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By Peter Schmäh

Pipe-jacked tunnels are considered for a large variety of applications from water and sewage, cable ducts to challenging pipeline crossings or landfall construction. In most cases, Slurry MTBMs are used to carry out these projects. Continuous further development of technological features for pipe jacking plays a key role to overcome feasibility limits and to meet increased project requirements. As tightened safety regulations in terms of accessibility and escape routes increasingly limit the options of small segment lining tunnels in the diameter range below 4 m, 13 feet, pipe jacking has partially taken over. During the last decades, a growing number of large-diameter and long-distance pipe jacking projects have been completed. Experienced contractors successfully use the technological capacity of the MTBM equipment. The machine and cutting wheel have to be designed according to the ground conditions. Bentonite lubrication and interjacking stations are key factors to keep push forces moderate. For long pipe jacking drives, a so-called push module can be installed in the machine can, to be able to switch from pipe jacking to segment lining in case the machine gets stuck. The overall aim is to provide clients and the tunnel construction industry with safe and economical solu- tions for successful project execution. This presentation will present international milestone projects and will also discuss the latest developments in automation, related opportunities and limitations, and the future of digitization and artificial intelligence in pipe jacking.

Jun 23, 2024

By S. Philipp

This paper describes several variants of placement and design, from a technical and economic point of view, of shafts, ore bunkers and drifts near shafts of a Russian potash mine. Advantages and disadvantages of the position of different workings are shown as well as an analysis of stratigraphic and geological layers and their use for excavating pit bottoms, haulage drifts and bunker installations. The potash mine consists of two hoisting shafts and one service shaft. The hoisting capacity of one of these skip shafts is planned to be approx. 7 Million tons of crude potash salt per year. Both shafts together will have a hoisting volume of about 14 Million tons. When the mine will increase their highest level of production, it will be one of the biggest potash mines in the world. The skips, the hoist drives and the bunker near the shaft will belong to the largest ones worldwide, too. This paper specifies the features of such a double skip shaft pit in detail and demonstrates problems, which depend on the fact that the pit bottom is in a depth of nearly 1200 m.

Feb 23, 2014

By Cary Hirner, Dan Lopez, Ross Webb, Stephen O’Connell

"Construction of the largest desalinization plant in the Americas has commenced in northern Chile. It is part of a several billion dollar expansion at a copper mine whose operations nearly stopped due to the challenge of securing a reliable source of water from the Pacific Ocean in a safe and environmentally sound manner. This paper discusses the risk management, design and construction of a quadruple chamber intake and outfall shaft, high capacity pump station, three 7m diameter vertically drilled marine shafts and three subsea tunnels constructed through challenging Andean hard-rock geology. The three 2.5m diameter subsea microtunnels are being mined with vertical curves through variable quality rock 30 meters beneath the ocean and retrieved in the wet from the 7m diameter marine shafts. INTRODUCTION AND BACKGROUND The battle for securing the rights to a constant water supply is a worldwide issue and nowhere is that more evident than the Atacama Desert of Chile, the world’s driest place with areas of the desert that have not seen rainfall in recorded history. The Atacama Desert also happens to be home to some of the world’s largest ore deposits which require huge amounts of water to extract and process. What available water there is comes from three main sources: deep seated wells, glacial water from the Andes Mountains, and desalinated water. Vying for water from wells and glacial streams and lakes are numerous agricultural and domestic facilities in the valleys surrounding the Atacama Desert. Environmental regulations and legal rulings have limited the amount of “natural” source water which can be used for mining purposes. Desalination plants are a known solution for combating water scarcity, albeit a costly one. The total estimated cost of constructing this desalination plant is over $3B USD, which will include a 2500lps capacity and an approximately 118km pipeline from the coast up to the mine located in the Andes. The overall scope of the project includes design, procurement, and construction packages for the 2500lps desalination plant including the seawater reverse osmosis plant, water conveyance to the mine, power transmission, the reservoir and the marine works package which forms the basis of this paper. Key components of the underground construction portion of the Marine Works are:"

Jan 1, 2016

By Matthew Preedy, Anthony Pooley, Mike Wongkaew, Dirk Bakker, Raghu Bhargava

Sound Transit’s ST3 program will add 62 miles of light rail to the Puget Sound area, including connections to the neighborhoods of West Seattle currently anticipated by 2031 and Ballard by 2036. These connections include considerations for both elevated and tunnel alternatives, as well as a new downtown tunnel for which different configurations are being considered with potentially very different construction logistics and risk profiles. This paper describes the latest developments in the ongoing evaluation process that will inform the consideration of different tunnel and station construction methods, technical and operational challenges and contracting methodologies, including construction of deep stations in dense urban environments.

Jun 13, 2021

By Erwan Yap, Brian Mangogna, Craig Romrell, Jeff McKay, Weishi Mang, Andrea Deml, Adam Steimel, Justin Dix

The Doe Run Company (Doe Run), a global supplier of lead (Pb), copper (Cu) and zinc (Zn) concentrates, and lead metal alloys, installed an enterprise expert control system— termed as Digital One—on the company’s Pb, Cu and Zn circuits at its Buick Mill in December 2022. Digital One was developed with Metso and deploys Metso’s product, VisioFroth™. This automated system is now running and optimizing the flotation processes for all three circuits (Pb, Zn and Cu), all plant air and methyl isobutyl carbinol (MIBC). In addition, Digital One also controls a second, newly built, modern flotation reagent system. Digital One also paves the way for automation and expert control of the entire mill, integrating grinding, thickening and filtration. Digital One is digitally immersed in a universal distributed control system (DCS); therefore, today’s mineral processing plants may be upgraded to it or designed around it. This presentation will explore the plant design and operation of this technology at the Doe Run Buick Mill.

Feb 1, 2024

By Rainer Antretter

The city of Garmisch-Partenkirchen in southern Germany is located at a main transit road to Tyrol in Austria and suffers of a very heavy traffic load. Therefore, the Kramertunnel as a by-pass tunnel is built to release/mitigate the traffic through the city centre. The 3,600 m long single tube road tunnel is designed with a parallel but smaller emergency tunnel and with cross passages, fitted with single- and doublesided emergency bays, a vent shaft, and an intermediate ceiling to separate fresh air supply from the road traffic. The tunnel, concrete lined along its entire length provided the challenge to find smart formwork solutions for quick set-up, repositioning, setup and pouring. Three particularly specific sections are discussed in this paper.

Jun 13, 2023

By M. Visnjic

Open Pit Mine Production scheduling under commodity price uncertainty suffers from an exponentially increasing problem size as simulations and real options flexibility are used to generate and evaluate multiple production schedules. Robustness evaluation techniques attempt to evaluate a production schedule that is generated on a single set of economic parameters against several varying prices and sources of uncertainty. This approach is invalid as the corresponding optimal LOM mine plan will change for each set of evaluation parameters. Using commodity market futures and treasury bonds as production schedule economic input parameters provides fully price and time-value-of-money risked scheduling parameters that maintain a deterministic problem size. This paper will provide comparative analysis of project NPV’s coming from traditional price uncertainty evaluation based on a single fixed LOM mine plan using varying prices versus evaluation based on varying LOM plans that are both generated and evaluated using varying prices. When cross evaluating constant price mine plans against simulations, the upside potential and downside risk of a project are significantly misrepresented. INTRODUCTION The life of mine (LOM) production scheduling problem seeks to answer the question of from where and when to extract a given block within the ultimate pit limit as well as where and when to process it. Solving this problem takes into account the constraints of extracting any particular block while seeking to maximize the net present value (NPV) of the mineral asset as a whole. A direct driver of the value of a block, and there for the entire asset, is the market price of the commodity in question. Complications arise when an optimal production schedule is attempted to be solved under price uncertainty. Many solution methodologies have been proposed in an attempt to optimize under this criterion, yet there are three salient aspects that are overlooked during this process. They are: • Generating a single production schedule and evaluating it against many simulated price paths. • Failing to understand the mechanism describing particular commodity price behavior • Inappropriate risk adjustment In an effort to address these aspects of production scheduling under commodity price uncertainty, we propose a methodology to define the economic parameters as input that is applicable to most if not all production scheduling approaches. This methodology will not only simplify the production scheduling process in terms of establishing block value but utilizes the risk adjustment of real options valuation to avoid the arbitrary blanket risk adjustment of traditional discounted cash flow valuation. Our findings conclude that attempting to optimize around individual price paths is futile and using a market risk adjusted single price forecast provides a justified economic basis for production scheduling while maintaining the same problem size as a deterministic production scheduling problem.

Jan 1, 2019

By Kyle Amoroso, Larry Applegate, Aaron K. McCain

The use of frozen soil as ground improvement and temporary ground support for the excavation and construction of cross passages and adits has gained in popularity over the last decade. Frozen soil provides a number of advantages for this application such as being waterproof, structurally stable, and working well with any soil type. One of the greatest advantages is the ability for the system to be adaptable to the project geometry and site limitations. Multiple case histories illustrate that freezing can occur from the ground surface, from within the tunnel, or as a combination.

Jun 13, 2023

By Yuting Xue, Khaled Mohamed

The failure of coal ribs is a major hazard in underground coal mines. Researchers from the National Institute for Occupational Safety and Health (NIOSH) have been working on the development of an engineering-based rib control method. A user-friendly standalone application, called Design of Rib Support (DORS), is being developed to ease the calculations of rib support. DORS can estimate the Primary Rib Support Density (PRSD, ton/ft2) for development loading. However, it still needs to take account of another key factor, bolt length, in rib support design. The bolt length can be estimated from the rib fracture depth, and this study focuses on the coal rib fracture depth analysis with numerical modeling and artificial neural network. A total of 331 FLAC3D simulations with different mining scenarios and rib conditions were conducted for this study. Machine learning was then used to predict coal rib fracture depth under different conditions. Based on the numerical simulations, the parameters for mining scenarios and rib conditions were collected as features for machine learning, and coal rib fracture depths were collected as the target to predict. Good data correlation (r-square) was obtained with the use of an artificial neural network. The

By Richard Campbell, Claire Pirona, MEHMET KIZIL, Ismet Canbulat, Stephen Giese, Ravindu Goonawardene, Edward Steed, Serkan Saydam

The Australian longwall mining industry spends millions of dollars per year on proactive and reactive ground consolidation applications across most of the operations currently in production. The design and effectiveness of the applications and products vary widely and are based predominantly on-site precedence or what were considered successful applications at other sites in similar situations. In the continual improve the effectiveness of how consolidation products are used and when by enhancing our knowledge of the mechanical properties of products used in underground coal applications and applying this increased understanding to geotechnical design. One of the current challenges to further developing more appropriate and accurate geotechnical design methods for consolidation activities is the lack of standardised materials testing and knowledge of rock mechanics data on in situ performance. The lack of industry standardisadesign of consolidation programs, with a reliance on experience-based guidance for rockmass consolidation design. consolidation products. The program was designed to provide the industry with a set of geomechanical property index tests and a data set that can be utilised by rock mechanics engineers as baseline information for product evaluation and engineering design. The laboratory work undertaken is critical to understanding the exact small-scale mechanical properties of these products and testing was carried out at Monash University for various states of curing of each product. Recognising that the speed at which a mixed product develops its desired properties to act as a support element in underground coal mines is critical to its serviceability. This paper presents the testing rationale proposed, the testing results, and a framework for how the data set can be used to improve the engineering basis for ground consolidation design, in terms of expected rockmass performance under various mining conditions and application parameters.

Jun 25, 2024

By Dan Preston, Shane Yanagisawa, Robert Marshall, Don Deere

Geotechnical Baseline Reports often estimate the number of cobbles that will be encountered in terms of volume or weight. These estimates are practically impossible to verify in the field. ClaroVia Holdings in conjunction with Frontier Kemper Constructors Inc. developed Digital Geologist 2.0 to classify and count cobbles discharged from an EPB TBM at the RSC7 project in Burbank, CA. The system worked by using two stereoscopic laser sensors with a global shutter to scan and count cobbles at 12 frames per second. Results of the effort are revealed along with lessons learned and paths for improvement.

Jun 13, 2023

By Erica McGlynn, Brian Negrea, Lance Jackson

There was no need for the people of Cleveland to ask “Where does the raw sewage go? We want to know!” because it was clear. The raw sewage was being discharged into Lake Erie during heavy rainfall events due to the outdated design of the combined sewer system. In efforts to resolve this ongoing issue for the City of Cleveland, the Northeast Ohio Regional Sewer District developed Project Clean Lake in collaboration with the US EPA. Project Clean Lake is a 25-year, $3 billion program consisting of seven large-diameter CSO storage tunnels to be constructed beneath the city’s existing infrastructure. The first four tunnels have been completed using traditional hard rock TBM excavation methods. The fifth tunnel, the Shoreline Storage Tunnel Project, presents unique challenges and complexities as it will be the first large-diameter EPB TBM to dig under the City of Cleveland. The project itself consists of one tunnel drive 14,100' (2.7 miles) in length, two pipe jacking tunnels, three large slurry wall shafts, two diversion structures, and three regulator reconstructions. Upon completion of the project, 12 permitted CSO locations along Lake Erie will be taken offline, reducing overflow volumes by approximately 350 million gallons per year. This paper will discuss the current status of construction and the chosen means and methods, including the myriad of nuanced differences between hard rock and EPB TBM tunneling methods. Particular attention will be given to the site preparation, setup, and organization; TBM assembly; and TBM launching practices.

Jun 13, 2023

By Yuting Xue, Taghi Sherizadeh, Mark Van Dyke, Dogukan Guner, Khaled Mohamed

The Coal Pillar Rib Rating (CPRR) technique has been developed to assist in rib support design in underground coal mines. One major challenge of the data collection process is the measurement of coal strengths in the field. Schmidt hammer has been verified as a useful tool to determine coal strength. An alternative approach is to obtain the representative strength of coal mass by determining the coal lithotypes in the field based on the coal brightness profile by experienced geologists or mining engineers. In this paper, image processing techniques have been used to quantify the texture of coal images of different lithotypes with the purpose of classifying coal lithotypes. The coal images were collected from the pillar ribs with exposed surfaces in underground coal mines, and the coal lithotypes were identified when taking the images. The method of Gray-Level Co-Occurrence Matrix (GLCM) was used to analyze the textures of coal images of different lithotypes, and the texture parameters, such as contrast, homogeneity, energy, and entropy, were compared. The results show that the images of coal with different lithotypes have different textures, which can be quantified through the image processing. The results from this study demonstrate the potential of classifying coal lithotypes using rib photos and easing the data collection process of CPRR.

Feb 1, 2024

By Lynn B. Hales, Randy A. Ynchausti

Expert supervisory control strategies have been used for many years to improve operating revenues in comminution circuits. Typical improvements in capacity range from four to eight percent. Several case studies of results will be presented as well as a general discussion of the technologies used to achieve the improvements. Crushing. SAG milling and ball milling circuits will be discussed.

Jan 1, 1997

By W. J. Pennstrom, J. R. Arnold

Gold Fields installed what was the mining industry's first commercial gold electrowinning/replate circuit at Ortiz in 1981. Its highly successful operation since that time provided the design basis for a similar circuit at Mesquite, which was started in early 1986. These circuits produce plated gold foil suitable for direct shipment to a refinery or melting directly into bars. Detailed descriptions of the electro- winning and replate circuits are given and advantages and disadvantages are discussed.

Jan 1, 1988

By P. Magnani

Quarry environmental reclamation can be achieved with favorable economical advantages and high energy efficiency, using stabilized materials obtained by the treatment of organic fraction of municipal solid waste (MSW).

Jan 1, 2005

By Hayward B. Oblad, Gary F. Meenan

Two optoelectronic detectors were developed by CONSOL R&D for fine coal processing applications. One sensing device is used to estimate the amount of fine coal in the solids fraction of the froth flotation tailings slurry. The other probe, based on similar technology, is capable of measuring sol ids concentrations as high as 10 weight percent in fine coal slurry streams. These patented optoelectronic sensors are installed in several CONSOL coal preparation plants and are an integral part of the fine-coal control systems.

Jan 1, 1993

By T. E. Wilson

The length of Alaska’s coastline, combined with the presence of a significant number of fjords, encourages consideration of marine disposal of mine tailings. However, since various factors govern the viability of the submarine tailings disposal (STD) option, the decision making process is complex. An expert system, called Submarine Tailings Disposal Expert System (STADES) that will help mining project planners explore the feasibility of STD, was developed. Existing literature, supplemented by engineering recommendations, on the various aspects of marine disposal of tailings was reviewed and formed the knowledge base for the expert system. The shell used to develop the expert system was LEVEL5®.

Jan 1, 2001

By H. H. Murray

New and improved beneficiation techniques are available to allow the production of clay minerals of exceptionally high purity. This is particularly true for kaolins and smectites. Wet processing techniques include particle size separation, high intensity magnetic separation, chemical leaching ,flotation, and selective flocculation. The blending of clay minerals with other minerals provides opportunities to make special ceramic materials such as cordierite and other minerals that have very special ceramic properties including low heat expansion, high fired strength, low absorption, and other desired qualities.

Jan 1, 1990

By Chen Ziming, A. Burkert, A. L. Mular

A mechanism has been proposed for autogenous grinding that involves three distinct types of breakage: self impact breakage, media breakage and abrasion. Based on this analysis a mathematical model and an autogenous grinding simulator have been developed. Using pilot plant data fitted to the model, the simulator was tested and employed to examine both the scale-up problem and the effect of feed size distribution on performance.

Jan 1, 1995