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By Lance R. Barron

The U.S. Bureau of Mines (USBM) conducted ground pressure analysis of a wide abutment-type chain pillar in a two-entry gate road of a Western U.S. coal mine with an extremely weak immediate roof. About 15 m of fragile, low-strength mudstone lies between the seam and the lowest competent roof member. Three-and two-entry gate road designs with several pillar sizes and various secondary support systems have been employed to improve tailgate-entry stability, with varying results. This report discusses gate road layout and performance and secondary support effectiveness. The results of the pillar pressure study are compared to pillar loading predicted by a widely used pillar design method and to similar studies in other mines. A stability evaluation of the most recent longwall headgate, using the USBM Analysis of Longwall Pillar Stability (ALPS) method, indicates marginal stability in first-panel mining and instability in second-panel mining. The ALPS method and the USBM Coal Mine Roof Rating system are used to evaluate tailgate-mining stability of the previous gate roads and to determine pillar and entry width and top coal thickness criteria for tailgate stability in future panels.

Jan 1, 2010

By R. J. Kuczynski

The U.S. Bureau of Mines Reno Research Center investigated, developed, and patented a high-temperature cyanide leaching process for recovering platinum-group metals (PGM) from automobile catalysts. A batch pilot plant was constructed at the center and operated to demonstrate this technology to industry. Approximately 1,600 kg of used pellet, monolith, and metal support catalysts containing 1,700 g (54 tr oz) of PGM was processed. Forty-five-kilogram batches of used catalysts were leached with sodium cyanide solution at 160°C for 1 h in a countercurrent processing sequence. This selectively dissolved the PGM. Average extractions from the used pellet catalyst were 96 pet Pt, 95 pct Pd, and 73 pct Rh. Average extractions from the used monolith catalyst were 84 pct Pt, 81 pct Pd, and 66 pet Rh. Heating the pregnant leach solutions to 275°C for 4 h destroyed the PGM-cyanide complexes, causing over 99.7 pct of the PGM to precipitate from solution. The PGM precipitate was predominantly a metallic powder concentrate, typically analyzing greater than 50 pct PGM. Heating destroyed the cyanide to less than 0.2 mg/L free and total cyanide. Both the pellet and monolith residues were evaluated for disposal using the toxicity characteristic leaching procedure developed by the U.S. Environmental Protection Agency.

Jan 1, 2010

By J. Kang

Supercritical fluid extraction (SFE) has became an attractive alternative technology to be a new process to recover metal, of which can be substitute the existing Leaching/Solvent extraction processes. Solvent extraction of metallic ions is a technically important and also well-established process that is used in the chemical and hydrometallurgical industries.1 Solvent extraction techniques use the chelation of metallic ions dissolved in liquid solution with organic ligands. Conventional solvent-extraction technique needs large amount of organic solvents and often creates environmental problems.2 More environment-friendly technology is needed nowadays, and there have been increasing attentions to extract metal ions by SFE. CO2 becomes one of the most notable alternative organic solvents due to its nonflammable, nontoxic, nonpolluting, and relatively inexpensive properties with its moderate critical point (73.8 bar, 31.06 °C). Many works have been reported in metal extraction under the supercritical CO2 (scCO2) solvent.3-5 In this study, to recover cobalt from wastes especially from spent lithium ion battery scrap, we selected two ligands ? Cyanex 272 and DEA (diethylamine) for the metal extraction in scCO2. Cyanex 272 is a commercially available extractant along with its series, Cyanex 301 and Cyanex 302. Smart and coauthors measured the metal extracting abilities of these three extractants, and found that Cyanex 301 and Cyanex 302 extracted metal ions much better than Cyanex 272 in the scCO2 solvent.10 The pH of water contacted with high pressure CO2 (70-200 bar, 25-70 oC) is about 2.8-2.95 based on the calculation and the measurement.6-7 Cyanex 272 is known to be less effective as a metal extractant in this low pH environment compared with other Cyanex series. However, when DEA is added to metal extraction reaction with Cyanex-272, DEA works as a strong base to Cyanex 272 converting Cyanex 272 to a deprotonated form (Figure 1), which results in an easy formation of metal complex and the enhanced extraction rate of metal ion.8 Therefore, the purpose of this paper is the metal extraction from spent lithium ion battery waste using scCO2 with Cyanex 272 and DEA.

Jan 1, 2010

By L. Garner McDonald

The U.S. Bureau of Mines, under contract to the U.S. Department of Energy, investigated the erosive-wear properties of seven commercial alloys with potential applications as valves for coal-conversion plants. A dry particle, jet-erosion apparatus was used to determine the wear of seven materials: 316 and 440-C stainless steels, K-68, K-701, and K-801 cemented tungsten carbides, HC-250 white cast iron, and Haynes 6B. The alumina abrasive entrained in the nitrogen gas jet had particle sizes of 27 or 50 µm, the abrasive velocities were 55 to 170 m/s, and the particle impingement angles were 15° to 90°. The maximum specific wear for ductile materials was found to occur at impingement angles of 15° to 30°, and the minimum specific wear occurred at 60° to 90°. For the brittle materials, maximum specific wear occurred at impingement angles of 50° to 85° and minimum specific wear was at the lowest angles. As the velocity and erosive particle size increased, the specific wear increased. The specific wear was related to the velocity by the power function WocAVn, where n was 1.8 to 3.9 for ductile materials and 1.8 to 3.6 for brittle materials.

Jan 1, 2010

By P. Oghazi

It is possible to have traceability in the mining industry, by parameters and signatures like particle mineralogy, mineral association, texture and mineral liberation. The study is on an apatite-iron ore deposit at Malmberget, Sweden, and characterizes an ore body both mineralogically and texturally in a quantitative manner by using analytical methods like optical microscopy, microprobe (EMPA) and an automatic SEM based system, Particle Texture Analysis (PTA). The mineralogy was evaluated by PTA and characterized by modal mineralogy, mineral liberation and mineral associations. Magnetite has a simple outline and straight grain boundaries and the gangue minerals have a finer particle size with a more complicated texture. The PTA analysis also shows that apatite is associated to magnetite as mixed particles, while smaller grains of magnetite are inclusions in feldspar. Result from particle texture analysis shows that there is a connection which link to the mine-to-mill context, and it may be used to create traceability. This link is not the associations of the main ore mineral magnetite, nor the modal mineralogy. Instead, it is the mineral associations of contaminating minerals (apatite and feldspar) that appear to be most promising since they survive from mine to mill. The modal mineralogy may be used to understand how contaminated minerals break into or out of particles size fraction during grinding.

Jan 1, 2010

By A. Spearing

According to a 2000 NIOSH report, about 100 million rock anchors are installed annually in coal mines in the USA. Most coal mines have conditions that are conducive to corrosion of the rock anchor and ancillaries (such as plates), yet the effect of this on the performance of the anchors has not been adequately researched and its effects are not understood or quantified in the USA. There is considerable research into corrosion in civil engineering applications on surface and underground but the corrosion of coal mine rock anchors is not necessarily the same because: ? In underground civil structures, water ingress is usually stopped as part of the construction process. ? Many rock bolts in mines are only partially resin grouted leaving part of the reinforcing member exposed to corrosive conditions. All cable bolts in coal mines are only partially resin grouted. ? Even when mine bolts are fully grouted, shrinkage cracks occur and the rock stresses can change due to adjacent mining that can cause the resin column around the bolt to fracture further under external shear or tensile stresses. Most coal mines therefore have ideal conditions for bolt corrosion.

Jan 1, 2010

The U.S. Bureau of Mines (USBM) has developed a test procedure to compare the initiating strength of detonators by using adjustable-sensitivity liquid explosives. Various tests of detonator strength are currently used by the industry, but many of them do not quantify the ability of detonators to initiate detonation reactions in an explosive charge. The USBM used mixtures of nitromethane and ethylene diamine, the sensitivity being "fine-tuned" by 2-nitropropane. Military standard J-2, commercial No.6, and commercial No.8 detonators were evaluated using three test configurations: (1) axially immersed in the test explosive, (2) tip just touching surface of the explosive, and (3) immersed transversely in the explosive. Markedly different results were obtained for these three configurations, indicating that the directional effects are important. This explains why different detonator strength tests do not correlate well with each other. Some tests, such as the sand bomb and underwater, measure the total energy out-put, while other tests, such as the plate dent, test measure the energy in the axial direction. The USBM's test data indicate the importance of conducting the experimentation in the manner in which the detonator is actually intended to function.

Jan 1, 2010

By Magnus Ericsson

The unexpectedly quick recovery in world crude steel production in the second half of 2009 was due almost entirely to increased production in China that began in late 2008. Previous peaks in monthly production in China were matched by April 2009. The rest of the world had still not reached pre-crisis production rates by May 2010. Chinese production drives growth, but there has been some growth in most other larger crude steel producing countries as well, compared to production in 2009. If the production rate of the first four months of 2010 continues, the total output of crude steel in 2010 will be somewhere around 1,410 Mt (1.5 billion st), the same as in the record year of 2007.

Jan 1, 2010

By Phil Shelton

What exactly does clean coal mean? Mining coal creates dust and releases methane gas. And burning coal liberates CO2 and emits particulates, including SO2 and NOx. Coal creates wastes that are often stored in unsightly and potentially dangerous slag heaps and lagoons. When clean coal technology is discussed, it sometimes seems that creating modern or ?ultra super critical? coal-fired power stations is presented as the main or even the only answer. However, there may be a more holistic approach. Using the energy potential of coal is always going to have environmental impacts. Some of these will be negative. But the need to secure future energy resources demands that society tackle these negative issues and find ways to minimize and offset them.

Jan 1, 2010

By Omotayo Kalejaiye

The Siwek 20-L chamber is widely used throughout the world to evaluate the explosibility of dusts. This research evaluated the quality of dust dispersion in the Siwek 20-L chamber using Pittsburgh coal, Gilsonite, and purple K dusts. A Pittsburgh Research Laboratory (PRL) optical dust probe was used to measure optical transmittance through the dust cloud at various locations within the chamber. A total of 540 tests were performed, with triplicate tests at five nominal dust concentrations and six locations. The two standard dispersion nozzles (rebound and perforated annular nozzle) were compared. The transmissions corresponding to the normal ignition delay period were used to: (a) determine variations in spatial uniformity of dispersion obtained with both nozzles; (b) make comparisons between the experimental transmission data and those calculated from theory for the three dusts; and (c) make comparisons with transmission data measured in the PRL 20-L and Fike 1-m3 dust explosion chambers. The uniformity of dispersion for the three dusts was similar with both nozzles, despite the differences in nozzle geometry and mode of operation. Transmission data of the three dusts were all significantly lower than those calculated from theory. This was discovered to be, in part, due to significant reduction in particle size that occurred during dispersion. By measuring particle sizes before and after dispersion, values of 60%, 50%, and 20% reduction in particle size (based on the surface-weighted mean diameter) were obtained for Pittsburgh coal, Gilsonite, and purple K, respectively. Transmission data from the PRL 20-L, Fike 1-m3 and the Siwek 20-L chambers indicated comparable results in terms of uniformity of dispersion. However, transmission data from the Siwek 20-L chamber were significantly lower than those of the PRL and Fike chambers. Again, this was attributed, in part, to the significant reduction in particle size that occurred during dispersion in the Siwek chamber. The design of the outlet (dispersion) valve of the Siwek 20-L apparatus charge vessel was largely responsible for the particle break-up. The contribution to particle break-up by the dispersion nozzles and the high level of turbulence in the chamber were found to be minimal. This is a significant finding in that the dust particle size tested for explosibility in the Siwek chamber is considerably smaller than the original dust sample.

Jan 1, 2010

By Joshua R. Omer

A numerical model is developed for predicting the load transfer and settlement behaviour of vertically loaded, bored cast in-situ piles. Based on analysis of full-scale pile tests, closed-form equations are formulated to uncouple the shaft and base transfer resistance components of the pile/soil system. Appropriate parameters are introduced to take into account: (i) the shaft resistance distribution in unlined and partially lined piles, (ii) the effects of ?soft toe? (voided toe pile) behaviour on base resistance development. For convenience, an interactive computer program has been developed in Matlab? with a user friendly interface system. The program can be applied to predict the complete load-settlement curve and axial force distribution in bored cast in-situ piles if reliable soil test data are available. To demonstrate its validity, the proposed method is applied to 4 test piles, which are also analysed using two previously published methods: (a) elastic solution method and (b) layer discretisation method. Methods (a) and (b) above are based on load transfer (t-z) and finite element models respectively. It is shown that the proposed method yields axial force distributions and load-settlement curves that are in good agreement with the observed pile test data.

Jan 1, 2010

By Dan Yang

Pile foundation designs are performed routinely based on geotechnical information available at the time of design, often with due consideration of large uncertainties inherent to soils and site conditions. These uncertainties frequently are the causes of piles being installed not the same as those designed, especially by factors beyond quality assurance and quality control. With a variety of both satisfactory and unsatisfactory pile test results from these nonconforming piles, the design engineers are required to examine the foundation performance as a whole against the project design requirements before signing off on them or calling for potentially costly remediation. Over the years, as-built analysis has been a consistent way of dealing with pile non-conformity and damage in our practice, avoiding many construction delays and it is an integral part of our pile foundation design. In this paper, the key elements of an as-built analysis along with several major bridge projects are presented.

Jan 1, 2010

By Adrian M. Keller

Borehole televiewers are downhole inspection devices available for high-resolution imaging of a borehole wall following rock coring. Borehole televiewers should be considered by geotechnical engineers and geologists as a supplemental way of investigating rock for deep foundations. The optical televiewer (OTV) produces a digital optical image and the acoustic televiewer (ATV) utilizes reflected acoustic waves to produce images of the borehole walls. These devices can be utilized to examine soft or fractured zones in the rock mass, solution features, open joints or other voids not observable from traditional rock coring techniques. These devices along with computer post-processing can determine the strike and dip of joints, bedding planes, shear surfaces, or other structural features, eliminating the need for expensive oriented cores or manned downhole logging. An acoustic televiewer was utilized in the Fall of 2008 during the investigation phase for the I-70 New Mississippi River Bridge (I-70 MRB) in St. Louis, Missouri. Voids and fractures in the upper portion of the rock were described by prior consultants. Further investigation of these features was necessary to evaluate deep foundation options to support the main towers. Ten borings were drilled from a barge in the river at the two main tower pier locations. An ATV was utilized in each of the ten borings to produce images of the rock mass in the borehole and allow further investigation of the voids. Voids interpreted as solution features were readily identified in the ATV logs in multiple borings and at similar elevations, suggesting connectivity. Measurements of the voids? width, location in the borehole and orientation allowed a more thorough understanding of the potential impact the solution features may have on the planned deep foundations. An extensive grouting program was eliminated based on the ATV results.

Jan 1, 2010

By Mohamed A. Sakr

An experimental study on the behavior of pile group's arrangement under lateral load was carried out in the level ground and at crest of sand slope 3H: 2V. Tests were conducted on single pile and pile groups with center-to-center pile spacing of 3D. The model piles were founded in sand with relative density 25%. Several configurations of pile groups were used to study the effect of piles arrangement in the group (series or parallel) with respect to slope crest. The behavior of the pile groups in the level ground was compared with the behavior of pile groups at different configurations at the slope crest. Based on the test results, the behavior of laterally loaded pile groups adjacent to a slope crest depends largely on piles arrangement in the group with respect to direction of the lateral load. Pile groups in the level ground have more resistance to lateral loads when they are arranged in a parallel configuration than in a series, whereas the reverse is true in cases of pile groups constructed near to the edge of a slope. It is advisable to use the pile group in series arrangement for groups constructed at slope crest to minimize the effect of the ground slope on lateral capacity of piles and the occurred deflection and maximum bending moment of the lead row in the group.

Jan 1, 2010

By Brian W. Wilson

A case study is presented that describes the design and implementation of a combined blast densification and deep dynamic compaction program which was undertaken to improve the foundation soils for a proposed tailings dam raise in Ontario, Canada. Based on the results of the geotechnical investigation it was determined that the foundation of the dam would be situated on tailings of both variable thickness and density, much of which would be susceptible to liquefaction under the design earthquake for the region and type of facility. Blast densification trials were completed by the owner and the results of these made available to prospective tenderers in response to a call for a fixed price contract for the design and implementation of a densification program for approximately 800,000 m3 of foundation tailings. The variation in tailings gradation and the impacts of such on the ground improvement program are discussed, as are details of both the additional blast densification field trials completed by the contractor, and the selected blast pattern and explosive charging used for production blasting. The applicability of the various ground improvement techniques to the actual conditions encountered, and the results obtained are also discussed.

Jan 1, 2010

By John C. Ryan

The Emeca Pile Splice, an innovative mechanical prestressed concrete pile splice, is the first robotically welded splice to be fabricated in the United States. An analytical and experimental study was conducted to establish the capacity of the standard splice for 12-in. and 14-in. square piles. The study illustrates compliance of the splice with International Building Code (2006) requirements. A case study for a large petroleum tank foundation project in Port Canaveral, FL is presented, demonstrating the efficiency achieved through use of spliced-piles. For the case-study project, single-piece 18-in.-square, 100-ft-long piles were replaced with 12-in.-square, two-piece, spliced piles. As a result, a significant reduction of material, labor, handling, and equipment was documented for the project. Savings realized on the installed pile cost was estimated to be in excess of 30% by the owner.

Jan 1, 2010

By Mark Koelling

This paper presents a case history of a ground improvement program conducted in a soft soil environment and seismically active region in the northwest corner of Washington State near the Canadian border. The program was performed over several years, and provided adequate soil bearing conditions for the construction of several structures. Completed development includes separate construction of four adjacent structures, each with unique total and differential settlement requirements and built at approximate two year intervals. Site soils consist of 45 feet of loose saturated sand and silt overlying 70 feet of very soft to stiff (N60 = 0 to 7) normally consolidated clay. Adding to the complexity of the site is the owner?s requirement that all existing structures remain open and in service during construction of each subsequent structure. The paper presents the site geotechnical information and the foundation design issues. Details of a combination of ground improvement methods is presented, including stone columns, wick drains, a preload surcharge, and staged construction to provide soil support for shallow foundation construction of all structures at this site. The soil test results and settlement observations are presented along with QA/QC measures. Lastly, a brief method sustainability comment will be made.

Jan 1, 2010

By J.N. Kohmuench

Teeter-bed (i.e., hindered-bed) separators are used throughout the mineral processing industry for both classification and density separation. The high capacity and sizing characteristics of these units make them ideal for feed preparation prior to coarse flotation (+0.100 mm) circuits. Teeter-bed separators are typically easy to control with two basic operating parameters, including fluidization water rate and bed level. However, data show that these two parameters greatly interact with one another. Given this finding, a high-level automatic control scheme was developed and implemented on a full-scale separator. In addition, dialogue with plant operators has led to several simple changes to an already established design that improves operational and maintenance characteristics.

Jan 1, 2010

By Walter Valery, Sarma Kanchibotla

Due to the global financial crisis, the world economy has turned upside down and most major economies in the world are facing severe recession for the past one and half year. During this period most commodity prices have tumbled by more than half from their peaks and such a sudden and severe economic downturn is not seen since the great depression. This sudden drop in commodity prices and lack of credit made many mining operations unviable and even those mines that are marginally viable at this point are operating under severe cost pressures and capital expenditure restrictions.

Jan 1, 2010

By Stephen Mansfield, Johannes Schoeman

In August 2006 a technical alliance was formed between Orica Mining Services and Century Mine to provide blasting solutions. The alliance is in the form of a Rock to Specification (R2S™) service, one of Orica’s Blast Based Services (BBS™). The ultimate goal was to facilitate the rapid expansion of material movement from 26 to 41M m3 (34 to 53M yd3) per annum while maintaining a reliable ore supply to the mill.

Jan 1, 2010