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By N. Aydogan, H. Dundar, Å. Partapuoli, A. Fredriksson, P. Wikström, K. Tano, G. Adolfsson

The Autogenous milling of ores holds an increasing attraction as the focus moves towards reducing energy usage, both direct and embodied in grinding media. However, most of the early AG mills were converted to SAG for improved stability and increased throughput. This imposes a huge penalty in steel grinding media consumption. The LKAB iron ore operations in Sweden process highgrade magnetite through fully-autogenous milling lines to a final product P80 of about 45µm. The outcomes of P9O AMIRA research surveys, covering a wide range of mill fillings and throughputs and with different feed blends, are presented. Insights are provided on operational strategies, opportunities, the influence of feed size control and balancing the blend of competent gangue and softer magnetite. Areas of importance in the successful operation and control of energy-efficient autogenous circuits are highlighted.

Jan 1, 2012

By F. Lindroos

A cornerstone in the LKAB Green Pellet concept is to produce pellets with a small footprint in terms of energy con-sumption, CO2 emission and emission of other elements harmful to the environment, like dust, sulphur dioxides, nitrogen oxides, chloride and fluorine. The concept also encompasses our determination to make pellet products that contribute to low environmental impact and low energy consumption in our customer?s processes. The presentation will focus on the pelletizing process. It will describe both how we have attempted to decrease the generation of unwanted components in the process gas, and how we have tested or evaluated equipment for external gas cleaning. We will discuss and give examples from recent and on-going efforts and outline some of the future challenges we see, to meet our own environmental standards and also the tough demands imposed by EU and national legislation, while striving to boost production.

May 1, 2011

By T. Naarttijärvi

The Fabian ore body near Malmberget, Sweden, has an ore reserve of 5 Mt of predominately low grade iron ore, containing 40-55% Fe. Mining began in 1971 with a new method called slot block caving. About 2 Mt were mined, but poor fragmentation resulted in too much secondary blasting. This decreased mucking efficiency to such an extent that the method was abandoned after only 40% of the ore volume had been mined. At this stage a large stope (180 x 30 x 100 m) had been excavated. Although the exposed area was quite large, no caving action occurred in the hanging wall or in the ceiling. LKAB decided in 1977 to introduce sublevel stoping using 105-mm-diam holes. This was the first time large diameter holes were used underground in Sweden. The method had been evaluated in collaboration with the University of Luleå (LuH), the Swedish Detonic Research Foundation (SveDeFo), and the Swedish Mining Research Foundation.

Jan 3, 1982

By Martti E. Maliniemi

The Svappavaara mine is located 47 km southeast of Kiruna C. The ore deposit now being worked, Leveäniemi, belongs to Luossavaara- Kiirunavaara AB (LKAB) and is the company's, and also Sweden's, third biggest mine after Kiirunavaara and Malmberget. The distance by rail to the Norwegian port of Narvik is 214 km and to Lulei on the Gulf of Bothnia 340 km (Fig. 1). The village of Svappavaara has about 800 inhabitants. The climate is arctic in character. The temperature during the months of December to February is about -20º to -35ºC, and the ground is covered by a blanket of snow for about eight months of the year. The brief, intensive summer often arrives with startling speed, bringing both sunshine and warmth. HISTORICAL BACKGROUND Mining operations took place in Svappavaara as far back as 300 years ago. During the period 1655-1684, copper ore was taken from the deposit called Gruvberget in the vicinity of the village. The total production of raw copper was probably about 1,045 tons. During the 18th and 19th centuries, several attempts were made to extract iron ore from the numerous deposits found within the district. These brave attempts, however, were foiled by the high phosphorus contents and the enormous transport difficulties. The present-day mine fields in Leveäniemi were discovered in 1897. At that time, it was difficult to determine the size and value of the deposit because of the thickness of the soil cover (3 to 15 m) and the

Jan 1, 1969

Continuous improvement has become the watchword of the 1990s for most iron-ore-processing operations. In many instances, this improvement has been achieved through stepwise application of advanced control techniques to optimize operations. The benefits of this stepwise application have been great. However, they have fallen short of the full potential offered by the prospect of overall plant optimization. The successful integration of computers, instrumentation and control software throughout a plant promises to deliver an additional 3% to 5% of productivity in even the best-run plants (Herbst and Bascur, 1984). LKAB is Europe's largest iron-ore producer and a leading implementer of advanced control technology. In the late 1980s, LKAB introduced advanced control in its concentrator at Kiruna, Sweden to improve plant performance through higher productivity, greater efficiency and lower costs at each processing step.

Jan 1, 1995

By Brad E. Melanson

Because mine haul trucks consume considerable quantities of fuel, they are ideal candidates for the adoption of cleaner and cheaper fuels like natural gas. Impressive fuel cost savings will be realized in regions where liquefied natural gas (LNG) has cost advantage to diesel fuel, while also providing significant reductions of air contaminants and greenhouse gases. High Pressure Direct Injection (HPDI) of natural gas utilizes the diesel cycle combustion process and therefore retains the diesel engine?s high performance and efficiency characteristics. HPDI has been demonstrated in on-road Class 8 trucks since 2001 accumulating almost 10 million kilometres to date. The supply of LNG fuel will be an essential parallel aspect in the introduction of HPDI to mining. LNG can be transported to site as diesel is today, or may be produced on or near mine operations that have access to methane sources or pipelines.

May 1, 2006

By Peter J. Szabo

Many mining engineers tend to think of the economic analysis of mining ventures and projects on an f.o.b. mine basis. This is especially true of mines that are operated in an established domestic mining district. Here, transportation costs are many times smaller in comparison to overall delivered prices. One has only to consider the development economics of taconite mines in Minnesota with production destined for lower lake ports to see the truism of this statement. In the international arena, however, with consumers such as Japan and Europe located thousands of miles from source countries such as Brazil and Australia, the situation is different because mineral transportation is often a critical factor in determining project viability. This article is being presented to provide a basic understanding of the factors that govern ocean transportation of the three largest bulk mineral commodities shipped around the world: iron ore, coal, and phosphate. The major dry bulk commodity trades as a percentage of volume shipped are iron ore, 45%; grain, 25%; coal, 20%; phosphate rock, 5%; and bauxite and aluminum, 5%. Most of these commodities are carried by bulk carriers rather than tankers. These are vessels that have cargo, usually in solid form, loaded directly into the hold of a vessel by shore-side materials handling facilities or, in the case of a geared bulk carrier by the vessel's cranes and derricks. Gearless bulk carriers are used in most cases for iron ore and coal. Geared bulk vessels are mainly used for minor dry bulk trades such as ore concentrates (copper, lead, zinc, etc.), fertilizers (phosphate, potash, etc.), cement, petroleum, and coke. There has been, however, a trend toward using more self-unloading ships in both iron ore and coal ocean transport. And large vessels, such as the Universe Kure of Japan, have been designed with a cargo capability of 157 kt (155,000 dwt (deadweight tons)). Trade patterns of major bulk commodities are influenced by the Panama and Suez canals. Both of these canals have draft limitations that prohibit large, deep-draft, ocean-going vessels from using them for shorter trade routes used by Panamax and Suex vessels. The shipping industry has developed two widely used vessel classes; the Panamax and Suex vessels. The former is the maximum size vessel that can pass through the Panama Canal, usually 51-61 kt (50,000 - 60,000 dwt), depending on the season and draft of the vessel. The Panama Canal is usually 0.6-0.9 m (2-3 ft) deeper in the winter than in the summer. Thus, less cargo can be carried by the same size ship in the summer through the canal than in the winter. The Suex vessel is in the 71-81 kt (70,000-80,000 dwt) class. This larger vessel is able to transit the Suez since Egypt deepened the canal following the Seven Days War. Recently, the Suez Canal has been deepened to accommodate vessels with drafts as deep as 152 kt (150,000 dwt).

Jan 10, 1982

By Leo Gilbride

Western U.S. longwall operators face increasing challenges with optimizing ground control and productivity as mines reach greater depths and coal bursting hazards increase. Some western U.S. mines, many known to be bump-prone, achieved a successful balance between ground control and productivity by transitioning to side-by-side longwall panel mining combined with a yield pillar gateroad system. With this design, development footages could be minimized and pillar bumping averted by controlled yielding at moderate depths, generally in the range of 450 to 600 m. Over the past four decades, the yield pillar system has won wide acceptance among western mines facing pillar bursting hazards, particularly those in the Wasatch Plateau and Book Cliff coal fields of central Utah. However, recent attempts among the deepest Utah operators to mine side¬by-side panels with yield pillars at depths in excess of 600 m have been met with mixed success and, in some circumstances, with serious difficulty. Challenges include violent face bursting and excessive tailgate convergence outby the face, which can be crippling to ventilation. The use of interpanel barriers, i.e., barriers left between longwall panels, offers one possible solution to mining under deep cover with bump-prone geology. Interpanel barriers have already been adopted by Utah's deepest longwall mine, and others are considering their use. The geomechanical implications of mining with and without interpanel barriers, and the competing tradeoffs between ground control and ventilation are discussed.

Jan 1, 2004

By Carlos Aranda S

El presente trabajo describe el proceso pirometalúrgico convencional y actual en el tratamiento de los concentrados de cobre en el Perú. En ese sentido, se comparan los procesos antiguos con los nuevos, así como el uso de equipos últimos como el Outokumpo, Noranda,Hitsubishl, Worcra, TBRC, Klvcet y otros. De acuerdo a esto, los cambios se efectuaron solo en el tamaño de los hornos y se recomendó que en el uso de las dos fundiciones de cobre: CENTROMIN y Southern Perú Cooper Corp, se utilicen las tecnologías más adecuadas dentro de las condiciones menos óptimas y así competir con países latinoamericanos como Brasil, Chile y México.

Oct 14, 1980

By P. Dosmond

In ore mining technology, the loading and hauling operations are undoubtedly the area where the most spectacular progress has been made during the last twenty years. In the iron ore mines of Eastern France production of 62 million tons for 1962 and 19863 constitute a worthwhile experience worldwide. These deposits which are located in Lorraine are of sedimentary origin and they contain many mineralized horizons with workable seams varying in depth from 330 to 830 ft.

Jan 1, 1970

By Reha Ozel

The stability in longwall faces depends on the interaction beman the roof strata, face supports and floor strata. The load distribution on the other hand, depends upon relative stiffness of the three supporting elements namely, the coal face, support and gob. Therefore, in defining support requirements, it is particularly important to analyze the strata loading, the face convergence and the controlling mechanism provided by supports. The controlling mechanism however, depends on the type and characteristics of supports used in long- wall faces. The design guidelines presented in this paper have bean developed based on a number of strata control oriented projects carried out in Turkey, load and convergence measurements carried out in 10 longwall faces, in Zonguldak Coal Region, and procedures given in literature. Evaluation of load and convergence measurements, and analyses of face supports were carried out by means of a computer program, called L0NGWAI.L-MEW, developed by the authors. The output of the design analyses include the following: (1) estimation of support capacity for roof supports namely; individual hydraulic props, chock-type power supports and various types of shield supports, and (2) analysis of loading conditions and response of shield support components in terms of stability and structural integrity.

Jan 1, 1990

By David C. Oyler, Gregory Hasenfus, Gregory M. Molinda

Few studies have specifically measured and documented the large-scale loading behavior and durability of ventilation stoppings to mining induced movements, particularly from longwalls. Ventilation stoppings are more commonly the concern of ventilation engineers, and ventilation stopping response to ground movement has only been documented in an incidental manner. This paper presents the investigations of underground measurements that have been conducted to determine the loading response of stoppings constructed from lightweight aggregate concrete masonry units (CMU). These investigations have produced some interesting results that may prove beneficial, not only for developing and assessing alternative stopping construction techniques, but also for designing and selecting standard construction methods for use in varying mining conditions. For instance, the interface friction that results from wedging a CMU stopping during construction plays a substantial role in its ability to resist both lateral and vertical loads. Although they are not intended for ground support, the study showed that block stoppings can resist vertical loads of at least 2,700 to 3,000 kN. Asymmetric loading of a stopping may result in localized failure of blocks within a stopping, which, depending on the severity, can be a precursor of impending stopping failure. In addition to measurement results and implications, the paper will also present details of field measurement methods used to assess stopping response. Stopping stiffness and material strength characteristics will also be presented.

By David C. Oyler

Few studies have specifically measured and documented the large-scale loading behavior and durability of ventilation stoppings to mining induced movements, particularly from longwalls. Ventilation stoppings are more commonly the concern of ventilation engineers, and ventilation, topping response to ground movement has only been documented in an incidental manner. This paper presents the investigations of underground measurements that have been conducted to determine the loading response of stoppings constructed from lightweight aggregate concrete masonry units (CMU). These investigations have produced some interesting results that may prove beneficial, not only for developing and assessing alternative stopping construction techniques, but also for designing and selecting standard construction methods for use in varying mining conditions. For instance, the interface friction that results from wedging a CMU stopping during construction plays a substantial role in its ability to resist both lateral and vertical loads. Although they are not intended for ground support, the study showed that block stoppings can resist vertical loads of at least 2,700 to 3,000 kN. Asymmetric loading of a stopping may result in localized failure of blocks within a stopping, which, depending on the severity, can be a precursor of impending stopping failure. In addition to measurement results and implications, the paper will also present details of field measurement methods used to assess stopping response. Stopping stiffness and material strength characteristics will also be presented,

Jan 1, 2001

By Dongwook Kim

Recently, load and resistance factor design (LRFD) is gradually being adopted internationally in geotechnical design due to the advantages of LRFD over the existing allowable stress design (ASD). LRFD is a more advanced design method compared to the ASD because resistance factor is calibrated based on the reliability analysis for a given target reliability index. Target reliability index changes with the importance of the structure. Typically, target reliability index of offshore foundation is less than those of onshore. The widely-used Imperial College Pile (ICP) design method is used for the calculation of pullout capacity of driven piles. The uncertainties regarding pullout capacities of driven piles are assessed using the statistical data reported in the literature. The first-order reliability method (FORM) is used to calibrate resistance factors for the pullout ultimate limit states of the driven piles for three different levels (2.5, 3.0, and 3.5) of target reliability index. The load factors used in this paper are the ones proposed in the AASHTO LRFD bridge design specifications.

Jan 1, 2010

By Silas C. Nichols, Jennifer E. Nicks

"Limit states design (LSD), or load and resistance factor design (LRFD), is a method to account for the uncertainty in loads and resistance through a reliability calibration that requires all applicable limit states (strength, service and extreme) to be checked during foundation design. LRFD has been in use internationally for several decades; however it wasn’t until recently that engineers working on highway projects were required to use the method for the design of highway bridges and other appurtenances. Although the bridge community has been using a form of limit states design for structural components since the early 1970s, the design of foundations for bridges, walls and other geotechnical features had long been performed using allowable stress design (ASD), whereby all uncertainty in loads and material resistance is combined in a single factor of safety. While the move to LRFD was viewed as a more rational approach for the design of bridges and structures, the transition to its use for geotechnical engineering has been met by many with confusion and difficulties in application. This article will revisit the history of transition from ASD to LRFD for geotechnical engineering, summarize the status of the transition and issues with its use, and briefly discuss some emerging research opportunities for improving and advancing the design platform.Background and HistoryUntil about a decade ago, foundations and substructures for bridges were traditionally designed using ASD, while the superstructure was designed using load factor design (LFD), a precursor to LRFD that incorporated factored design loads but no risk assessment. This combination led to uncertain and incompatible safety margins in design for the various bridge components. In 1986, the American Association of State Highway Transportation Officials (AASHTO) Subcommittee on Bridges and Structures (SCOBS) concluded that the standard bridge specifications in use at the time for U.S. transportation projects had significant inconsistencies and gaps, wasn’t up to date with emerging technology and that the development of new specifications was warranted. The proposed solution by the subcommittee was to transition to a more coherent method of design where applicable failure and serviceability conditions could be evaluated considering the uncertainties associated with loads and resistance."

Jan 1, 2015

By Stephen P. Signer

This paper presents an overview of laboratory and field tests on approximately 250 fully grouted roof bolts instrumented with strain gauges in order to study loading behavior. Laboratory work included pull tests, time-dependent tests, and shear tests. The field tests were conducted in 14 different mines extracting different commodities. However, because of the focus of this publication, only the results of tests in 9 coal mines are reported here. In the field tests, all but 14 bolts were loaded by rock movement; these 14 bolts were tested using pull gear. The variables studied included anchorage length, mechanical interlock, time-dependent behavior, shear, installation load, loading rate, and maximum load level. Such information will improve the understanding of the behavior of resin-grouted bolts, which in return will enhance the safety of miners by reducing the occurrence of rock falls. The influences of geology, overburden depth, entry width, mining-induced stresses, and bolt spacing are not described.

Jan 10, 2000

By Nic Slatalla

Resin anchored rock bolts are an effective tool to control the deformation of an underground opening because they combine high support capacity with fast installation. However, there are still numerous shortcomings concerning the understanding and interaction of the system bolt-resin-rock. Field and laboratory test series have been conducted for evaluating the load capacity and bond strength of resin grouted rock bolts in different host rocks under axial load. This paper describes that the behavior and shear strength of the system bolt-resin-rock depends on the rock type and discusses a simple correlation between peak shear strength and shear stiffness in the ratio 1:1000 which may moreover be helpful for estimating rock bolt capacity after installation.

Jan 1, 2006

By T. M. Klemetti, T. J. Batchler, T. J. Matthews

"From 2011–2016 there were 1,511 documented injures, including 7 fatalities, from ground falls in U.S. underground coal mines. The majority of these ground fall injuries were not caused by a major roof collapse, but from falls of smaller rocks from the immediate roof. Roof screen can significantly reduce the number of these injuries and has been widely utilized in underground coal mines for surface control. Because of the potential of reducing ground-fall injuries, the National Institute for Occupational Safety and Health (NIOSH) is further evaluating the performance characteristics of welded wire screen as used in underground coal mines by conducting a laboratory testing program at the Mine Roof Simulator (MRS) in Pittsburgh, PA. The load-displacement characteristics of a 2.4-m x 3.7-m panel of 8-gauge welded screen were evaluated using a newly designed, large laboratory screen test frame with multiple load pull locations. This screen was tested in a configuration that simulates current installation practices in U.S. coal mines. In this study, the effects of displacement loading rate, load pull surface geometry, and the inclusion of roof channel on the screen performance were evaluated. Ultimately, the type of information obtained in this and similar studies can be used to aid in developing wire roof screen design criteria and to assist mine operators in the selection and use of roof screen in underground mines. INTRODUCTION Over 1,500 injures, including 7 fatalities, occurred from 2011–2016 from ground falls in U.S. underground mines with the majority of these ground-fall injuries caused by falls of smaller rocks from the immediate roof. Various controls are currently being used in mines to control this surface rock, including the use of wire roof screen. In mines where wire roof screen has been installed, injuries from rock falls have been reduced dramatically (Robertson and Hinshaw, 2001). Roof screen has the potential to prevent hundreds of injuries caused by the fall of small rocks between permanent roof supports (Comptonet al., 2007). Because of this potential for reducing ground-fall injuries, the National Institute for Occupational Safety and Health (NIOSH) is evaluating the performance characteristics of welded wire screen as used in underground coal mines by conducting a laboratory testing program at the Pittsburgh Research Laboratory (PRL)."

Jan 1, 2018

By Dennis R. Dolinar

Screen material in the form of welded wire mesh and geogrids are used in underground coal mines to prevent the fall of small pieces of rock from the roof between roof bolts. Further, if the screen is installed during the production cycle, roof fall injuries can be reduced significantly. Therefore, the National Institute for Occupational Safety and Health (NIOSH), because of the safety implications, conducted an evaluation of screen materials commonly used in U.S. coal mines to determine their support characteristics and identify the parameters that could affect their performance with respect to controlling the fall of rock from the roof surface. To evaluate the load and stiffness characteristics of the screen, a test frame was designed and installed in the Mine Roof Simulator (MRS) at the NIOSH Pittsburgh Research Laboratory (PRL). With this test set up, the screen is bolted at four corners of the frame and a center load is applied. The test set up allows for up to 20 in of screen deflection while the load and screen defection are continuously recorded. A series of tests were conducted to evaluate the effects of various parameters such as bolt tension, the type of load bearing surface and the size of bearing plates on welded screen performance. The most common screen material used in U. S. coal mines is an 8-gauge wire welded in a 4-by-4-in spacing or aperture. The peak screen load was normally limited by wire breakage. The conditions at the bearing plate influence the nature of the wire breakage. However, the screen stiffness was controlled by slippage at the bearing plates, and by weld and wire failure. The size of the bearing plate had a significant effect on the performance of the welded screen. Therefore, the design capacity of the 8-gauge screen is evaluated based on plate size. For a 6-by-6-in bearing plate the average peak load is 2,900 lb with a stiffness of 250 lb/in. For an 8-by-8-in bearing plate, the average peak load is 4,500 lb with a stiffness of 430 lb/in. These test results are based on a 4-by-4-ft bolt spacing. A geogrid mesh was also tested.

By Dennis R. Dolinar

Screen material in the form of welded wire mesh and geogrids are used in underground coal mines to prevent the fall of small pieces of rock from the roof between roof bolts. Further, if the screen is installed during the production cycle, roof fall injuries can be reduced significantly. Therefore, the National Institute for Occupational Safety and Health (NIOSH), because of the safety implications, conducted an evaluation of screen materials commonly used in U.S. coal mines to determine their support characteristics and identify the parameters that could affect their performance with respect to controlling the fall of rock from the roof surface. To evaluate the load and stiffness characteristics of the screen, a test frame was designed and installed in the Mine Roof Simulator (MRS) at the NIOSH Pittsburgh Research Laboratory (PRL). With this test set up, the screen is bolted at four corners of the frame and a center load is applied. The test set up allows for up to 20 in of screen deflection while the load and screen defection are continuously recorded. A series of tests were conducted to evaluate the effects of various parameters such as bolt tension, the type of load bearing surface and the size of bearing plates on welded screen performance. The most common screen material used in U. S. coal mines is an 8-gauge wire welded in a 4-by-4-in spacing or aperture. The peak screen load was normally limited by wire breakage. The conditions at the bearing plate influence the nature of the wire breakage. However, the screen stiffness was controlled by slippage at the bearing plates, and by weld and wire failure. The size of the bearing plate had a significant effect on the performance of the welded screen. Therefore, the design capacity of the 8-gauge screen is evaluated based on plate size. For a 6-by-6-in bearing plate the average peak load is 2,900 lb with a stiffness of 250 lb/in. For an 8-by-8-in bearing plate, the average peak load is 4,500 lb with a stiffness of 430 lb/in. These test results are based on a 4-by-4-ft bolt spacing. A geogrid mesh was also tested.

Jan 1, 2006