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By Paul Lenchuk

The concrete block industry can trace its beginnings to the early 18th century when most of the experimental work was being carried out in England. In America, the concrete masonry industry got started shortly after the Civil War and has had sometimes a spectacular, but always a steady growth since then. From a few hundred thousand concrete masonry units made in the late 19th century, the industry today produces approximately 3.3 billion concrete masonry units making it the largest industry in the United States for masonry wall materials. There were 3500 concrete masonry plants manufacturing these units after World War II. This nwnber decreased to 1500 by 1970 although the production of concrete masonry units increased by over 100% in the last 25 years. One of the reasons for this increase in production by less than half of the plants which once existed, is the tremendous strides made in automation of production machinery. The concrete masonry plant of today is probably one of the most automated small businesses in existence. Within a few years it will be possible to push a button and the entire manufacturing process will begin with no human hands touching the units until they are laid up in a wall at the manufacturing plant and are trans-ported to the job site. No other concrete product has reached this state of manufacturing sophistication and it is one of the reasons why the price of a concrete masonry unit is not much different than it was 2S years ago. Because of automation, it is safe to say that concrete masonry will remain a highly competitive building material for many years to come. The problems that beset the continued use of this material are not related to the cost of manufacturing and delivering the product. What are some of the problems as well as some of the opportunities and is the golden age of opportunity knocking rather than a wolf in disguise? The use of concrete masonry has grown each year because a larger unit was provided at less cost than other competitive materials. Concrete masonry has had severe competition from the clay products industry as well as masons who laid the product in the wall and who resisted concrete masonry for many years. Even today

Jan 1, 1971

By Steven A. Savage

Agrico Chemical Company, as we presently know it, is the result of the coming together of several different fertilizer operations. The Williams Companies, our parent organization, first entered the fertilizer business in 1971, when it acquired the fertilizer operations of the Gulf Oil Company. This gave us, among other things, the manufacturing facility at Donaldsonville, Louisiana. In 1972, The Williams Companies acquired Agrico Chemical Company from Continental Oil Company, bringing in a manufacturing facility and phosphate mines at Pierce Florida. Our Florida Mines are in the region commonly known as the Bone Valley Region of Florida. The majority of the phosphate fertilizer produced in the United States utilizes rock mined in this region. The Donaldsonville Plant was originally built in 1967-68 on the site of the old Faustina Plantation at an approximate cost of $80,000,000. (This plant is commonly referred to as our Faustina Plant.) Until such time as Agrico was acquired from Continental Oil, the Donaldsonville Facility was solely used to upgrade phosphoric acid into finished granular products.

Jan 1, 1986

By Duane L. Whiting

The National Environmental Policy Act of 1969 (NAPA) provides guidance for federal agencies in making informed decisions. The Act has been used to determine the potential environmental impacts from mining and other natural resource operations, primarily in the Western USA. To accomplish the purpose of the Act, a process for developing environmental documents was established. The documents (EA/EISs) evaluate environmental impacts and are produced by federal agencies through public participation and cooperating agency review. Effective interactions and up front coordination between agencies and industry is required. An abbreviated history of environmental protection in the USA leading to NEPA, the driving regulation, objectives, provisions and limitations of the Act, and select mining related NEPA projects III the Western U.S. are discussed in this paper.

Jan 1, 1998

By K. H. McDaniel

Eight Mine Weather Stations (MWS) installed at the Waste Isolation Pilot Plant (WIPP) to monitor the underground ventilation system me helping to simulate real-time ventilation scenarios. Seasonal weather extremes can result in variations of Natural Ventilation Pressure (NVP) which can significantly affect the ventilation system. The eight MWS(s) (which previously collected and stored temperature, barometric pressure and relative humidity data for subsequent NVP calculations) were upgraded to provide continuous real-time data to the site wide Central Monitoring System. This data can now be utilized by the ventilation engineer to create real-time ventilation simulations and trends which assist in the prediction and mitigation of NVP and psychrometric related events.

Jan 1, 1997

By M. Botz

Alacer Gold Corporation is constructing the Çöpler Gold Mine in eastern Turkey. Mining commenced in the fourth quarter of 2009 and gold production started in the fourth quarter of 2010. The mine is a 15,500 t/day oxide heap leach with three-stage crushing, agglomeration, carbon adsorption and electrowinning for final metal recovery. Leach solution copper levels are expected to be relatively low during the first two years of production, but will increase in later years due to higher copper content in the mined and processed ore. Over the mine life, approximately 40 Mt of ore will be placed on the leach pad, which will contain about 35,000 t of copper. Metallurgical testing indicates copper extraction will vary by ore type and, if controls are not implemented, may lead to copper levels exceeding 1,000 mg/L in pregnant solution. High copper levels in leach solution have the deleterious effect of increasing cyanide consumption and potentially overwhelming the ability of the carbon circuit to effectively adsorb the principal economic metals, which in this case are gold and silver. Using data obtained from laboratory leach column testwork, the heap leach facility was modeled using METSIM process simulation software to estimate the build-up of copper in leach solution over the life of the mine. Laboratory testwork was also performed to evaluate process conditions for treating a portion of pregnant leach solution via sulfide addition to precipitate saleable copper as copper sulfide (Cu2S).

Jan 1, 2011

By A. Taghavi, I. Hassan, A. Solecki

"The Eglinton Crosstown Light Rail (LRT) Project is part of an $8.4 billion investment to expand transit in the Toronto, Canada area and is the largest transit project initiated in Province’s history. Settlement control and impact to over 1400 adjacent structures due to tunnelling was identified early as a critical project risk. The ground conditions along the 10km tunnel alignment consist of water bearing soft ground deposits (clays, sands, silts) which required careful analysis and control during design and construction. This paper will describe the process used to analyze settlements along the numerous of adjacent structures and evaluate achieved settlement results to those used during design. The paper will demonstrate that with the appropriate design specifications, selection of modernized EPB machines, and contractor performance, settlement can be maintained well below typical industry (volume loss) standards, expanding the application and suitability of soft ground tunnelling in sensitive settlement areas. INTRODUCTION The Eglinton Crosstown Light Rail Transit (LRT) Project is part of an $8.4 billion (2010$ CND) investment from the Ontario provincial government to expand transit in the Toronto, Canada area. The project is being developed by Metrolinx, an agency of the Government of Ontario to provide 19 kilometers of dedicated LRT service connecting the City of Toronto from the west to east along Eglinton Avenue. Upon completion in the year 2020, the Crosstown will be the first LRT constructed in Toronto. It will link regional and local transit, cut travel time along the route by half and provide over a thousand jobs during construction."

Jan 1, 2016

By R. H. Hanewald

The processing of EAF baghouse dusts from both the specialty steel industry and low alloy producers will be reviewed. In addition, the INMETCO process has been modified so as to recover nickel, chromium and iron from many other waste materials such as pickling solutions or filter cakes, spent nickel and chromium plating baths, carbon refractories from pickling tanks, and super alloy wastes including baghouse bags. INMETCO is the only North American company presently capable of recycling nickel-cadmium batteries by high temperature metals recovery. This, along with the details of INMETCO's BDAT Test Program and results performed to pre-agreed standards with the EPA will be discussed.

Jan 1, 1992

By Martha Gross, Amanda Wachenfeld, Brian Keaney, Jean-Michel Charpentier, Frank Perrone

The Hampton Roads Bridge-Tunnel (HRBT) Expansion widens the existing four-lane bridgetunnel corridor to eight lanes through construction of two parallel tunnels, interstate widening, and bridge expansions. As part of the design-build contract, a supplemental geotechnical investigation was completed to support the design. The investigation for the subaqueous tunnel segment consisted of over 48,400 linear feet of drilling and 7,100 laboratory tests. This paper discusses the challenges of planning and executing a large-scale geotechnical investigation for underground works in a marine environment and the use of big data for effectively managing, interpreting, and transmitting data to the design-builder consistently throughout the investigation.

Jun 23, 2024

By C. H. Bucknam

Acid neutralization titrations were applied to the characterization of soil and overburden for the control and prediction of acid rock drainage in the coal fields of the eastern United States in the 1970?s (1). These became known as the Sobek methods as a result of the early United States Environmental Protection Agency publication and the methods have been modified (2) to be adapted to many applications in the metal mining sector (3,4,5,6,), and, as a result, there are a large number of acid neutralization potential methods being used that are referred to as Modified Sobek methods. Standardization of neutralization potential methods for metal bearing ores and related materials based on carbonate carbon, rather than titration, commenced in the 1990?s through the American Society of Methods and Materials (ASTM) Committee E01 on Analytical Chemistry for Metal Ores and Related Materials Subcommittee E01.02 on Ores, Concentrates and Related Metallurgical Materials (7). A subcommittee section, E01.02.05 on Environmental Methods, was organized to coordinate the method and material standardization efforts of ASTM and the Acid Drainage Technology Initiative Metal Mining Sector (ADTI-MMS) Prediction Committee (8), which took on the project of standardization of the acid neutralization potential acidity titration method (ANPA) to supplement the carbonate carbon method in E1915 (9) for application to samples which have metal carbonates (10), in particular, which result in overestimation of the neutralization potential using the carbonate carbon methods (11).

Jan 1, 2010

By Jan Wolski

Increasing interest in the Bucket Wheel Excavator (BWE) technology calls for a universally understandable definition of suitable performance factors which would reflect the unique features of this technology. The importance of properly designed and calculated performance factors for the BWE systems cannot be overemphasised. They are used by all levels of management in any mining organization for a wide variety of purposes, in particular for budgeting, for selecting new equipment, for monitoring current equipment and for comparison with other operations.

Jan 1, 1984

By Hervé Le Bissonnais, Jean-Pierre Janin, Anne Bergère, Pierre Renier

"The most important impact on the environment of a tunnel excavation is the creation of surface settlements. Nowadays, the mechanized tunneling allows minimizing the settlements, applying a confinement pressure which counterbalances the ground de-confinement. It is thus essential to determine the correct amount of confinement pressure. In this paper, the authors present a 3D numerical study simulating the EPB-TBM excavation of a water tunnel, in the Flanders clays (north of France). Firstly, a simplified 3D simulation, based on the concept of instantaneous longitudinal settlement curve, was performed to predict the surface settlements for different values of heading confinement pressures. Secondly, the same pressures were tested by the EPB-TBM in a monitoring zone. The comparison between the prediction settlements and the measurements was very satisfactory and allowed validation of the numerical approach and the choice of the optimal confinement pressure value for a sensitive area of the project. INTRODUCTION The excavation of a tunnel can create displacements of the surrounding soil which may affect existing structures and generate unacceptable dysfunction. The development of the closed shield tunneling has permitted to reduce the volume loss generated around the excavation and consequently the surface settlements. In this case, as explained by different authors (Clough et al., 1985; Kastner et al., 1996; Mair and Taylor, 1997), the ground movements are influenced by the TBM works: the heading confinement pressure, the shield overcutting and conicity, the annular void grout injection parameters, the segment concrete lining rigidity, the consolidation of the grout. Hence, in the tunnel design, it is important to take into consideration these different processes of the excavation works to simulate correctly the tunneling process."

Jan 1, 2016

By R. Zhang, S. Azam, S. Liu, J. H. Golbeck, V. Kurashov, S. Bhattacharyya

Free radicals (FRs) present in coal dust directly influence the interaction behavior between lung cells and dust particles. FRs are atoms or groups containing unpaired electrons, with strong chemical reactivity and a short lifespan. FRs which are quite persistent in natural environments, termed environmentally persistent free radicals (EPFRs), have recently received much attention as new environmentally hazardous substances. EPFRs present on coal dust serves as an active intermediary to catalyze reactive oxygen species (ROS) production by oxygen molecules endangering mine workers’ health. Many EPFR species may be bonded to the particle surface or trapped within the particle during coalification and can be modified with progressive size reduction through cutting at the mining face or crushing/pulverization in the plant. This study measured EPFRs for lignite, sub-bituminous, and anthracite coal dust at various sizes. We especially focused on EPFRs for submicron coal dust prepared by cryogenic methods. The outcome of this study will directly improve the free radical-dependent toxicity quantification and ultimately contribute to the size-dependent coal dust toxicity quantification.

Mar 2, 2022

By Mehmet Ali Recai Önal, MAHMUT CAMALAN

Mineral liberation is one of the primary objectives in comminution circuits for the downstream separation of valuable minerals. Breaking minerals through their grain boundaries (grain-boundary breakage) enables mineral liberation in their natural grain size, removing the need for intensive grinding. This study aimed to evaluate if gaseous carbon dioxide, oxygen, or hydrogen can be used as grinding additives to promote the liberation of chromite grains by grain-boundary breakage. For this purpose, chromite ore particles in the −9.53 + 6.35 mm size fraction were pretreated by exposing them to carbon dioxide, oxygen, or hydrogen flow. Then, the untreated and pretreated samples were broken in a drop-weight tester under the same conditions. Finally, the graderecovery plots of chromite grains in the selected progeny size fractions and the overall progeny distributions were measured and compared. Pretreatment with carbon dioxide flow was found beneficial for grain-boundary breakage. It significantly enhanced the liberation of coarse chromite grains along with the overall progeny fineness. EPMAanalysis showed that the adsorption of carbon dioxide seems to reduce aluminum concentration at grain boundaries, which could be the reason for grain-boundary weakening. These results suggest that carbon dioxide can be used as a grinding additive, reducing the carbon footprint of the mining industry.

Oct 29, 2020

By Richard Campbell, MEHMET KIZIL, Ismet Canbulat, Serkan Saydam

The design and effectiveness of ground consolidation to regain stability of longwall faces vary widely and are often based predominantly on-site precedence or what were considered successful applications at other sites in similar situations. Little is known regarding product migration characteristics or change in rockmass conditions as a result of the application of consolidation chemicals. This paper presents the in-situ testing rationale designed and implemented recently across several longwall operations in the Bowen Basin, Queensland, Australia to provide quantitative measurement of the actual zone of influence of various resin injection products. Product migra- tion was physically measured by monitoring the change in rockmass temperature as a result of the exothermic chemical reaction of the various strata consolidation chemicals used. In conjunction with strata coring and Lugeon transmissivity testing pre- and post-injection to characterise the improvement in rockmass conditions due to consolidation product injection. The results of the testing programme, migration measurements, and rockmass assessment are presented, along with a discussion on how site- based Rock Mechanics Engineers can incorporate the data into the design of strata consolidation plans.

Jun 25, 2024

By S. C. Carniglia

Bayer-process alumina hydrate becomes in turn the source of a host of special products in addition to the calcines that feed aluminum reduction cells. Though relatively smaller in tonnage, specialty aluminas serve important industrial markets in an exciting and growing variety. Production methods and applications are discussed for: (1) trihydrate as flame retardant in organic materials; (2) high-surface-area transition aluminas as desiccants and scavengers, catalysts and substrates; (3) calcines for industrial ceramics, refractories, and abrasives; and (4) tabular alumina for refractories, bed supports and other uses.

Jan 1, 1977

By Yi Luo, Jian Yang, YUJIA LIAN

Scale physical models, constructed according to the principle of similarity theory, have been widely used to simulate the mining disturbances to surrounding strata and to evaluate the effectiveness of implemented ground control techniques. This technique has also been used for studying mining-induced surface and subsurface subsidence. The movements of the observation points installed on the physical model at different mining stages are currently measured using total station which is time-consuming and inaccurate especially on small scale models. A photogrammetry-based measurement system has been developed. During a physical modeling process, photos of the model can be taken during the simulation process reducing survey time from hours to a few seconds. A program, Photogrammetry Analysis for Physical Modeling of Mine Subsidence Process (PAPMMSP), developed based on photogrammetric principle is used to quickly identify the installed observation points and accurately determine their coordinates. The measurement accuracy is well under submillimeter level—an ultra-important advantage as any measurement errors in coordinates are magnified by the model dimension scale (commonly 20 to 400). A physical modeling case of subsurface strata movements and deformations associated with longwall mining operations is presented in the paper to demonstrate the functions and capabilities of the developed photogrammetry program.

Aug 11, 2020

By R. E. Hochscheid

Cyclones installed in three closed- circuit grinding systems were changed from conventional, vertical mounting to horizontal mounting with a favorable improvement in classification efficiency. In two of the installations, apex plugging problems were eliminated because horizontal mounting permit- ted the use of much larger apex orifices. Marked reduction in circulating load was accompanied by greatly reduced maintenance requirements for the cyclone and the cyclone feed pump in one of the installations.

Jan 1, 1988

By D. Kumar, R. J. Sweigard, J. Silva

The Forestry Reclamation Approach (FRA) recommends that the upper 1.22 m (4 ft) of spoil material on reclaimed surfaces should be left as uncompacted as possible to facilitate efficient tree root growth. However, the main concerns about applying the FRA to steep slopes is that the upper 1.22 m (4 ft) of loose spoil material could cause instability. Successful application of the FRA on the flat and rolling surfaces precipitated this investigation. Details of a field investigation conducted at a steep-slope mine site are available in an earlier publication (Kumar and Sweigard, 2011). A total of 70 survey monuments were driven into the slope in a regular pattern to monitor any type of slope movement. Quarterly surveying of the monuments were done to quantify slope movement, either horizontally or vertically. The methodology developed in this research for field slope movement monitoring was validated using computer model results. Analytical models based on the limit equilibrium method (LEM) and numerical models based on the finite element method (FEM) were developed for slope stability analysis. The LEM analysis was done using the Geo-Slope/W program following the simplified Bishop method. However, numerical models were developed using the PLAXIS computer program following the Mohr’s Coulomb failure criterion and strength reduction technique. The slope stability analysis was performed for two different scenarios: first with the top 1.22 m (4 ft) of loose graded spoil material and second without top loose graded spoil material. Finally, the field investigation results were compared with stability analysis results. Both of these approaches showed that application of the FRA on steep slopes is not causing any significant instability problems, due to 1.22 m (4 ft) loose graded spoil that would not exist otherwise for overly steepened slopes.

Jan 1, 2013

By M. S. Klima

Coal gasification solid residue (slag) contains unconverted carbon (char), which is considered an impurity for utilization applications of slag. Under this study, table concentration was used to process approximately 24,000 pounds of a nominal-3.4 mm gasifier slag (-85% ash) to separate high (-100%) ash slag from low (-50%) ash char. The results indicated a nearly ideal separation of the slag from the char for sizes coarser than about 1 mm. An overall slag yield of 71 % was obtained. The slag was sufficiently clean to be used as feed material for the production of expanded lightweight aggregate. The recovered char had an ash content of about 47% and was a nominal -1mm in size.

Jan 1, 1997

By Steven J. Schatzel, Kayode M. Ajayi, Bo H. Kim, Zoheir Khademian, Gabriel S. Esterhuizen

The stability of shale gas wells drilled through current and future coal reserves can be compromised by ground deformations due to nearby longwall mining. Depending on the longwall-induced rockmass permeability, the high-pressure explosive gas from the damaged well may reach mine workings and overwhelm the mine ventilation systems. This study uses geomechanical models to estimate the rockmass permeability induced by mining. A two-panel longwall model of a deep, 341-m-cover mining site in southwestern Pennsylvania is constructed in 3DEC to explicitly model the rockmass by a discrete fracture network (DFN) technique. Stress-induced fracture apertures and permeabilities are calculated across the model and are validated against permeability measurements. A fracture flow code (FFC) is developed to use these results to predict potential inflow to the mine should a gas well breach occur. One hundred DFN realizations are simulated, and the results show that for a gas pressure of 2.4 MPa, the average of the predicted inflow rates to this deep-cover mine is 0.006 m3/ s, significantly lower than the average inflow of 0.22 m3/ s for a shallow-cover mine (145-m deep) studied in the previous work (Khademian, et al. 2021). The result can help assess the potential hazards of a shale gas well breach for mine safety and evaluate the ventilation requirements to mitigate the risk.

Jun 19, 2022