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By James F. Kvitkovich, George V. Weisdack

Longwall mining techniques were introduced into U.S. bituminous coal mining operations in the early 1960s. These techniques were gradually adopted by many mines during the 1970s. By 1983, considered to be the peak of the longwall mine census, there were 118 active longwall faces in 79 coal mines throughout the United States. Beginning in 1984, longwall faces began a decline in numbers that has continued to the present day (Fig. 1). The geographic distribution of longwall faces today is shown in Fig.2 according to region. A breakdown of recent longwall mine production by region is shown in Table 1. An approximate breakdown of present longwall face installations by product (metallurgical and steam) is shown in Table 2.

Jan 1, 2005

By Ivan Weber

Asking the question, “What do the world’s leading corporations and cutting-edge practitioners of sustainability put forth to guide a given mine site for planning and action toward ‘sustainability’?”, this paper explores the spectrum of methodologies and mindsets in available literature, then constructs an example for the large near-closure facility at Kennecott Utah Copper. Values, opportunities and constraints spring from physical, unutilized byproducts, from critical ecosystems and wildlife populations, from location relative to those ecosystems and proximate communities, and from the political will to perform adequate feasibility investigations. Patience, determination and thoroughness are imperative. Identifying most productive and, simultaneously, most protective and restorative, practical methods to approach ‘sustainability’ has become a central mission of industry and business, worldwide. A survey of recent international initiatives finds no single approach that establishes either a readily adaptable methodology or an appropriate set of ‘attention’ points, or agenda, to guide individual mining operations at specific locations toward the elusive but essential goal of ‘sustainable’ mining. Untying this convoluted knot of contending factors requires willingness to recognize and work within ecological constraints for community long-term needs. Occasionally, the task requires the sword of Alexander the Great. Through integration that is unflinchingly honest ethically, culturally, economically, ecologically and scientifically, fully cognizant of place and community at whatever scales are of greatest significance, and integrative of both problem-response and opportunity, we may envision a mineral extraction and beneficiation future that achieves the best, most nearly sustainable, results possible. Industrial ecology (IE), with its clear emphasis on community, ecosystems, and sustainable economic stimulation, presents a sufficiently broad and adaptable discipline to facilitate planning and management toward sustainable mining. The creation of sustainable jobs encapsulates IE’s analogy to the niche survival strategies of organisms in nature. Open to common-sense recognition of faults and opportunities at appropriate scales, IE is less a discipline or prescribed methodology than a mindset, willing to be rigorously scientific when science is imperative, but also willing to exercise “art” when creativity or community engagement are needed. IE is also capable of future-looking compassion for peoples and nature. Looking beyond what has occurred to date, the case of Kennecott Utah Copper provides ample illustration of possibilities for community economic development, environmental management, and significant initiatives beneficial at regional and planetary scales, to become recognizable as deserving of the label, ‘sustainable.’ Through what this researcher terms “whole mine, whole region, whole planet” thinking, strategies become visible and subject to serious consideration, presenting a path to best possible accomplishment in mining. Constituting a maximal broadening of mining’s “traditional” scope, the integrative approach proposed here is the ‘paradigm shift’ being made by many other industries around the world. In aggregate, these steps are the only hope for avoidance of environmental, social and economic risks that threaten to curtail resource development and impair mining companies’ ‘social license to operate.’

Jan 1, 2005

By G V. R Goodman, G J. Chekan, J M. Listak

The extraction and transport of coal from underground coal mines can result in significant liberation of coal and/or silica dust into the mine atmosphere. Mine operators have long used ventilating air as a primary means of diluting generated dust, removing dust from the working faces and preventing dust from reaching the minersÆ working environment. As production levels have increased, mine operators continue to be challenged in maintaining dust concentrations below compliance levels. The need for maximising the effectiveness of available ventilating air in conjunction with other effective controls, such as water sprays and dust collectors, continues to be critical to the long-term health of mine workers. The National Institute for Occupational Safety and Health (NIOSH) has conducted full-scale laboratory and mine-site research to evaluate improved application of dust controls for both longwall and continuous mining methods. A summary of recent research results and recommended practices will be provided.

Jan 1, 2005

By P J. Ellen

The selection of the ore haulage system is a key decision made in the development of an underground mine. The haulage system is one of the components that define a mineÆs ability to respond to changes in mining inventory and market conditions. The complexity of this decision for Telfer Deeps was affected by the realisation during the feasibility process that the true scale of the potential underground mineralisation at Telfer was still to be quantified. This paper provides an overview of the process used in the Telfer Project Feasibility Study to select an ore haulage system for Telfer Deeps. The purpose is to highlight the value of impartially approaching tasks of this type with a robust process. The process should be able to respond to issues identified as the task progresses towards the objective of finding the best solution for an ore haulage system for the mine. For Telfer Deeps, this process resulted in the selection of a haulage system built around a shaft. The systems considered during the feasibility are discussed and the components of the haulage system constructed for Telfer Deeps are described.

Jan 1, 2005

By André Fouché

GFWW Bulk Sample Prep Plant INDEX ?Features ?Flow Diagram ?Pictures of Plant

Jan 1, 2005

By M Tessier, M Pahkala, L Sletmoe

The Red Lake mine is one of the richest gold mines in the world. The primary mining methods are overhand and underhand cut and fill. Starting in 2003, Goldcorp initiated an expansion program at the mine. The expansion includes a new 6.55 m diameter hoisting shaft currently under construction. The shaft will be driven to a length of over 2180 m. The shaft will be used as a primary ventilation intake to the mine. In addition to the new hoisting shaft, a return air raise is being driven approximately 1690 m from surface. This raise will be a parallel return to the existing mine infrastructure. This paper describes the ventilation and climatic analyses performed in support of the expansion project. The study included a full mine ventilation survey, in situ rock mass measurements, analysing options related to mine layout, airway sizing calculations, air heating options, and climatic simulations. Specifications were prepared for an air heating system and main and booster fans. Analyses were also performed related to heat in the stoping areas namely caused by auxiliary fans and backfill with high cement content.

Jan 1, 2005

By R. Butcher

Mud rushes are hazardous occurrences that have occurred frequently in mines in South Africa, and have been the cause of numerous fatalities in the past. Mud rush incidents not associated with accidents are believed to be common occurrences that are not generally reported. Many such incidents are probably associated with the operation of chutes and box fronts. This paper describes the conditions necessary for mud rush occurrences, postulated mud rush mechanisms, and methods of combating the mud rush hazard.

Jan 1, 2005

By L. M. Lenahan, J. D. Sheets

INTRODUCTION The Raleigh-Durham International Airport (RDU) in North Carolina is the fourth largest airport in the southeast region of the United States. The Raleigh-Durham Airport Authority is currently underway with planning, designing and constructing are placement Passenger Terminal as part of the Major Capital Improvements Program at Raleigh Durham International Airport. The Terminal C Expansion and Renovation Project will replace the existing Terminal C structure with a new processor building and concourse. The project is separated into several contracts. The early stage contracts are constructing a west side storm water management facility, relocating taxiways, installing new drainage systems, installing new aircraft apron pavement, Demolition, the Central Energy Plant and Early Foundations. The later projects are the Terminal Building, Passenger Boarding Bridges, Information Technology Systems and Integration, Furniture, Furnishings & Equipment and Specialty Millwork. The Terminal Building will be constructed in two phases. Phase 1 constructs the north half of the new terminal. Airline operations will move to the new terminal at the completion of this phase. Phase 2 completes construction of the south processor building. The full build out of the project, subject to funding availability, will replace the remainder of the south concourse. The Program’s primary focus is to replace the existing passenger Terminal C with a new terminal that will provide more passenger gates and larger passenger screening, ticketing and baggage handling facilities. The planning for the New Terminal C Program began in 2002 with construction starting in March, 2003. The continuing growth of passenger airline travel in the Raleigh/Durham metropolitan area requires RDU to expand its facilities to keep up with the present and future growth within the Region. In October of 2002, the RDU Airport Authority selected Parsons Transportation Group as the Program Manager/Construction Manager to help assist in the development of the Terminal C expansion program. RDU Airport Authority selected the Seattle Washington Office of URS Corporation as the Engineer of Record for the West Side Storm Water Management Facilities. The Westside Storm Water Management Facilities Project became one of the early critical path activities of the overall RDUAA Terminal C Expansion Program. The Briar Creek Reservoir had been constructed to accommodate storm water runoff to the west of the Airport. The existing 1.5 m culvert that drained runoff from the airport terminal (area) to the reservoir was insufficient in supporting the additional flows

Jan 1, 2005

By C. Sahyoun

The influence of microwave treatment on copper flotation has been investigated. Comparative batch flotation tests carried out on ore treated at 5?12 kW for 0.1?0.5 s showed that improvements in copper recovery of between 6?15 % could be achieved compared with untreated ore. Both recovery and cumulative grade increased with increasing treatment time and power. A preliminary economic analysis showed that microwave treatment will be economically viable if recoveries similar to those determined on laboratory scale can be achieved on a plant. Keywords: microwave treatment, copper ore, flotation, liberation, recovery

Jan 1, 2005

By H. -J. Langhoff

"The paper describes not a result, but a starting point to implement sustainable development to a region characterized by a typical down river landscape, agriculture, and extractive industry. The NaturFreizeitNiederrhein GmbH (NFN) is a private company with associates from administrative bodies, the local mining companies and multiple representatives of environmental protection groups (local and national), tourism organizations, cultural societies and also aquatic sport and fishing clubs. Center of the concept is the "NFN Lake District." The development concept aims to provide the agricultural industry with alternative means of income, while protecting wildlife and the ecological balance as well as preserving the social und cultural system and enhance the safety against flooding from the river Rhine. The mining industry contributes their coordination of obligation concerning reclamation and recultivation of the already existing individual projects. While designing the landscape components and establishing the infrastructure for the different tasks, the production of gravel and sand is yield as a by product. The result is a long term perspective for region and industry."

Jan 1, 2005

By M. Djivre, T. Eger, A. Godwin, I. Bhattacherya

Load-haul-dump vehicles (LHDs) are extensively used in underground mining, however, equipment design and operating conditions contribute to restricted operator sight lines. The inability to clearly see people, objects, or hazards around the machine has contributed to a number of accidents including fatal injuries. In order to identify vehicle design characteristics resulting in restricted and blocked sightlines, line-of-sight assessments are traditionally completed in the field. However, field methods are unable to evaluate lineof- sight under dynamic operating conditions, and are limited in their ability to provide feedback on the impact of various operator characteristics such as sitting height. Results of this research show computer simulation and virtual reality can be successfully used to evaluate line-of-sight during the operation of LHD vehicles. In order to benefit from virtual reality applications, the work environment, LHD vehicle, and human posture need to be represented as accurately as possible. A computer simulation program with ergonomic analysis features, Classic JACK 3.1, was successfully used. Threedimensional CAD models of LHDs were developed from manufacturer specifications and pictures taken from LHDs currently in use. The LHD models were imported into the JACK environment, a digital human was positioned in the cab of the LHD vehicle, and the vehicle and human were driven over a typical mine route. Real-time feedback in the JACK program was used to identify what the operator could see under different operating conditions. Machine characteristics and operating scenarios resulting in impaired line-of-sight were successfully identified with this method. The JACK program could also provide real-time feedback on the human’s joint forces and torques, strength requirements, postural comfort, and metabolic energy expenditure. As a result, this method could be used to successfully evaluate musculoskeletal injury risk factors along with system design recommendations to improve workplace safety and productivity in any setting. The LHDs evaluated in the JACK software package can also be combined with mine models and imported into other VR software packages (e.g. Blender) in order to enable viewing in Laurentian University’s Virtual Reality Laboratory. The VR models using these packages can be viewed in stereo to provide better appreciation of spatial vision issues.

Jan 1, 2005

By James McKelvey, Larry Drolet, Jason Swartz

INTRODUCTION When divers discovered that sections of a tunnel housing the pipeline that conveys wastewater from the Charleston Peninsula to the Plum Island Wastewater Treatment Facility had caved in, the Charleston Commissioners of Public Works(CPW) moved quickly to determine a long term solution for the city’s collection system, immediately focusing on the Ashley River sewer tunnel along the western boundary of the peninsula. Working with the Charleston community, as well as federal, state, and local officials, CPW developed a fast track yet long life design that can be used as a model for underground construction of tunnels in urban areas. The paper that follows summarizes key aspects of the Ashley River sewer tunnel project. HISTORICAL CHARLESTON Charleston, South Carolina is a culturally significant and historic city that was originally settled in 1670. There are over 100 buildings on the National Register of Historic Places within the Charleston area. Additionally, the first shots of the American Civil War were fired at Fort Sumter in the Charleston Harbor in 1861. As one can imagine, tourism generates significant business for the area with over 1.5 million people visiting Charleston each year. No project, especially one that requires digging, is done within the old city on the Charleston peninsula without careful planning. Many precautions are necessary to prevent damage or disruption to the historical properties. The Ashley River sewer tunnel project is exclusively in the old city. A lot of work was done during the design phase to minimize the impact to historical properties. Some of this work included: an archeological study (where pre-digs were monitored at all shaft sites by an archeologist); a building/structure assessment study (where structures near a shaft site were completely surveyed and cataloged); and an environmental study.

Jan 1, 2005

There is wide agreement that sustainability has multiple dimensions, but substantially less agreement on the appropriate balance among those dimensions. This occurs because peoples’ vision of a sustainable future, their goals for sustainable development, and their objectives for resource management are reflections of their values, culture, and life experiences. Even assuming agreement about the objectives of sustainable resource management can be reached; there is still a need for policy and decision makers to choose from among alternative courses of action, each of which has its own set of impacts and outcomes. One of several tools used to compare the consequences of alternative actions is the Computable General Equilibrium (CGE) model. This paper uses CGE modeling to demonstrate how policy decisions do not take place in a vacuum and how policy-makers must be aware that there are trade-offs involved in any decision.

Jan 1, 2005

By I. Kirman, B. Waters

World wide applications for nickel use will be summarized and examples of those uses given. Nickel products are critical to many important aspects of modern society. These products are just as important for modern China as they are in other parts of the world. It is argued that future pattern of nickel use in China should be expected to be very similar to that in the rest of the developed world. Total use of nickel in products in China is already very large. In 2004, it was the largest market for stainless steel (nickel containing) in the world. A survey of Chinese stainless steel applications will be presented. Current high nickel prices have revived speculation about substitution, particularly for nickel containing stainless steels. The presentation will discuss some of the complicating factors that need to be taken into account when considering substitution. These factors are as valid in modern China as they are in other developed economies. Recent substitution efforts and the reaction to them will be examined. The Nickel Institute position regarding appropriate application of the various grades of stainless steel will be discussed. Price-motivated substitution in China, and elsewhere, will occur but it is argued that the extent will probably be limited.

Jan 1, 2005

By Nick Salisbury, Alan Howard, Scott Tunison

INTRODUCTION Geotechnical investigations for tunneling projects typically use vertical test borings and, to a lesser extent, angled borings. Horizontal drilling applications were often limited to specialty testing programs and to perform probe drilling from a tunnel boring machine (TBM) as part of production tunneling. The former often involved cumbersome setups with skid rigs and cribbing in a pilot tunnel or shaft. The latter usually was limited to generic probing for rock quality and ground water conditions with no sampling. Neither yielded continuous core at production rates suitable for design and construction planning. Conventional vertical investigations still make sense in many instances, particularly for tunnels planned beneath urban settings where truck access is convenient and where the tunnel horizon is not readily accessible via a portal or shaft. However, equipment is presently available to conduct horizontal geotechnicall investigations at reasonable production rates and cost. Advantages include continuously sampling the tunneling horizon and minimizing “access drilling” to get the zone of interest at the underground construction horizon. Horizontal boring lengths of up to approximately 800 m are considered feasible and those in the range of 150 to300 m are now routine. These capabilities make horizontal borings an attractive option to consider when looking at deep tunnels beneath ridges, especially where access is limited. Fewer drilling staging sites can also mean reduced environmental impacts when investigating tunnels proposed beneath sensitive lands such as public wilderness areas. Investment in early construction packages to develop portals for investigation access and, possibly in excavating test shafts for the same purpose should even be considered. Potential benefits in the form of achieving improved overall project costs using horizontal borings exist because of the significant additional data collected in the tunnel horizon. For this reason they should be considered during the routine cost-benefit analyses generally conducted for planning geotechnical investigations for tunneling. The authors also believe that collection of such data will reduce Geotechnical Baseline Report (GBR) conservatism and lead to lower potential for

Jan 1, 2005

The hoisting system at the Newcrest Telfer mine is designed for a final duty of 7.35 million tonnes per annum at a hoisting distance of 1450 m. In terms of hoisting capacity (t/h) times hoisting distance it is one of the largest friction hoist installations. Initially, the hoist will be equipped for hoisting 6.5 Mtpa from 1100 m depth. This new drive technology is now well proven by ABB for mine hoist applications with the first installation in commercial operation since July 2001. To date 17 systems for medium voltage drives and another five for low voltage drives have been purchased from ABB for mine hoists. This paper will also deal with skip design and powerful data loggers with diagnostics for local and remote monitoring that are installed in the Telfer mine hoist.

Jan 1, 2005

By L. M. Oshinowo

The incorporation of advanced analysis tools, such as CFD, into the process plant design process has become possible through advances in commercially available computational fluid dynamics software and faster computers. Multiphase modeling is now typically employed in the design phase of process plant design at Hatch. The multiphase models include Lagrange-Euler and Euler-Euler treatment of the multiple phases. Additionally, mixture models with interface-sharpening algorithms are applied to the prediction of free-surface flows in complex geometry. CFD is applied to applications where traditional design rules are not applicable. The additional rigor of CFD modeling in 2D and 3D allows process engineers to come closer to realizing true virtual plant design. The objective of this paper is to outline the benefits and pitfalls in the application of multiphase modeling for rigorous design. Several application examples in the hydrometallurgical field will be presented.

Jan 1, 2005

By Laurence G. Britton

Accurate flammability and ignitability data for chemicals form the cornerstone of procedures used to assess the hazards associated with commercial chemical production and use. Since 1967 the ASTM E27 Committee on the Hazard Potential of Chemicals has issued numerous, widely used consensus standards dealing with diverse testing and predictive procedures used to obtain relevant chemical hazard properties. The decision to issue a standard rests solely with the membership, which consists of representatives from industry, testing laboratories, consulting firms, government, academia, and instrument suppliers. Consequently, the procedures are automatically relevant, timely, and widely applicable. The purpose of this paper is to highlight some of the widely used standards, complemented with hypothetical but relevant examples describing the testing strategy, interpretation, and application of the results. A further goal of this paper is to encourage participation in the consensus standards development process. The paper is published in two parts. The first part (in the preceding issue of Process Safety Progress) dealt with the E27 standards pertaining to thermodynamics, thermal stability, and chemical compatibility. The second part, published here, focuses on the flammability, ignitability, and explosibility of fuel and air mixtures. © 2005 American Institute of Chemical Engineers Process Saf Prog 24: 12?28, 2005

Jan 1, 2005

By Wenming Wang, Edgar E. Vidal, Scott A. Shuey, Patrick R. Taylor, Judith C. Gomez

Introduction In modern society, vanadium is defined as a strategic metal. Some 90% of the global consumption is used as an alloying agent for carbon steels, tool steels, and high-strength low-alloy steels (particularly for pipelines). Advanced titanium-aluminum-vanadium alloys are seeing application in the aerospace industry. Small but ever growing amounts are finding application as catalysts or in electronics. New uses are continually being discovered for this metal. One example of a new application is the vanadium-redox battery for use in generation plants and back-up power sources. Vanadium is found in a large number of minerals, of which the most important are carnotite, roscoelite, vanadinite, mottramite, and patronite. Just over a third of the world's vanadium is produced as a primary product; the balance is a by-product of the iron and steel, oil refining, power generation and uranium enrichment industries. Vanadium can also be sourced by recycling spent catalysts from the petrochemical industry and ash produced by the combustion of oil emulsion in power stations. However, recycling activities are believed to account for only a small amount of total world supply. Vanadium is recovered from these ores largely as the pentoxide (V2O5) [1]. The major sources of vanadium-bearing magnetite ores are scattered throughout Australia, China, Russia, and South Africa. Current estimates of world’s Proven & Probable vanadium reserves are of the order of 41.3 million tones [2, 3]. Commercial vanadium-bearing titaniferous magnetite deposits can be found in Kachkanar, Russia; Pan Zhihua, China; Bushveld, South Africa; and Windimurra, Western Australia [4]. Other deposits have been found in New Zealand, Canada, and India, among other countries. Vanadium consumption in the steel sector has increased some 7% per ton of steel over the last 10 years as new alloying applications have been found to improve steel's strength-to-weight ratio. Future demand from the aerospace and nuclear industries for non-ferrous vanadium alloys such as titanium and super-alloys is also likely to grow. Vanadium is usually added in the form of ferrovanadium, a vanadium-iron alloy. Vanadium compounds, especially the pentoxide form, are used in the ceramics, glass, and dye industries, and are also important as catalysts in the chemical industry. While established approaches may be used at an industrial scale to treat vanadium-bearing titaniferous magnetite ores in several countries, new alternatives are being developed worldwide. This review will give short overview of the treatment of vanadium-bearing titaniferous magnetite ores, an overview of direct reduction and direct smelting processes and an approach to determine technical alternatives for the property.

Jan 1, 2005

By G J. Massoth, K Faure, A G, R G. Ditchburn, I J. Graham

From modest beginnings in 1996, research into the mineral potential of New ZealandÆs Exclusive Economic Zone has progressed into a major multidisciplinary component of GNSÆs recently funded 6-year æMineral Wealth of NZ and its EEZÆ Programme. In excess of $7.5 M of research funding has been expended, plus $10 M leveraged via collaborations with NIWA (NZ), NOAA (USA), JAMSTEC (Japan), U. Kiel (Germany) and ANU (Australia), whose scientists have contributed hugely to research cruises, as well as subsequent analysis and publication. The 1999 NZAPLUME I cruise was the first research expedition to systematically locate, and chemically characterise, submarine hydrothermal venting associated with arc volcanoes of the southern part the Kermadec intra oceanic arc system. This was followed by the 2002 NZAPLUME II and 2004 NZAPLUME III cruises to the mid- and northern-sections of the Kermadec arc, respectively. Combined, these cruises have surveyed 1300 km of the volcanic chain (from Whakatane to Monowai), including 34 major volcanic centres. Together with concurrent surveys in the Tonga arc, this is now the longest continuous stretch of intra oceanic arc to be surveyed for hydrothermal emissions. Most of the volcanic centres are characterised by simple cones although 30 per cent contain caldera complexes, and compositions range from basalt through to rhyolite. Massive sulphide mineralisation has been recovered from several volcanic centres in the southern Kermadecs (Clark, Rumble II West and Brothers), suggesting the existence of significant Au and base metal bearing deposits along the arc front.

Jan 1, 2005