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By A. K. Sheik, W. G. Pariseau

A small underground mine in northern Idaho was used as an experimental facility for studying the role of water in the analysis of mine opening stability. Laboratory test data, borehole measurements and geological mapping assisted in constructing a coupled finite element model of the rock mass. The model was used to make quantitative estimates of: 1) rock stress, strain and displacement changes, and 2) water pressure and flow velocity changes that occurred during historical mining. Stope cuts and wet fills were included in the analysis. Stability of crown pillars between stopes was of particular interest. The relatively low effective stress and high rock mass strength showed that water pressure changes were of no great consequence in agreement with experience. The computational tools used in the analysis may be applied to other wet mines with appropriate changes to site-specific input data.

Jan 1, 1999

By A. K. Sheik

A small underground mine in northern Idaho was used as an experimental facility for studying the role of water in the analysis of mine opening stability. Laboratory test data, borehole measurements and geological mapping assisted in constructing a coupled finite element model of the rock mass. The model was used to make quantitative estimates of: 1) rock stress, strain and displacement changes, and 2) water pressure and flow velocity changes that occurred during historical mining. Stope cuts and wet fills were included in the analysis. Stability of crown pillars between stopes was of particular interest. The relatively low effective stress and high rock mass strength showed that water pressure changes were of no great consequence in agreement with experience. The computational tools used in the analysis may be applied to other wet mines with appropriate changes to site-specific input data.

Jan 1, 1999

By A. K. Sheik, W. G. Pariseau

A small underground mine in northern Idaho was used as an experimental facility for studying the role of water in the analysis of mine-opening stability. Laboratory test data, borehole measurements and geological mapping assisted in the construction of a coupled finite element model of the rock mass. The model was used to make quantitative estimates of rock stress, strain and displacement changes and to make estimates of the water pressure and flow velocity changes that occurred during historical mining. Stope cuts and wet fills were included in the analysis. The stability of the crown pillars between stopes was of particular interest. The relatively low effective stress and high rock-mass strength showed that water pressure changes were of no great consequence, which is in agreement with experience. The computational tools used in the analysis may be applied to other wet mines with appropriate changes to site-specific data.

Jan 1, 2002

By Joel S. Leventhal

The roles of organic matter in ore deposits are complex and represent a specialized effort in the larger subject of the geochemistry of ore deposits. The organic carbon cycle can be considered with particular emphasis to ore deposits in order to understand the origin and genesis of the organic matter. Organic matter may play one, several, or none of the following important roles in the formation of ore deposits: leaching, transport, concentration, reduction, and precipitation of metals. For deposits that contain organic matter, detailed field relationships and laboratory characterization of the organic matter are required to make an ore deposit model that Includes the organic matter and specifies its role(s). Examples of the involvement of organic matter in several types of uranium deposits are contrasted as being direct or indirect, syngenetic or epigenetic, and necessary or unnecessary. Examples of organic matter in deposits containing gold and lead-zinc, and In metal rich shale are discussed with respect to ongoing work and critical questions.

Jan 1, 2013

By Ching-Yi Tsai

The effect of various constituents on the pyrolysis and combustion of a pulverized coal in an entrained-flow reactor has been inves¬tigated. Predicted time-temperature histories of the coal' particles and experimental weight loss data indicate a strong coupling of heat and mass transfer to the pyrolysis and combustion rates. A higher combustion rate following ignition was observed as particle size was increased to 112 µm. This is related to a higher particle temperature after ignition for the larger particles. Although the heating rate prior to ignition decreases with increasing particle size, higher slip velocities and surrounding gas temperatures for the larger particles promote early ignition. The presence of liptinite in the coal increases the weight loss rate before and immediately after ignition. Similar behavior was observed for pyrolysis. Fractions of a HVA bituminous coal which were rich in mineral matter or semi-fusinite were found to have a higher heterogeneous char combustion rate than vitrinite rich samples.

Jan 1, 1984

By D. L. Murr, J. R. Jensen

Testing was conducted on a Minnesota Iron Ore concentrate with Cook Clay as a binder using compressive sheer mixing to enhance the performance of the agglomeration mechanism. The testing was conducted on a bench scale at the Midland Research Center the summer of 2004. Results of the test program will be presented that shows the impact of compressive sheer mixing had on the strength achieve in a green ball.

Jan 1, 2006

By Richard Komarek

When limestone (Ca03) is calcined in rotary kilns to produce quicklime (CaO), it is not unusual for 10% to 20% of the stone to abrade and emerge from the kiln as quicklime fines (-6.3 mm or -0.25 in.). While there are various industrial processes that can use fines, handling and shipping is tricky and dangerous. Due to the highly caustic nature of quicklime, airborne dust easily bums eyes and skin. On the other hand, money has already been invested in mining (or buying) the raw material and in the equipment and energy needed for calcining. Discarding the fines will not only waste that investment, but add even more cost in transportation and possibly dumping charges. So the question becomes, how can fines best be turned into a revenue-generating asset? Some plants convert leftover quick-lime fines into calcium hydroxide - Ca(OH)2, also known as hydrated or water-slaked lime - for sale into agricultural applications. For farm uses, hydrated lime fines are preferred over quicklime because they are easier to handle. And they are favored over raw limestone fines for their higher concentration of calcium and greater solubil¬ity. From the producer's viewpoint, quicklime fines are ideal for this use because they go through hydration faster than the larger chunks of quicklime. Those larger chunks, or "pebble lime," are more readily salable and more easily handled, for such uses as steel, copper, aluminum and magnesium production, water waste treatment, chemical, paper, glassmaking and flue gas desulfurization in coal- fired boilers.

Jan 1, 1993

By R. M. Williams

Introduction Ring roller mills are efficient size reduction machines embodying the following machine functions: 1) Size Reduction: from a feed size of 2 in. to various size products as fine as 400 mesh, or granulation from 2 in. to 6 mesh containing a minimum of fines. 2) Drying: fluid bed drying of wet feed materials. 3) Conveying: negative pressure air system results in dust-free conveying. 4) Beneficiation: liberation and removal of foreign materials from the auxiliary bottom discharge simultaneously while grinding. Operation Operation of the roller mill system, Figs. 78 and 79, is completely automatic. A feeder introduces raw material into the grinding chamber in the base of the roller mill at a rate determined by pressure variations within the roller mill as material is ground and air conveyed away. The feeder will be activated by the reduced static pressure and introduce unground material into the system, thereby maintaining a constant differential pressure. Plows located ahead of each grinding roll direct the material upward and between the grinding rolls and the bull ring where it is ground to size. The grinding rolls are free to swing out centrifugally, which forces them to bear upon and grind the raw material. Being free to pivot axially, the rolls automatically assume the proper position for grinding and need no adjustment to compensate for wear. Rotation of the rolls is by rolling contact. Once ground to size, material is swept out of the mill by the controlled air flow from the centrifugal main mill fan. Air suspended, the ground material passing through the adjustable spinner separator. In the separator, an accurate size classification is made which allows product-size material to be conveyed away from the roller mill while oversize material is returned internally for additional grinding. By varying the speed of the separator drive, more or less cyclonic action is achieved at this location, effectively controlling product size. Product sized material is removed from the airstream by the cyclone collector. Typically, a conveyor or product storage bin will be located to accept the product as it exits from the bottom of the cyclone collector.

Jan 1, 1985

By Wolfgang Pietsch

Roller presses were first invented in the middle of the 19th century, for the economical size enlargement of coal fines as fuels. Coal briquettes became quickly accepted for industrial and domestic use giving rise to a large and sucessful industry, particularly in Europe, Japan, and North America. When, towards the middle of the 20th century, coal was more and more replaced by other energy sources, such as electricity, gas, and oil, roller press manufacturers searched for alternate applications of this equipment. In addition to contemporary coal briquetting, in fields such as smokeless fuel and form-coke, it was found that redesigned and modernized roller presses, which are now capable of exerting high forces, are versatile machines for many tasks in mineral processing. Today they are used for: - the "classic" pressure agglomeration and - the "new" high pressure comminution. In pressure agglomeration, the characteristics of fine minerals are improved by forming briquettes or granulated products from compacts. During size enlargement with roller presses briquettes are directly obtained while granular materials are produced by crushing and sizing of compacted sheets. The processes are carried-out essentially dry and often do not require binders other than those inherently contained in the feed and "activated" by the high forces and/or elevated feed temperatures (e.g. hot briquetting). Therefore, no foreign materials (impurities) are added. Another advantage of the technology is, that wide particle size distributions are acceptable or desirable as feed materials, including millimeter or even centimeter sized particles. Plastic particles deform and brittle materials are crushed during pressure agglomeration. A relatively new application of roller presses in mineral processing is the utilization of the crushing effect when brittle materials pass the nip area between the rollers. It was found that this crushing mechanism is very efficient thus saving energy, particularly in grinding circuits handling large capacities. The paper introduces the fundamentals of the process and describes the design as well as applications of modern roller presses in mineral processing.

Jan 1, 1995

By R. S. Shepard

A quick glance at a-portion of the title of this discussion -'Rolling With The Punch" may immediately lead you to assume that I am about to expound on the so-called manly art of self-defense. So that you will not have been misled entirely we will devote our considerations to a far more important art and if I may, I should like to begin by quoting Vincent Van Gogh. According to a literal translation the artist in describing one of his famous paintings said "these peasants are eating their potatoes with those very hands that dug them from the earth' and put them in the dish". Vincent Van Gogh may not have realized at that time, that he could likewise have been describing what is probably one of the oldest of all arts - the art of Material Handling - an art that man with the aid of science has tried to improve since the beginning of time.

Jan 1, 1963

By Robert Stefanko

13.1-SUBSIDENCE AND GROUND MOVEMENT ROBERT STEFANKO 13.1.1-SUBSIDENCE AND FAILURE This treatment of subsidence and ground movement will be confined to subsidence control for limiting surface damage by assessing the significant parameters affecting ground movements during mining to optimize mining techniques. The material will be equally applicable to evaporite mining as well as coal but will not deal with block caving or similar systems where failure is deliberately induced and surface protection is not necessary or provided. When an underground opening is established, the original equilibrium is disturbed with resultant stress concentrations. While many factors are involved in opening stability, the span (W) undoubtedly is one of the most important factors in failure. Assuming it is relatively small, the overlying rock strata can bridge across the opening and little if any movement or convergence of top and bottom will occur. However, as the span increases, a point is reached where the stress in the overlying rock strata exceeds some strength value of the rock, and the top breaks. If the opening span is limited to some subcritical value (-We) and/or is at great depth (D), a pseudo-arch will form, achielring stability before rupture occurs to the surface. The boundary of this arch is thought to approximate an ellipse in form with the major axis vertical and equal to four times W, although there has been little field research to substantiate this theory. However, if the width of this opening is increased at this horizon to some critical value (W,) or the same span is created in a shallower seam, the overlying strata ill progressively rupture to the surface and the characteristic subsidence trough is formed (Fig. 13-1) The area of the surface affected is much greater than the area of the seam extracted, depending on the "angle of draw" (a), which is the angle between a vertical line from the edge of the opening and another line extended to a point at which subsidence tails out to zero. This angle has been found to be about 35° in Europe but is rather academic, being a function of instrument precision in detecting subsidence. Since the subsidence effect is so small at any point beyond n 25° angle, this latter may be considered the practical limit of subsidence. Further- more, indications are that the angle of draw varies with depth and nature of the strata.' In a field study over a 1,000-ft-deep potash mine in New Mexico, the maximum angle of draw was found to be 51.5°.2 So far, only a single opening has been considered. However, the width of the excavation applies to any complex mining system of entries, rooms and longwalls as long as the seam has been fully extracted and the width represents the distance from one solid rib to another. It will be noted that the amount of vertical displacement varies from point to point on the surface (s), but the maximum subsidence for a given trough occurs at the center (S). This latter value may not he equal to the maximum possible subsidence (Sm) which occurs only if a critical or super- critical (+W,) width has been exceeded (Fig. 13-1). Substantial surface damage can result when subsidence occurs. Factors affecting the amount and type of ground movement are: thickness and properties of the seam, angle of draw, width of excavation, depth and type of overburden, inclinations of strata and surface, and the amount of support left in the gob. In Europe,

Jan 1, 1973

By J. L. Ellenberger, T. Miller

"A limestone mine in Ohio has had roof instability problems that have led to massive roof falls extending to the surface. This paper describes a collaborative study of these events undertaken by the National Institute for Occupational Safety and Health and the mine owners. The study focuses on the roles that weak, moisture-sensitive floor and weak bands in pillars play in a general instability that led to roof falls at this mine. The NIOSH Stone Mine Pillar Design software (S-Pillar) does not include analysis for weak floor or weak bands and recommends that when such issues arise they should be investigated further using a more advanced analysis. It is important to recognize that without the impact of the floor or weak bands, the calculated inherent stability factor for these pillars is within the recommended design range. Therefore, to further investigate the observed instability occurring on a large scale at the Ohio mine, FLAC3D numerical models were employed to help determine the failure mechanism. Roof-to-floor extensometers were also installed in the areas predicted to have further instability. This case study will provide important information to limestone mine operators regarding the impact of weak floor causing the potential for roof collapse, pillar failure, and subsequent subsidence of the ground surface. This recent case demonstrates that weak floor can be a significant factor in pillar stability and should be assessed during the design stage of the mine.To an area-wide failure (Zipf, 2001). In that case, it appears that the pillars had actually remained intact. However, moisture-related yield of the weak floor caused deformations which passed through pillars and into the roof, triggering roof collapse around the intact pillars (Esterhuizen et al., 2011). This previous case and the case presented in this study, while not identical, both demonstrate that weak floor and/or bands within pillars can be a significant factor leading to instability."

Jan 1, 2015

By J. L. Ellenberger, G. S. Esterhuizen, T. Miller, M. M. Murphy

A limestone mine in Ohio has had roof instability problems that have led to massive roof falls extending to the surface. This paper describes a collaborative study of these events undertaken by the National Institute for Occupational Safety and Health and the mine owners. The study focuses on the roles that weak, moisture-sensitive floor and weak bands in pillars play in a general instability that led to roof falls at this mine. The NIOSH Stone Mine Pillar Design software (S-Pillar) does not include analysis for weak floor or weak bands and recommends that when such issues arise they should be investigated further using a more advanced analysis. It is important to recognize that without the impact of the floor or weak bands, the calculated inherent stability factor for these pillars is within the recommended design range. Therefore, to further investigate the observed instability occurring on a large scale at the Ohio mine, FLAC3D numerical models were employed to help determine the failure mechanism. Roof-to-floor convergence monitors were also installed in the areas predicted to have further instability. This case study will provide important information to limestone mine operators regarding the impact of weak floor causing the potential for roof collapse, pillar failure, and subsequent subsidence of the ground surface. This recent case demonstrates that weak floor can be a significant factor in pillar stability and should be assessed during the design stage of the mine.

Jan 1, 2015

By C. Mark, D. M. Pappas

From 1999 through 2008, groundfall events resulted in 75 fatalities, 5,941 injuries and 13,774 noninjury roof falls in U.S. underground coal mines, according to the U.S. Mine Safety and Health Administration (MSHA). A comprehensive analysis of these events was conducted to better understand where and why these incidents occurred. The first segment of the study used the MSHA database to evaluate groundfall injury rate trends related to mining method, year, locality, seam thickness, mine size, coalbeds and seasonal effects. In the past decade, roof fall injury rates have dropped 50%, but rib fall injury rates have remained constant. Room-and-pillar mines had a roof fall injury rate that was nearly 2.5 times the longwall rate. High groundfall rates occurred in the Illinois Basin, a finding that correlates with other studies that have shown that roof rock in the Illinois Basin is weaker than that in the central Appalachian coalfields. Finally, noninjury roof fall rates in the eastern and central United States were found to be 50% higher from July through September, possibly because of the changes in humidity levels that may cause shale mine roofs to deteriorate. The second segment of the study evaluated the root causes of failure by reviewing all MSHA groundfall fatality reports for 1999-2008. Pillar recovery was the leading cause of groundfall fatalities (19%), followed by rib falls, roof skin falls and traveling under unsupported roof (16% each). Defining prominent ground control incident trends and hazards will identify areas where additional study is needed and where innovative solutions need to be developed to reduce these severe occupational hazards.

Jan 1, 2011

By A. T. Iannacchione

Unfortunately from 1991 through 1995, 44 miners were fatally injured in the stone industry. Of these 12 occurred at underground mines from a total work force of less than 2,000 miners. Nine of these 12 miners were fatally injured in falls of roof or rib. A safer environment for the miners can be achieved by evaluating the nature of the hazardous ground and by developing more efficient and effective ground control strategies. Roof and rib conditions in the underground stone industry were observed and assessed at 33 mines in Illinois, Indiana, Kentucky, Maryland, Missouri, Pennsylvania, and West Virginia (Figure 1). Hazard assessment indicated that those ground failures occurring under moderate to substantial overburden ( > 30 m [100 ft]) were caused by stress concentrations and geologic structures. Ground failures near the surface are caused by solution (water) processes. Selection of the mining horizon and mine layout decisions tremendously influence ground stability.

Jan 1, 1997

By L. J. Prosser, A. T. Iannacchione

From 1991 through 1995, 44 miners out of a total workforce of less than 2,000 were fatally injured in the stone industry. Of these, 12 occurred at underground mining operations with nine deaths resulting from roof or rib falls. A safer environment can be achieved by evaluating the nature of the hazardous ground and by developing more efficient and effective ground-control strategies. Roof and rib conditions were observed and assessed in 33 underground stone mines in Illinois, Indiana, Kentucky, Maryland, Missouri, Pennsylvania and West Virginia (Fig. 1). Hazard assessment indicated that the ground failures that occurred under moderate to substantial overburden, i.e., >30 m (100 ft), were caused by stress concentrations and geologic structures. Ground failures near the surface are caused by solution (water) processes. Selection of the mining horizon and mine-layout decisions

Jan 1, 1999

By L. J. Prosser, A. T. Iannacchione

Unfortunately from 1991 through 1995, 44 miners were fatally injured in the stone industry. Of these 12 occurred at underground mines from a total work force of less than 2,000 miners. Nine of these 12 miners were fatally injured in falls of roof or rib. A safer environment for the miners can be achieved by evaluating the nature of the hazardous ground and by developing more efficient and effective ground control strategies. Roof and rib conditions in the underground stone industry were observed and assessed at 33 mines in Illinois, Indiana, Kentucky, Maryland, Missouri, Pennsylvania, and West Virginia [(Figure 1)]. Hazard assessment indicated that those ground failures occurring under moderate to substantial overburden (> 30 m [l00 ft]) were caused by stress concentrations and geologic structures. Ground failures near the surface are caused by solution (water) processes. Selection of the mining horizon and mine layout decisions tremendously influence ground stability.

Feb 24, 1997

By E. M. Frizzell

An ongoing research program at the Spokane Research Center of the U.S. Bureau of Mines is directed toward investigating drilling parameters (thrust, torque, penetration rate, and drill revolutions) during the drilling of roof bolt holes. A system that measures these drilling parameters calculates the specific energy of drilling, and determines drill bit position has been developed by the Bureau and mounted on a roof bolting/drilling machine, through the use of a microcomputer, critical drilling parameters can be immediately interpreted and analyzed. This makes it possible to inform the operator of hazardous roof conditions. Initial results of this program are presented here.

Jan 1, 1990

By M. R. Shahan, W. R. Reed, P. Zhang, J. P. Rider

Roof bolter operators may be exposed to high respirable dust concentrations on continuous miner sections with blowing face ventilation when bolting is performed downwind of the continuous miner. One solution to reduce the high respirable dust concentrations is to use a canopy air curtain (CAC) to deliver clean air from a filtered blower fan directly to the bolter operators under the canopies. The influence of CAC installation in the airflow and dust dispersion around the location of the roof bolter operator can be evaluated by using computational fluid dynamics (CFD). This study, performed by the National Institute for Occupational Safety and Health (NIOSH), considers two scenarios: (1) a roof bolting machine in the center of the entry for installation of the fifth row of bolts from the face, and (2) a roof bolting machine positioned close to the face for the installation of the last row of bolts. In both scenarios, the bolting machine is placed in an environment which contains 6.0 mg/m3 of respirable dust and is ventilated by a blowing curtain with 3,000 cfm (1.42 m3/s) of air. This environment is used to simulate the roof bolter machine operating downstream of a continuous mining machine. Two operation positions are simulated at the same bolting location: dual drill heads in the inward position for two inside bolts; and dual drill heads in the outward position for two outside bolts. The influence of the CAC on airflows and dust dispersion is evaluated with the CAC operating at 250 cfm (0.12 m3/s). INTRODUCTION Roof bolting machines are used to drill bolt holes into the roof of an underground mine at specified patterns and to install roof bolts to secure the roof from falling. At times, the roof bolting machine is also used to install rib bolts; however, only the roof bolting operation was considered in this simulation. Though the roof bolting operation drastically improved the safety of miners from roof falls, some roof bolter operators are experiencing health problems associated with respirable dust. Based on recent statistics [1], following a low point in the late 1990s where the prevalence of coal workers’ pneumoconiosis (CWP) in miners with 25 years or more tenure was approximately 5%, CWP now exceeds 10% for miners with 25 years or more of tenure. In central Appalachia (Kentucky, Virginia, West Virginia), 20.6% of long-tenured miners have CWP and 4.5% have progressive massive fibrosis, the most severe form of CWP. CWP, also known as black lung, is an occupational respiratory disease that has no cure and can ultimately be fatal. The only way to prevent the incidence of black lung is to eliminate miners’ exposure to respirable coal mine dust. Current U.S. regulations require that the overall respirable dust concentration to be 1.5 mg/m3 or less for a full-shift sampling if respirable quartz is not present; otherwise, the standard is 10 divided by the percent quartz (not to exceed the 1.5 mg/m3 respirable dust standard) [2, 3].

Jan 1, 2019

By B. T. Mirabile, D. Tang, Y. Luo, S. S. Peng, C. T. Holland

Knowledge of local coal mine roof geology is critical to the design of a safe and suitable mine structure. An automated drill control and data collection system has been designed for a J.H. Fletcher twin-head roof bolter. Drilling parameters collected during the drilling process can be used to interpret geologic features intercepted in the mine roof. The drill and data collection system have been tested in both laboratory and underground settings. Visualization of certain drilling data has shown good correlation with geology drilled. A quantitative prediction model was developed using drilling parameters examined with data visualization. The quantitative model was tested using laboratory drilling data.

Jan 1, 2004