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The U.S. Bureau of Mines (USBM) has developed a test procedure to compare the initiating strength of detonators by using adjustable-sensitivity liquid explosives. Various tests of detonator strength are currently used by the industry, but many of them do not quantify the ability of detonators to initiate detonation reactions in an explosive charge. The USBM used mixtures of nitromethane and ethylene diamine, the sensitivity being "fine-tuned" by 2-nitropropane. Military standard J-2, commercial No.6, and commercial No.8 detonators were evaluated using three test configurations: (1) axially immersed in the test explosive, (2) tip just touching surface of the explosive, and (3) immersed transversely in the explosive. Markedly different results were obtained for these three configurations, indicating that the directional effects are important. This explains why different detonator strength tests do not correlate well with each other. Some tests, such as the sand bomb and underwater, measure the total energy out-put, while other tests, such as the plate dent, test measure the energy in the axial direction. The USBM's test data indicate the importance of conducting the experimentation in the manner in which the detonator is actually intended to function.

Jan 1, 2010

By Magnus Ericsson

The unexpectedly quick recovery in world crude steel production in the second half of 2009 was due almost entirely to increased production in China that began in late 2008. Previous peaks in monthly production in China were matched by April 2009. The rest of the world had still not reached pre-crisis production rates by May 2010. Chinese production drives growth, but there has been some growth in most other larger crude steel producing countries as well, compared to production in 2009. If the production rate of the first four months of 2010 continues, the total output of crude steel in 2010 will be somewhere around 1,410 Mt (1.5 billion st), the same as in the record year of 2007.

Jan 1, 2010

By Phil Shelton

What exactly does clean coal mean? Mining coal creates dust and releases methane gas. And burning coal liberates CO2 and emits particulates, including SO2 and NOx. Coal creates wastes that are often stored in unsightly and potentially dangerous slag heaps and lagoons. When clean coal technology is discussed, it sometimes seems that creating modern or ?ultra super critical? coal-fired power stations is presented as the main or even the only answer. However, there may be a more holistic approach. Using the energy potential of coal is always going to have environmental impacts. Some of these will be negative. But the need to secure future energy resources demands that society tackle these negative issues and find ways to minimize and offset them.

Jan 1, 2010

By Omotayo Kalejaiye

The Siwek 20-L chamber is widely used throughout the world to evaluate the explosibility of dusts. This research evaluated the quality of dust dispersion in the Siwek 20-L chamber using Pittsburgh coal, Gilsonite, and purple K dusts. A Pittsburgh Research Laboratory (PRL) optical dust probe was used to measure optical transmittance through the dust cloud at various locations within the chamber. A total of 540 tests were performed, with triplicate tests at five nominal dust concentrations and six locations. The two standard dispersion nozzles (rebound and perforated annular nozzle) were compared. The transmissions corresponding to the normal ignition delay period were used to: (a) determine variations in spatial uniformity of dispersion obtained with both nozzles; (b) make comparisons between the experimental transmission data and those calculated from theory for the three dusts; and (c) make comparisons with transmission data measured in the PRL 20-L and Fike 1-m3 dust explosion chambers. The uniformity of dispersion for the three dusts was similar with both nozzles, despite the differences in nozzle geometry and mode of operation. Transmission data of the three dusts were all significantly lower than those calculated from theory. This was discovered to be, in part, due to significant reduction in particle size that occurred during dispersion. By measuring particle sizes before and after dispersion, values of 60%, 50%, and 20% reduction in particle size (based on the surface-weighted mean diameter) were obtained for Pittsburgh coal, Gilsonite, and purple K, respectively. Transmission data from the PRL 20-L, Fike 1-m3 and the Siwek 20-L chambers indicated comparable results in terms of uniformity of dispersion. However, transmission data from the Siwek 20-L chamber were significantly lower than those of the PRL and Fike chambers. Again, this was attributed, in part, to the significant reduction in particle size that occurred during dispersion in the Siwek chamber. The design of the outlet (dispersion) valve of the Siwek 20-L apparatus charge vessel was largely responsible for the particle break-up. The contribution to particle break-up by the dispersion nozzles and the high level of turbulence in the chamber were found to be minimal. This is a significant finding in that the dust particle size tested for explosibility in the Siwek chamber is considerably smaller than the original dust sample.

Jan 1, 2010

By Dan Yang

Pile foundation designs are performed routinely based on geotechnical information available at the time of design, often with due consideration of large uncertainties inherent to soils and site conditions. These uncertainties frequently are the causes of piles being installed not the same as those designed, especially by factors beyond quality assurance and quality control. With a variety of both satisfactory and unsatisfactory pile test results from these nonconforming piles, the design engineers are required to examine the foundation performance as a whole against the project design requirements before signing off on them or calling for potentially costly remediation. Over the years, as-built analysis has been a consistent way of dealing with pile non-conformity and damage in our practice, avoiding many construction delays and it is an integral part of our pile foundation design. In this paper, the key elements of an as-built analysis along with several major bridge projects are presented.

Jan 1, 2010

By Walter Valery, Sarma Kanchibotla

Due to the global financial crisis, the world economy has turned upside down and most major economies in the world are facing severe recession for the past one and half year. During this period most commodity prices have tumbled by more than half from their peaks and such a sudden and severe economic downturn is not seen since the great depression. This sudden drop in commodity prices and lack of credit made many mining operations unviable and even those mines that are marginally viable at this point are operating under severe cost pressures and capital expenditure restrictions.

Jan 1, 2010

By Stephen Mansfield, Johannes Schoeman

In August 2006 a technical alliance was formed between Orica Mining Services and Century Mine to provide blasting solutions. The alliance is in the form of a Rock to Specification (R2S™) service, one of Orica’s Blast Based Services (BBS™). The ultimate goal was to facilitate the rapid expansion of material movement from 26 to 41M m3 (34 to 53M yd3) per annum while maintaining a reliable ore supply to the mill.

Jan 1, 2010

By Gungor Tuncer, Ali Kahriman, Abdulkadir Karadogan, Umit Ozer

The environmental problems such as vibration, and air blast are often faced, and discussed on mining, quarrying, civil constructions, shaft-tunnel, pipeline, and dam operations where blasting is inevitable. It is necessary to establish national standards towards to minimize the environmental problems induced by blasting and judicial matters in our country as it is in USA, EU countries and the other developed countries. This necessity and the obligatory of accepting the European Union criteria for Turkey that has started the procedure of joining to EU emphasize the importance of this study. In other words, the establishment of a particular national standard related with this subject is inevitable for Turkey. This will be possible only by studying, applying scientific methods and techniques by the experts.

Jan 1, 2010

This paper outlines the complete failure of the U.S. in status and relevance in Rare Earth Oxides (REO). Although rare earth oxides are strategic and critical in their own right, refining these REOs into elements and alloys is even more important for the development of "Green Technologies" and advanced weapons systems. America does not have an active domestic source of rare earth oxides. America does not have any heavy rare earth elemental or alloy capabilities. The magnitude of this failure continues to become more apparent as the manufacture of REO based electronics and magnetic components moves eastward towards China. China has succeeded in outmaneuvering the United States and the world in its quest to control the rare earth oxides, elements and alloys, and the many industries dependent upon REO. What can be done?

Jan 1, 2010

By Geysen. Daneel

Better slag valorization is part of improving the sustainability of steel, stainless steel and non- ferrous metal production processes. Besides, it can improve the sustainability of other products and production processes as well. A sound and well established slag valorization is beneficial for the overall economics, marketing and appreciation of the metallurgical process and its products. On 6-7 April 2009, the First International Slag Valorisation Symposium was held in Leuven, Belgium. This paper gives a brief summary of the symposium, providing an overview of slag valorization opportunities. The authors believe that high temperature process slags can have interesting applications and that within the next 10 to 20 years slags will need such valorization options in order to compete with other materials and get general support for further production. On the other hand, the authors also expect a higher demand for slags for the production of various materials. High temperature processes should anticipate on the growing opportunities for valorization of slags and increase the resilience of their process by better understanding slag processing, slag quality and material requirements. More interdisciplinary research efforts are required to reach this level of knowledge for the different high temperature processes. Such an interdisciplinary research platform was recently established at KULeuven, Belgium, named SMART-PRO2 (Sustainable Materialization of Residues from Thermal Processes into Products).

Jan 1, 2010

By Eric S. Lindquist

Two microtunnel access shafts were constructed using the Cutter Soil Mixing (CSM) method in the San Joaquin Delta region of California, east of San Francisco. Unlike conventional slurry walls and diaphragm walls that utilize concrete, soil mixing relies on blending the soils in situ with a cement slurry to create a soil-cement wall. Cutter Soil Mixing technology utilizes two sets of vertically mounted cutting wheels rotating about a horizontal axis to produce rectangular panels of treated soil. Overlapping of the soil mixed panels enabled the construction of two circular shafts. CSM panels were constructed to a depth of 29 m (95 ft) for the microtunnel jacking shaft and to a depth of 19 m (63 ft) for the microtunnel receiving shaft. The site presented several challenges, including the high depth of treatment, the variable nature of the alluvial soils, and the high water table. This paper describes the CSM technique and presents the design, construction, quality control measures and advantages of using this method for this project.

Jan 1, 2010

By Satyajit A. Vaidya

This paper presents a case-study in the design and construction of deep foundation element supported mats for two residential towers on an18,000-square-foot site in Brooklyn, New York. Based on site sub-surface conditions, conventional mat foundations bearing on medium dense sand, having an allowable bearing capacity of 3 tsf, were originally anticipated for the 16 and 25-story towers. However, when the tower shear walls were relocated to the edges of the mat foundations due to architectural revisions, the significantly increased mat edge contact stresses applied to the soil subgrade resulted in calculated settlements of a magnitude that would adversely impact the proposed structures and the neighboring/bordering lot-line building and rail transit subway structures. To address this issue, deep foundation element supported mats were designed for the towers. The design was performed as an iterative process involving structural SAFE and geotechnical Plaxis finite element computer analysis to develop a coordinated geo-structural model of the foundation system. Initial presumptive design values of 45 pci and 445 kips/inch were used for the modulus of subgrade reaction and minimum deep foundation element stiffness, respectively. The designed foundation system consisted of 40 and 60-inch-thick mat foundations for the 16 and 25 story towers, respectively. Initially, the deep foundation elements were designed as 50-foot-long, 14-inch-diameter elements installed to sustain a maximum individual compressive load of 250 tons. The final deep foundation element design was subsequently refined to consist of a 48-foot-long, drilled and grouted IBO Titan 103/51 element designed to sustain a maximum load of 167 tons. Subsequent field load tests on the deep foundation elements confirmed element stiffness ranging from 1,040 to 1,530 kips/inch, with measured mobilized side shear of about 29 psi. The mat foundation reinforcement was adjusted for the pile stiffness values determined in the field load tests, and the deep foundation supported mats were constructed. The two towers were subsequently constructed, and have performed successfully.

Jan 1, 2010

By Helen D. Robinson

Traditional practice to resist large lateral loads on foundations is the use of large diameter caissons, battered driven piles, or battered micropiles. Dense urban construction environments, however, limit the usefulness of these systems due to the close proximity of below- and above-grade obstructions. This paper presents two micropile construction projects in the United States where a complex scheme of battered micropiles and grade beams was developed to counteract large lateral loads at the foundation level. The paper also presents a procedure used to design vertical micropiles for large lateral loads, which can greatly simplify the design of foundations subject to significant lateral loads in urban environments. A design example shows a case where vertical micropiles were used to support allowable design lateral loads greater than 80 kip per micropile.

Jan 1, 2010

By Lorie M. Dilley

Alaska Village Electric Cooperative (AVEC), an electric utility cooperative providing power to 51 Alaska villages, has made a concerted effort to install wind turbines in the villages they serve in an effort to mitigate the growing costs of electrical power generation. The subsurface soils in several of these villages consist of sands and silts with ground temperatures of between 30°F and 32°F. The presence of warm, degrading permafrost in three of the villages has required innovative foundation designs, including the use of helical piers and piles to support steel and concrete wind turbine foundations. The design of the deep foundations had to account for the effects of degrading permafrost likely resulting from observed climate change patterns. Uplift forces imposed on the foundations were approximately 100 kips per pile. Uplift pile load testing was conducted on the installed piers and piles in order to determine the actual working load that each pier or pile could sustain. In addition, pile driving analyzer testing was conducted on several piles installed in the permafrost and compared to pile load tests. Results indicated that the installed piers and piles achieved the necessary capacity with sufficient factors of safety. Thermosyphons were installed near the foundations in order to limit the effects of climate change on the permafrost. The two to four wind turbines in each of the three villages are currently operational. Refinement of the design based on the pile testing from the first village to the third has decreased the cost of the tower foundations and improved our understanding of designing for warm, degrading permafrost.

Jan 1, 2010

By Ismet Canbulat

"In order to ensure the stability of roadways, Anglo American Metallurgical Coal (AAMC) has developed a roof support design methodology that integrates analytical, numerical and empirical modelling. This methodology currently is based on a deterministic approach (a single factor of safety against failure is calculated). However, an improved methodology, based on stochastic modelling technique, has also been developed and currently being evaluated. The main advantage of this methodology is that the design is based on the probability distributions of input parameters; thus the outcome is based on a distribution of factors of safety rather than a single factor of safety. An evaluation of factors of safety may also be used to determine the likelihood of failure, which in turn may be utilized to quantitatively determine and evaluate the associated risks in decision making process. This methodology has been evaluated at Grasstree and Moranbah North Coal Mines in the designs of roof support in various critical areas and has been proven to be successful and a better way of determining the roof support requirements.This paper demonstrates the application of this methodology in a design of an install road roof support at Moranbah North Mine, where the 1,750 tonne capacity ''world's highest rated longwall"" has recently been installed.INTRODUCTIONAnglo American Metallurgical Coal Australia (AAMC) operates three longwall (LW) mines located in Central Queensland. There is an increasing emphasis on the reliability at these operations, as the longwalls are getting deeper and facing more geologically challenging conditions. In addition, the Anglo American Vision is to achieve ""Zero Harm"" through the effective management of safety at all businesses and operations. In order to accomplish this vision, AAMC has developed a proactive ground control management system for a safe and efficient production of underground reserves.Proactive ground control management involves understanding the impacts of the geotechnical environment on likely ground behavior, and it consists of approximately 15 major elements. One of the most essential fundamentals of proactive ground control management is to utilize a roof support design methodology that considers different failure mechanisms and also takes into account all important elements. The design methodology becomes even more important when the area in question is a critical area, which is defined as a high risk roadway where any failure may cause increased levels of safety and financial risks to underground workforce and operations."

Jan 1, 2010

By Maria I. De Rosa

The U.S. Bureau of Mines conducted experiments for predicting materials' ease of combustion (smoldering onset, smoldering, flaming, and decomposition rates) by means of submicrometer smoke particle characteristics for the development of a simple test method. The experiments were carried out in an approximately 20-L furnace, with a 10-L/min airflow through the furnace for a 14-min duration, at set furnace temperatures of 150°, 250°, and 1,000° C. The variables studied as a function of time were the onset time of smoke particles, time and duration of maximum smoke particle generation, average concentration of smoke particles, and particles' average diameter, mass weight loss, and furnace temperatures. Results show that the onset time of smoke particles is predictive of materials' ease of smoldering, and the time of maximum smoke particle generation and its duration, coupled with mass weight loss, are predictive of materials' ease of smoldering and flaming (depending on the experimental temperatures), and decomposition rates.

Jan 1, 2010

By S Grönstrand, C. Perez, A. B. Yañez, F. Coddou, P. Morales, H. Elgueta

"The TankCell® 300 forced air flotation cell designed and built by Outotec, with active volume of over 300 m3, was installed at Codelco’s Chuquicamata concentrator in September 2008. After that, a program was conducted, where the new cell was tested against the plant’s existing flotation cells of type TankCell® 160, with an active volume of over 160 cubic meters.Testing program was exhaustive and detailed. Grade-recovery curves for each setup were reported, along with recoveries by particle size. Secondly, operational characteristics like air feed and froth height setpoints, and power consumption are compared side-by-side. As the third topic, gas dispersion characterization included velocity mapping, holdup, bubble size and bubble surface area flux operating range. The fourth area of interest was the retention time distribution (RTD) of the 300 and 160 m3 cells in comparison. A detailed campaign using radioactive tracer tests was conducted to clarify this.All of the investigations mentioned above are reported in separate papers for more detail. The aim of this paper is to collect the key findings, and present them in real terms, always referring to operability and metallurgy of the cells. It is destined for people designing new plants and to those improving and expanding existing ones. The most frequently heard question is: will the new large cells operate at same efficiency as the smaller ones. In short, the answer is: NO. They operate at improved efficiency!INTRODUCTIONIn the last two decades of minerals processing, there have been three dominant trends of development in the flotation technology: equipment scale-up, cell characterization and circuit modeling. Equipment scale-up has been rapid in the past two decades. In the year 1990, the largest flotation cell in use was 50 cubic meters of size. This year, 300 cubic meters is the largest installed cell. Characterization of flotation equipment and circuits is a very popular subject nowadays and has helped many operations to improve their recoveries through better control strategies, for example by using optimized air feed and level control profiles (Gorain, 2005), (Doucet, Gomez, Finch, 2006), or through better maintenance (Coleman, Urtubia, Alexander, 2006). Characterization work is closely linked to circuit modeling. The aim is to produce sufficient amount of data to allow reliable model building. These models are then used to design new circuits and to improve existing ones. So in summary, these three lines of development have slightly different aims – from capital and operational cost to performance optimization. Ultimately, they converge in the same end result – maximizing the profitability of the operation. Following chapters will summarize the extensive test work and scientific studies at Codelco Chuquicamata. The aim was to compare a TankCell® 300 cell, with nominal volume of 300 m3, against two TankCell® 160 machines, with 160 m3 volume in each. The work should yield answers to questions: does the larger cell produce similar results – is the scale-up successful?"

Jan 1, 2010

By A. Taylor, E. Thorn Corthay, R. Storey

In response to requests from its stakeholders, the International Standards Organisation is engaged in development of an international standard for Energy Management Systems (EnMS) which will become "ISO 50001". This new standard will build on the successes of both the EN16001 EnMS standard that has been used by dozens of European companies, as well as the ANSI/MSE 2000:2008 EnMS standard that is currently being used in several pilot projects in the USA and Ontario. This paper provides an overview of the key points of the EnMS standards, and describes how they can be used to drive sustainable energy reductions in the metallurgy industry.

Jan 1, 2010

By F Debidin

The progressive rise of an H-pile during driving of an adjacent pile is described in this case history in which piles 15 to 18 m long were driven to end-bearing for the foundations for a 230 m long building. The use of a reaction beam-soil anchor system for compression load tests is discussed. The results of static load tests to determine pile capacity are compared with those obtained by the Pile Driving Analyzer and by theory. Unusual high temporary compressions were observed by field control staff. Proof testing was necessary to determine the need for restriking of some piles in which rise had occurred.

Jan 1, 2010

By Tom Blevins, Roland Walker, Jinsheng Chen

"The Dywidag-Systems International DSI Tandem Anchor bolt, with an improved expansion shell-washer design, can substantially reduce potential entry roof falls caused by twisted or deformed expansion shells of the traditional mechanical anchor bolts during installation. In addition, the improved anchorage system can also ensure that a consistent and high installed load is achieved, which is critical for effective beam building under thinly laminated or layered roof conditions. This paper discusses the genesis and anchorage performance of the Tandem Anchor bolt, and analyzes the tension/torque relationship of different mechanical shell anchors using data obtained from both lab and field tests. It also discusses roof bolting mechanisms, roof bolting systems, and factors influencing effective beam building. Finally, numerical modeling was used to analyze the effect of bolt pretension magnitude on entry roof stability.INTRODUCTIONThroughout the history of underground mining, keeping the roof from uncontrollable collapse has been the greatest concern of the miner. Tremendous strides have been made in better understanding, predicting, and supporting the mine roof. This conference has spent the last twenty-eight years sharing information and distributing it to the mining community. A paraphrased statement from former Secretary of Defense Donald Rumsfeld adequately describes the challenges to the mining engineer as it pertains to roof control: it is a study of known knowns, known unknowns, and unknown unknowns. It is the hope of the authors to address some of these unknowns.The paper discusses the development of bolt anchorage systems from dry shells to shells with resin-assisted anchorage. It looks at some of the issues faced with the anchorage shells being used when introducing the insertion pressures caused by resin cartridges. The rationale behind the shell design changes was to compensate for this resin induced stresses.An improved expansion shell assembly (a slotted expansion shell base, a tapered cramming plug, and a novel support nut with tapered top) for mine roof bolts makes up the Tandem Anchor (U.S. Pat. No. 6742966); this minimizes the possibility of twisting seen with traditional mechanical shells and thus prevents springy bolts and shell leaves from breaking. A fully grouted Tandem Anchor bolting system has the advantages of both the pure mechanical point-anchor and the non-pretention fully grouted bolting systems. Once installed, the installed load or pretension will be locked in and never bleed off. Compared with the fully-grouted (2-speed resin) tension rebar bolting system, the fully-grouted Tandem Anchor bolting system can (a) reduce bolting cycle time (about 15 seconds per bolt), boosting coal production and productivity; (b) provide a greater installed load or pretention; and (c) achieve a consistent tension/torque ratio, which gives better bolting quality control. Therefore, a fully grouted Tandem Anchor bolting system is the most effective means to reinforce a weak rock mass intrinsically by the theory of beam building. For thinly laminated or layered roof conditions, a higher installed load or pretention (50% or more of the bolt's yield strength) can make a roof bolting system much stiffer, which results in less roof movement. Numerical modeling results show that the magnitude of the roof's tensile stress and relaxation zone can be substantially reduced under a higher installed load or pretention."

Jan 1, 2010