domestic industry would increase graduate requirements significantly, and the export of U.S.-graduates to other parts of the world (as is currently occurring) also impacts the total graduate requirements.

By C. Coetzee

Additives are commonly used in copper electrowinning to improve cathode morphology. Polysaccharides such as guar are generally favoured as additives due to their compatibility with solvent extraction. Polyacrylamides are, however, being considered as possible alternatives. Understanding the influence of the structural chemistry of additives on electrowinning performance is critical to utilise them efficiently. This paper investigated polyacrylamide additives which are structurally different; their effects on copper electrodeposition were characterized and compared to that of guar. Electrochemical impedance spectroscopy (EIS) were used to characterize the effects of molecular weight and ionic charge of the polyacrylamides on electrodeposition. The findings were compared against results obtained with an industrially used guar product. Equivalent circuit modelling of EIS data indicated that an increase in polyacrylamide concentration and a decrease in additive molecular weight increased the overall system resistance.

By James D. Noll, M. Eileen Birch

A monitoring method for diesel particulate matter was published as Method 5040 by the National Institute for Occupational Safety and Health (NIOSH). Organic and elemental carbon are determined by the method, but elemental carbon (EC) is a better exposure measure. The US Mine Safety and Health Administration (MSHA) proposed use of NIOSH 5040 for compliance determinations in metal and nonmetal mines. MSHA also published a rule making for coalmines, but no exposure standard was provided. A standard based on particulate carbon is not considered practical because of coal dust interference. Interference may not be a problem if an appropriate size-selective sampler and EC exposure standard are employed. Sub micrometer dust concentrations found in previous surveys of nondieselized, underground coal mines were relatively low. If a large fraction of the sub micrometer dust is organic and mineral matter, sub micrometer EC concentrations would be much lower than sub micrometer mass concentrations. Laboratory and ?eld results reported here in indicate the amount of EC contributed by sub micrometer coal dust is minor. In a laboratory test, a sub micrometer EC concentration of 31µg m 3 was found when sampling are spirable coal dust concentration over three times the US compliance limit (2mg m3). Laboratory results are consistent with surveys of nondieselized coal mines, where EC results ranged from below the method limit of detection to 18µg m 3 when size-selective samplers were used to collect dust fraction shaving particle diameters below 1.5µm sub micrometer EC concentrations were ?7µg m3. In dieselized mines, sub micrometer EC concentrations are much higher.

By T. Freeman

In the past ten years, the Geotechnical Baseline Report (GBR) has arguably become the key document for tunnel construction. This report not only allocates much of the risk involved with the work, it serves as the basis for bid preparation and is used extensively in resolving disputes during construction. This paper discusses some important issues related to the GBR and presents suggestions for improving these vital reports.

By Michael A. Piepenburg

The East Side Access (ESA) Project will extend Long Island Rail Road (LIRR) into midtown Manhattan via 11 km of tunnels, a new terminal station and associated support facilities. In addition to the hard-rock tunneling currently underway in Manhattan, soft-ground tunnels in Queens will traverse beneath Amtrak?s Sunnyside Yard and Harold Interlocking, the busiest rail interlocking in North America. This paper details ESA?s coordinated approach to interfacing with both Amtrak and LIRR with regard to the planned tunnels, shafts and related construction beneath or adjacent to the operating railroads. This interface includes integration of railroad staff, extensive presentations, reviews and agreements with the railroads regarding settlement mitigation, real-time automated geo-instrumentation monitoring, ground improvement, and geotechnical/environmental controls.

Relatively few longwall mines in the U.S. operate under multiple seam conditions where the two seams are less than 200 ft apart. This paper describes the experience of six that do. These operations are located in PA, WV and UT, and include examples of both undermining and overmining. Some operate above or beneath their own workings, others are in historic mining districts and must contend with abandoned mines that are decades old. The lessons that these mines have learned cover a broad range of topics, including: • Whether to stack gateroads or place them under old gob areas; • How to size pillars and select artificial support to cross longwall stop lines; • How to use yield pillars to minimize multiple seam stresses and coal bump potential, and; • When to anticipate the creation of pathways for gas, water, or oxygen between current and abandoned gobs.

By Michael Schmitz, Eugene Ahrenholtz, William A. Heitbrink, Jeanne A. Zimmer, Andrew B. Cecala, Ernest S. Moyer, Earle H. Andrews, Chris C. Coppock, John A. Organiscak

Many different types of surface mining equipment use enclosed cabs to protect equipment operators from health and safety hazards. The overburden removal and mining process can be extremely dusty and can cause excessive dust exposure. To study this issue, a cooperative research effort was established between the National Institute for Occupational Safety and Health, U.S. Silica Co., Clean Air Filter Co., and Red Dot Corp. in an effort to lower respirable dust levels in an enclosed cab on an older surface drill at a silica sand operation. Throughout this research effort, a number of modifications were incorporated into the drill's filtration and pressurization system, as well as in other areas, to improve its design and performance. An average cab efficiency of 93.4% was determined with gravimetric sampling instruments when comparing the outside with the inside cab dust levels on the final design. Although this study considered just one operation, the goal was to identify cost-effective improvements that could be implemented on all types of enclosed cabs to lower respirable dust concentrations. Two critical components for an effective enclosed cab system are having a properly designed, installed, and maintained filtration and pressurization system, along with a method for maintaining structural cab integrity, which allows the cab to be positively pressurized. Another important component is maintaining cab cleanliness. Although this research was originally directed toward the mining industry, it is also applicable to agricultural or construction equipment.

By Thomas M. Barczak, Joe Bower, Jinsheng Chen

Pumpable roof supports provide an alternative longwall tailgate roof support and have grown in usage during the past few years. Heintzmann Corporation has been installing pumpable roof supports at the RAG Resources Emerald Mine in western PA since 1998, where they have provided effective roof control in their longwall tailgates. Despite the success of these supports in this application, questions remain regarding critical design issues for optimizing the use of this support technology. The support loading profile is characterized by a high initial stiffness with peak loading occurring at less than one inch of convergence, followed by significant load shedding with a post failure capacity comparable to that of wood cribbing. Therefore, the key to optimizing the support utilization is to provide sufficient load density to prevent convergence from occurring beyond the peak loading capacity. This requires an understanding of how the supports interact with the ground conditions, hence measurement of the ground reaction curve. In order to obtain this information, pumpable roof supports were instrumented to measure support loading. Roof deformation and roof-to-floor convergence measurements in the vicinity of the instrumented supports were also made. The experimental parameters for the installation were the support spacing and water-to-solids ratio of the grout, which controls the grout strength and ultimately the maximum capacity of the support. The study clearly shows that at this mine a 24-inch diameter support is fully capable of providing adequate ground control under depths of cover of 750 ft as only 50 pct of the available support capacity was utilized outby the longwall face. It was also shown that the 2.00 to 1 water-solids ratio, despite providing a slightly softer support response, is sufficient for maintaining the same degree of roof control provided by the traditional 1.75 to 1 grout mix. The 10-ft spacing of the supports did not cause any ground control problems outby the face. However, inby the face the performance of the support is degraded once the peak capacity of the supports is exceeded. It appears that the large load shedding behavior, which is characteristic of this support following peak loading, allows the immediate roof to separate. When this happens, the support is unable to regain control of the roof in time to prevent failure of the immediate roof beam.

By John R. Eckel

A Iaboratory drilling rig has been devised and placed in operation which permits the application of hydrostatic, terrastatic, and formation pore pressures to a rock sample for drilling under controlled conditions. Calibrated rests of this equipment in-dicate qualitative agreerment with field results on the effect of weight on bit, rotary speed, and rate of circ~~lation on drilling rate. Tests under pressure, using water and air as the drilling fluids, indicate that when drilling saturated limestone samples, a pressure differential between hydrostatic and formation pressure is the only pressure which affects drilling rate. A differential in either direction causes a reduction in rate, but the same diflerential from the wellbore into the formation causes the greater reduction. Also, in lime.stone, air favorably affected drilling rote only when compared to water at high hydrostatic pressurre, all other conditions remaining constant. Large increases in drilling rate with air could be obtained in the laboratory only while drilling a shale, which offered a limited permeability to nitrogen and which could be drilled with a differential from the formation into the wellbore. In general, the magnitude of the changes due to the pressure effect were small compared to changes in drilling rate obtainable by changing either bit weight or rotary speed. INTRODUCTION In the course of Humble's drilling research program, the desirability of investigating several factors which lend themselves to laboratory rather than field study became obvious. Principal reasons for this are the expense involved in field studies and the difficulty of exercising the required degree of control. Of primary importance are investigations of the effect of fluid pressure on rock rate, the effect of pressure on rock drillability, and a study of the fundamental mechanics of rock failure and chip generation. Several years ago some work in the laboratory on the effect of mud properties on drilling rate was re- ported to the API', but the completion of this work and the investigation of the other variables affecting drilling rate required equipment somewhat more elaborate than that used on these earlier tests. This equipment has been assembled to form Humble's Drilling Engineering laboratory. To date only the effect of pressure on rock drillability while using water and air has been investigated, and this work is not yet complete. Facilities are available to investigate the effect of fluid properties on rate of penetration, and information is being assembled on a current basis on the mechanics of drilling. The sequence of presentation in this progress report is somewhat different from that in which the data were obtained since the order of ex-

By Harry Asche

The last 12 months has seen the construction of the first Earth Pressure Balance (EPB) TBM excavated tunnel in New Zealand on the Project Hobson sewer storage tunnel for Watercare Services Limited, with the concurrent excavation of the second EPB tunnel on the Rosedale Outfall project for North Shore City Council. Together these tunnels involve a total length of 6km and follow an 8 year pause in TBM activity in Auckland. TBM performance on these two projects is thus of significant interest as there are four major tunneling projects totaling over NZ$8B being planned for Auckland, in similar ground conditions. Auckland?s bedrock is a weak sandstone/siltstone (East Coast Bays Formation), subject to infilled paleovalleys. The geology in the region has been significantly influenced by volcanic activity; 49 volcanoes are present within 20km of the city centre. The paper describes the design and construction challenges for the projects, including TBM performance, ?sticky spoil? management, and risks associated with basalt lava flows and two paleovalleys. Watercare?s Project Hobson also saw the successful implementation of a Geotechnical Baseline Report?one of the first uses of this type of document in Australasia. Rosedale Outfall is designed for high internal water pressures with varying hydraulic flows, with the risk of exfiltration explicitly addressed.

By J. D. Rice, P. L. Wearden, W. L. Hensou

Solutions to the unsteady-state partial water-drive reservoir performance problem can be obtained through the use of analogue computers or high-speed electronic digital computers. The solutions that have previously been resolved for use on digital computers, however, demand a knowledge of the aquifer parameters. Generally, the analogue computers now in use do not require this knowledge. A solution is presented herein where the aquifer performance, expressed in terms of difference equations, is related to the reservoir performance as expressed by the modified Scbiltbuis material-balance equation. A numerical procedure for a medium-sized digital computer also is presented in which a solution to the set of equations defining the aquifer and reservoir performance is obtained and the aquifer parameters (permeability and sand thickness) are automatically optimized while simultaneously matching the known pressure behavior. Predicted pressure behavior can be calculated using rates from any assumed future production practice. The procedure provides an output format which presents the cumulative, incremental and average rate of natural water influx, the per cent gas-cap expansion, the calculated reservoir pressure, the measured reservoir pressure, and the difference between the measured and calculated pressures. Results of a test problem are presented in comparison with results obtained by the Bruce Analyzer, Ohio Oil Co. 's Pace General Purpose Analogue Computer, and Sun Oil Co.'s Single-Pool Electronic Reservoir Analyzer. These results indicate that unsteady-state reservoir perlormance for a single-pool system can be adequately simulated by a numerical method employing a digital computer and that the special-purpose analogue computer can be supplanted by this method. INTRODUCTION The numerical approach to the unsteady-state partial water-drive reservoir performance problem heretofore has been limited in that solutions have been resolved only for certain fixed parameters. Also, prior to the advent of high-speed electronic digital computers in the last few years, calculations were so tedious and time-consuming that they ordinarily were neglected, or some other means of obtaining the solutions were used. The analogue approach had been used for obtaining solutions to the transmission-of-heat problem and, consequently, means were developed for applying the electrical analogue to the unsteady-state reservoir performance problem. Bruce submitted a paper for AIME publication in Sept. 1942, in which he described an electronic device (now called the Bruce Analyzer) for analyzing the water-drive performance of any reservoir, based on either steady or unsteady-state flow characteristics. 1 Sun Oil Co. adopted the analogue approach in 1949 and now has two special-purpose high-speed electronic reservoir analyzers in use.2,3 Two main features of Sun's analyzers are (1) the high repetitive rate of reproducing the entire history of reservoir performance cyclically a number of times per second, and (2) the elimination of the necessity of knowing the properties of the associated aquifer. Since the advent of larger and faster digital computers, the possibility of incorporating this second feature into a numerical approach appeared feasible. Previous work has been done and material published covering the application of numerical methods to the behavior of the pressure with respect to time at any point in an associated aquifer? However, the aquifer parameters must be known from some source. The material presented in Ref. 4 has been used to a great degree in developing the numerical method described herein. DIFFERENTIAL EQUATION AND BOUNDARY CONDITIONS The problem of simulating the performance of a reservoir and the associated aquifer is to determine the characteristics of the aquifer such that the