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By Vladimir G. Kochnev

Crushing and grinding account for the major portion (60 to 80 percent) of the overall expenses for ore processing. Autogenous (AG) and semiautogenous grinding (SAG) have been considered a step forward in comparison to conventional grinding circuits with several stages of crushing and using ball (and/or rod) grinding mills (Bassarear, 1982, MacPherson, 1989, Pithois, Casalis, 1983, Maripuu et al., 1983). However, there remains room for improvement to existing AG and SAG technologies and both technologies have immense economic benefit potential. Experience gained by the Technics & Technologies of Disintegration Ltd. (TTD) in the research of grinding processes shows that grinding in AG and SAG mills can be performed in a more effective way. The company's approach comprises the following elements: ? Novel mill design. ? New liners and lifters. ? Novel discharge grid design. ? Technique of treating material of critical particle size. Comparative tests that demonstrated the usefulness of these innovations are described in this article. Currently, there are hundreds of AG and SAG mills in operation throughout the world. Application of new internal elements of the mills and reconsideration of the circuit design of the existing grinding equipment using present technological solutions would significantly increase the throughput rate and diminish power requirement.

Jan 1, 2008

By G. Wozniak, R. Rostanski, H. Pfanz, G. Aschan, E. Sierka

"Industrial wasteland is a typical element of the landscape of all the industrialised regions in Europe. There are many examples from Poland as well as from other European countries that post-industrial sites have been undergone natural colonisation and succession to establish in some cases ecosystems of greater biological diversity than the original ecosystems. The post-industry sites regardless of any reclamation carried out, undergo natural successional processes. The respective biological diversity (number of species, and number of plant assemblages) reflects the micro-variety of the specific habitat. This paper summarizes the results of investigations, which have been carried out since 1989 on coal mine water sedimentation pools in the Upper Silesia Industry Region. The aim of this study is to demonstrate the diversity of spontaneous plant communities recorded on post-industrial waste sites. In the course of the long time fieldwork, plant assemblages representing nine phytosociological groups have been identified."

Jan 1, 2005

By Bill Cain, David F. Tsztoo, R. John Caulfield, D. Scott Kieffer

In 1994, the East Bay Municipal Utility District (EBMUD) commenced a system-wide Seismic Improvement Program to protect their facilities from catastrophic damage. A primary focus of this program has been on retrofitting the 75-year old Claremont Tunnel, which crosses the active Hayward Fault zone. A large earthquake on the Hayward Fault could generate enough right-lateral fault slip to effectively sever this important lifeline. The retrofit project involves construction of a new bypass tunnel through the Hayward Fault zone, together with systematic contact grouting and localized structural repair of the existing concrete liner. Several innovative design measures have been incorporated into the seismic retrofit design, including an oversized tunnel cross section, backfill concrete side drifts, seismic isolation of an internal structural pipe, and shear fuses in the final lining.

Jan 1, 2005

By R. L. Virta

Editor?s note: Each year, the June issue of Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue. Thank you to the industrial minerals annual review editor, to the technical committees chair and vice-chair, and to the authors of the individual commodity profiles. Jim Norman, member SME, of GeoTrans Inc., is the industrial minerals annual review editor. Abani Samal, member SME, of Pincock Allen & Holt, is chair of the industrial minerals technical committees. Technical committee vice chairs include: ? Abani Samal, member SME, of Pincock Allen & Holt, agricultural minerals. ? Aaron McMahon member SME, of Pincock Allen & Holt, ceramics and refractories ? Bradley S. Van Gosen, member SME, of the U.S. Geological Survey, chemical raw materials. ? Mark Zdunczyk, member SME, of Continental Placer Inc., construction materials. ? Jerry Gauntt, member SME, of Marston, fillers and pigments. ? Michael Cheshire, member SME, of Indiana University, sorbents, filters and process aids. ? Candace Trimble, Oil-Dri Corp. of America, specialty minerals. Their help makes possible this June industrial miner-als issue. On behalf of ME readers, the editors thank them. Ball Clay Four companies ? H.C. Spinks Clay (owned by Lhoist Group), Kentucky-Tennessee Clay (owned by Imerys Group), Old Hickory Clay, and Unimin Corp. ? mined ball clay in four states in 2008. Production, on the basis of preliminary data, was 964 kt (1.1 millon st) with an estimated value of $45.3 million. That was a 10- percent decrease in tonnage from 1.07 Mt (1.2 mil-lion st) with a value of $49.2 million that was produced in 2007. Tennessee was the leading producer state with 63 percent of domestic production, followed by Texas, Mississippi and Kentucky. About 73 percent of production was airfloat, 16 percent was crude and 11 percent was water-slurried.

Jan 1, 2009

By R. L. Virta

Twenty-three companies mined kaolin in nine States in 2004. Production was estimated to be 7.6 Mt (8.3 million st) valued at $912 million, based on preliminary data. This was a slight decrease from 7.68 Mt (8.46 million st) valued at $939 million in 2003.Georgia was the leading producer state with an estimated 6.5 Mt (7.1 million st) in production. It was followed, in decreasing order of tonnage, by South Carolina, Alabama, California, Texas, Arkansas, Nevada, Florida and North Carolina. Georgia accounted for nearly the entire domestic water-washed, delaminated, and pigment-grade calcined kaolin production. Consumption Sales to the paper industry accounted for 49 percent of domestic sales and 64 percent of total sales. Other major markets for domestic sales were refractory products (10 percent), paint (5 percent), fiberglass (4 percent), catalysts (3 percent) and rubber (2 percent).Paper coating and filler markets accounted for about 87percent of export sales of kaolin.

Jan 1, 2005

By L. M. Anisdahl

Ventiflex is a flexible ventilation duct system with a global market within mine and tunnel ventilation. The system is distributed in a wide range of qualities and dimensions. It is very important that ventilation systems are designed correctly in mines and tunnels. An incorrectly dimensioned system might result in bad air quality and too high costs. The objective of this study has been to assess some important design parameters for ventiflex comprising the friction loss factor for the duct wall itself, as well as the shock loss factors and the leakage factors for the different couplings systems. This has been obtained by carrying out a large scale experimental program on ducts with all the three different couplings: Velcro, zip and steel-ring. Pressure profiles and air flow rates have been measured, and based on these data the different factors have been calculated. The following results have been obtained: A friction factor l = 0,012 (K = 10) for the duct wall, a shock loss factor z = 0,0125 for velcro- and zip couplings, a shock loss factor z = 0,005 for steel-ring couplings, and a leakage factor f* = 0 mm2/m2 for all three coupling types. The latter result proves that no leakage is possible for a correctly installed duct with proper alignment. The results also confirm that ventiflex complies with class S, or better, according to the SIA-norm. However, whether ventiflex should be designed as class S, A or B according to the SIA-norm, depends on the particular application.

Jan 1, 2009

By Christopher J. Bise

INTRODUCTION Before a mine is planned in detail, a preliminary analysis is often conducted. This preplanning permits the mining engineer to make a rapid assessment as to whether or not a particular mining property warrants further consideration. In fact, a properly conducted preplanning phase can come within 10% to 20% of the actual results, thereby saving the mining engineer valuable time before committing himself to a fine-tuned analysis. The questions to be answered by mine preplanning are (1) What will be the operating conditions for the mine? and (2) How long will it take to complete the project? To answer these questions, calculations dealing with reserve estimation, production planning, man- power planning, and project scheduling are conducted. The following sections discuss these various phases of mine preplanning in greater detail. RESERVE ESTIMATION The estimation of the various characteristics of a reserve, such as quantity, grade, and thickness, is an ongoing process throughout the life of a mining venture. However, the reserve-estimation phase of mine planning is more closely associated with the preplanning phase. There are many different techniques employed in reserve estimation of solid mineral deposits; variations among them are introduced because of such considerations as ease of application or level of accuracy. In any event, each technique is developed in the following manner: (1) the mineral body is represented pictorially and then subdivided into blocks related to one or more samples of exploration data, (2) the area and volume of each block is determined, (3) the volumes are converted to representative tonnages (or, for example, grades), and (4) the results are tabulated. To illustrate this procedure, the polygonal (area-of- influence) technique will be presented due to its ease of application, flexibility in dealing with different deposits, and general acceptance. The polygonal method assumes that all characteristics of a mineral body extend halfway between a point of observation and any other point of observation. The explored portion of the mineral body is represented by polygonal prisms whose depths relate to the characteristic in question (grade, thickness, etc.) and whose plane bases relate to the area of influence of each point of observation (drill hole, etc.) as shown in Fig. 1. The polygons must be constructed in a definite order, usually clockwise and from the periphery to the center of the deposit. Table 1 can then be used to calculate the characteristics in question. Since, by definition, the polygonal method assumes that the characteristics of a mineral body extend half- way between points of observation, it becomes readily apparent that the evaluation of a vertical-drill hole exploration program requires that the sides of the polygons be formed by the intersection of perpendicular bisectors (Fig. 2). Figs. 3 and 4 show correct and incorrect construction of the polygons. The criterion for correct construction of the polygons is that all points within a particular polygon must be closer to its rallying point than those located in any other polygon. This is clearly not the case for certain points that are located in the polygon containing rallying point B in Fig. 4. Although this method can be used where the drill holes are irregularly spaced, calculations become less tedious when a square net (Fig. 5) or a chessboard (Fig. 6) grid is adopted. The numbers shown in Figs. 5 and 6 represent the relative weight for each of the shaded areas. In general, the greater the number of polygons, the more continuous the mineral body, and the more regular the grid, then the more accurate the computations will be. PRODUCTION PLANNING Before an acceptable evaluation of the production potential of a mine can be determined, a thorough exploration program should be conducted. It seems obvious that the nature and properties of the deposit and adjacent strata, the presence of impurities, and other mining conditions should be adequately determined prior to production planning and equipment selection. The lack of sufficiently detailed knowledge of the many mining parameters has led to the failure of numerous operations. For example, targeted production tonnages and equipment sizes for a coal mine are intimately related to the seam thickness. Needless to say the quality of information that is gathered from an exploration program can have a tremendous impact on the production plan. Production plans are developed initially by determining reasonable shift tonnages per operating section. Most of the time these values are developed from his-

Jan 1, 1986

By T. W. Beck

Overexposure to respirable dust remains a widespread health hazard to roof bolter occupations in underground coal mines. Recently implemented mist drilling technology was evaluated for its effectiveness in controlling respirable dust exposures for roof bolting personnel. This work presents the findings from NIOSH field and laboratory studies comparing respirable dust levels on mist drilling roof bolter machines to dust levels measured on machines using a conventional vacuum drilling system. Gravimetric and instantaneous respirable dust samples were collected for multiple drilling cycles. These dust measurements were used to assess the potential dust control capabilities relative to conventional drilling. Controlled laboratory tests found 0.3 mg/m3 more respirable dust with mist drilling than with the conventional vacuum method. A separate field investigation of the two techniques observed higher dust levels around the mist bolting machine.

Jan 1, 2008

By Kerry Gee, Gary Colgan, James Fricke

Introduction Elevated zinc concentrations are observed in groundwater within alluvium adjacent to Silver Creek east of Park City, Utah. The study area is located in a small valley one and one-half miles northeast of Park City, Utah in Summit County, Utah (Figure 1). Although surface water concentrations in Silver Creek are typically less than 1 mg/l, groundwater concentrations have been measured as high as 85 mg/l in a near neutral pH environment. The elevated zinc concentrations in groundwater result from several factors including: (1) dissolution of zinc from tailings exposed at the surface and within the alluvium, (2) oxidizing conditions created by surface/ground-water exchange, and (3) ideal geochemical conditions for the dissolution of zinc-containing minerals. These ideal conditions include readily soluble minerals, available anions for complexation, and lack of available surface adsorption sites.

Jan 1, 2005

By Thomas L. Richardson, David R. Chapman, Gary W. Gilbert

The two contracts of the Big Walnut Augmentation/Rickenbacker Interceptor(BWARI) sewer project for the City of Columbus, Ohio total nearly 35,000 feet of 14and 12-foot diameter tunnel. EPB TBMs will install precast concrete segmental lining through difficult glacial soils ranging from clean granular to hard till with high groundwater and boulders, crossing roads, railroads, and a large stream. Construction of 12 shafts and a large Interconnect Structure involving major ground stabilization work is required. The paper will review design of major project elements and present an update on construction progress.

Jan 1, 2005

By J. Drelich, J. Pletka

Lost foam casting patterns are foamed polystyrene shapes glued together into the shape of the part to be cast and are coated with a refractory material consisting of a mineral mixture and binders. Prior to casting, a significant number of the patterns are damaged and inevitably land-filled. In this study, a process is developed for the recovery of foamed polystyrene from the coating and glue contaminants. The process consists of shredding, impact comminution, size classification and density separation. It is successful in separating up to 97% of the contaminants, while recovering 95% of the polystyrene.

Jan 1, 2001

By R. J. Robbins

The mechanization of hard rock underground mines offers a large potential for reducing cost, improving efficiency, and increasing profitability. However, in spite of serious efforts by quite a number of equipment developers and mining company initiatives, the industry has achieved little real progress. The task is difficult and the blasting alternative to mechanical excavation is an effective and well-developed method, which continues to improve in spite of its inherent limitations. A large number of machines have been built and tried. Only a few developments have succeeded to make a major impact on underground hard rock mining. It is certain that hard rock mines would be laid out and designed quite differently if the mining engineers knew they had available continuous mechanical excavation machines. In the absence of the machines, mines will be designed for excavation by traditional methods. It is not easy to utilize mechanical excavation in a mine which is designed to operate with normal drill and blast excavation. This is certainly an impediment to machine development. But what if an ore body cannot be mined conventionally, simply because the mining company cannot get permits to satisfy the ever increasing strict EIS requirements of the general public and governmental agencies? This may provide the incentive necessary to develop the equipment that will be needed by a new mining method that will have almost no impact on the environment.

Jan 1, 2001

By W. O. Kerr

As in other industries, companies engaged in mining and extraction use and develop intellectual property (?IP?) in the form of new technologies or production processes. The development of IP assets in mining may occur as a byproduct of ongoing operations, or result from investment in dedicated R&D efforts. New technology may lower costs, increase quality of output, and/or increase operational efficiency or safety. Key business questions with respect to any new technology are how best to use IP assets, how to protect them and how to derive value from them. IP assets can provide a competitive advantage to a developing firm that uses the technology to improve its operating results. The developing firm can preclude others from using the technology if it believes that is the best way to exploit the technology?s value. Or, it can be shared with others taking care to ensure rights are maintained, thereby generating royalty income or strategic value through cross licensing or other business relationships. Either way, in order to fully realize the maximum economic benefit, innovators must protect the IP assets and control their dissemination.

Jan 1, 2012

The global tunneling industry has many challenges, both technically and financially, with the latter likely to be a significant feature over the next few years. Many industries have ad-opted standard practices in order to overcome specific technical challenges, from which standard out-comes are anticipated. In tunneling, however, every project is unique so standardized practice is not easy. This requires original thinking and being open to adopting new techniques and technologies as they emerge. Sprayed waterproofing is a hot industry topic and a paper recently presented at the North American Tunneling conference not only discussed this methodology for achieving a dry tunnel but also how it can reduce build costs and construction time. Despite their being relatively few ?universal truths? throughout the tunneling industry, there is one opinion that appears to be shared by most in the sector, ?all tunnels leak.?

Jan 1, 2010

By J. L. Hoover

The goal of the drill bit consumption study was to develop an equation(s) based on various components that affect bit drill wear and use the equation(s) to estimate the consumption of bits during production drilling. Drill bit data from various geographic locations were compiled and used to develop linear regression equations using the Microsoft Excel Software. Multiple drill bit consumption equations were developed and statistical analysis was used to verify the accuracy of those equations. The equations will allow mining companies to more accurately forecast drill bit consumption when evaluating new mine properties. This capability becomes increasingly beneficial to forecasting as the cost of consumables increases.

Jan 1, 2012

By Peter B. Dowden, Robert A. Robinson

Boulders, frequently found in tunnels excavated through soils, can pose major problems for full face TBMs in terms of slowing or halting the tunnel advance, cutter damage, and abrasive wear. The paper aims to consider the problem as a whole, from the geological characteristics of boulder sites, to the appropriate physical design of theTBM, and its operation in boulder-laden soils. In addition, visualization of boulders and other subsurface obstructions by seismic methods and ground penetrating radar are reviewed. The paper will assist the construction planner in assessing the risks and preparing appropriate specifications.

Jan 1, 2001

By Christophe Bragard

The Los Angeles Metro Eastside Extension light rail project included a 1.5 mile underground segment, which consisted of twin 18'?10" ID tunnels, bored with two EPB-TBMs. One of the major project challenges after the completion of the bored tunnels was the excavation of six cross passages within alluvial geology below the water table and with low ground cover. Sequential excavation methods were employed and this paper details the design, ground treatment, support measures, and construction methods used to mine these cross passages beneath the congested urban streets of the City of Los Angeles.

Jan 1, 2008

By Christopher J. Bambridge, Lee Seng Hoor

The Stormwater Management and Road Tunnel (SMART) Tunnel is a world first in the use of tunnel space transmitting both road and water through the same spatial envelope. The unique aspect of the SMART project is that the highway decks are used periodically for the conveyance of water. This aspect of the project has posed its own technical challenges that have been overcome in the design stage of the work allowing the project to be taken forward to construction with confidence in the systems to be Installed in the tunnel.

Jan 1, 2005

By C. Stoneback

The attapulgite industry saw a year of solid growth after a weaker 2003. Demand was up between 5 percent and 6 percent driven by almost all of the key markets. Construction continued to show record new housing demand, assisted by continued low interest rates. That drove strong growth in construction related markets like coatings, tape joint compounds and other construction materials applications. The agricultural markets rebounded modestly to increase sales for suspension fertilizers, animal feeds and pesticide carriers. Oil drilling also showed strong growth due to high oil and gas prices. Sales to molecular sieve applications grew due to petrochemical and construction demand. The export markets were assisted by further depreciation of the dollar. The only weak area was in nonagricultural granular sorbents, where other sorbent materials continued to dominate.

Jan 1, 2005

By Steve Chorley

Open-type, or main beam, tunnel boring machines (TBMs) can achieve impressive rates of production. This type of TBM typically outperforms other types of TBMs currently in use around the world. In good ground conditions, main beam machines have achieved production rates of more than 1 km/month (0.6 miles/month). However, installing effective ground support in poorer rock conditions on main beam machines can be a major cause of concern. The design of main beam machines is such that installation of ground support equipment, particularly at the front of the machine in what is commonly known as the L1 support zone, has traditionally been limited to rock drills and basic working platforms. Personnel working in the L1 zone have, until recently, been protected by roof supports and extended fingers, often with restricted access to working areas.

Jan 1, 2011