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By D. T. McMurray

INTRODUCTION Shabanie mine, situated some 180 km east of Bula¬wayo, has been a producer of chrysotile asbestos for more than 50 years. The ore bodies occur in serpentinized dunite, which overlies talc-carbonate schist. A zone of relatively competent rock of varying thickness occurs between the schist and the ore bodies, which are gen¬erally less competent. The hanging wall of the ore bodies is economic, and the hanging-wall serpentine carries a variable subeconomic amount of fiber. It is important to note that, in general, the ore body competence is less than that of the foot and hanging-wall formations. Historical After surface operations ceased, cut-and-fill stoping was used to win ore from underground; this was success¬ful until the increasingly stoped-out area caused insta¬bility in the stope pillars and back. Consequently, dur¬ing the early 1950s, a gradual change to cave-mining methods was made, the ore being won by hand lashing in drawpoints, situated in the basement of the stope blocks, and passed through orepasses under gravity to the haulage level some 13 m below. About this time, interest was focused on the sub¬level caving method in use in Swedish iron ore mines: it was felt that it might be applied economically to the Shabanie ore bodies. Accordingly, in 1958, an experi¬mental stope block was laid out in which sublevel inter¬vals and extraction tunnel spacing were 9 m. The tun¬nels (ring drilling drives) were oriented on strike-in contrast to the Swedish system, in which crosscuts that retreat from hanging to footwall are used. The advantages of the method were quickly appre¬ciated by the operating personnel and, despite the in¬evitable teething troubles pertaining to the introduction of any new mining method, it was not long before sub¬level caving was providing a high proportion of the mill feed. The disadvantages also became apparent at an early stage, however, and, from that time to the present, continuing modifications have been made to mining lay¬outs in an effort to improve ore recovery. GENERAL DESCRIPTION OF METHOD The mine is served by a vertical hoisting shaft, in which two skips, a man cage and a service cage, provide adequate capacity for production requirements. The rock hoist is a Ward Leonard control hoist, in which two electric motors drive a common gearbox. The man winder is driven by an a-c motor. Several auxiliary shafts provide secondary egress and intake and return ventilation. Main haulage levels are above (Fig. I a and b). Blasthole fan patterns are drilled by drifters of 100 mm bore, drilling 41-mm holes; when a sufficient strike length has been drilled, a slot is cut in the upper¬most sublevel and the rings are broken into the slot. Initially, a limited tonnage is drawn, since it is essential to ensure that the hanging wall caves behind the retreat¬ing stope face. Once this has been established, maxi¬mum tonnage can be drawn, as described later in this chapter, under the heading "Draw Control." The broken rock is loaded by 0.14 and 0.20-m3 load¬ers into cocopans (rocker-dumping type of tipping truck), which are hand trammed to orepasses, discharg¬ing on the haulage where 11-t electric trolley locomo¬tives haul 3.95-m3 Granby cars to the main shaft bins. As is evident from Fig. 1, the layout is simple, the block is brought rapidly into production, there is a high degree of selectivity and flexibility, and the result is a low-cost high-productivity mining method. DEVELOPMENT Main haulages are developed at 3.2 x 3.2 m, and once the service winze connections have been completed the development of the sublevels is undertaken. The footwall drives are cut first, to obtain access to the block. These ends are of the standard section, 2.4 x 2.8 m, and from them crosscuts at intervals of 70 m are driven through the ore body to the hanging wall. These crosscuts are used to supplement the geo¬logical information previously obtained from diamond core drilling, and they provide additional and more de¬tailed data on fiber percentages and lengths, structural features, and other relevant criteria which are used to build up the geological assessment of the area and to classify it in terms of the geomechanics rock classification (Laubscher and Taylor, 1977). The crosscuts also allow the necessary orepasses to be sited conveniently so that tramming distances from the loading points are not excessive. Development Drilling Once the skeleton development has been completed, the extraction headings are developed at 2.4 x 2.4 m as shown in Fig. 1. Standard development practice is to use crews of a machine operator and his helper, equipped with air-leg mounted jackhammers, to drill rounds of 1.8 m with integral tungsten carbide tipped drill steel. The round drilled is a normal drag round, as shown in Fig. 2, but considerable attention is paid to the drilling of the perimeter holes to use effectively the

Jan 1, 1982

By August V. Castelli

Drilling fluids have changed over the years from water and/or water frequently mixed with local clays to scientifically com- pounded materials (mud). This change has occurred due to changes in drilling methods from percussion to rotary: depth maximum from 21 m in the first oil well to more than 9 000 m; and variety in types of well or hole to gas, oil, water, and mineral exploration. Environmental concerns about the composition of the fluid as to heavy metals and oil on the cuttings has recently caused changes in the materials used in the mud. The drilling fluid should perform the following functions (Darley et al., 1980): 1) Carry cuttings from beneath the bit, transport them up the annulus, and permit their separation at the surface. 2) Cool and clean the bit. 3) Reduce friction between the drilling string and the sides of the hole. 4) Maintain the stability of uncased sections of the borehole. 5) Prevent the inflow of fluids-oil, gas, or water-from permeable rocks penetrated. 6) Form a thin, low-permeability filter cake which seals pores and other openings in formations penetrated by the bit. In addition to these, the fluid should: 1) Not injure drilling personnel nor be damaging or offensive to the environment. 2) Not require unusual or expensive methods of completion of the drilled hole. 3) Not interfere with the normal productivity of the fluid- bearing formation. 4) Not corrode or cause excessive wear of drilling equipment. A number of industrial minerals, chemicals, and other materials are used as additives in the drilling fluid to accomplish these functions. Industrial minerals make up the highest percentage of the additives in a drilling fluid. Drilling fluids are classified according to their principal components: water, oil, and gas. If the major component is either water or oil, the component along with the suspension of solids, cuttings and additives is referred to in the trade as a mud. The largest use of some industrial minerals, such as barite and bentonite, is in drilling muds. For other materials, such as gypsum and limestone, drilling usage is only a small percentage of total demand. RAW MATERIALS [Table 1] lists the industrial minerals used in drilling fluids, their form, specifications, and uses. Each raw material will be discussed as to its mineralogy, physical and chemical properties, and the location of major deposits with respect to drilling fluids. Attapulgite Attapulgite is a crystalline hydrated magnesium silicate clay mineral, prized for its viscosity in saline waters. The particles are needle-like rather than the platelets common to most clay minerals. The specific gravity is 2.5 and the Mohs hardness is 1 to 1.5. Attapulgite is one of the materials sometimes referred to as fuller's earth. The major producing areas in the United States are southern Georgia and northwestern Florida. It also is mined in Spain, Senegal, the Republic of South Africa, Turkey, India, and Australia. Barite Barite is crystalline barium sulfate. It has a high specific gravity for a non-metallic mineral, 4.5 when pure, and is used as a weighting agent. Generally, the specific gravity ranges from 4.20 to 4.35. It is relatively soft with a Mohs hardness of 3 to 3.5 and is not very abrasive. Barite is inert, non-toxic, and clean to handle. Common contaminants are quartz, iron minerals, gypsum, and calcium carbonate. If there is considerable gypsum in the barite, it will thicken the mud. The major deposits in the United States are in north central Nevada, near Battle Mountain. The major producing countries, other than the United States, are China, India, Mexico, the former USSR, Turkey, and Morocco. The major deposits in India and Nevada, and some in China, are stratiform, commonly quite pure bodies in bedded sedimentary rocks.

Jan 1, 1994

By Yu. A. Polozov, V. A. Lagunov, O. Yu. Lushinkova, Yu. I. Svirskiy, Eh. Ya. Kipko, Roy A. Williams

6.1 PRINCIPLES OF PLANNING GROUTING OPERATIONS FOR SHAFTS, DRIFTS AND TUNNELS The planning of integrated grouting of vertical, inclined or horizontal underground workings in saturated, fractured rock includes the following phases: 1. Planning for the collection and analysis of geological information concerning the characteristics of the struc¬tural deformation(s) that produced the details of the frac¬ture system being studied. 2. Planning for the acquisition of initial hydrogeological information produced by the flowmetric and hydrody¬namic investigations (described in Chapters 2 and 3). 3. Computing the initial engineering calculations of the ex¬pected or planned dimensions of the isolation curtains for each water-producing stratum (fracture zone) and the expected areal spreading pattern of the grout in each of these water-producing horizons. The selection of the lo¬cations, the initial optimal number of holes and the vol¬ume of grout needed to create each isolation curtain also are included in this phase. 4. The selection or development of a grout formula for the specific hydrogeological conditions that exist at the site. 5. Identification of a resource (deposit) required to produce the grouting clay. The planning of grouting operations must be supported by the acquisition of all necessary initial data, which in¬cludes: 1. The geographic location and administrative responsibil¬ity (ownership and regulatory constraints) of the mineral deposit and any peculiar features of the area where ex¬cavation of the underground workings is planned. The surface relief, the hydrographic network of the region, and the local climatic conditions must be evaluated prior to planning for buildings and waste discharges if any. 2. The economic status of the region, the available trans¬portation, the nature of the energy base, the water and heat supply sources, the location of construction mate¬rials suitable for making the grout all must be deter¬mined. 3. The geological and hydrogeological characterization of the work site must be accomplished. 4. The technical features of the shaft(s) and underground works must be characterized. 5. The organization's principal initial design plan features and the construction sequence of all buildings and struc¬tures must be developed. These must be correlated with the organization and schedule for excavating the under¬ground works. The technical characterization of a shaft or of other un¬derground workings must contain information about the purpose of the workings, the design depth, the planned excavation procedures along with cross-sections, and the parameters of the lining, if a lining is required. The geology of the section to be penetrated must include geological data obtained from existing exploration activities at the mineral deposit and conclusions about the shaft ex¬cavation conditions obtained from drilling technical moni¬toring holes and exploration drillholes. The interpreted stratigraphic regime, including the thickness, strike and dip of each stratum, must be shown in cross-section. The tec¬tonics, including all geologic structures, must be presented by cross-sections. The bedding orientations must be used to identify anticlines, synclines, monoclines and faults. The lithologic composition and the drillability of the rock com¬prising the section must be examined. The character of the rock's fracture pattern must be presented. Finally the per¬meability, porosity and storage characteristics of each aqui¬fer must be determined by in situ hydraulic property testing (injection tests or pumping tests, as described in Chapter 3). The fracture pattern of the indurated rock is presented in reports derived from geo-exploration borehole studies and from studies of outcrops on the surface and in all nearby underground workings. The extent of each fracture zone is mapped in three dimensions. The distribution of fracture apertures, the nature of the fractures according to each litho¬logic stratum, and the relationship of bedding planes to each fracture system are all determined. Acoustic logs, downhole cameras, caliper logs, oriented core, and any other appro¬priate geophysical tools available are used to construct the data base for this purpose. The hydrogeological characterization of the geologic section to be penetrated by the workings is based on the analysis of hydrogeological data collected during the drill¬ing and testing of technical monitoring holes and from in¬formation on ground water inflow collected during the ex¬cavation of nearby underground workings, if such workings exist. The hydrogeologic characterization must contain the following information: 1. The identification of all aquifers, their thicknesses and their locations in the section, 2. The distribution of hydrostatic head in the ground water in three dimensions, 3. The coefficient of saturated hydraulic conductivity (per¬ meability) of each aquifer, 4. The porosity and storativity of each aquifer, and 5. The projected rate of water inflow into the shaft, drift or tunnel for each aquifer prior to grouting. This step is used to identify the zones to be grouted.

Jan 1, 1993

By J. D. Patsey, G. T. Lineberry

Introduction A computer program was developed for analyzing drum-type hoists before modifying an existing system or designing a new one. Its use permits the preliminary evaluation of a system before seeking technical assistance from mine hoist designers and manufacturers. The user-friendly program accepts a variety of data and analyzes hoisting systems for any balance state. The program can be used to calculate skip capacity to yield a desired production rate, solve for drum face width, select a permissible wire rope, estimate total horsepower of the hoist plant, and estimate annual power cost. Whether required for a large mining complex or for a relatively small operation, a hoisting system must be carefully designed to ensure the efficient, reliable, and safe flow of material. Because shaft sinking and hoist installation can total between 2.5% and 3% of the cost of opening a deep mine, proper hoist selection is critical. Today's mining engineer has at his disposal the most powerful design and analytical aid ever, the micro- computer. There is, unfortunately, limited software for the study of hoisting systems, unlike that for other materials handling equipment (Manula and Albert, 1980; Prelaz et al., 1964; Bucklen, 1969; Thompson, 1985). HOIST reduces a time-consuming set of calculations to a concise package of interrelated subprograms. A literature review revealed no common-user pro- grams to analyze hoisting systems, although at least four major hoist designers/manufacturers/installers have their own in-house programs. To provide a tool with which the mining engineer could preliminarily analyze a materials hoisting system or could check the calculations of a hoist contractor, a computer program was developed. HOIST was written in BASIC for the IBM-PC for ease of program adaptation and to en- courage field use on compatible systems. Details of program development are omitted, since the basic principles of hoisting analyses are relatively straightforward, simple, and readily accepted (Har- mon, 1973; Nordberg, n.d.; Adler, 1957). Program features, intended usage, and benefits of the com- puterized solution are emphasized over theory development and mathematical rigor. Background The mine hoist system that is selected and installed at a mine is the "lifeline" of that mine, with installations lasting 20 years or more. Thorough study is warranted to ensure that productivity demands are met at a minimum cost per ton. The increased cost of a large, powerful, high-speed hoist must be offset by increased production to justify its selection. To optimize this tradeoff, an extensive hoisting analysis should be performed. The analyses to properly size the skip (or cage ) , the drum, and the hoist drive are conducive to computerization, permitting rapid evaluation of changeable operating and design parameters, such as velocity, acceleration, state of balance, and productivity demand. The program is particularly useful in conducting sensitivity trials, such as investigation into the effect of change of productivity on skip capacity and on horsepower of the hoist drive. HOIST is currently limited to the study of drum-type hoists with cylindrical drum(s). However, only minor changes to the program would permit analysis of friction hoists and conical drum configurations. Model development and testing The program is based on accepted equations and physical relationships. Examples of manual calculations formed the basis for decision points and program branching. Data is input in the order that it would be needed if the problems were solved manually. The choices are arranged likewise. HOIST was developed in sections, with manual solutions performed to check program logic. The testing became more rigorous as sections were completed. Output from one section becomes input for following sections, as appropriate. The simplified flow diagram of HOIST is given in Fig. 1.

Jan 1, 1988

By Bruce Kennedy, Charles Bruce

MINERAL EXPLORATION 'The Function of Exploration Mineral exploration aims at locating the presence of economic deposits and establishing their nature, shape, and grade. As all ore bodies are finite, exploration is essentially the lifeblood of the mining industry. It is divided into two phases, reconnaissance and target investigation. It involves geological mapping, geophysical prospecting (aerial and ground or both), geochemical surveys, prospect drilling, and/or exploratory under-ground workings. Successful exploration is followed by development drilling, mine development, and eventually operation. In underground mining, the term "ore" is applied rather loosely to metalliferous rock that can be profit- ably mined, but nonmetallic industrial minerals and energy related materials constitute a large and growing portion of the tonnage extracted by underground methods each year. It is appropriate, therefore, to consider exploration as the search for any useful substance occurring in the earth or in the oceans that is of sufficient value as to volume, grade, chemical and physical com- position, and location as to make extraction by mining commercially profitable for the investment required. The Selection Process The search for ore includes hundreds of mineral commodities. The more successful exploration organizations tend to restrict the search to the mineral commodities for which they have strong exploration expertise and which have a high probability of being concentrated in areas open to exploration and development in sufficient volume, grade, and proximity to the surface to warrant the large expenditures of risk capital in finding an ore body. Special expertise is needed to engage in mineral exploration and development for the extended periods required for success. Individual prospectors continue to discover mineral occurrences, but it generally takes an organization with strong financial resources to carry the exploration process forward to the point of developing "ore." Still greater corporate resources in the form of management, engineering, and sales capability are needed to develop an ore body into an operating mine. In the past, companies other than those engaged in mining rarely conducted exploration, since they lacked the technical skills and know-how to bring a mine to fruition. A notable trend in recent years has been the success of other resource-oriented firms, such as petroleum companies, that have not only acquired the necessary skills to engage in exploration for hard minerals, but are doing so on a far more intensive scale than known in the industry heretofore. The desire to diversify from increasingly regulated oil and gas, the potential for the discovery of a bonanza, and the large scale of mining projects for these capital-intensive firms are the attractions. US government and certain international organizations, such as the United Nations, have fielded sizable exploration programs in the past decade on behalf of Third World countries wherein many of the world's higher grade deposits and scarce mineral resources are located. The level of overall mineral exploration in the industry is, regrettably, closely geared to the business cycle. Accelerated search during the periods of strong demand, shortages, and high prices, together with the long lead times necessary to develop mineral finds, often creates surges in supply which invariably are followed by a collapse in prices. The trend is, therefore, to exploration funding by larger better-endowed firms having the staying power to weather the cyclical nature of mining. Tax incentives, tariff policies, and other incentives have a decided impact on the level and nature of exploration. Surface mining regulations and environmental forces have fostered a renewed interest in under- ground development despite the lower average costs of surface mining. Spiraling inflation has caused mining costs to outpace prices for many mineral substances. Organizations increasingly are directing their search away from high- grade but limited tonnage occurrences toward low-grade disseminated bulk tonnages amenable to mining on a vast scale. Mining continues, therefore, to grow even more capital-intensive with half-billion-dollar mine-mill- smelter complexes now commonplace, compared with the hundred-million-dollar projects of a decade ago. Reconnaissance Exploration Having elected to search for specific mineral commodities, the exploration company narrows its focus to a reconnaissance of those regions offering the best potential. A working hypothesis which is constantly up- dated concerning the geologic controls for ore occurrence guides the search. The possibilities for discovery are best in areas of existing mines and known ore bodies, where the probabilities are high for additional ore occurrences. In such areas, published data on the trends and geologic controls of known mineral occurrences aid the search. Even in some remote territories, a variety of geologic data is available to the explorationist. The major sources of basic geologic data are the libraries of the US Geological Survey (USGS), the state geological surveys, the American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME), the US Bureau of Mines, and various institutions such as Colorado School of Mines. Overseas, virtually all of the countries have their own geologic survey groups which are associated directly, or indirectly, with their respective ministries of mines. The objective of reconnaissance exploration is to narrow the search by pinpointing target areas having interesting mineralization. These favorable areas are then investigated in detail to delineate potential ore bodies.

Jan 1, 1982

By Donald C. Moore

Introduction Asamera Minerals (US) Inc. and its joint venture partner, Breakwater Resources Ltd., discovered ore grade gold mineralization on their 20 km2 (5000 acre) Wenatchee, WA land position in February 1983. Due to the high grade nature of the discovery ore and the known reserves of ore in the "B Reef' and "B West" zones previously outlined by other companies, a decision was made to construct a mine/mill operation near the known ore occurrences. Further drilling in the discovery area quickly expanded known gold occurrences to more than 3.6 Mt (4 million st) with tentative in-place ore grade of 7 g/t (0.25 oz per st) and minor silver values. Based on existing knowledge of the ore body and the rapidly increasing ore reserve, a decision to build a 1.8-kt/d (2000-stpd) mine and mill complex was made in the second quarter of 1983. A schedule was devised to begin immediate mine development, shaft sinking, environmental and land use permitting, and mill and tailings dam construction (Fig. 1). Meeting the scheduled startup date, April 1, 1985, required a fast track schedule in all areas. To this end, Asamera purchased the Oracle Ridge Partners concentrator. This was an assemblage of new equipment designed for use as a copper concentrator in southern Arizona. The purchase contained all of the major mineral dressing equipment - crushers, screens, rod and ball mills, etc. and an engineering package. It did not include most of the other required items, such as buildings, conveyors, pipelines, tanks, and pumps. At the same time, core samples were sent to two independent process development laboratories for initial flowsheet development. Due to the refractory nature of the carbonaceous ore, cyanide leaching was not feasible. Flotation was selected as the concentration process. Further testing showed that autoclaving of the flotation concentrate followed by cyanidation would result in overall recovery of about 85% gold. A mine manager was hired to begin assembling an operations staff, hire an environmental consulting firm, and begin mine development. Environmental and land use concerns were major obstacles due to the mine's close proximity to a city of 20,000 people. These concerns had to be rapidly defined so as to mitigate any adverse impacts from and mining processing operations. Baseline data dealing with weather, air and water quality, and sound were measured before start of mine construction. Concentrator and flowsheet development remained static until October 1983 while definition drilling and mine development proceeded. In late October, a process engineer was hired to coordinate development of a process flowsheet, purchase the remainder of the concentrator equipment, prepare a concentrator construction contract, finalize concentrator detail engineering, and combine environmental and process requirements with a tailings dam design. Process development There were only 17 months remaining to mill start up from the hiring date of the process engineer. Therefore, the process flowsheet had to be finalized rapidly. To accomplish this, samples of drill core from the highest grade (and therefore potentially the most commercial) ore zones were sent to an outside metallurgical laboratory to confirm beneficiation tests on the flotation process. Test results again showed that flotation would provide about an 86% gold recovery. Therefore, all further testing was concentrated on flotation and autoclave/cyanidation of flotation concentrates. Focusing on a well known process such as flotation was important in accomplishing the rapid design and construction of the concentrator. If, during these next phases, we were continually changing design concepts, layout, and process flow, the mill startup would have been delayed many months. Once a process flowsheet is selected the process engineer must obtain the process criteria needed to design the beneficiation system. For example, it was known in early December that the Oracle Ridge rod and ball mills were too small to grind 1.8 kt/d (2000 stpd) of Wenatchee ore. A decision had to be made to purchase a large, used ball mill and convert the Oracle Ridge ball mill to a rod mill. The process engineer must be cognizant of the process criteria needed to size and select equipment. If not, the process engineer must use the professional services of the equipment manufacturing companies to review the requirements that the equipment is asked to perform. For the Wenatchee system, this resulted in the adaptation of a ball mill to a rod mill with a weight limit of grinding rods to protect the mill bearings and drive trains. When a decision is required, the process engineer has to present the facts and options in a manner that allows a rapid decision. This information must include costs, equipment availability, and effect on the construction schedule. At the Cannon mine, there were process development details that resulted in decisions similar to the ball mill purchase. These included an increased flotation residence time from eight to 25 minutes, an increased thickener area requirement, a high pressure tailings pumping system, and area constraints in plant layout. All of these decisions had to be timely and required assistance from manufacturers' service engineers, and knowledge of the alternate costs and effects on construction completion. Equipment procurement It was decided in early 1983 to build the ore milling facility with Oracle Ridge equipment, augmenting it with used equipment

Jan 2, 1989

By E. F. Klein, R. L. Eacret

Introduction In contrast to the general type of crushing mechanism in which the crushing surfaces alternately approach and withdraw from each other, described earlier in this section, and continuous-pressure break¬ers such as rolls and roller mills that will be described in a later chapter, impact crushers load by striking pieces of rock while in free fall and hurling them at high speed against stationary surfaces. Because the impact crusher depends for its effectiveness upon high velocity, wear is greater than in the slower-moving jaw and cone¬type wear parts, and for this reason its use is strictly limited to rela¬tively soft, friable, and sticky rocks that are characteristic of many nonmetallic mineral deposits. A few of these are phosphates, lime¬stone, barite, clay, asbestos rock, and coal. However, several examples of their use on soft lead-zinc and precious metal ores have been known. Although the use of impact crushers is expanding today into the range of ores containing as much as 15-18% silica, Taggart16 set the practical limit at 5%, and in the 1940s and 1950s several installa¬tions in the US and western Europe exceeded the limits of economical maintenance and were quickly superseded by the slower-moving, con¬ventional crushers. A rock that tends to be plastic or bouncy in a jaw or gyratory crusher when the force is applied slowly to reach ultimate strength, may become brittle with rapid loading and thus increase the effective¬ness of the applied forces. For this reason it is to be expected that as the quality of hammers, grates, plates, and cages improves with advances in steel technology, the use of high-speed crushers of this kind will increase. Terminology Modern usage differentiates between the impactor and the hammer mill, the former relying primarily on the impact of hammers (fixed or free-swinging) and secondarily upon pieces striking one another or steel surfaces; the hammer mill relies on both the centrifugal impact force of free-swinging hammers and the attrition and shear action between these hammers and well-placed grates suspended at the bot¬tom just below the hammer circle. The hammer mill, because of its grate discharge, restricts discharge of oversize rock to the grate open¬ing, while at the same time providing a trap for removal of tramp iron or other uncrushables. The impactor discharges free, so generally works with a screen to control product sizes. The question of terminology, impactor vs, hammer mill, creates difficulties because the similarities appear to outweigh the differences by far; if one were to list the similarities in order of importance and then the differences, he would be forced to conclude that they would best be dealt with as a single kind of crusher. Taggart16 gave it four names and added "as it is variously known," but it must be remembered that in 1945 the machine was nearly exclusively of the flailing-hammer type, while today the fixed-hammer rotor is also com¬mon. In this chapter the terms impactor and hammer mill will be used where they seem to apply. It is perhaps unfortunate that this terminology is being confused with rock breaking at the mine, usually with hand-held tools, e.g., the article "High-Energy Impact Rockbreaking" by Grantmyre and Hawkes, CIM Bulletin, August 1975. General Description Impact breakers, impact crushers, and hammer mills accomplish material breaking and reduction primarily through impact action of the material with fixed or free-swinging hammers revolving about a central rotor. The material to be crushed enters through an opening at the top or top side known as the "feed opening" or "hopper opening" and falls into the path of rotation (hammer circle) of the hammers. Initial breakage is accomplished in midair by collision of the dropping feed material with high-speed hammers. The second stage of breakage occurs when the pieces hit plates or breaker bars which line the crusher boxlike frame. Hammer mills rely further on a shearing and attrition action between free-swinging hammers and grid bars or grates at the crusher bottom which restrict discharge of oversize material until it is broken sufficiently to pass through the grid opening. The term hammer is used in reference to the piece which strikes the material, whether it is fixed on the rotor or free-swinging. It

Jan 1, 1985

By Charles A. Weinstein

INTRODUCTION As a set of management practices, "Knowledge Management" (KM) has disappointed many of its early advocates. The core notion behind KM can be summed up in the oft- quoted adage, "If we only knew what we know." KM describes a set of tools, practices, and approaches for using data, information, and expertise-knowledge-resident in an organization to improve the performance of that organization. The idea was incubated, hatched, and grew among some the largest and most successful companies in the world. Some of these companies created "Chief Knowledge Officers." Many more collectively invested billions in a huge range of KM efforts, all designed to use their organizations' information and expertise to innovate, improve margins, sell, or accomplish any of a myriad of sound business goals. Some KM efforts were successful, and many were not.* Today, it is indisputably the case that KM as a named set of practices has fallen out of favor. Why, then, should KM be discussed at a conference on "Things that Actually Work" for plant operators? Because, in many instances, KM has actually worked. The practices that represent KM done right offer significant opportunities for plant operators to achieve real gains, especially in times of resource constraints and in the face of ever-increasing technical and commercial goals. The KM fad is all but over. The KM benefits continue to accrue to those who have applied the lessons learned from that fad, and implemented sound * Fair disclosure: I am not unbiased with respect to the potential impact of KM. Teltech has been a pioneer and leader in KM, both as a practitioner and as a leading consultant to other organizations.

Jan 1, 2004

By Joaquin Ruiz

Although Mexico is known for its important base-and precious-metal deposits, and lately oil, some industrial minerals play an important role in the Mexican economy. Sulfur, the most important industrial mineral produced, accounts for approximately 7.5 percent of the total value of mineral production. This commodity is followed by fluorspar, which accounts for 6.4 percent. Predominantly, the fluorspar deposits are very high grade (75 percent CaF) and are contained in lower Cretaceous limestone in the states of Coahuila and San Luis Potosi. Base-metal deposits in the area of Parral (notably San Francisco del Oro), however, have become important fluorite producers in their own right. (San Francisco del Oro has 12 percent fluorite gangue.) Salt from the Guerrero Negro solar-evaporation ponds in Baja California account for 6 percent of the total shares; phosphate from Baja California also accounts for 6 percent. Barite from man to deposits in Lower Cretaceous limestone in Coahuila and exhalative deposits in the Paleozoic section of Sonora account for 1.0 percent. In addition, Mexico is an important producer of gypsum, graphite, and celestite. Although graphite and celestite are not large-scale operations and thus do not contribute much to the Mexican economy, the Mexican graphite and celestite deposits are among the most important in the world; Mexico is one of the world's few sources of celestite. The celestite is in the form of large, high-grade mantos in Cretaceous limestones in northern Mexico.

Jan 1, 1987

By J. A. King, D. R. Weir, P. C. Robinson

The complex mineralogy of the Porgera resource has a pronounced effect on process selection for the recovery of refractory gold and silver. Intimate association of gold with pyrite necessitates a high degree of sulphur preoxidation to achieve acceptable levels of gold recovery. Acid pressure oxidation has been demonstrated to be the only commercially proven process capable of achieving the required level of pyrite oxidation. Gangue mineralization dictates preconcentration of the sulphides to limit the acid consuming capacity and carbon dioxide generation during oxidation. However, the relationship between concentrate sulphur grade and gold recovery to concentrate ultimately governs the optimum degree of sulphide preconcentration. Minipiloting of the preconcentration and oxidation stages of the Porgera flowsheet are described. The influence of these processes on subsequent recovery of precious metals together with the technical and economic necessity of concentrate pretreatment prior to oxidation are discussed.

Jan 1, 1987

By V. Duddempudi, B. Goertz, J. Brune, G. Bogin, F. S. Barreto

"INTRODUCTION In designing a new pneumatic Dust Sampling Device (DSD) for coal mines, it was essential to analyze the air and particle flow inside the device in detail using Computational Fluid Dynamics (CFD) modeling. Several CFD models were developed to simulate the air and dust flow and sample collecting process of the DSD. These CFD models were developed to assist in the design of the DSD instrument prototypes for laboratory testing. Nozzle and injection parameters such as geometry, air velocity and pressure, were varied across a wide range to obtain the optimal settings to accurately simulate the fluid dynamics of the multi-phase flow within the DSD. Accordingly, these parameters were used as a guide for the design of the DSD and to verify the dust scouring dynamics, which is designed to represent the dust entrainment during an actual methane or coal dust explosion. BACKGROUND The 2010 explosion at the Upper Big Branch mine has demonstrated the destructive violence of a coal dust explosion. A major contributing factor for this disaster was that the mine operators did not have a reliable, direct-reading method to collect mine dust and determine inert content and combustibility. This led to the development of a new prototype handheld, pneumatic mine dust sampling device (DSD), which blows a puff of air and entrains the mine dust by mimicking the entrainment process during a mine explosion. A computational Fluid Dynamics (CFD) model is used to analyze the air and dust flow inside the DSD. The objective of the CFD modeling effort is to find the optimum design of the DSD prototype, nozzle orientation, air pressure and pulse length by analyzing and varying these parameters so that the scouring action collects a valid, representative and repeatable mine dust sample. CFD MODEL DESIGN Figure 1 shows a wireframe image of the DSD which is utilized in the setup of the CFD model. The DSD has a triangular cross section and is 10 cm wide. Two nozzles with cross-sectional dimension of 2.8 cm by 0.25 cm act as inlets at the narrow end of the triangular cross section. The CFD model includes a reference plane 6 cm away from the nozzle to measure the quantity of dust collected. The geometry shown in Figure 1 was created for the model and it matches with the design of the actual device shown in the figure 2. Symmetry, along the plane X-Y through the center of the device, is used to reduce the number of computational cells in the CFD model. Figure 2 shows the prototype device used for experimental testing. CFD MODEL SETUP Figure 3 shows a hexahedral mesh with a cell size of 0.8 mm and the total number of cells is around 650,000. The ANSYS Fluent® pressure based solver with a transient case was used with a total duration of 40 ms. The 40 ms simulation time is based on experimental measurements to capture the injection of air and initial scouring of dust."

Jan 1, 2016

By Robert A. Jankowski, George E. Niewiadomski

INTRODUCTION The utilization of longwall mining technology in the United States has steadily increased since the first longwall plow system was installed in 1952. At the errs of FY 1992, some 76 coal mines were employing longwall mining systems for coal extraction, and approximately 78 shearer and 3 plow faces are operating nationwide at any given time. Although the number of operating longwalls has remained relatively constant over the last five years, longwall production levels have increased significantly during this period. During the same timeframe, the number of continuous miner sections has decreased by 13 pct., from approximately 1438 in FY 1988 to less than 1250 in FY 1992. According to Mine Safety and Health Administration (MSHA) data, the average production of longwall sections increased from approximately 2400 tons per shift (tps) in FY 1988 to more than 3100 tps FY 1992. In fact, the average production has more than tripled since 1978, when it was only 850 tps. Approximately 25 pct. of operating longwalls are capable of producing in excess of 4000 tps. Longwall production currently accounts for nearly 36 percent of U.S. underground coal production, compared to 4 pct. in 1978. These improvements are attributed to improved longwall equipment and increased availability, larger longwall panels and automation. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust compliance problems more frequently than other mining system. Although dust levels have remained relatively unchanged over the past five years, averaging 1.6 mg/m3 and 1.9 mg/m3 based on results of operator and inspector sampling, respectively, during FY 1992, approximately 25 pct. of the operating longwalls were in noncompliance during any given bimonthly sampling cycle. Although modest gains in longwall dust control technology have been made, these have been overshadowed by significant increases in production rates. As more coal is mined, more dust is generated (Figure 1). Therefore, the increase in longwall productivity has meant that far more dust is being produced which must be controlled. [ ] In view of the current compliance record, any efforts to further increase longwall output, as has been forecasted, must be accompanied by: (1) the reduction of dust levels at existing operations through the proper installation and maintenance of suitable engineering dust controls; and (2) the advancement of dust control technology for today's and future longwalls that will enable all face personnel o work in an environment that is free of excessive levels of respirable coal mine dust. MSHA'S RESPIRABLE DUST CONTROL PROGRAM Since 1972, federal regulations have required each coal mine operator to continuously maintain the average concentration of respirable dust in the mine atmosphere during each shift in the active workings at or below 2.0 mg/m3 through the application of environmental dust control methods. The regulations provide for further reduction in the dust standard whenever the

Jan 1, 1993

By R. W. Henn

Introduction Shotcrete, by the American Concrete Institute definition, is mortar or concrete pneumatically projected at high velocity onto a surface. The term gunite is still common in literature. It is a trade name established by Cement Gun Co. of Allentown, PA, around 1911 for a dry mix of fine aggregate material, hydrated at the nozzle, and pneumatically projected at high velocity onto a surface. This article will discuss shotcrete applications, ingredients, mix proportioning, batching and mixing, admixtures, testing, and steel fiber vs. conventional shotcrete. Applications Shotcrete is used primarily by the mining and underground construction industries to temporarily stabilize an excavated rock surface until a permanent cover can be installed. It may also be used as the permanent covering material. Other uses include refractory material, architectural finishes, slope stability, wearing surfaces, repairing existing concrete structures, fireproofing, and corrosion protection of steel. Wet Versus Dry Process In the wet process, all ingredients, including water but not accelerator, are mixed the same way as normal concrete before its placement by pneumatic projection. The accelerator is added in a liquid state through the nozzle at the point of placement. In the dry process, all ingredients, including acceleration in dry form but not water, are mixed just before placement by pneumatic projection. Water is added through the nozzle at the point of placement. Liquid accelerator may be added at the nozzle in the dry process. Ingredients Shotcrete consists basically of the same ingredients as concrete with some limitations. Type I, II, and III cements are used. However, Type II seems to be used most in underground applications. This can be attributed to ground water at most sites having slight to moderate concentrations of sulfates. Air-entraining cement or air-entraining admixtures are generally not used in dry mix shotcrete. It is generally agreed that it is impossible to entrain air due to the absence of the usual concrete mixing action, and the high velocity of impingement of the material on the application surface. Air-entraining cement or air-entraining admixtures are used in wet mix shotcrete. Their use, however, is not widespread due to the placement method and the fact that high velocity air drives off most of the entrained air. Test results are not conclusive in showing any durability increase of shotcrete to freezing and thawing by using entrained air. In spite of current practice, the trend is toward additional research, with more agencies and owners requiring the use of entrained air. The philosophy behind this is that some entrained air is better than no entrained air to increase durability to freezing and thawing. The aggregates used in shotcrete are the same as those used in concrete. However, the largest coarse aggregate presently used is 19 mm (0.75 in.). A typical gradation requirement is shown in Table 1. The water quality requirement for shotcrete is the same as that for concrete. Accelerators are by far the most important admixture in shotcrete.

Jan 6, 1984

By Victor M. Mercado, Jay B. Shah

Spalding DeDecker Associates, Inc. (SDA) designed a tunnel project that fulfilled the Sustainability Objectives of Social Equity, Environment, and Economics. The project translated the principles of Sustainable Development into actions that lessened the impacts of construction on environment, lives of residents, businesses, traffic, and other social systems (i.e., shopping, recreational, and educational). The project involved the construction of a 16,108 feet of 84 inch diameter sanitary sewer interceptor by tunneling 40 feet beneath the ground surface through difficult geological and hydrogeological settings. An effective public information and stakeholders relationship program was developed to achieve the stated objectives of sustainability.

Jan 1, 2003

By Floyd M. Thorman

Gypsum is the crystalline chemical compound CaS04?2H20. A close chemical relation - and frequently occurring with Gypsum ? is Anhydrite which is Cask. Gypsun has wide commercial use because relatively simple heat processing reduces it to Plaster of Paris. While Anhydrite can be converted to Gypsum and thence to Plaster of Paris, the procedure is not simple and is quite costly. Anhydrite, however does have use in the agricultural field and in the Portland Cement industry. Occurrence of Gypsum in the earth structure is usually near or at the surface. Most underground mining is at 60 to 100 feet although one mine in southwest Virginia reaches a depth of 1300 feet. Gypsum is one of our softest minerals, rating only 2.0 on the Mohs scale of hardness. Specific gravity is 2.3 to 2.4. It is soluble in water but only slightly so. Interestingly, it is more soluble in cold water than in hot. For example, one part Gypsum dissolves in 370 parts water at 106° Fahrenheit while at 212°F. the water requirement is 452 parts. Compressive strength of massive Gypsum runs about 3000 lbs. per square inch. Color ranges from grey and brownish-grey to white.

Jan 1, 1973

ShouSteel Mining Ltd., a subsidiary of ShouSteel (Group) Co., was founded in 1959 and is located in QianAn City in Hebei Province, China. ShouSteel?s pelletizing plant uses iron ore as a raw material combined with limestone, dolostone, or olivine, with bentonite as a binder. After mixing the raw materials and forming them into small, spherical balls, ShouSteel then fires pellets in kilns for hardening. The company sells the finished pellets as raw materials for blast furnaces used to produce industrial metals such as iron. ShouSteel?s handling capacity is approximately 24.5 Mt/a (27 million stpy) of ore. The company?s production capacity is 3.2 Mt/a (3.5 million stpy) of oxide pellets and 560 Mt (650 million st) of sinters. Until recently, ShouSteel Mining had not replaced its electronic scales in its series of ingredient chambers. Because of the wear and tear on these older scales, the weighing system began to encounter regular problems. The company experienced a high failure rate from the integrator, an unstable signal, weak anti-interference ability and low accuracy. ShouSteel also found that spare parts required during repairs were consistently high in cost and that system calibration was becoming increasingly frequent.

Jan 1, 2012

By W. Jacobi, F. Steinhausler, A. C. James

INTRODUCTION In 1979 the Committee on Radiological Protection and Public Health of the Nuclear Energy Agency (OECD) defined a programme of work needed to improve radon dosimetry and monitoring. A Group of Experts in this field was established by the NEA and at the first meeting of the Group the authors were designated an initial task with the following terms of reference:- To review dosimetry of radon, thoron and their daughters, and in particular:- - to examine analytical models for the assessment of dose to individuals who are exposed to aerosol mixtures of these nuclides; - to examine the state of knowledge of the characteristics of aerosol mixtures of these nuclides and other factors that influence the dose to the lung, and identify those parameters which should be measured for dosimetric purposes in radiological surveillance programmes; - to identify areas where further study or research are needed. In this presentation we attempt to examine, with these objectives, the relationship between exposure to radon and thoron daughter aerosols expressed in terms of the working level month l (WLM), or its SI equivalent, and dose accumulated by sensitive tissues of the lower respiratory tract. Over the past two decades many attempts have been made to calculate the lung dose equivalent to l WLM exposure in mine atmospheres, usually in terms of the maximum dose to basal cells in a small part of the bronchial tree. The calculations have employed variously detailed models of airway anatomy, aerosol deposition, ciliary clearance and dosimetry of tissue at the bronchial surface, and are well reviewed elsewhere (Walsh, 1970; UNSCEAR, 1977; Jacobi, 1977; Fry, 1977). They agree in the conclusion that basal cells in segmental bronchi (between about the third and fifth bronchial generations) receive the highest dose, although estimates of this dose differ by more than an order of magnitude, ranging from about 0.2 to 12 rads per WLM (2 mGy to 120 mGy). The most critical parameters of these models are the assumed depths of basal cells below the bronchial surface and the fraction of the WL carried by free ions. When more realistic values of these parameters are substituted (Jacobi, 1977), the dispersion in calculated maximum doses to basal cells is reduced to give a much smaller range from about 0.3 to 1 rad/WLM (3 to 10 mGy/WLM). The parameters and methods employed in these various models, however, remain too diverse to infer the sensitivity of the dose conversion to practical variations in aerosol characteristics and the additional factors determining lung deposition and clearance. We have therefore taken the approach of developing newer models (Jacobi and Eisfeld, 1980; James et al, 1980) that can encompass the range of available experimental data on the physical and biological behaviour of radon and thoron daughters and also accommodate the different interpretations that can be put upon them. We have paid particular attention to the averaging of dose over tissues of equal sensitivity in the lung

Jan 1, 1981

By Y. Kurokawa, R. Kurosawa, I. Iwata, I. Fukuoka, N. Sugita

INTRODUCTION The Ningyo-toge Mine is located in the western part of Honshu, about 800 km from Tokyo. Since the discovery of uranium ore deposit at Ningyo-toge in 1955, different kinds of mining and milling tests have been carried out. A new pilot plant of milling and UF6 conversion is also being under construction. Operations are scheduled to start by the end of this year. In 1979, the uranium enrichment pilot plant was constructed at Ningyo-toge and test operations have started. Thus, the Ningyo-toge area is assigned to undertake the Research and Development of the upstream of the nuclear fuel cycle in Japan. PNC has been strengthening its security measures more than ever. This paper will focus on the disposal of wasted material, especially on the disposal of heap leaching residue, in Japan. URANIUM ORE DEPOSITS The uranium of the Ningyo-toge Mine is characterized genetically by epigenetic sedimentary type deposits. They occur in the host rock of Neogene tertiary fluviatile conglomerates and sandstones which unconformably overlies the Mesozoic-Palaeogene granitic basement covered with lucustrine deposits and volcanic ejecta. More than 12 deposits have been found over the area of approximately 160 km2, and distribution of the deposits are strongly controlled by the so-called channel structure, probably remnants of paleo-streams on the denudation surface of the underlying grantic basement. Each ore body has different shape and dimension respectively, but about 2-3 meters thickness with the average grade of 0.05-0.2% U308 is common feature of the ore bodies. The ore is soft and loose, and it is composed of common rock forming minerals of allogenic origin and their altered products. The chemical composition of the ore depends on the constituents of the country rocks or the pebbles. A primary mineral, ningyoite and secondary mineral, autunite are major ore minerals, although three primary tetravalent minerals and thirteen secondary hexavalent minerals have also been detected. MINING EXPERIMENT Since 1959, various types of underground mining tests have been carried out at Ningyo-toge Mine. The room and pillar method was safe and simple, although the uranium ore recovery was below 70%. After experiment of the retreating long-wall method and slicing mining method, it was found that the modified long wall method was the most appropriate for the underground mining of the Ningyo-toge uranium deposits. This method was completed successfully to increase efficiency up to 2 or 3 times, as compared to conventional methods. MILLING EXPERIMENT In 1964, a small test mill was constructed at Ningyo-toge, and a milling experiment using the Ningyo-toge uranium ore was started. Re-modelling of equipments and improvement of the process lead to the establishment of the technique of the so-called wet process, and produce UF4 directly from the ore. The flow diagram is shown in Fig. 1.

Jan 1, 1981

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 M. Pawlik

Canadian sylvinites contain over 90% of KCl and NaCl and a few percent of water-insoluble minerals. Cationic flotation is used to produce KCl concentrates. Since water-insoluble minerals appear in the pulp as slimes, and since long-chain primary amines are utilized as a collector, desliming is essential. The potash industry utilizes different desliming methods. This may involve selective flocculation of the slimes with polyacrylamide and removal of the flocculated product by flotation, or mechanical desliming with the use of classifying cyclones. Whichever method is applied, desliming is never complete; the flotation feed after desliming still contains about one percent of the slimes which heavily affect collector consumption and flotation selectivity. Therefore, the remaining slimes have to be rendered inactive by “blinding” them with polymers such as carboxymethyl cellulose or guar gum. The commercial blinders used by the potash industry include natural and synthetic polysaccharides. The most common is the use of carboxymethyl cellulose (CMC) and guar gum (GG). These are quite different polymers, while CMC is anionic, GG is non-ionic; while the applied CMCs are of relatively low molecular weight (about 300,000) GGs have much higher molecular weight. Guar gums are also heavily used as the depressants of naturally floatable gangue in the processing of platinum-bearing ores, and according to Harris et al. (1999) quite a large variety of modified guar gums are available in South Africa for this application. Cheng et al. (2002) claim that natural guar gum’s molecular weight is 1.935 • 106. Robinson et al. (1982) found that the molecular weights of five grades of commercial guar gums ranged from 4.4 • 105 to 16.5 • 105. The highest molecular weight sample is then very close to the natural guar gum studied by Cheng et al. (2002). According to the manufacturer, the Rantec KP4000 guar gum which is used by the Canadian potash industry has a molecular weight of about 1.5 x 106. Since both KCl and NaCl are soluble in water, the flotation process is carried out in saturated brine. At 20 oC, 1450 kg of NaCl-KCl-H2O saturated solution contains about 0.300 kg of NaCl, 0.150 kg of KCl, and 1 kg of water (Gaska et al., 1965). Thus, in the saturated NaCl-KCl brine there are about 5.1 kmole of NaCl and 2 kmole KCl per 55.5 kmole of water. This gives 3.9 molecules of water per each ion assuming complete dissociation of NaCl and KCl. Thus, it is obvious that all water molecules in the saturated brine must be bound in the hydration shells around the hydrated ions. The surface tension of the NaCl-KCl saturated brine was recently measured to be 85 mN/m (Laskowski et al., 2003).

Jan 1, 2004