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By J. Herhold, S. Plaum

The focus within the economical optimization of projects, which are conducted underground, shifts more and more towards the conduction of construction work underground. Underground operations can be defined in a wide range of various projects, from underground mining tasks to the construction of engineering structures. Within these projects the conduction of construction work cannot only be defined as absolutely necessary, but sometimes also as optimizing for underground processes (e. g. installation of workshops underground to support the mining processes). Even though the conduction of underground construction might cause positive outcomes concerning the productivity, it also tends to be challenging due to local (sub-surface) conditions and influences. To minimize the risk of failure and sudden events within in the conduction of construction work underground, the tool “work preparation” shall be used. Under the given constraints, such as local influences, expected construction work and set time frame, the conduction of the construction work will be planned in advance by consideration of the construction logistics as well as the selection of a fitted construction technique. PROBLEM DEFINITION Economic Challenges - Raw Material Extraction Enterprises in the construction, mining and raw material extraction industries are increasingly under the pressure to perform economically to sustain their position on the global market. Profitability, efficiency and productivity are the basic conditions to be an active participant on the global market as well as a business partner and contractor for mining and construction projects or projects related to the extraction of raw materials. The completion of large-scale as well as common construction projects above ground has been under the pressure to minimize costs and time whilst maximizing the potential outcome, in the meanings of quality and economic gain, for more than a decade now. Whereas the construction industry has to fight the competition on the market with efficient project outcomes, the mining industry has to find ways to perform efficiently to further conduct the extraction of decreasing raw material deposits. The ongoing exploitation of existing raw material deposits to satisfy the constantly increasing raw material demands world-wide, led to the predicament that economically mineable deposits have decreased dramatically. Even tough mineral deposits do still exist on a global level, near-surface deposits decrease rapidly. Therefore, the extraction of raw materials within mining operations will be relocated further away from the surface in greater depths. With the growing distance from the surface to the mineral deposit, the extraction costs will increase many times over. With that in mind, the extraction costs will increase whilst the economic efficiency will decrease. The extraction of certain deposits will no longer be profitable with the common approach. To further extract raw materials efficiently even in greater depth, companies have to change their practice in different ways. That leads to the fact, if the deposits are in the depths, where the extraction processes won´t be economically, other (support) processes have to be in order to guaranty an economical corporate process itself. This precept will divert the focus from the actual mining process to support processes, where potential for optimization still can be found, as shown in figure 1.

Jan 1, 2019

By David G. Kidd

The principles of Ore Sorting in general and photometric sorting in particular are discussed with detailed reference to the Model 16 machine. The operating principles and design of the Model 16 are discussed and a case study presented to demonstrate the use of sorters to process an industrial mineral. In addition, an economic study is presented, to highlight the benefits of ore sorting, by evaluating the increased revenue that can be achieved using an ore sorter to process a particular ore body.

Jan 1, 1983

By Harland E. Cofer

A computer-assisted resources and sedimentological study of the Andersonville, Georgia kaolin-bauxite district was begun in 1975 under a grant from the Office of Mineral Resources of the U.S. Geological Survey (Grant # 14-08-1110-G-173). A preliminary report on the kaolin and bauxite resources of the district has been placed on open file at the U.S.G.S. in Reston, Virginia; the Georgia-Geological Survey in Atlanta, Georgia; and Georgia Southwestern College in Americus, Georgia. In addition to a resources estimate, the objectives include the determination of the mineralogical variation, sedimentological parameters, and paleogeographic patterns of the deposition of the high alumina materials and their associated sediments. In the process of compiling data for the resources estimate, isopach maps were developed that provide information as to the shape, size, and distribution of the kaolin deposits and the kaolinitic sediments that contain them. These or similar maps developed for other districts can be useful exploration tools.

Jan 1, 1977

By C. J. Newman

Before 1995, the smelting process at the Kennecott Utah Copper Corp. (KUCC) smelter consisted of Noranda reactors and Pierce-Smith converters. When considering expansion, it was decided that the existing process would not lend itself to a program geared toward processing the total output of copper precipitate and copper concentrate from KUCC mining and concentrating operations. During 1989 and 1990, several smelting options were evaluated. The final selection was the Outokumpu flash smelting process, coupled with the new Kennecott-Outokumpu flash converting technology. Facilities were designed and installed to process 1 Mt/a (1.1 million stpy) of copper concentrate, with the ability to expand to 1.2 Mt/a (1.3 million stpy). The smelter facility that used the Noranda technology was shut down in May 1995. The flash smelting furnace operation began in June with the flash converting furnace start-up a few weeks later.

Jan 1, 1999

By Bradford F. Townsend, Colin R. Speers

INTRODUCTION This is the first in a series of papers addressing practical tunnel lining design. The format for this and future papers is to present a particular topic and support the presentation of the guidelines by the practical application of a case history. The primary intent is to provide guidelines for the geotechnical and structural design of tunnels where the tunnel size and/or ground conditions dictates that systematic support of the excavation is required following each increment of excavation. This method of tunneling is commonly referred to as Sequential Excavation and Support(SES) and is also commonly termed the New Austrian Tunneling Method (NATM) The authors developed the design guidelines from experience gained over the past two decades during the design and construction of several major railway, highway and water-transfer tunnel projects in Africa and Asia. During this time it has been possible to compare the performance of the as-constructed structures to the predicted performance as given by the design process. Excavation was typically carried out in widely varying ground conditions (weak-bedded rock, jointed hard rock, and soil-like poorly cemented rock with groundwater). It is therefore intended that the design guidelines could be applied, in general terms at least, to any tunnel excavated in any ground mass condition with any ground material type (hard rock, soft rock, bedded rock, soft ground, and soil) with or without ground water. This first paper is an introductory paper that defines the scope and a brief outline of the design issues that may be presented in detail in later papers. What is design? It may be thought of as any rational/verifiable/justifiable process whereby a concept is transformed into information that can be used to bring the concept to reality. In the case of a civil structure, design may be defined as that process, which is documented and can be audited, that determines information such as the shape (form) of the structure, the dimensions (size) of the structure, the thickness and strength of structural members that comprise the structure, etc. This information can be used to compute the time, money and resources required for

Jan 1, 2005

By Y. Wang

China is a big mining country with a long mining tradition and history. At present, there are nearly 200,000 different mines and 21 million workers. The total production value of mining makes up 6% of GNP. With the development of economy, the mining industry has played a more important role in our economic market, supplying more than 95% non-reusable energy, 85% of industrial and agricultural raw materials, over 75% of fertilizers and 30% industrial and agricultural water.

Jan 1, 2001

By G. Danko

MULTIFLUX, a new thermal, hydrologic, and airflow model and software is being developed to solve the flow of heat, moisture, and air in and around an underground opening. MULTIFLUX couples two distinct domains that are solved separately first and re-coupled as an iterative task: (1) the rockmass, and (2) the airway. The airway is solved with a lumped-parameter Computational Fluid Dynamic (CFD) module which is an embedded part of the MULTIFLUX code. The CFD model includes convection, conduction, and radiation for heat, as well as convection and diffusion for moisture transport in an air-filled opening. The CFD model also solves for the airflow field. The surrounding rockmass model may be from any analytical solution, or from a complex thermal-hydrologic numerical model such as NUFT or TOUGH2. The rockmass model is interfaced to MULTIFLUX using a novel technique called Numerical Transport Code Functionalization (NTCF). The method provides fast convergence on a personal computer platform. The paper reports the results of MULTIFLUX simulations for a mine drift, comparing calculations with a known mine climate software, CLIMSIM, and with measured data. Through this validation example, the performance of MULTIFLUX is demonstrated. The results show excellent agreement due to the use of realistic modeling assumptions and boundary conditions.

Jan 1, 2009

By James N. Orlich

Meridian Gold Company's Royal Mt. King mine (RMK), a subsidiary of FMC Gold Company, is located approximately 40 miles east of Stockton, California on the western edge of the historic mother lode belt. Gold ore at RMK is associated with a series of northwest trending fault zones hosted in either meta-volcanic or meta-sedimentary rock types commonly referred to as greenstone sulfide and carbonaceous phyllite. Mineralogy studies show gold in both ore types to occur primarily as electrum in the form of 1 -20 um inclusions in pyrite with varying amounts of free milling gold. In carbonaceous ores, gold was not found to be closely associated with carbon. At the start of the current mining operation, three major ore resources were identified. North Pit and Gold Knoll pits were the major greenstone reserves while Skyrocket Pit contained over 60% of the total reserves as carbonaceous ore. Since North Pit and Gold Knoll were to be the first areas mined, the mill began operation in February 1989 with a flowsheet designed for greenstone ores with a carbonaceous expansion anticipated after depletion of the greenstone reserves.

Jan 1, 1992

By S. Christiansen, G. R. Winslow, R. W. Kobler

Todays End of Life vehicles are shredded and their metal components recovered and recycled by standard methods. The remaining non-metallic fraction is shredder residue, and contains vast amounts of high value engineering plastics. None are today recovered. Discussed are the developmental approaches used in the first process to recover these valuable plastics. Examined are initial laboratory studies, pilot plant design and construction, product development, results, and flowchart explanations.

Jan 1, 2001

By J. D. Potts

Dust surveys were conducted at six underground coal mines to determine if deep-cutting practices expose face workers to higher levels of respirable dust. The surveyed mines were able to successfully mine deep cuts without significantly increasing the dust exposures of face workers. For exhausting face ventilation, field data indicate that scrubber airflow is the most important factor for controlling dust. Data collected for this study indicate that 20-mesh screens should be cleaned for every 40 ft of advance because 22% of the deep cuts surveyed for this study experienced a 20% to 35% decrease in scrubber airflow over the course of the cut. For blowing face ventilation, field data and past research indicate that dust control is aided by maintaining a proper curtain-to-scrubber airflow ratio of 1.0 (measured before scrubber activation) as well as a curtain setback distance that allows the miner operator to stand at the mouth of the curtain for the entire cut. Dust levels on the bolting faces did not appear to be affected by the longer cycles associated with deep-cut mining when good ventilation practices were used.

Jan 1, 2011

By Daniel J. Dobbels, Eric R. Drooff, James R. Wheeler

Construction of Boston’s C11A1 Section of the Central Artery (I-93)/Tunnel(I-90) Project beneath the existing MBTA Red Line Subway at South Station required excavation to depths in excess of 33.5 m (110 ft) through permeable sand and gravel subject to almost 27.4 m (90 ft) of hydrostatic groundwater pressure. As tacked drift tunnel underpinning system was designed to provide positive support to the active station prior to mainline tunnel construction. As part of this system, a permeation grouting program was developed to facilitate tunnel excavation. This paper describes the design and implementation of the grouting program, in sit testing, and the overall performance of the grouted soil mass.

Jan 1, 1999

By Rameshwar Sah, Bharath Kumar Shanmugam, Govinda Raj Mandela, Marutiram Kaza, Harsha Vardhan, Harish Hanumanthappa

Iron ores obtained from different sources differ in their chemical and physical properties. These variations make the process of grinding a difficult task. The work carried out in this context focuses on three different samples of iron ore, viz., high silica high alumina, low silica high alumina, and low silica low alumina. The grinding process for all the three iron ores is carried out individually in Bond’s ball mill and the total retention time taken by each iron ore sample is calculated. The present investigation focuses on utilizing the calculated retention time of the iron ore as a standard grinding reference time to the laboratory ball mill for optimizing the grinding time of each ore. The desired P80 (150 μm) with an acceptable range of hematite liberation (> 75%) was obtained in the laboratory ball mill after reducing 6 min from the total retention time taken in the Bond ball mill.

By Rameshwar Sah, Bharath Kumar Shanmugam, Govinda Raj Mandela, Marutiram Kaza, Harsha Vardhan, Harish Hanumanthappa

Iron ores obtained from different sources differ in their chemical and physical properties. These variations make the process of grinding a difficult task. The work carried out in this context focuses on three different samples of iron ore, viz., high silica high alumina, low silica high alumina, and low silica low alumina. The grinding process for all the three iron ores is carried out individually in Bond’s ball mill and the total retention time taken by each iron ore sample is calculated. The present investigation focuses on utilizing the calculated retention time of the iron ore as a standard grinding reference time to the laboratory ball mill for optimizing the grinding time of each ore. The desired P80 (150 μm) with an acceptable range of hematite liberation (> 75%) was obtained in the laboratory ball mill after reducing 6 min from the total retention time taken in the Bond ball mill.

By H. Maleki

As mining continues toward deeper reserves in thick western US coal fields, the control of mining induced-seismicity has become a priority in many operations in Utah, Colorado, and Wyoming. Gradual floor heave, common in many coal mines, has historically not been a safety issue. However recent occurrences of sudden floor heave accompanied with seismicity in a few deep mines have fueled this investigation. The focus is to identify and study the mechanisms resulting in sudden heaving of the mine floor in western U.S. deep coal mines through analytical calculations and back analyses of an actual event in a cooperative mine. Based on review of available data in three mines, underground observations and back analyses of an actual event, the authors have identified the following contributing factors (1) presence of stiff stratigraphic units and thick seams mined at depths exceeding 1000-ft (2) presence of geological discontinuities reducing the in-situ strength of the coal with calculated factor of safety near 1 for the mine floor (3) mining approaching areas of higher than normal stress gradient associated with previous mining or structural anomalies or surface topographic highs and (4) an additional source of energy triggering sudden failure such as periodic caving or slip along geological discontinuities. Preliminary examination of seismic data for the actual event in the cooperative mine and underground observations excluded fault slip at the mining horizon as the triggering mechanism but highlighted the significance of weak, anisotropic strata conditions near the intersection of two faults.

Jan 1, 2009

By Hamed Khodadadi, Hamid Ghadiri

In this study, a fuzzy logic self-tuning PID controller based on an improved disturbance observer is designed for control of the ball mill grinding circuit. The ball mill grinding circuit has vast applications in the mining, metallurgy, chemistry, pharmacy, and research laboratories; however, this system has some challenges. The grinding circuit is a multivariable system in which the high interaction between loops, the variation of the system parameters with time, and time delay are some of the problems that pose a challenge. Since the controller parameters are determined offline in classic PID control, these gains are unchangeable and cannot overcome the mentioned challenges in this system. Hence, a fuzzy logic self-tuning PID controller, which is a combination of fuzzy logic and a conventional PID controller, is proposed to control the grinding system, especially in the presence of model mismatch and disturbances. In addition, in order to solve the system challenges, a multivariable control approach based on an improved disturbance observer is proposed to suppress the effects of the disturbances. The most important feature of the algorithm proposed in this paper as the combination of fuzzy logic self-tuning PID and improved disturbance observer is its ability to eliminate system interaction, attenuate internal and external disturbances, and compensate the effect of system uncertainty on the performance of the ball mill grinding circuit. Simulation results in the cases of the set-point change in particle size and circulating load in the presence of model mismatch and external disturbances confirmed the controller performance compared to other controllers.

By Hamed Khodadadi, Hamid Ghadiri

In this study, a fuzzy logic self-tuning PID controller based on an improved disturbance observer is designed for control of the ball mill grinding circuit. The ball mill grinding circuit has vast applications in the mining, metallurgy, chemistry, pharmacy, and research laboratories; however, this system has some challenges. The grinding circuit is a multivariable system in which the high interaction between loops, the variation of the system parameters with time, and time delay are some of the problems that pose a challenge. Since the controller parameters are determined offline in classic PID control, these gains are unchangeable and cannot overcome the mentioned challenges in this system. Hence, a fuzzy logic self-tuning PID controller, which is a combination of fuzzy logic and a conventional PID controller, is proposed to control the grinding system, especially in the presence of model mismatch and disturbances. In addition, in order to solve the system challenges, a multivariable control approach based on an improved disturbance observer is proposed to suppress the effects of the disturbances. The most important feature of the algorithm proposed in this paper as the combination of fuzzy logic self-tuning PID and improved disturbance observer is its ability to eliminate system interaction, attenuate internal and external disturbances, and compensate the effect of system uncertainty on the performance of the ball mill grinding circuit. Simulation results in the cases of the set-point change in particle size and circulating load in the presence of model mismatch and external disturbances confirmed the controller performance compared to other controllers.

By Harry M. Conger

Thirty years ago, the U.S. gold mining industry was hanging on by its fingernails. Save for one great mine, the Homestake, most production was coming from copper smelters such as Kennecott and Magma. Even Homestake itself was under great pressure from rising costs and a fixed price for gold. The outlook was dim, to say the least. Today, as it has for most of the past decade, the American gold mining industry stands among the world leaders in production, and in the development of mining and mineral processing technology. What caused this dramatic change? Obviously, the freeing of the gold price was a major factor, as was the decline in South African production, but these events alone could not have created the U.S. strength we see today. It was technology, investment, and the determination of miners to build an entirely new industry that were the indispensable ingredients. The U.S. Bureau of Mines, with great foresight, had begun the research that led to heap leaching before the gold price began to rise, and Newmont had committed to build a small mill at Carlin, a move then considered quite risky. From that point, the U.S. gold mining industry was placed on lower-grade ores then being found in Nevada and elsewhere, but it was soon apparent that we would have to develop new technologies to deal with more refractory ores, carbonaceous as well as sulfide-bearing. This is now being done with considerable success. Despite its success, or perhaps because of it, the gold mining industry has come under pressure from various groups who characterize their activities as motivated by "public interest." The public interest they refer to properly include the health and safety workers and impacted communities, as well as protection of the environment, and with these concerns we miners have relatively little argument. In fact, we consider health, safety and the environment among our highest priorities, and not just because regulations may require us to do so. The argument, however, is not about the regulation of a viable mining industry, it is about a well-organized movement to attack and condemn mining in the media and to misrepresent its importance to the Nation and its willingness to accept responsible regulation. Once largely local or regional, the interest groups to which I refer are now quite large, national in scope, and even becoming international. This trend, taken together with finances raised from their dues and contributions, would make the interest groups formidable adversaries for mining, but their grip on the media enormously magnifies their influence. Unfortunately, it also makes possible the wide dissemination of incomplete, incorrect or slanted information. I am not here to "bash" the interest groups. On the whole, I believe that many of them have made positive contributions to society. As conservationists, however, I question their authority to make, or foster, decisions about which American industries and communities live and which die. To illustrate, I would like to present for your consideration the problem of cyanide, one of the issues over which the gold mining industry is most threatened. CYANIDE-POISON OR MIRACLE SOLVENT? Let me get this out of the way right up front: cyanide in most of its chemical forms is toxic. In some forms it is also listed as a carcinogen. These are adverse characteristics cyanide shares with a considerable number of industrial chemicals, including some that are widely used without the stringent regulations already in place for the mining uses of cyanide. In these uses, by the way, the risk to humans comes from direct ingestion of cyanide or cyanide-bearing solutions, or from the accidental acidification of solutions leading to release of hydrocyanic acid gas. That these risks are under control in mining can be seen from the fact that, in modern U.S. practice, there has never been a documented fatality attributed to cyanide! Because of its toxicity, cyanide cannot enter and be accumulated in the food chain. It can, however, be a threat to birds and animals that ingest cyanide-bearing solutions. Protection against this is, quite properly, a responsibility of individual mining operations, and considerable sums are spent each year to prevent or reduce bird and animal exposures. It should be evident, though, that many human activities, including highway traffic, windmills, use of pesticides and the like, result in bird and animal losses. Mining's use of cyanide, and the measures taken to protect birds and animals, should be considered in context. Cyanide must be kept out of surface streams and groundwater, and existing regulations mandate this. Any cyanide residues left in leach heaps, waste dumps and disused facilities must be eliminated, and we have proven technologies to do this now, just as we have means to detoxify tailings prior to disposal. The gold mining industry decries those rare instances when irresponsible operators fail to deal with contamination, and agrees that they should be held responsible. We do not agree, however, that the great majority of responsible companies should be punished, in advance, for accidents that have never happened. So much for the poison, what about the "miracle solvent?" Is that an overstatement? Well, consider the fact that gold has been called "noble" from earliest times, because it does not oxidize under atmospheric exposure, and that it appeared to the ancients to be utterly insoluble. Later generations of scientists did discover that it could be dissolved, but only by a combination of acids so potent that it became known as aqua Regia. Later still, it was found that chlorine would also dissolve gold, and attempts were made to base commercial processes on this, without a great deal of success. It remained

Jan 1, 1995

"The Ohio River Bridge East End Crossing Tunnel requires a 75-year service life of its cast-in-place reinforced concrete lining. This twin-tube 3-lane (each tube) highway tunnel is about 55-ft wide and 30-ft high. Since unified tunnel service life prediction methodology does not exist in the US, challenges occurred during the design-build phase of this project. These challenges include the methodologies in determining the reinforced concrete’s degradation mode, the lining’s surface chloride concentration level, the reinforcing steel’s critical chloride threshold value for corrosion, how to verify the concrete’s diffusion coefficient, and the durability impact from concrete crack width. This paper presents a methodology in verifying the proposed concrete mix can achieve the service life requirements. This methodology can be adopted for service life prediction for future tunnels to be built in the US. INTRODUCTION The Ohio River Bridge East End Crossing (ORBEE) Tunnel is part of a Public Private Partnership project, which connects transportation network between Louisville, Kentucky and southern Indiana. Located in Louisville, Kentucky, the twin-tube highway tunnel provides northbound and southbound lanes of the Kentucky approach to a new bridge across the Ohio River. Tunnel lengths are approximately 1,675-ft and 1,685 for the northbound tube and the southbound tube, respectively. Connected by two cross-passages, both tubes have a roadway width of 40-ft, for 3-lane traffic, and a vertical clearance of 26.5-ft.The tunnel was constructed by drill and blast method with shotcrete and rock dowels as initial ground supports. The final tunnel lining system includes: •,Nominal 16” cast-in-place reinforced concrete lining, with 2” and 3” concrete covers over reinforcing steel for its extrados and intrados, respectively. •,20” cast-in-place reinforced concrete invert slab, with 4” and 3” concrete covers over reinforcing steel on its top face and bottom face, respectively. •,PVC waterproofing system around tunnel perimeter, excluding invert slab. •,Perforated PVC groundwater collection pipes on both sides of the tubes and one below the invert slab of each tube."

Jan 1, 2016

By B. W. Lawrence

Shaft alignment requirements are consistently met using conventional shaft sinking methods. Little attention has been given to achieving similar alignment accuracies using rotary drilled shaft methods. Alignment of these shafts is difficult to control and guarantee. Bare shafts and shafts that use drum hoisting systems can accept some deviation. However, combining drilled shafts with Koepe hoist installations presents new accuracy requirements for drilled shafts. This paper describes the importance of verticality with practical examples, and discusses various methods of measuring verticality and their respective limitations.

Jan 1, 1989

By Larissa Koroznikova, Steve Durkin, Patrick Bouwmeester, Michael Tuck

In currently used mining methods, blasting techniques often causes dilution of valuable ore and results in costly processing requirements. In the context of narrow vein mining of thin and highly concentrated orebodies there is a need of a mining method that can reduce dilution in order to remain economically viable. This research project explored the viability of a new mining technology, thermal fragmentation, in narrow vein mining. Thermal fragmentation technology uses a flame jet to produce extreme heat that spalls the surrounding rock to a strategically located drill hole, as an alternative to traditional blasting. This paper creates a net present value (NPV) model of a mining method using thermal fragmentation, as well as for an existing method used for narrow vein mining; comparisons and evaluations were made regarding the feasibility of the new technology. It was found that while overall costs for thermal fragmentation were relatively high, reductions in wages, haulage and processing costs, as well as increased productivity and ore recovery, meant that the new method would improve the financial performance of any operation. These results identify that there is an opportunity to introduce the thermal fragmentation technology to narrow vein mines within Australia, in order to lower costs and increase profit.