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By Martti Hagfors, Jussi Saavalainen

The underwater explosions has been used as a test method for the determination energy content of explosives. The test method is suitable for all kind of explosives; homogeneous, heterogeneous, wa-ter-resistant, no-water resistant, cap sensitive, booster sensitive, explosives with hard confinement, explosives without confinement etc. It is also the only test method by which shock, gas heave and to-tal energy values of the explosives can be measured separately. This feature makes it possible to use the test method to develop the explosives for different purposes; the military high explosives need more shock energy where as the gas heave energy is very important feature for the blasting and sea mine explosives.

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 J. Kennedy

Rare Earths: Understanding The United States complete failure of status and relevance in Rare Earth Oxides, Elements and Alloys. Although rare earth oxides are strategic and critical in their own right, elements and alloys are 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 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 Josef K. Alter

Long-term performance and behavior of post-tensioned ground anchors subjected to axial cyclic loading constitutes an important aspect of the stability, reliability and overall performance of wind turbine deep foundations. Axial cyclic loading of post-tensioned (PT) ground anchors in soils has not been thoroughly investigated as evidenced by the research conducted for this topic. This paper evaluates research test data, available literature, and industry expert opinion on the current status and problems of deep foundation post-tensioned ground anchor (PTGA) technology, as applicable to the wind energy industry. It also introduces a proposed design solution that addresses the problems of construction cost and long-term performance of wind turbine deep foundations in soils subjected to dynamic cyclic axial loading. Deep foundations using ground anchors for wind turbines have only recently gained attention as a possible viable alternative to the mass spread footings currently in use. One of the primary problems with general acceptance of current PTGA designs is the need for long-term anchor maintenance. The research that was conducted for this study indicates that current literature only partially addresses the many factors influencing load capacity and pullout performance of ground anchors. The lack of information indicates the deep foundation industry has fallen behind in designing and implementing new technology to improve safety and performance, ensure sustainability, reduce costs, and address environmental responsibility. This paper describes the significance of this problem as it applies to the wind energy market, and proposes a new technology solution. The research, expert opinion, and analysis presented by the author is used to support the premise that ground anchor construction cost and long-term maintenance can be reduced with PTGA systems using the Con-Tech Systems (CTS) patent-pending Groutable Void Form (GVF) technology.

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 Ameir Altaee

Unconventional means and methods were utilized to install over 650 contractor-designed micro-piles for the replacement of the Bronx approach to the Bronx-Whitestone Bridge in New York City. The method utilized reverse circulation (RC) drill rods and down-hole-hammers (DHH) along with grouting through the DHH bit. The overall construction sequence of drill-down, grout-up, place reinforcing is similar to auger-grout piling. The extremely tough drilling conditions required the use of a percussive DHH. The piling subcontractor refers to this pile as a hammer-grout pile. Project background, constraints and subsurface conditions are given. The proposed means and methods as well as the collaboration between stakeholders are detailed. Results of load testing and production installation are summarized.

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

By Alexander Hauck, Dimitri Jung, Uli Leiste

This paper describes results from small scale tests conducted to determine the distribution of impulse on target plates when subjected to loading due to the detonation of a buried mine. The tests were conducted with saturated sand, dry sand, and water as the loading media. Tests were conducted for flat plates and for plates with angled bottoms. Previous testing has shown that angled bottoms can reduce the total vertical impulse delivered to the vehicle significantly. Different stand off distances were investigated as well as loading of the targets both on center and off center. It is very important to know not only the total impulse delivered by a detonating charge but also how this impulse is distributed over the bottom of the vehicle. A complete understanding of specific impulse will permit those parts of the vehicle, taking the greatest amount of loading, to be sized properly. Experimental results were compared to analytical expressions provided by Westine and Tremblay.

Jan 1, 2010

By Anthony Iannacchionc, Jessica Benner, Harold Miller, Megan Witkowski

"Longwall bituminous coal mining has been practiced in Pennsylvania since the 1970""s. Hundreds of longwall panels have been mined during the last 40 years but only 24 have actually undermined Pennsylvania's Interstate Highway System. The impact to interstate highways are summarized in this paper and the factors that influence the magnitude of these impacts are examined.INTRODUCTIONOver the last 30 years, interstate highways in Pennsylvania have been undermined by portions of 21 bituminous coal mine longwall panels. From 2003 to 2008, three of the panel were extracted by the Emerald Mine and six by the Cumberland Mine both in Greene County and both owned by Alpha Resources. Previous assessments of longwall mining under Pennsylvania’s interstates have identified impacts to the highways but no danger to public safety. In general the magnitude and extent of impacts during the recent undermining of Interstate 79 or 179 appears to be similar as those identified in previous studies. The nine longwall panels are among some of the widest in the U.S. They are supercritical in character with overburdens ranging from greater than 152 m (500 ft) to less than 305 m (1,000 ft).The Pennsylvania Department of Environmental Protection (PA DEP) requested that the University of Pittsburgh summarize observations collected by their staff during the recent undermining of 179. Observations and photographs of impacts to the highway were made by PA DEP staff and entered into reports prepared by California District Mining Office (COMO) staff and statements written into the Bituminous Underground Mining Information System (BUMIS) database. In addition to the observations by the PA DEP, the Pennsylvania Department of Transportation (PennDOT) conducted a series of detailed land surveys along portions of the highway undermined from 2003 to 2008. To characterize the subsidence basin fanned by longwall mining. PennDOT information has been analyzed by another research group within the university (Guticrre7, et al., 20 I 0)."

Jan 1, 2010

By Christopher C. Jobes

Computer-aided control of a mining machine requires a guidance system to aid remote positioning of the machine by determining its position and heading. The mechanical position and heading system (MPHS) developed by the U.S. Bureau of Mines provides such navigation information during face maneuvers. This report describes the required theory, which yielded a reliable algorithm for calculating machine position and heading, and implementation of this theory in hardware and software design, which made surface testing of the MPHS possible. Analysis of the errors and test results showed that the MPHS provides reliable results and can, therefore, provide useful guidance information for face navigation.

Jan 1, 2010

By Emily Wortman-Wunder

As the 2010 president of the Society for Mining, Metallurgy, and Exploration, Inc., I am pleased to present the 2010 issue of Transactions of the Society for Mining, Metallurgy, and Exploration, Vol. 328. A significant portion of the contribution that we as a professional society make is the publication of professional and technical papers that accelerate the advancement of scientific knowledge and enable transfer of technology. Communication within the mining community is the key to a successful society. Through books, magazines, meetings and electronic media, we accomplish the technology exchange that is fundamental to the existence of the Society. This technology exchange continues a tradition that dates back to the 1871 meeting of 22 mining engineers in Wilkes-Barre, Pennsylvania, that resulted in the founding of AIME; those individuals envisioned that these transaction volumes “would form a most valuable and greatly needed addition to our professional literature.” This volume certainly fulfills that pledge. The 2010 Transactions is the first Transactions to take advantage of new publication technologies. It appears solely as an e-book. The decision to go to an all-digital format for this longstanding publication was a difficult one, but one which will certainly better serve the mining community. I am excited about this development and the opportunities it presents. The 2010 Transactions also contain some of the most exciting research from the past year, including new developments in mineral processing, safety and exploration. Be sure not to miss the two Minerals & Metallurgical Processing issues on the subject of gold hydrometallurgy. This 2010 Transactions comprise of a total of 78 technical papers (582 pages including index), including all 21 papers (136 pages) that were published in 2010 in the Technical Papers Section of Mining Engineering magazine (Vol. 62) and all 34 papers (231 pages) that were published in 2010 in Minerals & Metallurgical Processing (Vol. 27). Addition, this volume contains 23 papers (194 pages) that are being published for the first time in this issue. The papers presented in this volume were written by some of the most distinguished professionals in the industry worldwide. All 78 technical papers were peer-reviewed. The process of review and publication requires much hard work by authors, reviewers and our publications staff. As the 2010 president of SME and on behalf of all our members, I would like to extend our gratitude to all whose volunteer efforts contributed to the publication of this volume.

Jan 1, 2010