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By Stanley C. Suboleski, C. B. Manula

INTRODUCTION In any mining operation all possible steps should be taken to increase efficiency. One area for improvement is mine planning and design, particularly in the area of equipment selection for room-and-pillar systems. Be- cause of the availability of a wide variety of face machines, a fair degree of selectivity can be exercised in the choice of equipment for a particular job. However, this choice must be made on the basis of quantitative facts and forecasts related to the mining application. The purpose of this section is to develop and analyze the details of the mining process. Some specific areas studied include the relationship of system design to productivity, suboptimization as a result of equipment changes, and measurement of system performance. The plan of work leading to a quantitative description of these study areas is based on the growing interest in total system design using simulation as an analytical method (Manula, 1963). CHARACTERISTICS OF PRODUCTION OPERATIONS FROM ROOM-AND-PILLAR SECTIONS For a given mining method, raw production in a given section of a mine is primarily dependent upon the coal seam thickness, roof and floor conditions, methane emission, the mining methods, and the man-machine element. Average section production varies from 300 to 800 st per shift for conventional and continuous mining in high seams and from less than 100 to 300 st per shift in low seams. Since the reject varies from 0 to 40%, these figures must be decreased by the appropriate percentage to reflect the amount of clean coal mined. Personnel requirements per production section per shift for the various methods are listed in Table 1. Table 1. Production Personnel Method No. Method No. Conventional 12-1 5 Longwall 9-14 Continuous 9-1 2 Shortwall 9-12 MINING VARIABLES To evaluate the constraints and interrelationships for various mining methods, it is necessary to categorize the variables which underlie system production potential. Seven critical independent variables which determine production can be identified and categorized (Suboleski, 1978) : Seam Height The five categories are as follows: less than 36 in.;. 36 to 55 in.; 55 to 100 in.; 100 to 180 in.; and greater than 180 in. Floor Quality Floor quality ranges from : Excellent: Smooth, hard, grades less than 1 to 1 % % , and dry. Good: Smooth, soft but dry, with grades less than 3 % . The floor will deteriorate, but cautious operation can prevent it. There may possibly be heaving at some later time. Fair. Soft and damp. There is occasional interference with equipment operation; requires the use of four-wheel drive shuttle cars; ruts with regular use, and may have adverse grades of 5 to 7%. This may be coupled with slippery bottom and/or occasional steep rolls. Poor: Soft and wet. Requires blocking of the bottom to support equipment. There are frequent steep rolls and grades in excess of 7%. Roof Quality Roof quality ranges from : Excellent: Men are able to work under the unsupported top during the initial production cycle if legally permitted. Good: The roof is bolted on a 4 x 4 or 5 x 5 pattern with short bolts (442 in.) or <seam height if the seam >42 in., or requires posting with no bolts on a 4 x 4 or 5 x 5 pattern. There are no falls. Average: The roof is normally bolted on a 4 x 4 or 5 x 5 pattern, but with long bolts (>seam height or >6 ft.). There are infrequent minor falls or there may be an excellent roof which is difficult to drill. Fair: This type often requires spot bolting in addition to the regular pattern or bolting with planks. The roof conditions require shorter than planned cuts, or narrow cuts. Poor: This type requires bolts plus crossbars and posts, or installation of yielding supports or truss-type support. It is almost certain to fall if this is not done. Methane Liberation This ranges from none detected to low (no buildup at the face, even with minimum ventilation requirements) to moderate (the curtains must be extremely tight and tubing close to the face or methane will build up to 1 % during the loading of the car) to high (methane will build up to 170 if the miner is operated at the normal rate, even with proper ventilation). Hardness of Coal Coal hardness falls into the following categories: Soft: Soft coal is easily cut by a continuous miner. A plow could be used by longwall. Average: Coal of average hardness could be easily cut by a miner, and a shearer would be used in the longwall. Moderate: Moderately hard coal causes difficult cut-

Jan 1, 1982

By J. Alton Burks, Roy C. Bartholomae

The chain conveyor is utilized extensively in underground mining to convey raw ore, especially coal. It is estimated that several thousand loading and continuous mining machines rely on this type of conveyance. Although the chain conveyor is both efficient and highly reliable, its use is generally associated with the production of noise levels that often exceed 105 dBA at the operator&apos;s position. Thus, it is one of the most significant contributors to the occupational noise problem experienced by miners in the underground coal mining environment. Conventional engineering noise controls that result in an average reduction of 4 dBA have been previously designed and implemented. However, a novel solution involving a change in conveyor operation has been proposed that takes advantage of two aspects of conveyor noise: 1) conveyor noise has an approximately cubic dependence on conveyor chain speed and 2) due to the damping provided by coal, a full conveyor is 5 dBA quieter than an empty one. An engineering analysis has shown that a significant reduction in the operating noise level of a typical continuous miner can be achieved through the use of an adjustable speed drive automatically controlled by a coal loading sensor that maintains a full conveyor at all times. The potential reduction depends primarily on the mining conditions (coal seam thickness and the presence of either rock or water) and varies from 7-18 dBA. Other benefits to be derived from the use of a variable speed drive include reductions in power consumption, dust, and maintenance costs.

Jan 1, 1992

By M. P. Adamson, Bryson D. Trexler, R. V. Ramani, Mark L. Koenig, V. Rajaram, Alan Burton, C. S. Crocker, Kim. Y. C., A. G. Law, William C. Larson

Another record year vas experienced by the mining industry as the value of nonfuel minerals production soared to $23.5 billion-up 15% from the previous year. Based on preliminary estimates by the Bureau of Mines, US mine output was the basis for about $225 billion worth of minerals-derived materials. Metal mining accounted for $8.5 billion, or 36%, of the total. Of the 22 metals produced in the US, 11 showed quantity increases, while 16 had value increases. Business Week&apos;s survey of 1200 companies (Mar. 17, 1980, pg. 81) revealed that 21 metals and mining companies had sales increases of 30% with earnings up 104%. Higher prices and increased demand for metals were primary factors behind the improved performance. The steel sector reported a 30% decrease in earnings for the year, but the slump was primarily the result of a $383-million loss for US Steel coupled with a 17% decrease in earnings at Inland Steel. Other firms did well in 1979, with earnings up 279% at Interlake and 269% at Kaiser Steel. Major obstacles facing the steel industry included substantial tonnages of dumped and subsidized imports, environmental expenditures, runaway inflation, and price controls. Turning to nonmetallic production, of the 49 commodities reported by the US Bureau of Mines, 29 had higher outputs and 39 had increased values. While production statistics may seem encouraging, government regulations continued to stifle industry efforts to develop needed new capacity. A case in point may be publication of the Environmental Protection Agency&apos;s simplified procedure to streamline five permit programs by consolidating them into one. The five included: hazardous waste management, national pollution discharge elimination, dredge and fill, underground injection control, and prevention of significant deterioration. The new procedure, published by EPA in the Federal Register, took 149 pages. AMC&apos;s J.A. Overton, Jr., noted that (MCJ, Nov. 1979, p. 39) to visually depict the complexity of the proposed regulations, Sell Oil Co. developed a flow chart mapping a path through one section. The chart required 10 days to map and two weeks for two draftsmen, using computerized drafting techniques, to plot the results. Overton said, "Perhaps the greatest service EPA has performed in preparing its proposal is to demonstrate again that federal regulations have become a complexity compounded by confu¬sion that culminates in a conundrum." While regulatory agencies promulgate new regulations, the lack of a cohesive government minerals policy remained a matter of significant importance to mine management. A non-fuel minerals study to provide input to the Administration for a national minerals policy program was a dismal shock, according to Rep. Jim D. Santini (D-NV). He said the first phase of the program, which was to identify industry problems, failed to come to grips with the hard decisions necessary regarding these problems, their impact, and their interrelationship. Santini said the report failed to acknowledge government&apos;s role in the process and absolved the government of any adverse influence on the domestic minerals industry. In response to the phase one report, eight senior mining executives testified before Santini&apos;s House Subcommittee on Mines and Mining concerning mineral supply, access to foreign sources, environmental protection, conservation and recycling, national security, and capital formation. By year&apos;s end, Rep. Santini promised to prepare a hard-hitting committee report on problems affecting the non-fuel minerals industry to provide a better base for subsequent policy recommendations (MCJ, Jan. 1980, p. 34). On the technological front, interest again centered on mechanization, automation, and scaleup to improve and expand production. Computer use increased for calculation of ore reserves, mine planning, operations research, and mineral processing.

Jan 5, 1980

An appropriate scale-up methodology is very useful for ball mill design and optimization of the grinding circuit. To date, the scale-up is based on the selection and breakage function method using lab mill data. However, a major drawback of that approach is that the charge motion in a lab mill is vastly different from that in a large industrial mill. Therefore, in the methodology proposed here, first the energy of individual collision in the mill is computed employing the discrete element method (DEM). Then the breakage of particles as a function of collision energy is studied in a separate experiment. Together, this information constitutes what is known as collision energy based population balance method. The appropriateness of this method is shown for 38-cm ball mill.

Jan 1, 1998

By LeRoy Kienitz

There may be someone here who is not required to run his equipment at its maximum capacity. There may be some fortunate enough to have more crushers than needed, wider conveyor belts than required, and other mill equipment equally oversize. If so, then this paper will have no interest for him; but if most of you are in the situation we in the aggregate producing industry are in, then you probably wish to crowd your mill equipment to its limit. When you do this you must watch for block-up and overloads of all sorts. You need more eyes than you have to guard the critical points. The human eyes that now do nothing much, but watch should be freed for more productive work.

Jan 1, 1961

By James J. Olson

INTRODUCTION The need for Government-sponsored research and development to increase excavation rates and lower costs for tunneling and mining operations in a variety of rock types has been emphasized in a wide range of publications from advisory panels, symposiums on rapid excavation, and individuals. In response to the predicted demands for mining and construction-oriented underground excavations for the next two decades (1970-1989), a comprehensive 10-year, $200-million research program in rapid excavation was proposed by the National Academy of Sciences in 1968 (1). Although the large program recommended by the Academy has not been funded, substantial Government-sponsored research in rapid excavation has been conducted during the past several years. This paper reviews some of the significant research accomplishments obtained under a three-year, $6.6-million research program in rock mechanics and rapid excavation sponsored by the Defense Department&apos;s Advanced Research Projects Agency (ARPA) and managed by the Bureau of Mines. In addition to the rock mechanics research, five major phases of excavation; systems analysis, geologic prediction, rock disintegration, ground support, and materials handling were represented by the projects funded under the ARPA program. The brief outline below recapitulates the major research areas and some of the projects summarized by this paper: Excavation Process Modeling by Computer Geologic Prediction Geologic Reconnaissance for Site Selection Longhole Probe Drilling for Hazard Detection

Jan 1, 1974

By Carl D. Broadbent

The goal of slope mechanics is to achieve efficient and safe pit slopes. In the case of ultimate mine slopes the objective is to minimize the stripping ratio by steepening the slopes to their maximum stable limit. On the other hand, the inclination of working slopes is normally established by operating space requirements and the function of slope mechanics should be the continuous surveillance of slope conditions to assure long-term stability and to provide timely warning of impending slides so that corrective measures may be incorporated in production planning. In 1956 Kennecott instituted a program to provide the resources necessary to develop and maintain a slope mechanics capability, including technical knowledge, engineers, and instruments. Although the goal has not been fully achieved, very significant progress has been made. Other papers (3, 4, 7, 8, & 12) have described the purposes and detailed results of the most recent study carried out at the Kimbley Pit. The study has provided valuable experience and has given the industry a three dimensional picture of the stability variables that influence a mine slope. The study has better defined those areas which require further investigation and has indicated those design and analytical techniques which can be used with confidence. In effect, the study has paved the way for the next step; that of refining the design process and applying it for profit.

Jan 1, 1968

By K. Norris

The Amax Gold Guanaco mine is located in the Atacama Desert, approximately 260 km southeast of Antofagasta, Chile. The 6,000 tpd leach operation produces approximately 90,000 oz of gold, and 360,000 oz of silver per year. Production began in 1987, and the operation has been managed by Amax Gold since 1992. The mine has been plagued in the past by high operating costs and low production. Several significant changes have been made to the operations which have resulted in lower costs and higher operating efficiencies. A review of these changes is presented herein.

Jan 1, 1997

By R. Y. Wan, Corby G. Anderson, L. Ernest Krys, M. C. Fuerstenau

Since 1942, refractory precious metal concentrates at the Sunshine mine have been processed for antimony metal recovery using a novel leach-electrowin method. This is counter to most antimony production facilities where pyrometallurgical techniques are usually relied upon. The key step for removal of the antimony has been an ambient pressure alkaline sulfide leach. In 1990, a comprehensive laboratory study was undertaken to better understand this process. Factors studied included temperature, agitation, concentrate regrind, alkaline species concentrations, sulfur species concentrations and solids concentration. Details of these studies, as well as a brief description of Sunshine metallurgical processes, will be presented.

Jan 1, 1993

By Thomas D. Kaufmann, Robert C. Drury

Few factors are as important as fluctuations in aggregate economic activity and exchange rates in determining the profitability of mineral investments. Macroeconamic theory explains how the two factors are interconnected in today&apos;s world and in tomorrow&apos;s. We can use macro¬economic theory to lessen some of the risks in mineral investments. And in the current state of the world the risks are high. The above paragraph summarizes our argument. Our goal in this paper is to examine the nature of contemporary business cycles so as to explain their implications for the metal industries, particularly the implications for capacity. Thus, our first section examines the workings, causes, and history of the recent economic fluc¬tuations. In doing so we must understand how current world economy is interconnected, that is, how economic events in one country are trans¬mitted to the rest of the world. Our view is that governments and central banks are key actors in the creating of economic fluctuations. Then, in section two, we work out the implications of section one for the metal industries focussing on comparative advantage, trade, and capacity decisions. Over the last fifteen years the world economic system has had slow overall economic growth and has had strangely unpleasant recessions. While future business cycle will not repeat the de¬tailed pattern we have seen, there will be similarities. The similarities need to be under¬stood before investment occurs. The slow growth in the world economy since the early 1970s has aggravated the problems from business cycles, created its own problems, and has partially hidden the effects of other events. Major realignments of currencies are likely to take place over a business cycle. The nature of the causes of the cycle will determine the direc¬tion of change in the exchange rates. For example, whether a USA recession will be accompanied by a weaker or a stronger dollar will be determined by the cause of the recession. The realignment of currencies over a business cycle leads to a realignment of comparative advantage in the metal industries. Thus, not only will world metal consumption vary over the business cycle but the impact on various countries&apos; metals industries will differ consi¬derably. Competitiveness often depends more on the value of the dollar than it does on inherent efficiency and wage rates. Capacity decisions are inherently riskier due to the country specific nature of exchange rate risk. A realignment of currencies changes the pattern of trade if and only if the country with the cheaper currency also has idle capacity. The importance of our topic is indicated by Table 1 which shows the impact of cyclical and exchange rate shocks on the USA metal industry. In the cyclical downturn, from the peak of 1979 to the trough of 1982, consumption dropped by a fifth to a third. Metal price moved in the same

Jan 1, 1989

By Michael J. Shulman

The DEAREX knowledge acquisition and engineering system is a teaching and exploration tool designed to facilitate the under- standing and development of expert systems by explorationists without the aid of a knowledge engineer and without recourse to expert system languages. To fulfill its objective, the DEAREX system considers the selection of exploration methods in desert areas. The system consists of three parts: 1. A tutorial which introduces the basic and selected advanced concepts of expert systems, 2. A sample program illustrating how an expert system works and can be used, and, most importantly, 3. A knowledge acqusition and engineering program which enables users to develop their own expert systems. The tutorial provides a brief and concise introduction to expert systems, a 10 rule exploration example which defines, explains and illustrates the basic concepts and design of expert systems, and a glossary of expert system terms including cross references. The sample program is a larger, self contained example of an expert system with some commentary illustrating addition- al expert system concepts and the role of the knowledge engineer in particularizing rules and ascertaining the knowledge base. Restricting itself to the selection of exploration methods in desert areas, the knowledge acquisition and engineering program questions the user and converts the answers into an expert system. Questions pertain to geology, infrastructure, availability of instrumentation, personnel, etc. Additional information may also included. In conclusion, some salient points concerning knowledge engineering toolkits, shells and knowledge acquisition capabilities such as contained in DEAREX are discussed.

Jan 1, 1992

By R. L. Pozzo, I. Iwasaki

A previous investigation showed that corrosion currents estimated from polarization curves for the pyrrhotite-grinding media system under abrasion correlated well with corrosion currents estimated from marked ball wear test data by applying Faraday&apos;s law. Freshly abraded metal debris were magnetically attracted to pyrrhotite and lowered the rest potentials of the mineral particles, thereby affecting the corrosive wear. The investigation was extended to explore the interactions between a non- magnetic sulfide mineral, pyrite, and abraded metal debris and their effects on the corrosive wear mechanism. The electrochemical behavior of a three-

Jan 1, 1988

By J. Schleifer

On short term, planning techniques require more details to ensure feasibility, giving importance to operation constraints and use of available resources. In GUEMASSA (Morocco), the ore mass is mined by cut-and- fill method. Correct organization requires to forecast a few weeks ahead the schedule of blocks to be mined, in order to respect ore quantity and grade constraints. While operating constraints are tackled, feasibility is assumed with an average production capacity suggesting that resources will be available. In ST-SALVY (France), scheduling operations is not possible if not considering account resource allocation. In any stope within the vertical vein zinc deposit, the cut-and-fill method enables to mine each horizontal slice according to various strategies, de- pending how to use manpower and equipment, and selecting among predefined scenarios known as realistic. For KOFFIEFONTEIN (South Africa), the kimberlite pipe is mined by a sub-level-stoping method. To achieve the production target, precise organization over one month is obtained, using on& resources when available and respecting all mining rules. This combined operation scheduling and resource allocation is called sequencing. While following the BONANZA concept, providing a planning- retrieval process, sequencing offers more. Very detailed, it is possible to check the impact of resource parameters and mining rules. The sequencer, like a simulation platform, enables expertise. Each sequencer must be tailor-made to fit to each specific mine. The next challenge is to produce a generic environment.

Jan 1, 1996

By K. F. Unrug

Extrapolation of the rock properties obtained from the cores exploration holes to the surrounding areas often causes problems because of frequent sudden changes in the geologic composition of strata. To address this problem, the author has been developing a method of rapid strength testing "in situ," with application of a borehole penetrometer. This method, as opposed to conventional laboratory testing, does not require rock samples to be retrieved and handled/machined before testing. The results are generated by strength determination on the wall of a drill hole at a site. The newest development is a borehole penetrometer that requires only a 1.38.mm (1.5 in) diameter hole. The small diameter of the penetrometer body allows for drilling test holes with production mine equipment such as roof bolters. It opens the possibility of broad application in coal mines, as well as in hard rock mines and tunneling. The principles of the apparatus are described and are illustrated with examples of its applications.

Jan 1, 1999

By Ernest Koenigsberg

In 1961 Lerchs and Grossman presented a method, based on graph theory, to determine the optimum ultimate pit limits for an open-cast mine. At the same time they demonstrated a dynamic programming algorithm for the optimum pit limits for a two-dimensional open-cast mine. Since then many methods for determining optimum limits for three-dimensional mines have been programed, and even more have been reported in the literature. The methods include computer "simulation" of the manual methods used by engineers, the development of sets of conic sections and fitting to exclude overlap, integer linear programming (and its equivalent network flow model), and dynamic programming. Many of the methods do not guarantee optimal solutions but seem to satisfy the user. Other reported methods have never been applied, partly because they did not yield optimal solutions. We have developed a three-dimensional dynamic programming algorithm which requires a single pass through the data. Large problems can be solved on a small computer because only a small part of the data is required at any time. In this paper we will review the state of the art and to demonstrate the connection between linear programming (and network flow) models and the dynamic programming method.

Jan 1, 1982

By Frederik P. Agterberg

During the past 20 years, methods of multivariate statistical analysis have been developed on mainframe computers for the integration of geological, geophysical, geochemical and LANDSAT data in mineral resource appraisal. At present, it is becoming increasingly feasible to perform mathematical image analysis of digitized patterns on microcomputers. This has led us to develop a new method of statistical pattern integration for mineral exploration. In this paper, the new method is used to outline, by means of posterior probabilities, exploration targets within small areas of which the prior probabilities for occurrence of new mineral deposits had been estimated by multivariate analysis.

Jan 1, 1989

By R. L. Loofbourow, Robert R. Miller

Deep, stable, unlined space promises secure, efficient, acceptable solutions to several current problems. With truly favorable conditions, it can be economic as well. The basic requirement is sufficient sound, tight rock at required depth. This and unusual surface requirements point to special testing. An objective is to describe conditions for planners, estimators and contracts. A first stage concept study needn&apos;t be prolonged but should overlook nothing significant. Although observations and tests on core are considered essential, time and expense can be cut by supplementing then with tests on walls of rotary or percussion holes. In some places initial drilling could be shallow.

Jan 1, 1981

By D. W. Park

Longwall mining is popular in underground coal production in the United States due to higher production rates and safety concerns. Because of the extreme complexity, it is necessary to plan an adequate design to achieve a safe and efficient working place. The proper sizes of yield and abutment pillars and panels can be determined by simulation using numerical modeling techniques. By means of three-dimensional modeling, stresses to be imposed on the pillars, panels, gob, and powered supports can be analyzed. In this study, an initial three-dimensional finite element model was developed and then modified into four different models. Using these models, the numerical outputs of distributed stresses on three different sizes of yield pillars, three different sizes of panels, and two different sizes of abutment pillars were compared and analyzed to determine the most adequate pillar and panel sizes. Progressive failure theory based on the Hoek and Brown failure criterion was used to determine redistribution of stresses in the yielded and failed areas in the longwall mine.

Jan 1, 1992

By Dave Willis

In ME&apos;S 1994 Powder River Basin (PRB) coal transportation article, the lead author described some destinations pursued by the railroads. As with many destinations, though, they turned out to be merely stops on the way to places that have yet to be reached. Along the way, the railroads discovered that making it better is a continuous process, not just something done in several phases. This was always known but not at the awareness level that exists in 1998 railroad environments. This update of the 1994 article includes railroad companies&apos; plans for the future of rail transportation in the PRB.

Jan 1, 1998

By U. E. Paakkinen

Progress in computer control of flotation circuits has developed parallel with advances in reliability of on-stream X-ray analysis (Cooper, 1976). Attainment of acceptable results with X-ray fluorescence analysis over the past ten years has led to application of computer control in more than 30 concentrators. Gains in applying flotation control also have given incentive to improving measurement and control devices for other essential functions in control systems. At the same time, advancing technology has made available computer systems having characteristics practical and economical for the physical environments of concentrators and ore processing plants. Benefits from flotation control have centered on increased efficiency in mineral separations, derived by stabilizing circuit operation subject to changing ore characteristics. The gains have been most evident in processing complex ores for multiple concentrate products. In many cases, particularly when coupled with grinding control, the economic results from on-line control have been substantial compared to investments in monitoring and control equipment.

Jan 1, 1979