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By E. R. Mueller

The natural lives of machines and components vary tremendously! Maintenance managers struggle constantly to maximize their equipment lives while minimizing their maintenance costs, but they normally lack the tools and techniques they need to do this properly. This paper proposes a methodology based on probabilities of failure and expected values for repairs that recognizes the variation among individual machines and components as well as the high costs associated with catastrophic failures. It enables a user to determine the optimum change-out intervals for many types of equipment. The approach proposed here is sophisticated enough to be reliable but simple enough to be applied by the maintenance staff on the shop floor. It will complement existing preventive and predictive maintenance programs.

Jan 1, 1995

By A. R. Rule

As part of the Federal effort to help maintain an adequate supply of fertilizer minerals, the Bureau of Mines is conducting research to characterize complex, low-grade western phosphate rock and to develop methods for economic recovery of phosphate. The rock varies from soft, friable, altered phosphatic shale to hard, tightly cemented, unaltered phosphate rock. To supplement current beneficiation by sizing, a flotation procedure was devised that included depression of phosphate minerals with H2SiF6 and anionic flotation of carbonate minerals, followed immediately by cationic flotation of silicate minerals. Application of the procedure to several different ores resulted in phosphate concentrates that ranged from 28 to 31 pct P20S in grade and from 60 to 70 pct in phosphate recovery.

Jan 1, 1977

By Rei Arai, Yuta Yamamoto, Tetsuo Yamazaki, Naoki Nakatani

"Methane hydrate is of interest as an alternative energy resource in Japan and the R&D program has been ongoing for ten years (MH21: http://www.mh21japan.gr.jp/english/). Rare-earth element-rich deep-sea mud (REE Mud) is also of interest as an alternative resource in Japan and an exploration program has been launched in 2013.For methane recovery from the hydrate, a depressurization method pumps up water in a production well and has been successfully applied in field production tests (MH21: http://www.mh21japan.gr.jp/english/). However, micro-bubbles, which appear in the hydrate dissociation and water recovery processes may present an environmental issue. It may stick on clay and silt particles that accompany the recovered water, and may disturb settling of the particles in the water separation tank. For exploitation of REE Mud, an air-lift system has been proposed in the feasibility study (Abe et al., 2012). The same micro-bubble issue is expected during the air, water, and mud particle separation processes. In this research, the authors conducted a preliminary tank experiment for clarifying the effect of micro-bubbles on settling behavior of fine kaolinite particles. The behavior was continuously recorded by a still camera and the images were analyzed by the gray scale intensity. From the results the authors found a suspension effect for the settling of fine particles as the result of micro-bubbles. The effect should be studied in detail for preventing some serious environmental impacts during deep-sea mining."

Sep 1, 2014

By James Wonneberg, William Edgerton

"Today’s underground construction megaprojects are tremendous feats of engineering on a massive scale, excavating through ground conditions once thought impossible, using new and innovative contracting practices. But one important truth remains unchanged; projects are built by people. What separates winning projects from the rest? Great people, working in great organizations. In straight-talk fashion this paper sets forth fundamental differences between good project leaders and bad ones, on topics ranging from client relations, design management, and scheduling, to use of the whiteboard, and everything in between. Broadly applicable to all corners of project delivery, this paper will resonate with project leaders from around the world and help identify skills necessary to succeed in the management of underground facilities. A NOTE FROM THE AUTHORS This is a training document, and not really a “paper” per se. We have attempted to tackle some big and potentially complex topics using bite-sized paragraphs, each of which are intended to promote thoughtful introspection and dialog. So please feel free to skip around, or even set this document down while you reflect on your own personal experiences, tactics, and philosophies. We have found that providing examples of “what not to do” is oftentimes more instructive than simply listing “what to do”, hence the Good/Bad format of this document. Please note that “PM” refers loosely to anyone on the project management team not just the “Project Manager”. We also wish to preface this with the following cautionary statements: • The authors do not pretend to be the “Good PM” in all cases. In fact, we’re almost certainly the “Bad PM” for some. We aim to improve on those areas. • It has been said that “The only real training for leadership is leadership.” (Antony Jay) We all started somewhere, and nobody has 20 years of experience on day one. • Converting this text into some sort of prescriptive checklist would be a disservice to the evolution of project management. Our world – and our awareness of it – is constantly changing. We must always be open minded to new ideas and different perspectives on project delivery."

Jan 1, 2016

By Paul H. Johnson

Heap leaching is a simple means of recovering copper from oxide and oxide-sulfide ores. Although this method requires relatively low capital investment, it suffers from low copper recoveries and relatively high acid consumption. The objectives of this study were (1) to determine what factors influence these shortcomings, and (2) to establish a basis of correlation. between laboratory and field testing. The principal methods of leaching copper ores at the present time are heap, dump, in-place, and vat. A number of references are presented in the bibliography on the theoretical and practical aspects of these methods. In the heap-leaching method, crushed or uncrushed oxidized copper ore is placed on a prepared drainage pad. Acid leach solutions are dis¬tributed over the top of the heap, caused to percolate downward through the ore bed by gravity, and are drained from its base. The leach duration is generally a matter of a few months. Dump leaching is used to recover copper from very low-grade oxide-sulfide pit-waste materials. Here again, leach solutions are, percolated downward through a heap. However, in this method, little or no acid is added to the leach liquors, prepared drainage pads are not used and the leaching cycle is generally measured in terms of several years. Leaching agents are usually autogenously generated by the breakdown of sulfide minerals within the dump.

Jan 1, 1970

By R. Fedors, T. Ghezzehei, D. Or

The phenomena of dripping into cavities (e.g. tunnels and drifts) within an unsaturated fractured porous medium under ventilated conditions is studied to improve estimates of dripping rates, drop sizes, and chemical composition of droplets that could affect the integrity of high-level nuclear waste packages placed in drifts. The sensitivity of dripping rates and water chemistry to ventilation is analyzed at various flow rates using analytical expressions linking flow on fracture surfaces to drop formation and evaporation. The model was tested using laboratory experiments involving machined aluminum slabs designed to represent a simplified morphology of a fracture face intersecting a cavity and using natural fracture surfaces from a welded tuff. Comparison with ten years of data on dripping in natural caves showed good agreement with model predictions. In particular, for low dripping rates, evaporation due to ventilation leads to larger drop sizes and alters drop chemistry by increasing the concentration of solutes in the drop relative to that in the water flowing on the fracture face.

Jan 1, 2000

By Jan Van Greunen, Mark Vanderzee, David Haug, Geoffrey Hughes, Yiming Sun, Roozbeh Geraili Mikola

"The Sanitation Districts of Los Angeles County is planning to construct a new, approximately 7-mile-long (11.3 km) effluent outfall tunnel to be excavated by TBM and lined with precast concrete segments. Anticipated net operating pressures within the tunnel are expected to approach 3 bar. To counteract joint opening and exfiltration leakage, an approach has been investigated to post-tension the precast concrete tunnel lining with steel tendons. The tunnel alignment crosses several seismically active fault zones, at which installation of steel pipe is proposed as a secondary inner lining to mitigate potential offset displacements. This paper discusses the tunnel lining design approach and methods used to address these unique challenges.INTRODUCTION The Sanitation Districts of Los Angeles County (Sanitation Districts) is planning to construct a new 18-foot-diameter (5.5 m), approximately 7-mile-long (11.3 km) tunnel from the Joint Water Pollution Control Plant (JWPCP), located in the City of Carson, to the existing White Point outfall manifold structure at Royal Palms State Beach (RPSB) (Figure 1). The project is part of the Sanitation Districts’ Clearwater Program, which will improve overall system reliability through the repair and replacement of the existing aging infrastructure. The existing system includes two 6-mile-long (9.7 km) tunnels, 8- and 12-feet in diameter (2.4 and 3.7 m), and four ocean outfall pipes with a maximum capacity of approximately 675 million gal/day (MGD) (2.6 billion L/day). Addition of the new parallel tunnel will increase overall capacity to accommodate peak wet weather wastewater flows of up to 1,262 MGD (4.8 billion L/day) and will allow inspection and repair of the existing tunnels. The new outfall tunnel will be excavated using a pressurized face tunnel boring machine (TBM). Shafts at the north (JWPCP Shaft) and south (RPSB Shaft) ends of the proposed alignment will connect the tunnel to the existing wastewater treatment plant and existing ocean outfalls manifold and during construction act as launch and receiving shafts for the TBM. The tunnel will be excavated from north to south as a single heading."

Jan 1, 2016

By W. M. Luff

Introduction The Brunswick No. 12 mine is located about 27 km (17 miles) southwest of Bathurst, New Brunswick. The deposit is a stratiform massive sulfide deposit occurring in a series of sedimentary and volcanic rocks of the Tetagouche Group. These rocks are generally considered to be Ordovician in age. Ore reserves at Brunswick No. 12 are 104 Mt (115 million st) grading 3.72% lead (Pb), 9.01% zinc (Zn), 0.32% copper (Cu), and 97.9 g/t (2.8 oz per st) silver (Ag). Production in 1984 was 3.5 Mt (4 million st) at 3.57% Pb, 8.91% Zn, 0.32% Cu, and 100 g/t (2.9 oz per st) Ag. Total payable silver production that year was 211 t (6.8 million oz). This made Brunswick one of the largest silver producers in Canada. Bathurst-Newcastle area and Brunswick Mining Interest in the Bathurst area was aroused in 1897 when W. Hussey discovered an iron formation at Austin Brook, just south of Brunswick No. 6 deposit. This area, and the current No. 6 area, was explored from 1897 to 1907. Iron ore was mined at Austin Brook from 1907 to 1913 and from 1942 to 1943. Any occurrence of sulfides was overlooked until 1952. In 1952, M. J. Boylen Enterprises investigated the small sulfide body associated with the Austin Brook iron formation. Other electromagnetic anomalies associated with the iron formation were investigated. The No. 6 deposit was found late in 1952, when hole B12 intersected 97.5 m (320 ft) of massive sulfides. The No. 12 deposit, 10 km (6 miles) to the north, was found in 1953. More than 30 massive sulfide deposits have since been identified in the Bathrust area. In the 1950s, St. Joe Lead Co. did extensive test work on the No. 6 and No. 12 deposits, including shafts at No. 12, lateral development at No. 12, and testing at both deposits.

Jan 10, 1986

By F. Stanley, A. Noble, G. Luttrell

"The supply chain for coal-fired power stations involve a multi-stage network of mining units, preparation plants, blending facilities and transportation systems. Attempts to optimize the supply chain have historically been difficult due to the lack of communication/coordination between the various groups involved in coal production, transportation and utilization. In light of this issue, a new approach for globally optimizing the coal supply chain called Micro-Price Optimization has been developed to simplify the optimization problem and to provide coal producers with fundamental insight needed to improve the profitability of their operations. This fundamental concept assigns unit values to each particles (or groups of particles) passing through production units. Optimization occurs whenever the maximum tonnage of positive value particles are recovered and passed to market, while the minimum tonnage of negative value particles are recovered. Elements considered by the concept include factors such as target boiler cost/efficiency, waste disposal costs, coal quality parameters, emission penalties, transportation charges, or other quantifiable impact factors. This article reviews the basis for the micro-price concept and provides a detailed industrial case study involving the determination of optimum coal qualities that need to be supplied by mine operators to feed a coal-fired power station. INTRODUCTION The performance of coal preparation plants have long been known to play an important role in determining the overall profitability of mining operations. This significance is due to the fact that the misplacement of just 1 ton/hr of clean coal to reject resulting from poor plant performance can represent nearly $300,000 per year in lost revenues for a mine producing a steam market coal (i.e., 1 ton/hr x $50/ton x 6,000 hr/yr = $300,000/yr). This loss can be even more pronounced, occasionally approaching $1 million per year for each 1 ton/hr of misplaced clean coal, for operations producing high-quality coking coal products sold into the premium metallurgical market (i.e., 1 ton/hr x $150/ton x 6,000 hr/yr = $900,000/yr). Detailed economic studies indicate that improvements in plant yield resulting from increases in organic efficiency have one of the largest overall impacts on mine revenue when compared to other cost centers within the mining operation. One of the first studies to show this important financial impact was reported by Norton-Hambleton Consultants (Norton, 1979). Their study indicated that an unfavorable change in plant efficiency was second only to coal transportation in terms of its impact on profitability, while an unfavorable change in the cost of underground mining was a distance third. This longstanding realization has continued to provide a strong financial incentive for coal producers to optimize the separation efficiency of their coal processing and blending operations."

Jan 1, 2015

By D. Kwietnewski

The 4th bore of the Caldecott Tunnel is a 50-ft horseshoe shaped highway tunnel located in the hills east of Oakland, California. Tunnel excavation was mostly completed using one of the world?s largest commercially available roadheaders, a Wirth T3.20. The geologic profile included seven different geologic units, which displayed a range of different behavior with regard to excavation and initial support. Following a brief introduction to the excavation and support methods, this paper will discuss roadheader performance in the various geologic units encountered during excavation. Comments will also be made concerning the relationship between the roadheader method of excavation and observed ground convergence during excavation.

Feb 27, 2013

By M. R. Yalamanchili

Recently, noequilbrium electrokinetic measurements using laser-Doppler electrophoresis were reported by Miller et al. (1992) for alkali halides and the sign of their surface charge thus determined. These results are generally as expected from simplified lattice ion hydration theory with KCI, under normal circumstances, being the most significant exception. In this regard, lattice defects (F centers and oxygen imperfections) have been found to influence the surface charge of KCI and its electrophoretic mobility. In particular, the presence of oxygen defect states in the crystal lattice has been found to be responsible for KCI's unexpected behavior. The concentration of oxygen defect states in KCI, as characterized by UV/Vis absorption, was varied in order to study their influence on the electrokinetic behavior and subsequently on the flotation response of KCl. At low oxygen contents « 60 ppm) KCI is positively charged as expected from lattice ion hydration theory. However, typically, KCI contains substantial oxygen (>300 ppm) sufficient to impart a negative surface charge which accounts for the selective flotation of KCI from NaCl by hetero-coagulation with oppositely charged alkyl amine hydrochloride collector colloids.

Jan 1, 1994

By R. F. Yap

Although laboratory studies of tin flotation have been reported as far back as the 1920`s(1), the commercial application has only been realized within the past few years(2,3). The principal technical difficulty in the application of the process to tin ores has not been in the flotation of cassiterite itself, this mineral being readily recoverable with the common collectors, including xanthates with heavy metal ion activation(2). The difficulty has been with the depression of the gangue minerals commonly associated with tin ores, and to a lesser extent with the problems of collector consuming semi-colloidal minerals which are in some cases present. The application of sulfosuccinamate collectors to flotation of cassiterite from the Catavi, Bolivia, slime tailings has recently been described(3). The investigation which led to this successful process development included studies of other samples of gravity plant tailings as well as of lode tin ores. A common flowsheet with few significant variations was applied to most of these ore samples with acceptable results. In the following the process is described and the results of its application to samples from Bolivia and elsewhere given. Among the factors considered are: gangue depression, particle size and slime effects, and reagent and pulp density levels.

Jan 1, 1971

By S. S. Klima, H. Jiang, T. W. Beck, Y. Zheng

Researchers at the National Institute for Occupational Safety and Health (NIOSH) performed a series of lab tests to evaluate the respirable dust removal capacity of an industrial air-cleaning fan. Limestone and coal dust were tested separately in NIOSH’s full-scale drill table simulator at the Pittsburgh Mining Research Division (PMRD). Gravimetric samplers with Dorr-Oliver Cyclones and 37-mm filters were used at two upstream and four downstream locations inside and outside of the drill shroud chamber. There were six tests performed for both the limestone and coal dust experiments. In the limestone tests, an average respirable dust concentration of 98.86 mg/m3 was achieved upstream of the air-cleaning fan. The filter results show that the averaged respirable limestone dust reductions were 7.84%, 8.81%, 10.94%, and 18.02% at the four sampling locations downstream of the fan. In the coal tests, upstream samplers achieved an average of 129.03 mg/m3 of respirable coal dust. The averaged dust reductions were 9.54%, 9.83%, 18.54%, and 19.21% at the four downstream sampling points. The results indicate limited cost benefits of using this technology because of the relatively low dust reductions determined from this laboratory study.

Feb 1, 2023

By B. Caro Vargas

The Toulon South Tunnel in France is the second part of a project started 20 years ago. After the problems and delays suffered during the construction of the North Tunnel, due to a complex geologic context of highly fractured and soft rocks under a highly urbanized environment, a very dense automatic monitoring system was implemented to control the settlements of surface (more than 1000 points), the structures adjacent to the tunnel alignment and the underground galleries being constructed. The latest automatic instrumentation systems were installed, using for example AMTS capabilities in terms of ?automatic prismless settlement monitoring?. All the data (geotechnical, structural and geological) was gathered in a global automatic data acquisition system and continuously available on a web based interface. Three different threshold levels (notification, anomaly, alert) were set up, each one with a differential and an absolute value for settlements. Depending on the actual geological site conditions and the actual monitored settlements, different supporting systems and excavation techniques were used. Furthermore, the monitoring data was also used to predict and anticipate the future settlement, by comparing it continuously with the theoretical Peck settlement curves. This method allowed a better risk management by limiting the settlement on existing structures and helped to secure the Works progress schedule, for a project that lasts from July 2007 to March 2011. The implementation of this observational method application is presented in this paper.

Jan 1, 2012

By Dr. Ing. Hermann Boldt

The Bituminous Coal Mining Industry of the Federal Republic of Germany produces nearly 100 million t/yr of clean coal. The largest coal mining area is the Ruhr District with dimensions of 100 x 40 km (65 x 25 miles). Figure 1: Here is the general administration of Ruhrkohle Akteingesellschaft RAG with its three divisions. Other coal mining areas in Germany are the Saar District and the Aachen District. Ruhrkohle produces 70 million t/yr of clean coal. The company operates 28 mines in the Ruhr District with an average raw coal production of 18000 t/day. Their average mining depth is 831 m (2740 ft.) and the average seam thickness is 177 cm (70 in.). Figure 2: Preparation plant reject is 44.6%. All following production figures will be with reference to raw coal because the raw coal production is the technically relevant number. Mining operations are mainly in non-dipping coal deposits whereby mechanized equipment for flat seams is also applied to deposits dipping up to 45? Coal extraction is done exclusively by the longwall method. Approximately 200 longwall installations are in production at any time. The average longwall length is 221 m (730 ft) ranging between 140 and 290 m (460 ft and 960 ft). The average longwall advance of all operations is 2.8 m/day (8.4 ft per day). Average production

Jan 1, 1977

By Paul Headland

The Washington Suburban Sanitary Commission (WSSC) has recently completed design for the Bi-County Water Tunnel Project. The project will include a 10-foot diameter, 5.3-mile long hard rock tunnel located within the Piedmont Physiographic Province in Montgomery County, Maryland. The rock formations present along the alignment are comprised of igneous and metamorphic lithologies. This paper presents the steps taken to characterize the complex geology along the tunnel alignment into a single ?Engineering Unit? based upon the intact rock and rock mass properties. The Rock Mass Rating (RMR) system is planned to be used as the basis for dividing the ground into three ?Excavation and Support? classes. This RMR approach was selected to establish contractual baselines as presented in the Geotechnical Baseline Report (GBR) and is intended to facilitate management of the ground support characterization during construction.

Jan 1, 2008

By Henry E. Keniston

In every business today costs come under almost microscopic scrutiny. It's hard to conceive that less than 30 years ago there was no such cost consciousness apparent in overall industry. Railroads, through their almost absolute monopoly on freight handling, were one of the industries where little thought was given to overall costs. True regulation kept rates in line, but railroads did very little in the area of supplying equipment intended to help the shipper minimize his costs and at the same time result in savings to the rail carrier. During this period, except for isolated cases, railroads placed standard cars for loading. Most railroad car fleets consisted of box cars, hopper cars, flat cars and low side gondola cars certain roads having unique movements developed special cars to accommodate the particular product, but seldom did these cars move in general interchange service. Most of you are aware that several large companies built railroads of their own as an integral part of raw materials handling from remote sources to production plants located near concentrations of usage. On these railroads special cars were built with little thought to inter-change service. Examples of such railroads are the Duluth, Missabe and Iron Range, the Elgin, Joliet and Eastern, the Union Railroad, the Bessemer and Lake Erie and the Birmingham Southern.

Jan 1, 1972

By R. L. Howell, L. C. Atkinson

Typical sedimentary sequences overlying coal seams consist of interbedded sandstones, siltstones, shales, and rider coal seams. In many surface coalmine settings, these sediments are saturated; and prior dewatering of them is necessary for effective and economic mining, including the stacking of saturated spoils. Such sedimentary sections usually have a very low vertical hydraulic conductivity that does not allow them to drain in a timely manner prior to their being stripped. One potential solution is installation of drainwells. Drainwells are small diameter wells that can collect water laterally from the various more permeable layers in the overburden and then gravity drain it to a lower layer – often the coal seam being mined – where it can be removed by pumping wells or sumps located in the bottom of the pit. A ground-water flow model utilizing the 3-dimensional finite element code MINEDW has been used to evaluate the effectiveness of usingdrainwells in a hydrogeologic setting that is typical of the Powder River Basin. A series of numerical simulations were completed using various combinations and spacings of drainwells and pumping wells to dewater the overburden and coal seams. The numerical simulations suggest that drainwells can be a very effective method of overburden dewatering.

Jan 1, 2000

By C. L. Schneider

The problem of predicting the liberation spectra produced by a closed continuous grinding circuit is of fundamental importance for the design, optimization and control of most operations in an ore dressing plant. The only known approach through which such a calculation can be performed is the population balance model equation. The latest and certainly most significant progress made in this area is the solution proposed by King (1990), which requires one textural parameter that can be measured directly from the ore being studied. The main advantage of King's solution is that it does not require the estimation of hundreds of arbitrary parameters that cannot be independently measured, as required by the existing conventional solutions. However, King's solution relies heavily on a knowledge of the detailed internal structure of the Andrews-Milm diagram (Andrews and Mika, 1975). This has never been measured for any ore. The characterization of the internal structure of the Andrews-Mika diagram requires the measurement of the liberation spectra at several progeny sizes produced by the breakage of monosize, monograde particles at several different grades. In this paper, a procedure based on magnetic fluid fractionation for generating seven narrow-size, narrow-grade samples is presented. Each of these samples was then broken into six progeny size classes in an ultrasonic mill. The one-dimensional liberation spectra of each of the 42 progeny and seven parent particle samples were then measured by image analysis. The measured linear-grade distributions are presented in this paper. The calculation of the correspondent volumetric-grade distributions is discussed.

Jan 1, 1994

By Arthur Darby

The city of Kuala Lumpur was founded in 1857 by miners seeking tin near the confluence of the Klang and Gombak rivers. The rapid development of the city and surrounding area since independence has led to more rapid runoff during rainstorms and to gradual canalisation of the rivers with some restricted sections. The outcome has been more frequent and more severe floods (Abdullah 2006). At the same time the centre of Kuala Lumpur has become a modern inter-national city with tall office buildings, hotels, and shopping centres connected by a network of wide roads and commuter rail systems. With these the cost of dislocation during floods has risen as has the cost of making good damage afterwards. The Government of Malaysia considered these consequences unacceptable and sought ideas from the private sector for a solution. Potential solutions consisted of variations on the themes of bypassing the city centre with a flood relief tunnel or of providing off channel storage or a combination of both. Since under Malaysian law a tunnel cannot be constructed under private property unless this is first purchased or agreement reached with the owner, it was necessary for most of the tunnel alignment to run below existing heavily congested roads. After considering these facts Gamuda Berhad and MMC Berhad, two leading Malaysian development and construction companies, decided to propose to Government an innovative solution in which the tunnel would be used to carry road traffic except during floods.

Jan 1, 2008