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AUGUST 2010 VOL. 62 NO. 8

Freeport builds DMLZ Mine

Heavy equipment back on a roll Resolution Copperâ&#x20AC;&#x2122;s mine a showcase for Rio Tinto www.miningengineeringmagazine.com

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Changing the Way You Look at Mining

Always Moving Forward Editorâ&#x20AC;&#x2122;s Introduction, page 8

OFFICIAL PUBLICATION OF SME www.miningengineeringmagazine.com

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Feature Articles 20

Overview of Freeport-McMoRan’s proposed DMLZ Mine at Grasberg

I. Duckworth, T. Casten and M. Rakidjan

Caterpillar joins shovel market

Resolution Copper: A showcase for the Rio Tinto philosophy

William M. Gleason

Emily Wortman-Wunder

Bismuth and antimony: A look at 2009 activity

Common clay and shale: A look at 2009 activity

H.A. Taylor, Jr.

R.L. Virta

Technical Papers (peer-reviewed and approved) 39

Investigation into the practical use of belt air at US longwall operations R.B. Krog and C.J. Bise

Estimating excavator teeth consumption rates C.J. Roos, P.W. Conrad and S.D. Rosenthal

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Copyright 2010 by the Society for Mining, Metallurgy and Exploration, Inc. All rights reserved. MINING ENGINEERING (ISSN 0026–5187) is published monthly by the Society for Mining, Metallurgy, and Exploration, Inc., at 8307 Shaffer Parkway, Littleton, CO, 80127– 4102. Phone 1–800–763–3132 or 303–973–9550. Fax: 303–973 –3845 or e-mail: sme @smenet.org. Website: www.smenet.org. Periodicals postage paid at Littleton, CO and additional mailing offices. Canadian post: publications mail agreement number 0689688. POSTMASTER: Send changes of address to MINING ENGINEERING, 8307 Shaffer Parkway, Littleton, CO, 80127–4102. Article copies and back issues available on microfilm or microfiche from Linda Hall Library in Kansas City, Mo. Printed by Cummings Printing Co.

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The Group

Editorial Staff Editor Steve Kral kral@smenet.org

OFFICIAL PUBLICATION OF SME www.miningengineeringmagazine.com

Senior Editor William M. Gleason gleason@smenet.org

AUGUST 2010 VOL. 62 NO. 8

Senior Editor Georgene Renner renner@smenet.org

SME News 53 54 55 56 59 60

SME Foundation Coal & Energy Division views Environmental Division news In the aggregate Obituaries Personal news

AUGUST 2010 VOL. 62 NO. 8

Politics of mining Industry newswatch Media review Coming events New media New products Web directory Classifieds Professional services Index of advertisers Drift of things

Production Designer Nate Hurianek hurianek@smenet.org

Freeport b u DMLZ Mine ilds

Business Staff Media Manager/Advertising Johanna McGinnis mcginnis@smenet.org

Heavy equip back on a rolment l Resolution mine a showCopper’s for Rio Tinto case

Departments 6 8 18 52 61 62 64 65 66 71 72

Technical Editor Emily Wortman-Wunder wunder@smenet.org

www.miningen ginee

Phone: 1–800–763–3132 Fax: 303–973–3845  www.smenet.org

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ine.com

Cover Story

P.T. Freeport Indonesia, a unit of Freeport-McMoRan, is developing its new DMLZ copper mine in Papua, Indonesia. Production from the new underground mine, scheduled to begin in 2015, will replace ore from the DOZ Mine, which is scheduled for depletion in 2015-2016, page 20. Heavy equipment manufacturers are beginning to see an uptick in orders. And Caterpillar is entering the shovel market, page 27. And Rio Tinto’s Resolution Copper subsidiary continues work on developing its proposed Resolution copper mine in Arizona, page 33.

Society for Mining, Metallurgy, and Exploration, Inc. Officers President Nikhil C. Trivedi President-Elect John N. Murphy Past President William H. Wilkinson Executive Director David L. Kanagy

Mining Engineering Committee

Jamal Rostami (Chair), Joseph C. Zelanko (Vice Chair), Jurgen F. Brune, Robert W. Reisinger, William H. Langer, D.R. Nagaraj and Christopher J. Bise

Peer Review Editorial Board

Christopher J. Bise, Kirk McDaniel, Kelvin Wu, Vladislav Kecojevic, Keith Heasley, Jurgen F. Brune, Nikhil Trivedi, Rajive Ganguli, Catherine Dreesbach, Hugh Miller, G.T. Lineberry, Henry McCarl, Biswajit Samanta, Gerrit Goodman and Rossen A. Halatchev Reproduction: More than one photocopy of an item from SME may be made for internal use, provided fees are paid directly to the Copyright Clearance Center, 27 Congress St., Salem, MA, 01970, USA. Phone 978–750–8400, fax 978–750-4470. Any other form of reproduction requires special permission from, and may be subject to fees by SME. SME is not responsible for any statements made or opinions expressed in its publications. Member subscription rate included in dues. Nonmember subscription rate, $245; in Europe, $275. Single copies $25, July directory issue, $150.

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Politics of Mining

Rare earth elements legislation introduced to U.S. Congress Two resoluTions with the aim of restarting rare earths elements (REE) production have recently been introduced to the U.S. House and Senate. Congressman Mike Coffman (R-CO) introduced measure HR4866, the Rare Earths SupplyChain Technology and Resources Transformation Act of 2010 (RESTART Act) to the U.S. House on March 17. On June 22, Sen. Lisa Murkowski (R-AK) introduced a similar bill to the U.S. Senate. “Rather than further restrict mining in this country, the industry could be creating American jobs and protecting minerals that are essential to clean energy technologies,” Murkowski said in a news release.

“Unless action is taken, we will trade our dependence on foreign oil for an equally unsettling dependence on foreign minerals.” The U.S. Geological Survey said that between 2005 and 2008, 91 percent of U.S. REE consumption came from China, which is now reducing its REE exports. National Mining Association chief executive officer Hal Quinn said Murkowski’s RESTART Act “provides a needed blueprint for meeting this nation’s technology and security needs by focusing on our near-total reliance on imported rare earths elements.” The Coffman and Murkowski bills would, through a series of assessments and specific programs, attempt to re-

establish a competitive domestic rare earths supply chain. The measures would create a federal REE working group to assess strategic needs, create a national defense stockpile, evaluate international REE trade, establish a China Rare Earth OPEC, and facilitate loan guarantees for U.S. supply chain development. The legislation would also require the Secretary of Energy to establish REE industry loan guarantees, while the secretaries of Commerce, Defense, Energy and Interior would be required to provide research and development funding to academic, government labs, corporate, nonprofit research and development, and industry associations for REE projects. n

Reforms would strengthen mining safety rules wiTH neArlY 90 PerCenT of all mines in the U.S. completing 2009 without a single lost time accident to bolster his case, National Mining Association (NMA) senior vice president Bruce Watzman urged the U.S. House Education and Labor Committee to examine current mine laws before passing any sweeping changes to the Mine Act. Waltzman spoke in testimony regarding H.R.-5663, The Miner Safety and Health Act of 2010. Watzman explained that NMA looked at the proposed legislation and questioned if it would improve mine safety and health; ensure greater transparency; build upon, rather than dismantle, the positive features of existing law; avoid additional layers of enforcement already provided for under the law, but not fully utilized; protect due process; maintain a robust mining industry

and examine if proposed penalties are commensurate with the severity of violations. Recent findings of the Inspector General point to problems in the execution of Mine Safety and Health Administration (MSHA) programs and authorities due to half the mine safety inspectors being new to their job and half not receiving mandated or adequate training. Watzman questioned whether we would not “be better served to stress improving implementation rather than imposing more changes on inspectors and operators struggling to attain clarity, consistency and credibility in the application of existing safety laws and regulations?” “We remain ready to work with the committee on actions we should be taking,” Watzman concluded, “just as we did before Congress enacted the MINER Act.” n

South Africa sticks with target of transferring 26% of ownership souTH AfriCA unveiled the country’s new mining plans and there is little change from the previous mining charter’s target of transferring 26 percent of mine ownership to black people by 2014. The revised plans will seek to speed up black ownership, skills development, employment equity, procurement, housing and living conditions and mining beneficiation, Reuters reported. Mineral Resource Minister Susan Shabangu said plans to raise black mine ownership had been implemented slowly 6

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both by foreign mine owners and also black people who were forming companies merely to profit from the program instead of seriously mining for metals. “The 15 percent target for 2009 was missed and there is now an opportunity for the industry to make up for that,” she said, adding “The 26 percent target is confirmed for 2014.” Shabangu and South African mining executives signed a document that sets out a strategy to raise competitiveness and enhance transformation or ownership of mines by black people. n www.miningengineeringmagazine.com

S.A. Ravishankar, Ph.D.

Tarun Bhambhani

Carmina Quintanar. Ph.D.

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Industry Newswatch

Miners strike a deal with Australian government AUSTRALIA’S LABOR Party replaced Prime Minister Kevin Rudd with Julia Gillard on June 24 after Rudd stepped aside. Gillard worked quickly to settle fears of miners in Australia over Rudd’s proposed super profit tax that would have taxed miners 40 percent on high profits. On July 2, following three days of meetings with mining giants BHP Billiton, Rio Tinto and Xstrata, Gillard delivered on her promise when the Australian federal government announced a new taxation agreement, the Minerals Resource Rent Tax (MRRT), on mined iron ore and coal. Key points of the negotiated terms that still must pass through the Senate will see the new tax, capped at 30 percent, applying only to iron ore and coal and it may not hit any miners with profits below $A50 million. BHP Billiton, Rio Tinto and Xstrata welcomed the new resources tax regime. “The companies agree that the proposal presented by the government represents very significant progress toward a minerals taxation regime that satisfies the industry’s core

Newswatch contents 12

Bucyrus’ hopes for a $600-million deal get a second life

Virginia considers lifting uranium moratorium

Department of Energy distributes $52 million

August 2010

“The companies agree that the proposal presented by the government represents very significant progress toward a minerals taxation regime that satisfies the industry’s core principles.” BHP Billiton, Rio Tinto and Xstrata principles,” the three miners said in a joint statement. “The companies will continue to work constructively with government to ensure that the detailed design of minerals taxation maintains the international competitiveness of the Australian resources industry into the future.” With the news, Rio Tinto and Xstrata both said they would reconsider projects that had been put on hold because of the proposed super profit tax. Rio Tinto said it has recommenced studies on its multibillion dollar Pilbara iron ore expansion after the recent mining tax deal. “With the certainty that we’ve now got with the Minerals Resource Rent Tax, we are now reconfiguring those numbers and the impact back into our projects,” Rio Tinto iron ore chief executive Sam Walsh reportedly said. The company wants to increase iron ore production to about 330 Mt/a (364

million stpy) from about 230 Mt/a (254 million stpy) by 2015. Xstrata also said its coal division will restart $186 million of investment into its major development projects in Queensland. Its $6 billion Wandoan coal project is one of the biggest development projects for the company with a final investment decision due to be made in the second half of 2011. Gillard and Treasurer Wayne Swan claimed the new taxing system would bring an added $9 billion in revenue within three years. This is about $2 billion less than was targeted under the super profit tax structure. While the uproar from the super profit tax was not the only issue troubling Rudd, turning Australians against Labor, it was severe enough in the key mining states to show a swing to the Liberal opposition from Rudd’s Labor Party, thus forcing Rudd to step down. n

New look for Mining Engineering READERS of Mining Engineering magazine will see a new look in this month’s issue that has been a long time coming. The editorial staff of ME first embarked on the redesign in 2009 with a meeting with the design team of Ayers and Johanek, who were responsible for the previous design of the magazine done in 1995. While the look of the magazine is new, rest assured the content that you have come to expect is still here. The table of contents section on pages 2 and 3 have been expanded while the Drift of Things column has been moved to the back of the magazine for some final thoughts from Editor Steve Kral. Inside, you will still be able to find all of the relevant news in the Industry Newswatch section, get a taste of what’s going on in the political environment of mining in the Politics of Mining page and read a few words from the SME president on the monthly President’s Page. Feature stories and peer-reviewed Technical Papers will have a new look, but the same high quality technical content and you will still be able to keep up on all the news of the society in the SME News section. We hope you enjoy the new Mining Engineering. n

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Industry Newswatch

Alaska’s Kensington gold mine finally goes into production FOLLOWING THE approval won from the U.S. Supreme Court, Coeur d’Alene Mines commenced production at the Kensington gold mine in Alaska. Coeur said that it anticipates that Kensington will produce 1.5 t (50,000 oz) of gold during the remainder of this year and will average 3.8 t/a (125,000 oz/year) of gold over the mine’s initial 12.5 year life. Production began ahead of schedule. “Kensington represents Coeur’s third new precious metals mine to commence production in the past three years and will provide continued, meaningful growth to the company’s production and cash flow,” said Dennis Wheeler, Coeur d’Alene chief executive officer. “In addition, the startup of

production at Kensington represents the culmination of a community-wide effort by the Juneau, AK community, which has supported the project from the beginning and who will participate in the economic benefits Kensington will provide.” The gold concentrates produced at Kensington will be processed by China’s largest gold producer, China National Gold, through an agreement that is the first of its kind between a state-owned corporation of the People’s Republic of China and a U.S. precious metals mine. Coeur director of corporate communications Tony Ebersole said China National Gold has a “world-class facility and a huge presence.” China

National Gold is the largest gold producer in China and operates approximately 60 gold mines throughout the country, which comprise more than 20 percent of it’s gold production. The company also owns and operates a number of smelters and refineries throughout China. Ebersole noted that the “mechanism by which we convert our concentrate into revenue will be much faster than is typical. China Gold will be paying upfront, which means that in terms of timing, Coeur will get paid seven days after shipping vs. the typical twothree months that most concentrate producers must wait, while the metal is being processed at the smelter/refinery.” n

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Industry Newswatch

Bucyrus’ hopes for a $600-million equipment deal get a second life RELIANcE pOWER LTD. of India was invited to reapply for guaranteed loans from the U.S. Export-Import Bank and Bucyrus International’s hopes of orders for equipment worth approximately $600 million were kept alive. The U.S. Export-Import Bank, which is funded by the U.S. Congress, initially denied the several million dollar loans to Reliance Power on the grounds that the loans would have been used to purchase mining equipment that, in turn, would have been used to feed a new coal-fired power plant that will create carbon dioxide emissions, The Wall Street Journal reported. Faced with the possibilty of costing as many as 1,000 jobs to Bucyrus alone, the federal export-credit agency

said its board would reconsider the decision. In a letter to Reliance Power, the bank said it would take into account Reliance’s plans to build renewable energy plants in India and their potential to offset environmental damage from the coal project. Reliance is developing several hydro-power and wind projects and has said it will explore nuclear energy and solar power opportunities. Bucyrus said a denial of the guarantees was likely to cause it to lose orders totaling as much as $600 million. Bucyrus’ chief executive officer, Tim Sullivan, said at the time that the U.S. government was “throwing 1,000 jobs in the ditch.” Top Democratic politicians in Wis-

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consin protested loudly to the White House and Congress over the denial of the guarantees. Export-Import Bank officials then scrambled to find a way to rethink the decision. “We are very pleased with the decision of the U.S. Export-Import Bank to change course and support this project. This is great news for Bucyrus, but more importantly, it is great news to be keeping this work in the U.S.,” said Sullivan. He said the 1,000 jobs supported by the project include 300 in the Milwaukee,WI region and 650 in the company’s supply chain across 13 states. The reversal came just in time for a visit by President Barack Obama to Wisconsin, the home base of Bucyrus International, which hopes to sell the mining equipment to Reliance with the help of loan guarantees. About 10 percent of India’s roughly 160,000 MW of power now comes from renewable sources, while more than half comes through coal-fired plants. n

Farallon plans second mine HIGH pRIcES for gold have sparked Farallon Mining Ltd. to begin feasibility studies at four deposits at its Campo Morado property in Mexico. The company already operates a zinc mine, G-9, at Campo Morado and has mining and milling infrastructure in place. It said it expects to start the new mine by 2013. Farallon also said indicated resources at the four deposits at Campo Morado totaled 30 t (960,000 oz) of gold and 1.8 kt (60 million oz) of contained silver. The company is targeting an annualized production rate of 54.4 kt (120 million lbs) of zinc and 6.8 kt (15 million lbs) of copper, it said in a statement. n www.miningengineeringmagazine.com

Industry Newswatch

Virginia considers lifting uranium moratorium; deposit could have $300 million impact vIRGINIA URANIUM INc. submitted a study to the Virginia Coal and Energy Commission’s uranium mining subcommittee regarding a 54- kt (119-million lb) uranium deposit in Pittsylvania County, VA near the border of North Carolina. The company employed Lakewood, CO-based Lyntek Inc. to conduct an economic analysis on the project. Lyntek found that a uranium and milling operation would result in an initial private capital investment of $200-$225 million and create 250 to 300 construction jobs and 300 to 350 positions for the mining and milling of uranium. The life of the mine is estimated at 30 to 35 years and the study found that it would generate an annual local impact of $40 - $50 million in jobs and material costs and have a combined indirect and direct impact of $240 - $300 million. The Virginia Coal and Energy Commission’s uranium mining subcommittee scheduled a public meeting to determine if the state should end its 1982 moratorium on uranium mining. It is one of a number of studies either under way or planned. Patrick Wales, project manager for Virginia Uranium, said the study is largely consistent with the company’s own estimates. “Certainly the state has a pretty good road map

for where we’re heading,” he told, the Associated Press. Wales said the U.S. imports approximately 90 percent of the uranium used in domestic nuclear power plants. With the construction of 56 reactors under way around the world and the Obama administration supporting the development of domestic nuclear power plants, demand for fuel is growing. “People talk about this nuclear renaissance and whether it’s coming,” Wales said. “It’s here.” The city of Virginia Beach has launched its own study of the possible impact on its drinking water supplies if a storm or heavy rain washed away waste millings from the mine. About a dozen uranium mines are operating in the U.S., primarily in the West. Globally, the largest producers are Africa, Australia, Canada and Eastern European countries. The National Academy of Sciences’ National Research Council has just begun a study to examine the technical and environmental aspects of uranium mining in Virginia. The study is expected to take 18 months. The Danville Regional Foundation is considering proposals from two research groups to assess the uranium mining in the Dan River Region. That study, expected to be completed late next year, is intended to look at the regional impact of waste management and local economies. Before uranium can be mined in Virginia, the General Assembly would have to lift the 1982 ban. n

Xstrata moves ahead with $1.47-billion expansion XSTRATA ANNOUNcED that it has approved a $1.47-billion expansion of its Tintaya copper mine in Peru with the development of the Antapaccay deposit 10 km (6.2 miles) from the current operation. The expansion will boost output by 60 percent and extend the life of the mine for at least 20 years. The existing operations at Tintaya were due to run out of ore in 2012, Analysts said the announcement was expected and is a key element in Xstrata’s plan to boost the group’s overall volumes by 50 percent by 2014, Reuters reported. Xstrata said the expansion will boost average production of copper in concentrate at Tintaya by 60 percent to 160 kt/a (176,000 stpy) for the first six years. Construction is due to start in the third quarter and the new mine is expected to be launched in the second half of 2012. Last year, Xstrata’s overall mined copper output fell by 4.8 percent to 907 kt (1 million st), while in the first quarter, it rose 3 percent to 223 kt (246,000 st). n 14

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Industry Newswatch

Diamond mine in Botswana moves closer to production THE Ak6 DIAMOND MINE in Botswana will begin production near the end of 2011. The joint venture of Lucara Diamonds, which holds a 60-percent interest in the project, and African Diamonds announced the approval of the mine’s development. The diamond companies said that the project engineering had been awarded to DRA Africa and that work would start immediately. A proposal included in an updated study was a process plant designed with an initial throughput rate of 2.26 Mt/a (2.5 million stpy) and then increasing its capacity to 3.6 Mt/a (4 million stpy) after four years. The revised mining plan called for a smaller number of carats being produced at a higher diamond value. The indicated resource at a 1.5-mm

bottom cutoff has an average grade of 16 carats for every 91 t (100 st) milled and average diamond price $243/carat from 0 m to 400 m (1 to 1,312 ft). The bottom of the openpit is 324 m (1,062 ft) and would be mined over an 11year life. The updated study showed that the first phase required a capital investment of $120-million, which included the process plant, all mine site and offsite infrastructure, as well as a 13-percent contingency. African Diamonds’ managing director James Campbell said that the new $120-million price tag was an increase over the conceptual value engineering study that was done earlier. The sizable differences included a 25-percent increase in throughput that accounted for a $14-million increase, foreign exchange movement and es-

calation, accounting for a $20-million increase and scope changes that hiked the price tag with a further $20 million. The most noteworthy scope changes were the addition of a pebble crushing circuit and increases in indirects and housing. Operating costs over the lifeof-mine were estimated at $18.95/t ($17.20/st) of ore treated. The most significant increases in the operating costs were the factoring in of higher electricity supply costs and foreign exchange movements. African Diamonds also reported that an agreement has been reached with the Botswana government that allowed the joint venture company, Boteti Mining, to sell its entire production of diamonds through an open tender process and/or negotiated exclusivity contracts. n

Cummins to expand engine product line

cUMMINS INc. announced that it is expanding its High-Horsepower Technical Center and high-horsepower engine product line at its manufacturing facility in Seymour, IN. The expansion of the center will provide the company with more opportunities for producing high-horsepower, clean-diesel and natural gas engines in the future. Cummins plans to invest approximately $100 million in the expansion at the Seymour plant, which changed its name to the Seymour Engine Plant, from the Cummins Industrial Center. The expansion is expected to result in approximately 200 engineering and manufacturing jobs over the next five years. The plant currently employs nearly 450 people. A new, larger-displacement engine will complement Cummins’ current high-horsepower lineup, which powers applications in mining, power generation, marine, oil and gas, and rail markets around the world. The product investment will increase the plant’s capacity and manufacturing capability, including a new assembly line, paint area and production test cells. The technical center expansion will almost double the current engineering footprint in the facility and increase Cummins’ high-horsepower mechanical development capability. Other capital expenditures will include additional equipment, test cells and other facility upgrades. n www.miningengineeringmagazine.com

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August 2010

Industry Newswatch

Department of Energy distributes $52 million; money to be used for carbon capture projects THE U.S. DEpARMENT OF ENERGY (DOE) has doled out $52 million to 10 companies and academic groups in an effort to help finance the development of technology that reduces carbon dioxide emissions from power plants through carbon capture techniques. Among the companies receiving the largest share of the DOE grant dollars are Membrane Technology & Research Inc., Siemens AG unit Siemens Energy Inc. and ADA-ES Inc. (AD-ES). The goal of the Energy Department’s program is to improve the efficiency of the carbon-capturing process. Current capturing technology can increase the cost of electricity for a new pulverized coal plant by as much as 80 percent. In the U.S., power plants are the largest man-made source of carbon dioxide. Coal plants, however, produced about 44 percent of the country’s electricity in 2009, according to federal data. “We feel coal is critical for the foreseeable future,” said James Markowsky, the Energy Department’s assistant secretary for fossil energy. “We need a cost-effective way of carbon capture.” DOE said it wants to foster the development of technology that removes 90 percent of carbon dioxide while increas-

ing the cost of electricity by no more than 30 percent. The problem with carbon capture technologies is that they are expensive because they require a lot of energy, said Michael Durham, ADA-ES chief executive. Carbon dioxide is only 12 percent of the waste gas, so it must be extracted and concentrated, Durham said. In the existing processes, the exhaust gas is run through a solution that binds with the carbon dioxide. The solution is heated, releasing the carbon dioxide and the solution is reused. The process consumes 30 percent of a power plant’s energy, Durham said. The goal of the Energy Department program is to cut the cost by a third, Markowsky said. ADA-ES’s process replaces the solution with a solid sorbent — something like a large sponge — that can be heated to release the carbon dioxide using less energy, Durham said. In some initial tests, the sorbent technology was able to use half as much energy. ADA-ES has a small mobile test device operating in Texas. ADA-ES is moving it around to test it on plants using different types of coal, Durham said. The $11-million grant will enable the company to build a larger pilot plant as part of a 39-month trial. n

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THE INTERNATIONAL CONFERENCE ON HOISTING AND HAULAGE Hoist and Haul covers systems or technology associated with the handling of ore from the point of extraction in the underground mine to the stockpiling on surface. The Conference will also include a focused trade exhibition and local tours. The program encompasses a wide range of topics including shaft hoisting, incline and drift hoisting, conveying, underground rail haulage, tramming and truck haulage.

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New Mine Development

Overview of Freeport-McMoRan’s proposed

DMLZ Mine at Grasberg by I. Duckworth, T. Casten and M. Rakidjan

.T. Freeport Indonesia operates a mining complex located in the highlands of Papua, Indonesia. This district consists of underground and surface operations. The East Ertsberg skarn system (EESS) is one of the major orebodies in this district. Subsurface caving of the EESS has been carried out in a systematic series of mining lifts dating back almost 30 years. Present production from the third lift deep ore zone (DOZ), has reached 80 kt/d (88,000 stpd) during 2010, with this rate sustained through 2015. The orebody was proven below the existing caving level, with the next vertical block called the deep mill level zone (DMLZ). This article presents an overview of the DMLZ Mine based on a recent feasibility level study. The mine is being designed for a peak production rate of 29.2 Mt/a (32.2 million stpy), with 1,803 total ore draw points spread over a panel caving footprint of about 1.3 km by 375 m (0.8 miles by 1,230 ft). The present reserves for this mine total 501 Mt (552 million st). Located 1,400 to 1,800 m (4,600 to 5,900 ft) below the original surface, the DMLZ will be one of the deepest caving operations I. Duckworth, and T. Casten, in the world. Production is members SME, are senior scheduled to commence in 2015. project manager and director, The DMLZ is within the underground planning, FreeportErtsberg mining district in McMoRan Copper & Gold, Papua, Indonesia. The Ertsberg Phoenix, AZ. M. Rakidjan is district is operated by P.T. superintendent P.T. Freeport Freeport Indonesia (PTFI) Indonesia, Papua, Indonesia, under contract to the Republic e-mail ian_duckworth@fmi.com. of Indonesia. PTFI is currently

A haul truck dumps ore into a crusher at FreeportMcMoRan’s underground operations in Papua, Indonesia.

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producing copper and gold ore from the Grasberg openpit (GRS) and DOZ block cave mine. The GRS is scheduled for depletion in 2015-2016. PTFI plans to replace GRS openpit production with ore from the following underground sources (Fig. 1): • •

• • •

DOZ block cave mine: presently producing at 80 kt/d (88,000 stpd) with closure scheduled in 2020. Big Gossan (BGN) open stope: initial production commenced during 2010 with plans to ramp up to peak rate of 7 kt/d (7,700 stpd) in 2012. DMLZ block cave mine: early development commenced. Production scheduled to start in 2015. GBC block cave mine: under development and scheduled for production in 2016. Kucing Liar (KL): future cave adjacent to the GBC.

The DMLZ block cave reserve totals 501 Mt (552 million st) at 0.89 percent copper, 0.74 g/t (0.022 oz/ st) gold and 4.4 g/t (0.13 oz/st) silver. Total payable metal over the mine’s life is projected to be 3.8 Mt (8.4 billion lbs) of copper and 286 t (9.2 million oz) of gold. The mine is planned as a mechanized block cave operation with a peak production of 80 kt/d (88,000 stpd). Production from caving is scheduled to commence in January 2015. It will reach peak production during 2020, sustained through 2033. The mine will operate at or near 80 kt/d (88,000 stpd) for 13 years and is projected to close in 2037. www.miningengineeringmagazine.com

New Mine Development Figure 1 PTFI’s existing and planned underground mines.

Previous studies

The reserves that comprise the present DMLZ were previously split into the mill level zone (MLZ) and the DMLZ, with the MLZ to be developed first and the DMLZ overlapping. Prefeasibility level designs for the MLZ and DMLZ were advanced during 2004-2005. Since these original studies were issued, further exploration core drilling, updated resource calculations and redefined metal pricing resulted in revisions to the orebody block model and the projected minable footprint. As a result, the MLZ and DMLZ orebodies presented during the prefeasibility study were combined into a single entity referred to in its entirety as DMLZ. The changes involved removal of all MLZ workings and a footprint expansion on the DMLZ 2,590 m (8,500 ft) (extraction level). The revised DMLZ will provide earlier metal release when compared to twin lifts and a higher peak tonnage and metal production rate.

Geology and hydrology

The DMLZ orebody is a part of the EESS. The EESS is a vertically continuous mineralized zone that is developed within diorite with proximal skarns along the northern margin. It is a single copper/gold diorite and sedimentary rock-hosted skarn orebody that has been subdivided into various mining volumes. The EESS was originally discovered through surface mineralization exposures, now no longer visible due to subsidence related to block caving operations. The mining volumes have been given different names for identification/mining level purposes. The upper part of the EESS, between the 4,000 and 3,626 m (13,000 and 11,900 ft) elevations, constitutes the Gunung Bijih Timor (GBT) deposit. The GBT was mined out by the mid-1990s. Below the GBT is the intermediate ore zone (IOZ), located between the 3,456 and 3,626 m (11,340 and 11,900 ft) elevations. This has also been mined out. The DOZ is located below the IOZ and is situated between the 3,456 and 3,125 m (11,340 and 10,250 ft) elevations. The DOZ is currently being mined from the 3,125-m (10,250-ft) level. The DMLZ reserve is located below the DOZ, between the 3,125 and 2,590 m (10,250 and 8,500 ft) elevations hosted in both diorite (vein-style mineralization) and skarn (disseminated and vein style mineralization). EESS mineralization continues downward from the current DMLZ reserves and is being actively explored for continuity along strike to the northwest. A hydrologic finite element model was prepared for the DMLZ area (inclusive of DOZ). Results were computed life-of-mine for the www.miningengineeringmagazine.com

DMLZ. The lateral passive inflow, representing the portion of ground water than can be removed by dewatering programs, is predicted to peak at 785 L/sec (12,400 gpm) by the end of the mine life. The modeling results indicate that there will be a critical inflow increase from the present through approximately 2030, during which time dewatering drilling must be aggressively executed. Up to 29 km/a (18 miles/year) of drilling is required, starting no later than 2015. In terms of overall quantities, depending on how effectively water can be captured off the DOZ levels following closure of that mine, then the DMLZ water handling is estimated to peak at between 946 and 1,287 L/sec (15,000 and 20,400 gpm).

Mine design

General. Development operations at DMLZ commenced in November 2008, with the start of the DMLZ rail spur leading from the AB adits.

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Future rail portals to FreeportMcMoRan’s underground mines.

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Figure 2 DMLZ Mine development schedule (coded by year).

In January 2009, work started on the DMLZ conveyor and service decline access (Fig. 2). The mine layout focuses on multiple main levels and key infrastructure installations, as indicated in the following list. All level values are elevations above sea level. Main mining levels and accesses • Undercut level – 2,605 m (8,545 ft), extraction level – 2,590 m (8,500 ft), intake level – 2,565 m (8,415 ft), exhaust level – 2,550 m (8,365 ft), haulage level – 2,525 m (8,285 ft), DMLZ terminal – 2,525 m (8,285 ft). • Internal ramp between the extraction level and the bottom of the service decline. • Other mine level access ramps. Key infrastructure • Crushing plants: truck dump on haulage level – 2,525 m (8,285 ft), transfer main conveyors – 2,453 m (8,050 ft). • Main pump station – 2,520 m (8,270 ft), discharge at 2,990 m (9,810 ft). • Incline conveyor No. 1 and access decline: Tail pulley – 2,440 m (8,005 ft), head pulley – 2,635 m (8,645 ft), length – 1,355 m (4,445 ft). • Incline conveyor No. 2 and access decline: Tail pulley – 2,625 m (8,610 ft) elevation, head pulley – 2,820 m (9,250 ft) elevation, length – 1,335 m (4,380 ft). • Incline conveyor No. 3 and access decline: Tail pulley – 2,810 m (9,220 ft) elevation head pulley – 3,000 m (9,845 ft) elevation 1,440 m (4,725 ft). Production plans are centered on a block cave mining approach, similar in many respects to current operations at PTFI’s existing DOZ Mine. A departure from the DOZ operation, main 15 percent incline conveyors are planned to transport production ore up to the mill area. The DOZ, being located at mill elevation, required relatively short, 22

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flat conveyors to transfer ore from the crushers to surface stockpiles. The DMLZ orebody measures roughly 1,300 m (4,265 ft) in length (oriented southeast to northwest) and is between 350 and 500 m (1,150 and 1,640 ft) in width. There are 43 production panel drifts planned. Panel length between the first and last drawpoints varies from 72 m (236 ft) at the southeast end of the level, to 474 m (1,555 ft), with an average of 372 m (1,220 ft). Orepasses are installed along the panel drifts at a maximum spacing of 170 m (557 ft). Twelve of the panels are short enough to require only a single orepass, and the eastern two panels share an orepass. The remaining 30 panels require two passes, for a total of 72 passes in the current design. Rock breakers are planned on 1 m x 1 m (3 ft x 3 ft) aperture grizzlies located at the top of each orepass. The DMLZ orebody is to be mined using an advance undercut method as successfully applied in the DOZ. Drawbells are drilled and blasted from the drawpoint drifts into caved material previously broken above on the undercut level (Fig. 3). Drawbells are blasted in one shot using programmable detonators. The undercut blast forms the major pillar apex. The drawbell blast forms the minor pillar apex. Undercutting will lead drawbelling by a minimum of 15 m (49 ft) horizontally. Undercutting will typically advance beyond this minimum point but, as a general rule, should not lead drawbelling by more than three months. Exceeding this maximum creates an elevated risk of undercut recompaction. Caving operations are planned to commence at the east side of the minable footprint, sweeping across the ore zone from east to west in a series of production blocks. The orebody has two distinct draw column height regimes, divided roughly in half along the long axis. Draw columns along the north side of the mine tend to be shorter in height, averaging approximately 245 m (804 ft) height of draw (HOD). The majority of production activity will occur in the southern half of the mine where HODs reach 526 m (1,725 ft), as indicated in Fig. 4. DMLZ primary personnel and material access is through the AB adits, serviced from a surface rail yard using shared rail haulage infrastructure and rolling stock. Secondary access for rubbertire equipment and service vehicles is through the conveyor access decline, which extends from the DOZ intake adits down to DMLZ. The service decline parallels the conveyor, from existing drifting down to the DMLZ crushing plant, located below the southeastern end of the mine. The service decline also provides a secondary escape route in the event that the AB adit systems are unavailable. www.miningengineeringmagazine.com

Figure 3 Undercutting and drawbelling methodology. Geomechanical. The DMLZ will be the deepest and highest stress block cave mined in the Ertsberg district to date. Feasibility level assessment was carried out to establish key details with regard to the geomechanical aspects of the proposed operation. Caving and fragmentation. The DMLZ is cavable. Fragmentation is predicted to be similar to the diorite sections of the existing DOZ Mine. Experience gained in the DOZ will assist in refining the DMLZ fragmentation and drawpoint hangup predictions. The DMLZ footprint has a hydraulic radius (HR) of 134 m (440 ft) and based on Laubscher’s method requires a footprint with a HR of 30 m (98 ft) to initiate caving and 56 m (183 ft) to sustain caving. Cave and crack limits. The DMLZ cave and crack limits were projected at five-year intervals for the project. On the south side, these limits generally do not extend past the farthest boundary of the expected DOZ cracking (governed by prior caving above). In the other directions, the surface crack limit will expand based on the cave angles (which vary by direction) and the increased depth of the DMLZ. Interaction with the DOZ Mine. There is a fiveyear overlap projected between first production in the DMLZ (2015) and final production in the DOZ (2020). Based on numerical modeling, adverse impacts to DOZ facilities are not expected within the first two years of DMLZ caving. Between years three through five, the cave progresses up and will be within 150 to 400 m (492 to 1,312 ft) of certain critical DOZ facilities and related infrastructure. Prior experience within the EESS indicates that some damage to the openings will likely result as the cave progresses up, including rockfalls and increased convergence. The modeling indicates that, during years five through seven of DMLZ caving, changes in the stress field are significant. Heavy support and rehabilitation of DOZ drifts will be required if certain openings have to be maintained.

Ground conditions are considered generally good to fair for all areas on the main mine levels, although further characterization drilling is required to improve confidence. Extraction panel drifts are oriented at N35E in the direction of the regional stress field and with respect to rock fabric. This orientation is consistent with the IOZ and DOZ mines. Mining schedule and sequence. There are some concerns identified during the feasibility study that are being examined during the next phase of engineering. Based on convergence observations in the

Figure 4 Isometric view of the DMLZ reserve.

Fixed facilities and mine layout. Permanent facilities are located at or below the DMLZ extraction level at horizontal distance greater than 150 m (492 ft) to the south of the cave boundary. This minimum distance was recommended based on geomechanical assessment. The proposed mine layout is considered feasible for the undercut, extraction, fixed facilities and AB terminal. There are concerns associated with certain drifts located in the northern skarns, which are considered at higher risk of collapse. www.miningengineeringmagazine.com

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and include, but not be limited to, microseismic, time domain reflectometry (TDR), drift convergence, multiple-position borehole extensometers, load cells, and measurement of fragmentation distribution and drawpoint hangup frequency.

A 6-m- (20-ft) diameter raisebore.

DOZ Mine, the active portion of the cave width should advance at a rate of at least 80 m/a (262 ft/ year). During certain periods, the DMLZ feasibility schedule does not meet this criterion. The cave front advance rate averages approximately 65 m/a (213 ft/ year) for 2019 through 2025. The undercut should be at least one drawbell in advance of drawbell completion but no more than three drawbells ahead. The DMLZ schedule meets this criterion. The active cave width should not exceed some limit that is expected to be on the order of 400 m (1,312 ft). This cave width criterion is a function of the rock mass properties, cave geometry, depth and associated stresses based on parametric modeling and experience at other caves. It is noted that DOZ has exceeded this criterion in 2009. However, operational complications have been identified associated with the long cave front. A linear to convex-shaped cave front should be maintained (cave shape criterion). DMLZ meets this criterion. Rock stress. Stresses in the proposed extraction and haulage levels start at approximately 50 to 60 MPa and are predicted to increase due to mining. High stresses of 80 MPa in diorite and up to 100 MPa in skarns and limestones are expected in the 80 m (262 ft) zone in advance of the undercut, extending down to the haulage level. These stresses remain through mining on the northern fringe drifts of the extraction level. Stress results were analyzed with both elastic and Mohr-Coulomb models. Openings in diorite and skarn are expected to be serviceable but are predicted to have increased potential for bursting events when compared to the DOZ. It is felt that some of the stress effects on the northern fringe of the extraction level can be reduced by maintaining a linear cave boundary on the north. Monitoring. Monitoring is required to assist in draw control and to understand how the stresses will be transferred in front of the cave and progress to the surface. Monitoring methods should be redundant

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Oreflow. DMLZ crushing infrastructure is planned similar to DOZ, using twin FLSmidth FFE Minerals Inc. 54 x 77 gyratory crushers. These are to be fed by trucks operating above on the DMLZ haulage level. Ore is transported to the surface stockpile over a series of 1,829 mm (72 in.) conveyor belts totaling approximately 4 km (2.5 miles) in length. This conveyor system raises the ore 550 m (1,800 ft) vertically from the crusher discharge up to an existing conveyor near the surface. The crusher chamber is a multi-level facility designed to accommodate crusher installation, operation and maintenance efficiently within a minimum excavated volume. Access to the crushers is by the lower extension of the internal ramp. The top level is the truck dump, crusher inlet, crane bay and control room area. An eccentric access level is 16 m (52 ft) below the dump elevation. This level not only provides access to the eccentric for maintenance and replacement, but also houses the crusher electrical bay and the hydraulic system reservoirs and cooler, as well as the crusher station transformers and high-voltage switchgear. The eccentric level initially serves as excavation access to the top of the crushed ore bin. Ventilation and refuge. The DMLZ Mine will be developed below the existing DOZ. Much of the DOZ ventilation infrastructure will be unavailable for ventilating the DMLZ operation due to the impact of caving. However, a section of the horizontal ventilation drifting accessing the DOZ Mine can be used by connecting primary ventilation raises up from the DMLZ Mine. For the DMLZ, the air will enter the mine through a combination of the DOZ intakes (~70 percent of the intake volume), the service decline and the AB adit spur. The primary intake system is completely open with no regulators or booster fans required. The majority of the intake air is routed down three 6-m- (20-ft) diameter raisebored shafts. This air is then transferred across the 2,565 m (8,415 ft) intake level to the main mine levels. Intake air flows through a free-splitting network to ventilation raises along the north and south fringes, leading up to the extraction and undercut levels, and down to the haulage level. Other minor splits are directed into various infrastructure and facilities areas. In all, approximately 7 km (4.3 mile) of ventilation drifting is required on the intake level. In addition, 1.6 km (1 mile) of 6-m- (20-ft-) www.miningengineeringmagazine.com

diameter raises, and approximately 400 m (1,312 ft) of 3-m- (10-ft-) diameter ventilation raises will be necessary. All of the air exhausts the mine by the 2,550 m (8,365 ft) exhaust level, then up through five 6-m- (20-ft-) diameter smooth raises. These raises connect to the DOZ exhaust system, expanded to comprise five drifts and five parallel HowdenAustralia 3.5-m- (11.5-ft-) diameter mixed-flow axial fans. All mine exhaust is through these primary fans, inclusive of the ore flow allowance. The exhaust level serves multiple functions as primary exhaust ventilation and haulage level development access. Early development of exhaust ventilation headings is critical to the development plan. One of the first development priorities was gaining access to the top and bottom of the first exhaust ventilation raise to facilitate raise excavation. The DMLZ Mine will have two separate intake air splits for emergency egress. The first is the AB adit spur that will connect the lower mine to the portals. In the event of a fire anywhere but the actual AB tunnels, this will remain clean of smoke and serve as an intake escapeway. The second escapeway is by the service decline. In the event of a fire in the AB adits, this route will remain clear of smoke and serve as an escapeway. Within PTFI’s existing underground operations, egress is considered to be the first priority. However, since both escapeways are lengthy and would involve transportation to fully evacuate the mine, permanent refuge stations are planned at each main level, allowing all personnel from those levels to wait in safety. PTFI’s standard for refuge specifies a system incorporating oxygen generation, scrubbing and refrigeration, with a rated capacity of 36 hours. In addition mine worked are required to wear oxygen generating self-contained self-rescuers. Pumping. Water will report to the DMLZ mining area in increasing flow volumes as the mine transitions from preproduction to full production. The expanded subsidence area will increase surface collection and broaden the volume in which subterranean sources may be intercepted. The majority of the water will be collected from sources throughout the DMLZ by a series of ditches on the various mining levels that will report to a drainage pipe on the intake ventilation level. Any inflow entering the mine workings below the intake level elevation (namely the exhaust and haulage levels) is directed to a drainage level by a system of ditches and drain holes. Flows are directed through the drainage level to a sump pump station installed at the lowest point in the DMLZ. Approximately 505 L/sec (8,000 gpm) of the DMLZ water capture will be pumped up to provide water for milling operations. The remainder will www.miningengineeringmagazine.com

flow by gravity out of the AB adit. The main pump station will consist of two operating banks of dirtywater pumps in parallel. In the event that a bank of pumps should go offline, the water bypasses the pump station and joins the overflow volume out the AB adits. The main pump banks each comprise five centrifugal slurry pumps in series driven by 373-kW (500-hp) motors. The first pump in each operating bank is equipped with a variable frequency drive to regulate discharge flow. This feature provides the ability to limit the number of main pump motor starts per hour.

Schedule, costs and manpower

Schedule and costs. The project schedule was prepared using Datamine’s Mine 2-4D and Enhanced Production Scheduler (EPS) software. Vulcan was retained as PTFI’s primary mine design tool. The project schedule is driven primarily by excavations. Underground construction activities must wait for excavations to be completed. Construction time requirements are developed on a case-by-case basis and are entered into EPS as a hard duration. A comprehensive coding structure was developed for the DMLZ. The full code is a 19-digit series comprised of four sub-codes, as follows: • • • •

Facility code (two places). Asset group (AG) code (four places). Work breakdown structure (WBS) code (four places). Estimating code (nine places).

The facility code is derived from the layer names in Vulcan and allows costs to be cleanly grouped according to facility. An example would be a crusher with costs from excavation, fixed equipment, construction, EPCM, indirect and contingency grouped under one facility code. The next two codes, the AG and WBS, incorporate project and financial control coding. Applied in combination, these codes ensure that costs are forecast and tracked correctly and reported into the appropriate cost centers. The last nine digits represent the estimating code. The estimating code is divided into six sublevels based on; (1) class, (2) type, (3) description, (4) single/ multi-task, (5) material and (6) ground support. The estimate code is used to link schedule quantities with estimate productivities, unit costs and resources (manpower and equipment). An example of an estimating code would be contractor capital (level 1), lateral development (level 2), 5.5 m x 5.5 m (18 ft x 18 ft) drift (level 3), single heading (level 4), waste development (level 5) and medium ground support classification (level 6). Resources and consumables consistent with contractor crews driving a single-heading 5.5 m x 5.5 m (18 ft x 18 ft) Mınıng engıneerıng

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Figure 5 DMLZ manpower by department.

drift with medium ground support would then be allocated against this quantity in the cost model. A significant effort was made to develop flexible and accurate cost models for the DMLZ. Although zero-based procedures were used almost exclusively in preparing the capital and operating portions of the estimate, components were modified, as necessary, to reflect actual PTFI key performance indicators. Manpower. As PTFI’s underground operations continue to branch out, the provision of manpower becomes an increasing commitment. Attracting, training and retaining a competent workforce for the various operations and projects is an ongoing challenge. DMLZ manpower was estimated using ratios consistent with current DOZ direct and support staffing. Manpower is forecast to peak at 2,550 employees during the 2009-2021 preproduction and production rampup years, with a range of 1,950 to 2,400 for the full production period. As development activities taper off, manpower drops to about 1,550 people by 2030. This number is maintained for the following few years, after which the workforce gradually drops to 750 people by the end of the mine life in 2037. A graph showing lifeof-mine manpower by job category is presented in Fig. 5. The numbers are inclusive of all rotation crews, indirect manpower, vacation and sick leave, absenteeism and training.

Risk

The DMLZ represents the continuation of caving of the EESS. The caving design and peak tonnage are consistent with the present DOZ and, as such, there is considerable confidence associated with caving of the DMLZ. PTFI is one of the world leaders in block cave mine production, having successfully constructed and extracted three previous caves, all within the EESS. The operational risks are, therefore, considered to be manageable. However, insufficient data in some areas raises concerns that elevate risk profiles. During the feasibility study, 119 risks were

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identified associated with the development and operation of the proposed DMLZ Mine. Out of the highest 22 risks, 10 of these related to geomechanical concerns such as high stress, knowledge of structures, burst potential, wet drawpoints and early dilution. A number of the risks, both geomechanical and operational, were connected with the undercutting sequence and the concern that the cave front stresses and abutment loading will result in damage, or rock conditions that impact upon development and caving schedules and costs. Recent resequencing during basic engineering has resulted in a reduction of the effective cave width and improved confidence with this aspect of the design. Operationally, one of the key risks is associated with the ability to handle tramp steel from old mine levels above, that can result in nuisance shutdown of the ore handling system or, in extreme cases, damage. In the DOZ, this is an ongoing issue and one worthy of further study. Five of the higher level risks are connected with staffing, manpower, and associated housing and support facilities. It is recognized that the timely sourcing and training of sufficient personnel (at all levels) represents one of the highest risks to successful on-time completion of the DMLZ project. The combination of the remote location, coupled with multiple large projects peaking at similar times, will stretch resources.

Conclusions

The DMLZ is technically and financially feasible and PTFI has made the decision to move forward with the development of this new mine. As with most large projects, a number of areas have been identified where additional data or further studies are necessary to improve knowledge and understand/mitigate risk. These technical studies and design work are presently ongoing in order to advance knowledge beyond the level of the feasibility study. Early development of critical openings started late 2008, and development will ramp up significantly during the next four years, peaking at about 15 km (9.3 miles) during 2013. At this time, the first drawbell tonne is schedule for January 2015, with peak production of 80 kt/d (88,000 stpd) achieved during 2020. n

Acknowledgments

The authors thank the management teams of PTFI and Freeport-McMoRan Copper and Gold for permission to prepare and publish this paper.

References

P.T. Freeport Indonesia, Jan. 2010 “Deep MLZ Mine Feasibility Study,” Final Report, 482p. www.miningengineeringmagazine.com

Heavy Equipment

Caterpillar joins shovel market Equipment manufacturers position themselves to meet demand from rising commodity prices by William M. Gleason, Senior Editor

n early June, Rio Tinto’s chief executive officer Tom Albanese said that he expected demand for iron ore, aluminum and copper to double in the next 15 years. Driven by global industrialization and urbanization, Albanese said during his company’s annual general meeting that to meet the demand in 2030,

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the additional supply required will be equivalent to replicating the iron ore output of Australia’s Pilbara region every five years, adding another aluminum production complex the size of Canada’s Saguenay every nine months and developing another copper mine the size of Escondida, in Chile, each year. Future energy requirements could be such that an entire coal supply chain the size of Hunter Valley, in Australia’s New South Wales, will need to be created each year, as well as a uranium mine the size of Ranger, in Australia’s Northern Territory, every four years. “These trends will require a significant response from producers,” Albanese said. Albanese’s statements are in line with many prognostications about the future of the mining industry, which appears to be coming out of the doldrums of the global recession as mines around the world are putting people and machines that make mining possible, back to work. Less than two weeks after Albanese’s statements, Caterpillar, the world’s largest mining and construction equipment manufacturer, reported an 11-percent rise in the dealer sales of its heavy machinery in the three-month span that ended in May. The company followed that news by announcing a $700-million, multi-year investment in its global mining division that will expand truck capacity and add a full line of mining shovels to its offerings. The positive financial report snapped a 19-month stretch of declines for dealer sales. For the first time since 2006, sales in North America were up 15 percent and Asia-Pacific sales were up 38 percent. Likewise, Komatsu earlier reported that it expected to see robust sales in Asia. Komatsu, the world’s second-largest maker of mining trucks, said in March that it expected sales in China to rise by half as the country’s 10-percent growth rate drives demand for resources such as coal and iron ore. Sales in the year starting April 1 were exMınıng engıneerıng

In June, Caterpillar announced that it was entering the mining shovel market as part of a $700-million investment in its mining division. The investment comes as rising commodity prices around the world send mines back into production. AUGUST 2010

pected to rise by between 40 and 50 percent from the current fiscal year, Kazuhiko Iwata, the president of the company’s mining division, said (ME April, page 13). Mining machinery sales account for about 30 percent of Komatsu’s construction equipment division revenue, which is forecast to be $14 billion this year. Global sales of machinery are forecast to increase 10 percent to near record levels achieved in the year to March 31 last year, Iwata said.

Included in Caterpillar’s $700 million investment in its mining division is an update to its electric-drive mining trucks, like this 795 ac.

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Caterpillar invests $700 million in mining

Already the world’s leading producer of off road mining and construction equipment, Caterpillar will begin to produce a line of five mining shovels while also expanding truck capacity through a multi-year investment of nearly $700 million. The shovels will range from a 113-t (125-st) model through a 725-t (800-st) model. “The message from our customers has been clear,” said Chris Curfman, president of Caterpillar Global Mining. “They want us back in it. They want a truck-shovel combination system that we will have for them.” Caterpillar did produce shovels before — the 5,000 series — stopping production in 2003. Curfman cited poor market conditions and difficulties with the product as reasons for the demise of the shovel line. Since then, Curfman said, Caterpillar has spoken with a number of customers, including mining giant Xstrata. In January 2010, it was determined that the time was right to return to the mining shovel market. “The marketplace itself has increased since 2003 by a factor of about three and we expect the market to continue growing,” Caterpillar truck and shovel product manager Ed McCord said. “As we saw the industry rapidly coming out of a recession Mınıng engıneerıng

in the later part of 2009, we decided to accelerate our internal study and in January we began putting the final details together. We have invested heavily in truck capacity and something has to load these trucks. Our customers have asked to have a Caterpillar line beyond our wheel loaders and we decided it was an appropriate time to launch an internal program to offer a full line of shovels.” Caterpillar has selected its manufacturing facility in Aurora, IL, for initial production of the new product range and is conducting a study of additional production sources in other parts of the world. In early 2011, Caterpillar will begin pilot production of the new 113-t (125-st) class shovel. The Aurora facility also produces Caterpillar’s largest wheel loaders, which are an alternative method for loading mining trucks. “We are on an very aggressive time line,” said McCord. “Our intention is the matching of a loading tool from Caterpillar for each one of our trucks. That starts with the 54 t (60 st) 773 class all the way up through the 360 t (400 st) 797 class. We are sizing the shovel for a three-four-or fivepass match depending on the size of the tuck. The shovels will line up with our competition, we will match up model-tomodel with the primary shovels in the market, although the focus will be to match our shovels with our trucks.” The first commercial shovels produced in Aurora are expected to be available in 2011. The larger shovels are planned for commercial availability beginning in 2013 and through 2014. “The key driver with Xstrata, and some of our other customers, is that they want the combo truck shovel loading capability from us,” said Curfman. “They are bullish on the trucks and we are keen to leverage that on the shovels, which we think, with the support we offer, should be very advantageous.” Caterpillar also announced that it will update the status of its new electric-drive mining trucks. Caterpillar currently has pilot units of its 310-t (345-st) 795F ac truck at customer sites for final evaluation, with commercial production set to begin in late 2010. Initial interest in the new Caterpillar 795F ac trucks has been strong, and the company has increased its planned build rate for 2011 by more than 40 percent to meet demand in all major mining markets throughout the world. In early 2012, the company also plans to produce pilot units of the 793F ac truck with a 220-t (240-st) payload. Both the 793F ac and 795F ac will www.miningengineeringmagazine.com

complement Caterpillar’s full range of mechanical drive trucks. Additionally, Caterpillar announced that it is accelerating previously announced capacity expansion plans for trucks in Decatur, IL, with additional capacity expected to come online beginning in 2011. The expansion in Decatur will increase truck capacity at the facility by nearly 30 percent. Decatur produces Caterpillar’s largest mining trucks, including the flagship 797F series truck. In addition, Caterpillar plans to increase capacity for 54- and 90-t (60- and 100-st) trucks at its existing manufacturing facility near Chennai, India. The capacity expansion would more than double truck production capabilities in India. The expansion in India should be completed by early 2012. “The increased production in India and Decatur will better position the company to serve our mining customers in every region of the world, with a particular focus on the growing demand and customer base in the emerging markets of Asia and in Russia,” Curfman added.

Market consolidation

When the first shovels are built, Caterpillar will become the latest, but not the only company to offer a comprehensive line of products for mining companies. Liebherr has offered haul trucks, excavators and loaders for many years, as have Komatsu and Hitachi. In February 2010, Bucyrus joined the fray when it completed its acquisition of the mining equipment business of Terex Corp. Already a leader in the world of large surface and underground mining equipment such as draglines, drills, shovels and excavators, highwall miners and room-and-pillar machines, Bucyrus paid US$1 billion in cash and issued more than 5.8 million shares of stock to Terex to acquire its mining division. The mining equipment business of Terex produced the world’s largest hydraulic excavators, rugged haul trucks, advanced drilling machines and highwall mining systems. The Terex mining equipment business has 38 facilities around the world with approximately 2,150 employees. In a press release following the acquisition, Bucyrus said it has now extended the organization’s geographic footprint, diversified its product portfolio and positioned the company as a more globally competitive organization. Bucyrus doubled its addressable market from roughly US$15 billion to more than US$30 billion. “This transaction is a natural extension of our current operations. We are one company with a proud history powered by hard-working, loyal employees who are passionate about mining,” www.miningengineeringmagazine.com

Bucyrus president and chief executive officer Tim Sullivan said. “We’ve reinforced our long-held values of safety, customer focus and reliability at work.” The moves by Bucyrus and Caterpillar certainly position the companies well to take advantage of the recovery from the Recession. However, there is still plenty of turbulence in the marketplace. “There is a lot of quoting activity going on in the industry right now, but it will be interesting to see if the orders from Bucyrus and Joy Global and others do pick up because there is still a lot of uncertainty out there at the macro level,” said Ann Duignan, managing director, JP Morgan Equity Research who covers the heavy equipment sector. Much of the industry’s future will hinge on what happens in Asia and India. The Asian market remains the largest consumer of commodities with India close behind. The growth from that part of the world is not only driving the price of commodities such as copper and iron ore, it is influencing the decisions of the equipment makers. “The Asian-based economies, with the commodities deposits that are there, have been phenomenal in terms of their growth,” said Caterpillar’s Curfman. “We are also seeing it in Russia. With regard to the shovels, that is where the market is going. Particularly with shovels in the 91- to 181-t (100- to 200-st) class. It’s booming there, coal, iron ore and copper. The growth is commodity based and that is where our market has moved.”

In February 2010, Bucyrus acquired the mining division of Terex, adding haul trucks and excavators to Bucyrus’ line of mining equipment.

Liebherr T 282 C: One of the world’s largest and most efficient mining trucks

For those who were able to make it to the 2010 bauma show despite the flight cancellations because of the volcanoes in Iceland, they were able to see, for the first time in public, Liebherr’s new T 282 C haul truck. The T 282 B has held the distinction of the world’s largest truck for the past seven years. The 363-t (400-st) payload truck has set benchmarks worldwide for high production and low fuel consumption resulting in increased orders and a repuMınıng engıneerıng

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tation of lowest cost per ton. Not content, Liebherr made numerous design improvements to increase the efficiency and reliability of the truck. Recent improvements that include a new cast frame, axle box and cab and drive system were so substantial that the truck also got a name change, T 282 B to T 282 C. With an empty vehicle weight of 237 t (261 st), the T 282 C can carry a payload of up to 363 t (400 st). Available engine options for the T 282 C include the MTU DD 20V4,000 (20-cylinder 2,800 kW/3,755 hp) or the Cummins QSK 78 (18-cylinder 2,610 kW/3,500 hp). Meeting the size requirements for bigger being better, the Liebherr T 282 C is also productive with a top speed of 64 km/h (40 mph). The first pre-series of the T 282 C units are already in testing and the official product release is scheduled for the fourth quarter of 2010. The new frame, axle box, cabin, IGBT ac drive system, Liebherr vertical integration and load management design philosophy will increase performance and provide a designed reliability in the T 282 C. This culminates in a truck with superior performance and reliability, ultimately providing the end-user with the lowest possible cost per ton.

Liebherr vertical integration

The Liebherr vertical integration philosophy incorporates proprietary truck components, specifically developed to serve the needs of the mining industry. By being in control of all components of the drive system, innovative design solutions can be developed within the Liebherr group to accommodate operations with high altitudes, high ambient temperatures and other unique mining applications. Along with the proven background of the T 282 B, these new features will result in greater uptime for the trucks. The largest, and one of the most important

Liebherr’s T 282 C 363-t (400-st) haul truck features many upgrades from the T 282 B.

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structures on any mining truck is the truck frame. It uses strategically located castings only in high stress areas to minimize the empty vehicle weight of the truck and subsequently maximize its payload and production potential. The design is unlike its competitors whose frames are predominantly cast material. This design follows Liebherr’s load management design philosophy of maintaining the lowest possible empty vehicle weight to optimize payload and minimize cost per ton. With an elimination of all stress concentrations, a reduced chassis weight from the previous generation frame and no compromise in durability, the T 282 C frame is designed for reliability. In addition to the new frame, a completely redesigned axle box is now available with the T 282 C. The new axle box now has two service doors, improved cable routing, vertical linkage and greater air flow across the electric drive motors and service brakes. With both increased service accessibility and better airflow, especially in high altitudes and ambient temperatures, the T 282 C’s axle box has been redesigned for reduced downtime and increased reliability. Significant design focus has been dedicated to making the cab of the T 282 C more operatorfriendly while simultaneously increasing the reliability of the truck and its components. Some of the cab’s major upgrades include new dash display gauges and a 300-mm (12-in.) integrated color touch screen for all operator alerts, faults, warnings, cameras and other control functions. In addition, the cab now features more amenities including an increased number of vents for air circulation, increased width for greater interior space. Another technical step forward, and major part of Liebherr vertical integration, is the new Liebherr drive system with IGBT frequency inverters. Together, with the Liebherr regulating system, the liquid-cooled IGBT power modules optimize control of the traction motors. The frequency inverters for auxiliary equipment are supplied with electrical energy regenerated, if circumstances permit, when the vehicle is braked. The new system includes wheel motors and planetary gear sets developed by Liebherr. It guarantees that the diesel engine runs independently of travel speed and its fuel consumption can therefore be optimized. The only deciding factor is the performance called for in any particular application. Liebherr recently got an order for 14, 360 t (400 st) trucks from Peabody Energy for its mines in Wyoming’s Powder River Basin. www.miningengineeringmagazine.com

The new Liebherr mining excavator

Liebherr’s new 100-t (110-st) excavator is powered by a new Liebherr V12 diesel engine that will be able to comply in the future with all U.S. Environmental Protection Agency (EPA) Tier 2 and Tier 4i emission limits. Based on 50 years of Liebherr experience, the R 9100 is ideal for the mining industry’s needs. With a rated power output of 565 kW (757 hp), the R 9100 supplies the high breakout and digging forces needed for day-to-day operation. The Liebherr bucket, with a nominal volume of 6.8 m3 (240 cu ft), is an optimized pattern for mining work, designed for improved penetration and a high fill factor. Separate radiators with hydrostatic fan drive for the hydraulic system and the engine keep the mechanical assemblies at optimal working temperatures. This efficient cooling concept keeps energy consumption for the auxiliary drives to a minimum but maintains a high level of reliability even in the extreme conditions encountered in the mining industry. The raised operator’s position and the large panoramic windows provide an excellent view of the complete work area. Areas that cannot be observed directly are monitored by two cameras, which display their images on a new 267-mm(10.5-in.-) screen. The cabin’s highly effective noise insulation makes a further contribution to productivity. The R 9100 incorporates systems and components of proven quality that Liebherr has developed. Together with the revised single-line lubrication circuit and the fuel and oil filter systems, they are part of the key to this mining excavator’s reliability and performance potential. Cost-effectiveness is enhanced by the reduced volume of maintenance work. A wide catwalk makes it easy to reach the individual assemblies for rapid and reliable servicing. All maintenance points are accessible at a practical height from one side of the machine. The first R 9100 prototypes are currently undergoing Liebherr’s intensive factory and field testing programs.

Hitachi introduces new EH4000ACII

After several months of field testing, Hitachi’s newest model of rigid-frame trucks— the electric-drive EH4000ACII — is ready to roll. It combines Hitachi’s front trailing arm and NEOCON-E suspension system with the vertical integration of Hitachi’s own IGBT ac-drive technology for smooth operations. Because it uses ac-drive technology, the EH4000ACII 222-t (245-st) has lower life-cycle costs and better performance on grade uphill www.miningengineeringmagazine.com

or downhill with superior rimpull and retarding capabilities than mechanical drive trucks. The brushless motors of the ac-drive system provide lower maintenance costs while providing increased uptime. Trolley assist options are available to improve performance on grade by

increasing productivity while reducing fuel consumption during the haul cycle. The EH4000ACII maneuvers easily in tight spaces. Its turning diameter is 30.2 m (99 ft). It comes equipped with a Cummins QSKTA60-CE, 1,864 kW (2,500 hp) engine with a maximum speed of 56 km/h (34.8 mph). Hitachi is not new to the electrical drive system business, with hundreds of drive systems running in applications varying from bullet trains and large production plant automation systems to electrically powered mining shovels and backhoes. Competitive models all depend on outside suppliers for this technology. In fact, Hitachi is the only truck manufacturer in the world that provides its own IGBT control, alternator, and ac-drive wheel motors.

Hitachi recently introduced its new EH4000 ACII 222-t (245-st) ac haul truck.

New hi-tech ROPS/FOPS cab layout

The newly designed air-ride seat and optional semi-active seat, combined with a threepoint rubber isomount on the cab, deliver a comfortable ride. A new Hitachi-made controller monitors truck systems and replaces multiple outsourced controllers. A simple flat-panel dashboard consists of a 26.4-cm (10.4-in.) LCD monitor that eliminates all independently placed gauges and lights. The philosophy behind the monitor in the trucks is the same as the Hitachi EX-6 series mining excavators — it allows for quick troubleshooting on the machine to reduce costs and downtime. Mınıng engıneerıng

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Auto cruise control keeps vehicle speed constant within the set range by limiting the minimum vehicle speed. Auto retarding control keeps vehicle downhill speed constant within the set range by limiting the maximum vehicle speed. The truck is slowed to near-zero ground speed with ac-retarding, which greatly reduces brake wear. To come to a complete stop, the service-brake blending feature automatically kicks in to combine the braking action of the service brakes with the dynamic retardation of the IGBT ac-drive system. This means there is just one pedal to use to achieve a smooth-braking action all the way down to zero. A hill-hold brake feature is also included as a part of service-brake blending.

Other new features include: • • • • •

• •

Planetary design with two fixed planetary gears. Final drive with gear-oil circulation system. Upgraded frame similar to Hitachi EH5000ACII. Body design with sloped floor and tail chute for less spillage and smoother shedding of materials. Hitachi load-weighing system with correction by axle/weight ratio and slope angle for greater accuracy. External display is optional. Easy-access front ladder, standard. Fast-filling system is ground-level accessible for coolant, grease, hydraulic oil, and engine oil; couplers optional.

The EH4000ACII is well matched to Hitachi excavators. It takes six passes from an EX3600-6, four to five passes from an EX5500-6 and three passes from an EX8000-6.

Bucyrus introduces new generation of rope shovel

Bucyrus International, Inc. introduced its next generation rope shovel, the Bucyrus 495HR2. The shovel includes Bucyrus innovations like the HydraCrowd and the LatchFree Dipper System, coupled with the efficiency of ACIGBT electrics, enhanced propel power, an upgraded and more comfortable cab, the Bucyrus 495HR2’s safety, reliability, and productivity will surmount that of its predecessors. A more than two-year, $1-million plus research and development project, including industrial research, “voice of customer” field surveys, partnership with a leading ergonomics expert, and collaborative workshops with 32

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customers from around the globe, provided the foundation from which the cab design emerged with more comfort, added safety, greater reliability and enhanced productivity. The cab includes a fully adjustable and isolated operator’s seat, infinitely variable armrests and a fully pneumatic suspension system with an integrated air compressor. Efforts were taken to minimize cab vibration and noise, further enhancing the overall comfort of the newly designed operator’s cab. Structurally, the cab is bolstered by an extended machine house underneath for improved stability. The cab boasts an adjacent positioned trainer seat, consistent with Bucyrus’s previous cab design, providing optimum visibility for trainers and ready access to a new second emergency stop (e-stop) button. Safety was further enhanced by the cab’s dual access/egress doors located on the right and rear sides of the cab. The rear entry/exit and single-level floor facilitate unimpeded stretcher access to the operator station, as well as ease of entry and exit, in case of an emergency. In conjunction with the single level floor, the efficient cab layout and spacious interior facilitates easy access to storage areas and work stations, as well as safe movement about the cab. Increasing the shovel operator’s external visibility and situational awareness, as a means to greater safety, was also incorporated. The operator’s station was repositioned to offer unobstructed vertical line-of-sight extending from the crawler tracks to the point sheave. Another feature of the rope shovel is an enhanced propel system, garnering a 12-percent increase in maximum propel torque. This system was designed to combat propel challenges encountered in the mine environment, most notably in the soft footing found in oilsands and wet digging environments. It provides the necessary power boost to maneuver the machine in tough digging situations, avoiding downtime associated with ground-lodged shovels. The upgraded propel power system comes standard on the new rope shovel and can also be retrofitted to existing Bucyrus 495HR/HF rope shovels. Current owners of the Bucyrus 495HR/HF rope shovels are now able to boost the overall performance and productivity of their machines by way of the upgraded propel system retrofit. Likewise, for future owners of the next generation rope shovel, the 12 percent increase in propel power will prove to be one of many features on this innovative machine that will contribute to more material moved and more profits realized. n www.miningengineeringmagazine.com

Mine Development

Resolution Copper:

A showcase for the Rio Tinto philosophy by Emily Wortman-Wunder, Technical Editor

ust 104 km (65 miles) from Phoenix, AZ, Rio Tinto hopes its new Resolution Copper Mine will be a showcase for the Rio Tinto management philosophy. Its goal is to have a net positive impact. In every place that Rio Tinto mines, it wants to be able to have an overall beneficial effect on the local community, environment and economy. “We’re constantly working to understand our impacts, to understand how to minimize our impacts and understand how to mitigate those impacts,” said Resolution Copper Mining chief executive officer David Salisbury, from the global headquarters of Rio Tinto Minerals in Greenwood Village, CO. Resolution Copper, developing on the site of the defunct Magma Mine, is still in the pre-feasibility stage, but already has a substantial presence in the area, with more than 70 employees and more than $500 million invested. From Resolution’s new and rehabilitated infrastructure, its brand-new dewatering facility, its environmental cleanup efforts and its community development projects, it has touched the lives of many residents of nearby Superior, AZ. And it should, said Salisbury, because it is hoping to be in the area for the next 75 years. Such upfront investment in the area is an essential part of Rio Tinto’s management philosophy. “Rio Tinto has an obligation to the communities we work in,” he said. Resolution Copper is a project that Rio Tinto www.miningengineeringmagazine.com

expects will pay off in the long run. Initial exploration indicates a deposit containing an inferred resource of 1.624 Gt (1.79 billion st) at a grade of 1.47 percent copper and 0.037 percent molybdenum. It is thought to be able to produce 454 kt/a (500,000 stpy) of copper, or 20 percent of U.S. demand, for several decades. Rio Tinto estimates that at peak production, Resolution will have 1,200 employees and 200 contract workers on site, an annual local economic impact of $535.5 million and a total economic benefit to the state of Arizona of $46.4 billion over the life of the mine.

Apache Leap is the iconic rock formation behind Superior, AZ. Resolution Copper will sterilize part of its resource in order to prevent mining activity from damaging the landmark.

Land exchange

Resolution has some major hurdles to overcome to reach that point, the most significant of which is the passage of Senate Bill 409, the Southeast Arizona Land Exchange and Conservation Act. This bill is part of an Omnibus Lands Package making its way through Congress; however, Salisbury pointed out, “2010 has not been a productive lands bill session” and progress has been slow. He anticipates action on the bill by the end of 2010. The bill’s key component is an offer to exchange 2,226 hm2 (5,500 acres) of Arizona open space owned by Resolution Copper for 974 hm2 (2,406 acres) of federally owned land in order to develop mining operations. In addition, this bill allows Resolution Copper to conduct mineral exploration within a 308-hm2 (760-acre) parcel of Mınıng engıneerıng

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land previously off limits to mining exploration. This parcel includes the Oak Flats Campground, and part of the exchange package will enable Resolution to pay compensation so that equivalent recreation areas, including a new campground and rock climbing territory, can be established nearby. This is the third time the bill has gone before Congress. Salisbury said that Resolution is happy with this version of the bill. “We’ve done everything that was discussed after the failure of the last one,” he said, most notably the addition of full National Environmental Policy Act (NEPA) compliance and a comprehensive environmental impact statement (EIS).

History

The resurrection of copper mining in this area of Arizona can be attributed to advances in mining technology. The Magma Mine, Resolution’s predecessor, sat at the heart of Arizona’s historic mining district near Superior. During the middle part of the 1900s, it was one of the most productive copper mines in Arizona and produced substantial amounts as silver as well. By the midnineties the accessible copper was gone. When the mine closed its doors in 1996, it was thought to be tapped out. Exploratory work a few years later showed a different story. After extensive exploration from 2001 to 2003, Rio Tinto became a majority partner in 2004. One of its first tasks was to dewater the existing mine shaft, an ongoing project that is expected to take two to three more years. Water pumped from the mine is treated at a new facility located by the mine offices in Superior. The slightly acidic water is treated with lime and gypsum and released downstream to the New Magma Irrigation and Drainage District, where it is mixed with 10 parts fresh water and used for irrigation. In order to facilitate exploration and dewatering, a new shaft was drilled onsite. Upon its completion in 2013, this shaft will be more than 2,134-m- (7,000-ft-) deep and 9-m- (30-ft-) wide. It will ultimately be one of the smaller mine shafts drilled on the site. Prefeasibility studies are expected to be completed by 2012, with production scheduled to begin in 2020. The mine is expected to be active for 66 years.

Mine of the future

While Resolution Mine is a showcase for Rio Tinto’s management style, it is also a showcase for Rio Tinto’s innovative approach to the technology of mining. Along with Rio Tinto’s Pilbara in Australia and Oyu Tolgoi in Mongolia, Resolution Copper is billed as a Mine of the Future, one that will be driven by cutting-edge technological ad34

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vances and innovation, including unprecedented levels of automation. The orebody at Resolution lies approximately 1.6 km (1 mile) below the surface. The mine will eventually have six shafts (currently there are two), each 2,134 m (7,000 ft) deep or more. Resolution will be one of the deepest underground mines in the world. It will also be one of the hottest mines: parts of the mine will be hotter than 79.4° C (175° F). Adam Hawkins, Resolution spokesman, said in June that, “It is not the deepest Rio Tinto mine, and it is not the hottest Rio Tinto mine, but it is the deepest and hottest mine that Rio Tinto has operated.” In addition, Resolution Copper is located within a sensitive ecological and historic zone, less than 1 k (0.5 mile) from the stunning rock formation known as Apache Leap. Rio Tinto is striving to minimize the surface footprint of the mine. The ore will be collected by panel caving, a form of block caving, in which ore is broken up and funneled downward at collection points, and then hauled to the surface. One of Resolution’s technical challenges is to efficiently hoist 99.8 kt (110,000 st) of ore a day. Another challenge is to minimize the amount of surface subsidence caused by the block caving. This is both a technical challenge and an environmental challenge; it will be an ongoing safety challenge once the mining gets under way. It’s also a key test of the Rio Tinto philosophy of net positive impact.

Net positive impact

“We like to design our operations from closure backwards,” explained Adam Hawkins, from Rio Tinto Minerals offices. “It means we work on leaving a positive net impact right away.” Resolution has already invested $500 million in the Superior region. Much of that sum has gone toward cleaning and rehabilitating the old mine site, from dewatering the old shaft to moving and consolidating leaking tailings piles that bounded the town of Superior to the east. It has invested heavily in PhD-level experts to model and monitor environmental and geologic conditions at the mine site, trying to predict and lessen potential impacts before mine activity gets under way. Resolution currently has an ISO environmental management rating of 140001:2004. While block caving was chosen as a mining technique with a substantially reduced footprint, it presents the problem of surface subsidence. Current estimates of the eventual subsidence at Resolution Copper range from very little to 1,310 m (4,300 ft). Resolution’s efforts to minimize subsidence began early, as geologists modeled the likely responses of local rock to both block caving and www.miningengineeringmagazine.com

the first proposed solution, which was to fill the mined-out stopes with tailings. Work continues in this area, with current research including the perfecting of state-of-the-art “smart rocks” that can monitor ground movement and mass flow. Once mining begins, in addition to continuous monitoring and reassessment, parts of the reserve will be “sterilized,” or not mined. Both monitoring and research will continue up to and beyond closure. Work to minimize the impact on water has been similarly detailed. “It’s no secret that mining uses a lot of water,” said Salisbury. Strategies include the water treatment plant, which will help Resolution recycle water up to seven times. In addition, it has already bought a 10 year’s supply of water from the Central Arizona Project (CAP), which it hopes to trade for less clean water to use in mining operations. It is currently working on a project with the University of Arizona to determine if municipal effluent can be used in mine processing. Other impacts of the mine are social and cultural, and Resolution has worked hard to determine the potential pitfalls of revving up a mining economy that has been in decline for half a century. “With mining, we want to know: how do we break the boom and bust cycle of traditional mining?” said Hawkins. “How does our company fit into the overall vision of the community — how can it be a catalyst, instead of the only blood in the veins?” One way is by improving the educational opportunities of the local community. This effort has the added benefit of training the future workforce. The first generation of Resolution Copper miners just finished third grade, and Resolution has accordingly begun partnering with the local elementary school to improve math and science scores among the students there. In the 2009-2010 school year Resolution helped to fund the rigorous state math curriculum known as Rodel MACRo. It has also funded several scholarships and internship programs for high school and college students from the area. Another effort has focused on developing the local economy. Resolution partnered with the Arizona State Department of Commerce to help Superior build community committees that would learn how to attract sustainable businesses that would help shape the community into a desirable place to live. One of the recurring statements from the community is that they would like to build their ability to attract ecotourism and artistic activity. To that end, they have made historic and environmental preservation a community priority. Resolution has accommodated that priority by striving to maintain historic structures — the Superior office is housed in the building of the www.miningengineeringmagazine.com

old Magma hospital, which was recently restored in a historically sensitive manner. Resolution has also worked with the community to build the Legends of Superior Trail, which will connect with the Arizona Trail, effectively making Superior a gateway community to the trail. As Resolution communications manager Jennifer Russo noted in June, “So far $500 million has been spent on this project, most of it on developing the net positive impact, on building trust, on integrating with the community.” “We’re not altruistic,” Russo added. “We’re up front: we’re doing this to help our bottom line.”

Head frame for shaft number 10 at Resolution Copper. The shaft is expected to be completed by 2013.

Risks

Resolution Copper prides itself on being open to dialogue with any member of the community willing to approach it — a favor that is not always reciprocated. Salisbury has observed that many groups will ignore invitations to meet or will rebuff such invitations. Others will meet with them but are unable to find common ground. When asked if this strategy of dialogue brings risk, he shrugged. “Where’s the risk?” Then he reconsidered: “There’s the added cost. And there’s another risk if you’re not committed to followup. We have that commitment. We will follow through. “As I told the World Bank back in 2000,” Salisbury said, “A company’s legacy isn’t defined by itself but by its neighbors.” n Mınıng engıneerıng

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Industrial Minerals

Bismuth and antimony compounds A look at 2009 activity by H.A. Taylor, Jr., Basics/Mines

ismuth, one of the heavier chemical elements, is a pinkish metalloid that is chemically related to antimony. It is a byproduct of lead and tungsten extraction and, to a lesser extent, of copper and tin extraction. Antimony is a metalloid and less heavy chemical element, an extraction coproduct of metals such as lead, silver and gold. While both bismuth and antimony are metalloids, their major uses are as chemical compounds. The most frequently updated resources that always cover bismuth and antimony are the Bismuth Advocate News (BAN) and link at www. basicsmines/bismuth and the frequently updated Basics Mines Update blog at http://basicsminesupdate.blogspot.com. The Bismuth wiki on Wikipedia also can be very helpful.

Characteristics of the end uses

Bismuth compounds and antimony compounds and related nonmetallic uses account for most of the consumption of these chemical elements. Little is used as a metal or alloy. The largest end-use group for bismuth is the chemicals group, which includes pharmaceuticals such as stomach medicine (bismuth subsalicylate), cosmetics for a pearlescent effect (bismuth oxychloride), catalysts and other chemical uses such as paint (bismuth vanadate yellow). The next most important end use group of bismuth is the metallurgical additives group, whose components prevent the crystallization of graphite from molten steel supersaturated with carbon, facilitate free machining in steel, copper and aluminum, and facilitate an even coat in galvanizing. For all of the applications in this group, the bismuth is not acting as an alloying agent but more like a catalyst that discourages, encourages or creates certain reactions or properties. Steel needs only 0.1 percent bismuth or selenium to give it good machinability. In addition to this, the bismuth alloy group accounts for a minor amount of bismuth, which is used in fusible alloys, other lowmelting point alloys and in ammunition. The largest use of antimony is in the flame retardant group, mostly in treating plastics, adhesives and textiles. Antimony oxide has a special role among flame retardants as a gas phase radical quencher, amid a variety of mostly halogenated materials that are used as flame retardants. The other nonmetal product group includes major uses in pigments and in glass (including ceramics). Antimony oxide in most glasses and ceramics acts as an opacifying agent, but antimony in specialty glasses can clarify them.

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The antimonial lead and alloys group mostly comprises the antimonial lead used in gasolinedriven automotive storage batteries. An important question for each bismuth and antimony end use is whether or not and to what extent is it recyclable?

Recyclability

Recyclability ranges from the impossible, which is the bismuth in stomach medicine and cosmetics because it is completely scattered, through lessening degrees of difficulty, such as antimony in flame retardants, bismuth in metallurgical additives and galvanizing, antimony additives in glass and bismuth in catalysts. The easiest recycling occurs with bismuth in fusible and other alloys and antimony in the antimonial lead plates of storage batteries.

Statistics

U.S. imports of bismuth metal, the largest volume category, was 1.9 kt (2,100 st) in 2008 and 1.2 kt (1,300 st) in 2009, a decrease of 35 percent. U.S. imports of antimony oxide, the largest volume category, was 26.2 kt (28,800 st) (gross amount) in 2008, and 18.3 kt (20,200 st) in 2009, a decrease of 30 percent. There are other less important statistical categories for bismuth and antimony. The drop in imports of both bismuth and antimony was related to the recession of 2008-2009.

Developments

Nippon Mining & Metals Co. Ltd. in late 2008 brought onstream the Hitachi Metal Recycling Complex to recover metals from wastes of its other subsidiaries in Japan. When fully onstream, this complex should recover 200 t (220 st) of bismuth, 150 t (165 st) of antimony and 500 t (550 st) of tin. The entire complex was scheduled to be completed by March 2009. In China, six Hunan bismuth producers, with a combined annual capacity of 3.2 kt (3,500 st) of bismuth, formed a consortium called the Hunan Bismuth Industry Co. to cushion speculation and improve China’s stature in the world bismuth market. Hunan province is also one of the two leading provinces for antimony. The consortium accounts for 30 percent of China’s refined bismuth metal production, and its formation could be a reflection of the 2007 merger between MCP Aramayo Ltd. and Sidech S.A. The Chinese government lowered its 2009 export quota for antimony and a number of other metals, such as indium and tin. The 2008 quota www.miningengineeringmagazine.com

for antimony and antimony products was 59.9 kt (66,000 st) and the 2009 quota was dropped to 58.7 kt (64,700 st). The Chinese government also raised the export VATs (tax) on a number of minerals it is a major exporter of, such as graphite. This is a part of a long-term effort to favor Chinese raw material needs over foreign customers and the world market.

Outlook

The outlook for both elements appears to be better than the depths seen in early 2009. The U.S. Geological Survey’s (USGS) quarterly bismuth consumption statistics by end use for first quarter 2008 through third quarter 2009 shows a drop in consumption in the chemicals group until the first quarter 2009, to less than half of where it began, and a clear upward move to the third quarter 2009. The majority component holding up the best was pharmaceuticals-cosmetics and the balance (catalysts) did not do as well. The consumption in the metallurgical additives group behaved analogously by quarter, bottoming in first quarter 2009 to less than half where it began, then clearly bouncing back. Consumption statistics for

the bismuth alloys group may not be valid, but were minor, in any case. While an examination of consumption for an end use by quarter is revealing for bismuth, it is not so for antimony. The USGS reported that 2008 U.S. antimony consumption totaled 7.6 kt (8,400 st), and by end use was 3.2 kt (3,500 st) in the flame retardants group (2.3 kt or 2,500 st of which in the plastics component), 2.7 kt (3,000 st) in the other nonmetal product group, i.e., with components of ammunition and fireworks, pigments, glassceramics and plastics-rubber, and 1.7 kt (1,900 st) in the antimonial lead and alloys group. The prospects for 2010 are mildly encouraging. Bismuth in the chemicals group should do better in its pharmaceuticals-cosmetics component than in catalysts-others component. Bismuth in the metallurgical additives group should also do better but not quite as well as the pharmaceuticalscosmetics component because they are industrial. For antimony, the flame retardants group is likely to do better, the others less so, and the antimonial lead and alloy group the least because it is fossil-fueled automotive related. n

Common clay and shale A look at 2009 activity by R.L Virta, U.S. Geological Survey

ommon clay is a natural, fine-grained material composed of hydrous aluminum silicates. Shale is a laminated sedimentary rock formed by the consolidation of clay, mud and (or) silt.

Government and legislative programs

The U.S. Environmental Protection Agency (EPA) invited industry to nominate representatives to a review panel that will help the EPA develop rules to regulate air toxics from the production of brick and structural clay products. The EPA was required to establish a review panel because these regulations will significantly affect small businesses. The regulation of air toxics falls under the Clean Air Act.

Production

About 129 companies produced common clay and shale in 43 states. Estimated domestic production in 2009 was 12.5 Mt (13.7 million st) valued at $138 million, based on a preliminary survey of the common clay and shale industry. This was a 29-percent decrease in tonnage from 17.5 Mt (19.3 million st), valued at $208 million, in 2008. The top producing states, in decreasing order by tonnage, were Texas, Alabama, North Carolina, Ohio and Georgia. These five states accounted for 41 percent of U.S. production in 2009. www.miningengineeringmagazine.com

Boral Bricks Inc. announced that a plant in Augusta, GA was reopened in May. The plant had been closed to reduce excess inventory that had accumulated as a result of the housing downturn. This plant was to supplement output from another plant owned by Boral Bricks that remained open during the economic downturn. A third plant in the area was to remain closed for an indefinite period of time.

Consumption

Sales or use of common clay and shale were 12.5 Mt (13.7 million st) in 2009. Based on sales in 2008, the major uses in 2009 were building brick, lightweight aggregate and portland cement clinker. Approximately 7.13 Mt (7.85 million st) of common clay and shale was used by the brick industry, 2.38 Mt (2.62 million st) for the production of lightweight aggregate and 1.75 Mt (1.92 million st) for portland cement clinker manufacture. These three markets accounted for 90 percent of the common clay and shale market. Lightweight aggregate sales are subdivided into concrete block (1.13 Mt or 1.24 million st), structural concrete (540 kt or 595,000 st), miscellaneous lightweight aggregates (500 kt or 550,000 st) and highway surfacing (210 kt or 231,000 st). About 427 kt (470,000 st) of common Mınıng engıneerıng

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clay and shale was sold for the manufacture of refractory products, and 172 kt (189,000 st) for floor and wall tile. Other markets for common clay and shale include miscellaneous ceramics and glass, drain tile, flower pots, flue linings, roofing granules, sewer pipe and structural tile. The slowdown in commercial and residential construction activity in recent years had a significant and negative impact on sales of common clay and shale for heavy clay products. Statistics through the first nine months of 2009 from the U.S. Bureau of the Census show that production and shipments of brick were 58 percent and 65 percent, respectively, those in the first nine months of 2008. Production and shipments of clay floor and wall tile through the first nine months of 2009 were 3 percent and 6 percent, respectively, greater than of those of the first nine months of 2008. Production and shipments in the second and third quarters of 2009 were greater than those of all quarters in 2008 and those of the first quarter of 2009. Production often strengthens early in the year with increases in home construction following a winter lull, but the rise may be enough that it suggests a market improvement. Finally, production and shipments of vitrified clay sewer pipe and fittings in the first nine months of 2009 were 70 percent and 63 percent, respectively, compared with those of the same time period in 2008. Residential and commercial construction projects are major markets for common clay and shale and provide a gauge of the demand for products manufactured with common clay and shale. The Census Bureau reported the number of privately owned housing units started was 555,000 in 2009 compared with 906,000 in 2008 and 1.36 million in 2007. The value of total construction

(residential and nonresidential) put in place was $939 billion in 2009, compared with $1.07 trillion in 2008. Housing starts increased slightly in late 2009 and early 2010.

Prices

The average unit value for all common clay and shale produced in the United States and Puerto Rico was $11/t ($9.97/st) in 2009, essentially unchanged from 2008. The unit value of common clay and shale sold for lightweight aggregate production was estimated to be $28/t ($25.40/st) in 2009, unchanged from 2008, with the bulk of lightweight aggregate products valued between $30/t and $70/t ($27.22/st and $63.50/st) for most applications.

Outlook

The U.S. recession continued to negatively affect markets for common clay and shale. The industry has seen 15 to 20 percent declines during the past two years. There are some signs of a slight recovery in common clay and shale markets, with housing starts increasing slightly in early 2010. Credit required to construct and (or) buy commercial buildings and private residences remains tight and, given the large number of home foreclosures, there is still an oversupply of residential housing available. Another potential concern is possible financial troubles in the commercial office market, similar to what arose in residential housing in 2008. Consequently, producers of common clay and shale are expected to continue to face difficult markets in 2010, with sales possibly experiencing 5 to 10 percent declines, less than in 2009, but still significant. n

New Technology

Magnetek introduces drive system for mining M agnetek Inc., introduced its new M-Force SD500 severe duty ac traction drive system for mining applications. The system can be used in a variety of battery-operated mobile vehicles including locomotives, muckers, shuttle cars, continuous miners and battery haulers. The M-Force SD500 system is designed to be connected to permanent magnet or induction ac motors for high efficiency at a range of motor speeds. While the M-Force SD500 severe duty ac traction drive system is a standard platform, Magnetek also provides custom engineered systems that include fully regenerative drives, explosion-proof displays and rugged controllers. Magnetek’s M-Force SD500 incorporates a U.S. Mine Safety and Health Administration(MSHA) approved display with enhanced

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graphics and external buttons for diagnostics and control. Multiple display options allow the operator to choose what is displayed to help fully maximize the productivity of the drive system and vehicle. The external configuration controls allow for system programming and reconfiguration, data recording and troubleshooting within a permissible area. The machine does not have to be moved from its production area to make adjustments or verify system conditions. The controller has the capability to control up to four drives and incorporates Magnetek’s CANBUS and radio frequency hardware technology. The SD500 is capable of direct machine control of motors and hydraulics and other CAN-BUS compatible devices. n www.magnetekmining.com

www.miningengineeringmagazine.com

Technical Papers

Investigation into the practical use of belt air at US longwall operations by R.B. Krog and C.J. Bise

Abstract n The use of belt air as an intake source at longwall operations has changed greatly

over the past decades. The practical considerations for the use of belt air are controlled by a variety of factors, including airflow quantity and velocity, coal methane content, methane desorption rates, coal mining rate, belt length, stopping leakage and the number of gateroad entries. At longwall operations, the advantages and disadvantages of belt air are different than for gateroad development and longwall panel extraction. During gateroad development, the use of belt air to ventilate the working section will reduce the leakage from the intake to the belt compared to the belt air being ventilated outby the working sections because of lower pressure differentials. A greater quantity of airflow will reach the last open crosscut with the belt on intake than outby, given the same amount of pressure and airflow available at the mouth of the section. This paper will investigate the current ventilation practices regarding the use of belt air during gateroad development and longwall panel extraction. Operating considerations regarding air quantities and pressures to deliver the required airflow will be investigated using ventilation network modeling.

Introduction

In December 2007, the Technical Study Panel on the Utilization of Belt Air released a report concerning the use of belt air in US coal mines (Mutmansky et al., 2007). The panel’s report covered a wide range of topics and their recommendations should be considered in all longwall ventilation systems. The ventilation system for each longwall primarily depends on the number of entries used in the gateroad development. As of February 2008, there were approximately 48 operating longwall panels mining coal in the United States (Fiscor, 2008): R. B. Krog, member SME, is an associate service fellow at the National Institute for Occupational Safety and Health, Pittsburgh, PA. C.J. Bise, member SME, is chair of Mining Engineering at West Virginia University. Paper number TP-09-020. Original manuscript submitted March 2009. Revised manuscript accepted for publication January 2010. Discussion of this peer-reviewed and approved paper is invited and must be submitted to SME Publications by November 2010. www.miningengineeringmagazine.com

• five four-entry panels (Blue Creek - Mary Lee seams in Alabama / Pocahontas #3 seam in Virginia / Powelton seam in West Virginia) • 39 three-entry panels • four two-entry panels (Utah) The four-entry gateroad longwalls are characteristically located in the gassiest coal seams in the United States. To handle high methane emissions during development, the outer two entries are placed on return air and the middle two entries on intake air. The most common three-entry system generally consists of a belt entry (ventilating the working section or not), a middle intake and a dedicated return (Fig. 1). Belt air can either be directed to the working section or not. For the rest of this paper, airflow in the belt that is sent to the working section will be called ‘belt air’ and airflow in the belt that is not used to supply the working section will be called ‘belt outby.’ The middle travelway entry may or may not have an installed track, but is the primary escapeway unless trolley haulage is being used. All two-entry gateroads are located in Utah, where ground control issues preclude the use of developments with

more than two entries. The yielding pillars that are required to control possible bump conditions cannot easily and safely be developed with a three-entry system. During development, the belt is located in the return and the travelway is in the intake. During panel extraction, both entries are used to supply intake air to the end of the longwall section. It is important to remember that there are several safety considerations that must be instituted as conditions for granting a petition for modification to allow the belt entry to be used as a section return on development and as an intake split on retreat. The airflow requirements for gateroads are controlled by a number of factors, primarily methane emissions at the face and along the solid ribs. Emissions from the active face are assumed to be independent of the length of the gateroad and require sufficient fresh airflow at the last open crosscut for dilution. If the intake air contains methane, a greater airflow is required. For shorter gateroads, development methane liberation in the face area is the primary factor influencing airflow requirements. As gateroad distance increases, however, the exposed rib length increases and a greater amount Mınıng engıneerıng

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Figure 1 Model layout (belt air used to ventilate working section).

Figure 2 Airflow at the last open crosscut with belt on intake and return with different stopping resistances (Ns2/m8).

of methane flows into the ventilation system, mainly from the outer coal ribs. This methane inflow rate is a function of the coal’s methane content and desorption rate. However, for long gateroads, rib emissions can far exceed the methane liberated at the development face. In this case, the total amount of air available at the section mouth for dilution of the rib emissions limits gateroad development distance. All of these methane emission sources can be affected by premining or in situ methane drainage. Model setup. VnetPC 2007 (Mine Ventilation Services, Fresno, CA) ventilation simulation software was used to analyze gateroads of various lengths, using 300-m (984-ft) long segments, each with six crosscuts. It should be noted 40

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that turbulent airflow was used to determine leakage for the stoppings, not laminar airflow. Total pressure across the mouth of the section was held constant at 1 kPa (4.1 inches water gauge), while airflow rate was allowed to change. Entry sizes of 4.7 x 2.4 m (15.5 x 8 ft) or 6.1 x 1.82 m (20 x 6 ft) both yield a similar resistance of 0.025 Ns2/ m8 (0.224 x10-10 in·min2/ft6) per 300-m (984-ft) segment using common k factors (Hartman et al., 1997). Because of the high equipment blockages, the belt entry was given a resistance 20% higher 0.030 Ns2/m8 (0.279 x10-10 in·min2/ft6) than the other entries. Stopping resistances were set at 2,000, 2,500, 3,500, 5,000, 7,500 and 10,000 Ns2/m8 (17,900, 22,300, 31,300, 44,800, 67,100 and 89,500 x10-10 in·min2/ ft 6) to represent poor-to-excellent stopping construction (Oswald, 2008). Total lengths of gateroads modeled ranged from 300 m (984 ft) to 6,300 m (20,670 ft). Crosscuts were set on 50-m (164-ft) centers with six stoppings grouped together to indicate standard gateroad crosscut layouts. Longer 60-m (197-ft) centers were also modeled to indicate the longwall operation with crosscuts farther apart, but the results did not differ much if a higher stopping resistance was used. For example, six 5,000 Ns2/m8 (44,800 x10-10 in·min2/ft6) stoppings are almost identical to five 3,500 Ns2/m8 (31,300 x10-10 in·min2/ ft6) stoppings if placed in parallel over the same 300-m (984ft) segment (Table 1) where equivalent parallel resistance is equal to stopping resistance / (number of stoppings)2.

Airflow at the last open crosscut

The amount of airflow reaching the last open crosscut www.miningengineeringmagazine.com

Figure 3 Theoretical maximum gateroad development using belt air on intake with relative pressure differentials and variable stopping resistances. is controlled by several factors: 1. 2. 3. 4. 5. 6.

Number of entries and their layout. Stopping resistance. Number of stoppings. Entry resistance. Pressure differential across the entries. Limitations in entry velocities or pressures across stoppings.

With the same pressure differential at the section mouth, a three-entry system can deliver more air to the last open crosscut using ‘belt air’ toward the working sections rather than ‘belt outby’ the face (Fig. 2). Using ‘belt air’ to ventilate the working sections reduces the quantity of leakage from the middle intake into the belt, but increases the possibility that the belt entry may eventually carry more airflow than the intake or be at a higher pressure relative to the intake. This possibility establishes a limit to the maximum gateroad length that can be developed with the belt on intake air. Figure 2 illustrates that a maximum development distance of 3,300 m (10,800 ft) is obtained when placing the belt entry on intake air and using a stopping resistance of 2,000 Ns2/m8 (17,900 x10-10 in·min2/ft6). For gateroad lengths exceeding 3,300 m (10,800 ft), total pressure or airflow in the belt entry exceeds those values in the intake entry. For all six curves, the resistances of the entries are shown in the previous section and the pressure at the mouth of the section is 1 kPa (4.1 in. w.g.). The relative pressure of the belt to the intake was 75% for the ‘belt air’ curves and 20% for the ‘belt outby’ curves. As the stopping resistances increase or if the belt entry is placed on ‘outby’ airflow, maximum development distances can increase. The ideal cases of ‘no leakage’ through the stoppings are also shown in Fig. 2 to show the theoretical maximum airflow rates. In addition to stopping resistance, maximum gateroad development length is impacted by the pressure differential between intake and belt entries at the section mouth. Figure 3 shows the maximum gateroad development distance that keeps intake entry airflow higher than belt entry airflow. The percentages in the graph are the total pressures in the belt entry relative to those in the intake airway measured at the section mouth. “LOC” (last open crosscut) and “mouth” refer to the locations that limit gateroad development. The kinks in Fig. 3 are caused by the model setup using 300-m (984-ft) long segments. Total pressure in the belt airway cannot be lowered too much, in that a lower relative pressure translates to a lower belt airflow measured at the section mouth. With total pressure in the belt entry at 70% of the total pressure in the intake entry, gateroad development is not restricted by the high belt airflow at the last open crosscut but, rather, by low www.miningengineeringmagazine.com

Table 1 Equivalent parallel resistances. Resistance

Parallel stoppings

Ns2/m8

(50 m apart)

(60 m apart) (75 m apart)

10,000

278

400

625

7,500

208

300

469

5,000

139

200

313

3,500

140

219

2,500

100

156

2,000

125

belt airflow at the section mouth. Using the guidance of the technical study panel on the utilization of belt air (Mutmansky et al., 2007) of a minimum air velocity of 0.5 m/s (100 ft/ min) and an entry opening of 11.2 m2 (120 ft2), the minimum airflow quantity is calculated to be 5.6 m3/s (12,000 cfm) at the section mouth for these models. Using the above example of the belt entry pressure at 70% of the intake entry pressure and stopping resistances of 7,500 Ns 2/m8 (67,100 x10-10 in·min2/ft6), the maximum gateroad development is not limited to 6,000 m (19,700 ft) by airflow at the LOC, but by the low airflow at the mouth of the section when the gateroad is developed to 4,800 m (15,700 ft). The maximum distance for gateroad development occurs Mınıng engıneerıng

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Figure 4 Leakage from the belt entry into the intake (0.02 and 0.04 m3/s) before the belt entry transports more airflow than the intake (17.30 and 18.69 m3/s), 4200-m model with 1 kPa of pressure at the mouth of the section and 5000 Ns2/m8 stoppings.

Figure 5

a new problem arises with the belt entry carrying more air than the intake entry. Gateroad development limit using belt air at 75% of pressure of intake Using the same model parameter as before, entry with different stopping resistance. Leakage total is from intake the maximum gateroad length that can be ventiinto return. lated using belt air is controlled by two factors: 1) leakage into the belt and 2) methane emissions. Excessive leakage into the belt near the start of the section and continued leakage from the intake into the return can cause the belt to be at a higher relative pressure than the intake at the end of the gateroad. Eventually, the belt will be supplying a greater airflow than the intake to the working section, contrary to regulation (Code of Federal Regulations, 2008). When belt air starts leaking into the primary intake, the major concern is that a belt fire will contaminate the intake air split with CO and smoke and make escape more difficult. The belt entry will have a higher resistance than the intake entry, due to obstructions such as belt structure, belt take-ups, etc. Air from the belt entries will leak into the intake entries long before the belt carries more air than the intake (Fig. 4). Figure 5 shows that once leakage into the return from the intake when both the restriction on airflow at the last open crosscut approaches 41%, the ventilation system, regardless and minimum airflow entering the belt at the mouth of the of stopping resistance, has a problem with the belt entry besection occur at the same time. The 75% LOC line repre- ing at a higher pressure than the intake. sents the maximum development distance while balancing Point feeding the belt entry is a common practice and a both requirements at the LOC and mouth of the section. In beneficial one for shorter gateroad developments. This paper the above example of 7,500 Ns2/m8 (67,100 x10-10 in·min2/ft6) is concerned with calculating the maximum distance that a stoppings, if the total pressure in the belt is 75% of the intake gateroad can be developed if ventilation is the limiting factor. at the mouth of the section, the maximum development was As the gateroad length increases, so does the point feed, and calculated to be 5,100 m (16,700 ft), not 4,800 m (15,700 ft). there is a steep increase in the percentage of airflow being The purpose of gateroad development is the mining of delivered to the working area from the belt entry. The limitathe subsequent longwall panel. Ventilation of the gateroad tion of a higher pressure belt entry compared to the intake development should not be the only consideration for us- entry increases as the amount of point feeding increases. ing three or four entries. Ultimately, the gateroads provide Point feeding for the belt entry is simulated in this paper as important ventilation flow paths through the worked-out the relative pressure difference between the intake and the area and have significant impact on the bleeder system per- return entry (70%, for example). formance. While this paper covers belt air issues on gateroad Increased belt resistance. The belt resistance was set 20% development, the important future use of the gateroad and higher than the other two entries, but was also modeled at the bleeder system should also be considered. 0% and 40% greater than the other two entries, to represent Limitations of belt air the increased obstruction of the belt assemblage. There was Using belt air to ventilate the working sections does no significant change to the pattern of airflow in the belt or make it possible for a higher percentage of intake air to reach in the leakage quantity from belt to intake. The two controlthe last open crosscut because leakage is reduced. However, ling factors for the development of very long gateroads are 42

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www.miningengineeringmagazine.com

Figure 6

Figure 7

4,270-m longwall panel at startup with belt air.

4,270-m longwall panel at startup with dual intakes.

stopping resistance and pressure differential at the mouth of the section. The mixing problem. The ventilation models show that a higher percentage of airflow will reach the working section if the belt is placed on intake rather than return, assuming similar resistances. The methane loading of the intake air will be quite different and will affect the air’s ability to ventilate the active workings. The main assumption is that little methane will enter into the middle intake, while methane will bleed into the outer entries off of the solid coal rib. When the outer belt entry is used to ventilate the working section, methane emissions from the rib will be carried to the active face and can increase the starting methane concentrations at the working section. Higher starting methane levels for the combined intake and belt air would require a higher airflow quantity to dilute the methane liberated in the working places. The final methane emissions at the last open crosscut can be calculated by the following formula:

Figure 8 A 3,670-m gateroad with belt air on intake, plus a 3,600-m ventilation model (432 Pa).

Figure 9 A 3,600-m ventilation model with belt air on return, with better stoppings (835 Pa).

(1) Where: CI = Intake concentration QI = Intake air quantity CB = Belt concentration QB = Belt air quantity CF = Concentration where the belt air and intake air mix The quantity of methane released by the coal transported on the belt changes during panel development and panel extraction. The quantity of coal mined by the continuous miner is less than 10% of what a shearer produces and is more cyclical during the shift. The methane emission rate of the mined coal on the belt during panel development is low compared to the rib emissions rate. For example, the 26 m3/s (55,000 cfm) supplied by the intake track entry, compared to the 14 m3/s (30,000 cfm) of intake air and 12 m3/s (25,000 cfm) of belt air, may not have the same diluting ability. Assuming the intake track entry has a methane concentration of 0.1%, and the belt 0.3%, the final mixed methane concentration will be 0.19% using the above equation. This figure represents a reduction of 10% in the quantity of fresh air, diluting the methane in the working sections on a per m3 (ft3) basis, but this example does not have the higher airflow quantity usually associated with using belt air to ventilate the working www.miningengineeringmagazine.com

sections. In gassy four-entry longwall operations, adverse rib emissions preclude the practice of bringing outer entry airflow towards the working section. Panel extraction. During longwall panel extraction, the belt can be fully loaded with coal that can add a significant amount of methane to the air used to ventilate the longwall headgate. With so much methane being liberated by the coal, it may be more appropriate to ventilate the section belt airflow outby from the longwall section and convert the outer gateroad development return entry into a secondary intake. This has a number of benefits, such as increasing safety with two semi-isolated escapeways and supplying a greater quantity of airflow to the headgate end of the longwall face at a higher pressure. For example, a longwall panel with a length of 4,270 m (14,000 ft) was initially ventilated with belt air and one intake entry. Upon longwall panel startup, airflow was reduced to the return entry to maintain adequate airflow across the longwall face. Soon thereafter, a problem arose with high methane concentrations in the belt entry once the shearer had been operating for one cut cycle to load the belt with Mınıng engıneerıng

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coal. A methane concentration of 0.7% on 12 m3/s (25,000 cfm) airflow at the working section of the belt entry necessitated a major change to the ventilation system (Fig. 6). The belt was switched to outby airflow and the outer return entry was converted into a secondary intake. This enabled 62 m3/s (131,000 cfm) to reach the headgate end of the longwall face rather than 50 m3/s (106,000 cfm) before the switch (Fig. 7). The methane emissions from the solid coal rib of the converted return entry are now routed to the longwall face. The higher air quantity outweighed this added methane loading. Entry resistance. Entry resistance plays a significant role in determining how much air is delivered to the last open crosscut. By doubling the resistance of the entries, the expected flow rate should decrease to approximately 71% of the original airflow. Note that the pressure differential is kept the same at 1 kPa (4.1 w.g.). (2) In the ventilation models, the stopping resistances are kept constant and, therefore, the system will have a higher leakage percentage. The above simplification will only hold true if stopping resistance also increases by the same ratio as the entries’ resistances. With the stopping resistances kept constant and the entries’ resistances doubled, the calculated airflow at the last open crosscut can be reduced to less than 50% of the base case.

Case study

A three-entry longwall gateroad was converted from using belt air on intake to return for gateroad development on subsequent panels. The mine indicated that everything was kept the same in the development of the two adjacent gateroads, except for reversing the airflow in the belt and the higher pressure at the mouth of the section of the new gateroad. This conversion was possible because the mine had just connected to a new ventilation shaft. The initial measured airflow distribution is shown in Fig. 8. The gateroad was 3,670 m (14,000 ft) in length and had 65 crosscuts. The layout placed the belt in #1 entry, the intake in #2, and the return in #3. The supplied airflow to the last open crosscut was 26 m3/s (55,000 cfm), with leakage from the intake entry into the belt entry. While there was still more airflow in the intake for the last 600 m (1,970 ft), the 3,600-m (11,800 ft) ventilation model showed that belt air may have been leaking into the track entry (as previously shown in Fig. 4). The individual stopping resistances utilized were chosen to be 3,500 Ns2/m8 (31,300 x10-10 in·min2/ft6) using a 3,600-m (11,800 ft) VnetPC ventilation model constructed before. The modeled airflow pattern corresponds closely with Fig. 8, which represents both the measured airflow patterns of the actual 3,670-m (12,000 ft) gateroad and the 3,600-m (11,800 ft) ventilation model. The model was changed to have the belt on outby and the pressure at the mouth of the section increased, but there was too much leakage to match the field-measured airflow distribution. The modeled stopping resistances were increased to 5,000 Ns2/m8 (44,800 x10-10 in.·min2/ft6) to better match the actual airflow pattern. Figure 9 shows the ventilation models’ airflow pattern, which matches the field measure44

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ments. The mine site was contacted again and the authors were told that a second sealant coat was applied to the stoppings months after installation to reduce the air leakage that occurred because of the higher pressures and deterioration of the stopping. The stoppings were constructed using the same material, but the higher pressures and leakage necessitated resealing. In this case study, converting the belt entry to return increased the pressure and airflow requirement from 42 m3/s @ 432 Pa (89,000 cfm @ 1.8 in. w.g.) to 62 m3/s @ 835 Pa (131,000 @ 3.4 in. w.g.) at the mouth of the section. This calculates to a 185% increase in static air power (quantity x pressure) to ventilate the same length gateroad. If the original stoppings were not resealed, the static air power would have increased 306% (73 m3/s @ 1010 Pa) (155,000 cfm @ 4.1 in w.g.). Higher pressure requirements at the mouth of the gateroads will also result in higher leakages in the mains and submains and a further increase in pressure on the total mine ventilation system.

Summary

The use of belt air to ventilate the working section during gateroad development can increase the total airflow at the last open crosscut, but has some possible disadvantages. The physical ability to move more airflow to the last open crosscut can outweigh the added methane emission from the solid coal rib, so long as it is not displacing fresh intake air. For long gateroad distances or poor stopping resistances, there could be situations where the belt air leaks into the intake entry. When belt air starts leaking into the primary intake, the major concern is that a belt fire will contaminate the intake air split with CO and smoke and make escape more difficult. This paper showed that ventilation pressure at the section mouth and stopping resistances are the limiting considerations for the maximum length gateroads that can be developed using intake belt air. In a case study, a threeentry gateroad that converted from belt air ventilating the working section to belt airflow outby the working section increased the air power requirements at the mouth of the gateroad 185% to maintain the same airflow at the last open crosscut.n

Disclosure

The findings and conclusions in this report are those of the authors and do not necessarily represent the views of the National Institute for Occupational Safety and Health.

References Code of Federal Regulations, Title 30 Section 75.350(b)(6), http://www. msha.gov/30cfr/75.350.htm. Hartman, H.L., Mutmansky, J.M., Ramani, R.V., and Wang Y.J., 1997, Mine Ventilation and Air Conditioning, Wiley Interscience. Fiscor S., 2008, US Longwall Census 2008 – February 2008, Coal Age, February 2008, 28 pp. Mutmansky, J.M., Brune, J.F., Calizaya, F., Mucho, T.P., Tien, J.C., and Weeks, J.L., 2007, The Technical Study Panel on the Utilization of Belt Air and the Composition and Fire Retardant Properties of Belt Materials in Underground Coal Mining, December 1999. http:// www.msha.gov/beltair/BeltAirFinalReport122007.pdf. Oswald, N., Prosser, B., and Ruckman, R., 2008, “Measured values of coal mine stopping resistance,” 12th U.S./North American Mine Ventilation Symposium, pp 103-106. www.miningengineeringmagazine.com

Coming Events Upcoming SME Events International Conference on Hoisting and Haulage September 12-15, 2010 Mirage Hotel Las Vegas, NV, USA

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For Additional Information, Contact: Meetings Dept., SME Phone 800-763-3132 • 303-948-4200 • Fax: 303-979-3461 • E-mail: sme@smenet.org • www.smenet.org

August 2010 17-19 • Sustainable Mining 2010

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University of Minnesota-Duluth, Duluth, MN USA Phone: 218-726-6582 • Fax: 218-720-4329 E-mail: prc@d.umn.edu www.d.umn.edu/prc/workshops/F10workshop

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SME News

SME Foundation

Presidential Scholarship issues call for applications T

he Mining and Metallurgical Society of America (MMSA) and the Society for Mining, Metallurgy, and Exploration Foundation (SMEF) are committed to the long-term sustainability of the extractive minerals industry. MMSA and SMEF recognize that sustainability hinges on the quality education of the next generation of engineers and scientists who will lead our industry into the future. While it is critical that our education system produces many highly qualified engineers and scientists, the MMSA/SMEF Presidential Scholarship seeks to identify the best of the best. A single scholarship is offered to an outstanding student studying any aspect of the extractive minerals industry. The application form and guidelines for the scholarship can be completed online at www.smenet.org/scholarships. The deadline for applications is Oct. 7, 2010.

Criteria for applicants

To qualify for this award, the student must meet the following criteria: • •

•

The applicant must be a student member in good standing with SME. The applicant must currently be enrolled in a college or university in the United States within an ABET-accredited, minerals-related program or a recognized geology program offering courses in economic geology or mining geology. However, the student need not be an American citizen. The applicant’s study program must be focused on mining or geological engineering; metallurgy, metallurgical engineering or chemical engineering as related to metal recovery; mining or mineral exploration geology; or environmental science or engineering as it relates to mining activities. The applicant should typically be in his or her third or fourth year (junior or senior) of an undergraduate university program majoring in one of the areas defined above. The applicant must be in good academic standing at his or her university and have a minimum grade point average of 2.5.

If you know a student who meets the qualifications for this prestigious award, please encourage him or her to apply. Applications will be evaluated on letters of support from the chair and another member of the faculty of the department in which the student is enrolled. Such letters should include a statement by the departmental chair attesting that the student is in good standing and showing the student’s academic grade point average and the grades received in courses completed specific to the minerals industry. It should also include the relative rank of the student in his or her department. Please note that a department chair www.miningengineeringmagazine.com

may nominate only one student from the department per academic year. Applications must also include a statement from the student describing why he or she is interested in pursuing a degree in the area of study selected and how he or she hopes to use that education to pursue a career in the extractive minerals industry. Prior work experience within the minerals industry should be clearly stated, along with a description of any internships and co-op appointments. The first three MMSA/SMEF scholarship recipients are on their way to establishing their careers. Our expectation is that each Presidential Scholarship recipient will be a future leader in the mining industry and a passionate, committed SME member. Past recipients are: James J. Martin, 2007-2008, was a 4.0 gpa graduate from Virginia Tech. He is now a mining engineer and assistant to the general manager at BHP San Juan Coal in Farmington, NM. Alek C. Duerksen, 2008-2009, was named the Outstanding Senior in the College of Engineering at Virginia Tech for 2009 and received a National Science Foundation graduate fellowship. Duerksen is now a graduate student at Virginia Tech working on a project to determine the feasibility of wind power as an alternative post-mining land use in surface coal mines in West Virginia. His Ph.D. project will be an iterative economic simulation of the U.S. energy infrastructure using GIS data, somewhat similar to the Department of Energy’s national energy modeling system. Scott Shields, 2009-2010, will graduate in May 2011 from the University of Arizona with as B.S. in mining engineering. He is employed by the university as the mine engineer at the San Xavier underground mining lab. He is a member of the National Engineering Honor Society, Tau Beta Phi. Shields also received the Leonard Judd/FreeportMcMoRan Copper and Gold scholarship and the Copper Club scholarship. MMSA and SMEF are 54 proud to have supported Coal & Energy Division these future industry leadNews ers through the Presidential Scholarship award and look 55 forward to inducting a fourth Environmental member to this prestigious Division News class at the 2011 SME Annual Meeting, Feb. 27 to March 56 2, in Denver, CO. In the Aggregate If you or your company 59 would like to contribute to Obituaries (continued on page 60)

SME News contents

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SME News

Coal & Energy Division Views

Excerpts from the minutes of the

Coal & Energy Division Executive Committee meeting By Thomas Camm, 2010 division chair

he regular meeting of the Coal & Energy (C&E) Division Executive Committee was called to order by 2009 division chair Jurgen Brune at 9 a.m. on Feb. 28, 2010 at the Sheraton Downtown Phoenix hotel, Phoenix, AZ. Those present included Brune, Thomas Camm, Michael Trevits, Joe Zelanko, Dan Alexander, Nikky Manke, Keith Heasley, Manoj Mohanty, Barbara Arnold, Royce Watts, Rick Honaker, Madan M. Singh, William Wilkinson, Steve Gardner, Charles Beasley, Gary Buchan, Susan Bealko, George Richardson, Maochen Ge, Nikhil Trivedi and John Murphy. The agenda and the minutes were unanimously approved as distributed.

Open issues

Wilkinson, 2009 SME president, provided an overview of what is happening in SME. He noted that this is the fifth straight year SME has had an operating surplus and mentioned the continuing growth of OneMine.org, particularly how it is used by young members and students. He thanked the Executive Committee for input on the energy website. Trivedi briefly described three initiatives that he will emphasize as 2010 SME president: a strategy session to frame a five-year plan for SME; an ad hoc committee to address how SME can be a better source on health and safety and making the SME annual meeting a compelling stop with relevant programming. Murphy, 2011 president-elect, said he will focus on providing more opportunities for young members and try to be more proactive with student sections. He expressed interest in learning where new graduates go and what do they do in their careers. He would like to have human interest articles on this topic published.

New business

Division finances — Revenues were $22,614 and expenses were $19,139 leaving a new balance of $28,961 as of Sept. 30, 2009. The Scholarship Endowment Fund lost $15,275 during the Coal & Energy Division Views period ending Sept. serves as a forum for the presenta30, 2009, expended tion and discussion of facts, ideas and $17,500 for scholaropinions pertaining to the interests ships and $90.20 and technology of the Coal & Energy costs and received Division. Accordingly, all material $12,217 income for published herein is signed and reflects a total of $479,352. the individual view of the authors. It is Scholarships not an official position of SME or the division. Comments by readers will be — The commitreferred to that division for response. tee awarded seven The division chair in 2010 is Thomas W. 2009 scholarships, Camm. including one re54

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search scholarship, and the committee approved an award $2,500 per scholarship. Discussion followed concerning whether the bylaws allowed the University of Pittsburgh’s mining certificate program in the Civil and Environmental Department to be included. The C&E bylaws only refer to “established selection criteria” as a guide for the committee selection process. The written C&E Division scholarship guidelines (undated) limit eligible SME student members to those “pursuing a course of study leading to a degree in mining engineering … in an ABET-accredited program within the United States and engaged in coalrelated activities.” Honaker suggested a calendar as another fundraiser for scholarships, and the idea was discussed. It was approved that the division form an ad hoc committee to explore additional ideas and methods of fundraising. Volunteers for the committee were Heasley, Trevits, Arnold and Brune. The ad hoc committee is to report on scholarship fundraising at the SME midyear meeting in September. SME has initiated an online scholarship process that will be discussed more fully at the midyear meeting when all changes to the C&E Division scholarship guidelines can be presented. The transfer of funds from the Eavenson Fund was passed unanimously. Donation to SMEF — $2,000 was donated to the SME Foundation (SMEF) in support of the PE, ABET and GEM operating fund activities. The SMEF now controls an endowment of $1.4 million. Program chair — Zelanko reported that there were 15 sessions, 87 papers and a good mix of relevant topics. Some of the papers usually given in C&E sessions were presented in the 100 years of mining symposium. Thirteen papers are included in OneMine.org that did not meet the deadline for the preprint CD. Abstract Central — Tessa Baxter, SME staff, has asked for suggestions on improvements to the use of Abstract Central. 2010 and 2011 programming — Unit committees met in the afternoon. SME Tech online — Representatives Bill Hancock, Lee Saperstein and Lorrie Underwood discussed the online platform for delivery of professional training and presentations. They are seeking authors who will receive a royalty of 40 percent. Division luncheon — The division luncheon is sponsored by Preptech. Alpha Resources will match the auction proceeds. Committee members are encouraged to bid generously and often. Committee vacancies — The group discussed possible (continued on page 55) www.miningengineeringmagazine.com

SME News

Environmental Division News

Excerpts from the minutes of the

Environmental Division annual business meeting T

he Environmental Division’s annual business meeting was called to order at 8 a.m. on March 18, 2009 by chair Anne Williamson. Attendees introduced themselves. Those present included Williamson, Casey McKeon, Scott Benowitz, Robert Zick, Robert Reisinger, Mark Stock, Alicia Duex, Theresa Ballaine, Rob Mongrain, George Robinson, Virginia McLemore, Patrick Williamson, Douglas Peters, Charles Bucknam and William Lipps. Scholarship Committee — Stock reported that the scholarship program was successful for 2009. Funds were approximately $63,000 as of Sept. 30, 2009. Sara Milney and Alan Hepworth each received a division scholarship. It was suggested that the division increase the amount of scholarship aid from $3,000 to $5,000 per year. There was a discussion about adding an environmental question related to mining in the application. The silent auction was held March 2. $2,400 will come from the SME general fund. Robinson noted that the 2011 uranium conference may have additional funds for scholarships. 2011 program — McLemore reported that the 2011 field trips are planned. Reisinger said the 2011 program is set and co-chairs are welcome. He is putting a handbook together to circulate to chairs. Acid Drainage Technology Initiative (ADTI) — Bucknam reported that the ADTI meeting discussed a measuring and monitoring workbook. The International Network for Acid Prevention is funding a pit lake database currently in production. The Global Acid Rock Drainage (GARD)

Guide short course was presented at the annual meeting and was full of participants. The next meeting is April 10 for the Virginia Task Force. Bucknam will raise the question of translating the GARD Guide into Spanish. EMS Committee — The Environmental Management Science guide was presented last year but was too complex to use. The committee will work with the National Mining Association over the next six months to refine. SME Tech Online — Peters reported that online, webbased training courses are being developed and may include the GARD Guide, Introduction to Mining and Mineral Processing and the PE exam review course. Sustainable Development Committee — Duex will go to the meeting to see what is new. Mining Engineering article — It was suggested that the first article after the annual meeting be related to opportunities to be involved with the division. Environmental Division Handbook — Reisinger and Williamson will review the book. Outreach programs — Video-conferencing, Facebook and LinkedIn may be good platforms for the Environmental Division. Williamson will check with Heather Gravning to see about getting a page on Facebook for the division. There are 12,000 members of SME, and the division needs to find a way to get some of them involved. Professional engineers exam — Robinson reported that the PE Exam Committee needs representation from the division and some environmental questions added to the test. n

Coal & Energy Division Views (continued from page 54) contacts to fill current vacancies on C&E committees. U.S. Energy Policy Coalition website — Richardson gave an update and overview of the website and discussion followed. He said that the overall energy policy issues we need to communicate to the public and policy makers are that we need to plan for the future and that there is no free lunch. See www.usenergypolicycoalition.org for more information. Members of the C&E Committee had several suggestions. Richardson is planning a session at the 2011 annual meeting and a 2012 symposium. Geothermal energy — Masami Nakagawa from the Colorado School of Mines discussed the growing interest in geothermal energy and proposed a session on geothermal energy for the 2011 SME Annual Meeting. The World Geothermal Conference will be held in Bali this year, in Australia in 2015 and in the United States in 2020. This is an www.miningengineeringmagazine.com

opportunity for the division to become involved. This was referred to Tuncel Yegulalp as chair of the Energy Unit Committee. Trevits volunteered to take the lead coordinating the development of a strategic plan to embrace the energy part of the division. A motion was passed to spend no more than $7,500 on a facilitated planning session for the division. A first step is to define what the division means by energy. Is it energy minerals — nuclear, geothermal, liquids, gases, tar sand, oil shale or bitumen — and does it include wind or ocean? Next meeting and adjournment — The next meeting of the Executive Committee will be at the SME midyear meeting in Philadelphia, PA Sept. 17-18, 2010. The meeting was adjourned at 12:10 p.m. by Brune. The time and location for the next general meeting will be set at a later time. n Mınıng engıneerıng

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SME News

In the Aggregate

The history of aggregate production —

A timeline for the IM&AD 75th anniversary By William Langer

n 1935, when the Industrial Minerals Division was chartered, the world was six years into the Great Depression. It was a time when thousands upon thousands of Americans were out of work. Aggregate production, which had plunged 36 percent since its 1929 high of 314 Mt/a (345 million stpy), was just beginning to show a weak recovery. It would be four more years before aggregate production was back to its level before the Depression. Construction on the Hoover Dam in the Black Canyon of the Colorado River, between the states of Arizona and Nevada, was completed in 1936. Construction of the dam consumed about 7 Mt (7.7 million st) of concrete. The first edition of Industrial Minerals and Rocks in 1937 contained two chapters devoted to the geologic and engineering aspects of the crushed stone and sand and gravel industries. Those chapters have been repeated in every subsequent edition. The production of aggregates jumped to 439 Mt/a (482 million stpy) due to the construction of wartime factories during the early involvement of the United States in World War II. The high demand disappeared as the country demobilized after the war, depressing U.S. aggregate production by 31 percent. In his 1947 report, Business Booming in the West, W.B. Lenhart described how aggregate resources are “sterilized” by zoning, sprawling growth and encroachment. The second edition of Industrial Minerals and Rocks in 1949 documented the modernizing trends in the aggregate industry, including delayed action blasting, a shift to motorized trucks for in-pit hauling, the use of surge piles to keep the crushing and screening plants uniformly loaded and the entry of aggregate operations into the ready-mix and asphalt business. Bror Nordberg, writing in Rock Products in 1950, encouraged a new image for the aggregates industry stating, “Reclamation is of utmost importance in a program that must also eliminate hazards, noise, dust and all other sources of complaint.” During 1956, aggregate consumption passed 1 Gt/a (1.1 billion stpy) for the first time. During the same year, passage of the Federal Aid Highway Act enabled four decades of construction of more than 67,592 km (42,000 miles) of paved roads and 55,000 bridges, which ultimately consumed more than 18 Gt (20 billion st) of aggregate. The third

edition of Industrial Minerals and Rocks (1960) identified encroachment as an issue limiting aggregate development. The destructive expansion of concrete due to the alkali-silica reaction is also noted as a problem. Rachel Carson’s 1962 book, Silent Spring, created a new environmental awareness whereby aggregate businesses were expected to integrate environmental considerations into their operations. The Clean Air Act, passed in 1970, required control of SO2 emissions from power plants, creating a new market for limestone. Demand for scrubbing limestone would eventually exceed 2 Mt/a (2.2 million stpy). During 1972, the volume of crushed stone production surpassed the production of sand and gravel for the first time since 1921. In October 1973, OPEC stopped exports of oil to the United States and other western nations. The price of gasoline rose from 25 cents per gallon to more than a dollar in just a few months, plunging the United States into a 16-month recession. Aggregate production followed the downward national trend. The fourth (continued on page 58)

In the Aggregate serves as a forum for the presentation and discussion of facts, ideas and opinions pertaining to the interests and technology of the Industrial Minerals & Aggregates Division. Accordingly, all material published herein is signed and reflects the individual views of the authors. It is not an official position of SME or the division. Comments by readers will be referred to the division for response. The division chair in 2010 is Fred G. Heivilin.

The chart shows trends in aggregate production from 1935 to 2010. The first quarter of 2010 shows a slowing in the decreases in aggregate production. 56

AUGUST 2010

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SME News

Environmental Division News

SME members travel to Brazil to support SANAP T

errence Chatwin of the International Network for Acid Prevention (INAP) and Rens Verburg of Golder Associates, members of the Environmental Division and the Acid Drainage Technology Initiative (ADTI), traveled to Belo Horizonte, Brazil to present a May 30 short course on the Global Acid Rock Drainage (GARD) Guide. In Brazil, they were joined by Flavio Vasconcelos of the AECOM/ Federal University of Minas Gerais who organized the short course. This course was similar to the one presented in Phoenix, AZ at the 2010 SME Annual Meeting. The GARD Guide is a global best practices guide for the prevention of acid rock drainage (ARD), saline drainage (SD) and neutral drainage (ND), which are some of the mining industry’s most difficult and costly problems. Chatwin, Verburg and Vasconcelos presented material on the ARD process, characterization, prediction, treatment, monitoring and other topics found in the guide to more than 50 attendees at the Federal University of Minas Gerais. Since many of the attendees spoke only Portuguese, the presentations were simultaneously translated from English to Portuguese. Verburg stated, “I was impressed with how effectively the translation was performed. The speed of the translation enhanced the audience participation during the question and answer period. It went very smoothly.” The short course was held in conjunction with the II Symposium on Mining and Groundwater Resources, which covered three days of vigorous debate. The symposium was organized by the Minas Gerais Groundwater Association and sponsored by Vale, Kinross Gold, Anglo American, INAP, Anglo Gold Ashanti and others. More than 150 ground water and mining industry professionals and stakeholders from North and South America attended the symposium. The symposium was also simultaneously translated into English and Portuguese. Impacts on water from mining, ground water issues, water regulations and other topics of interest to the audience were presented. The discussions were lively and raised some important issues. Chatwin pointed Environmental Division out, “The symposium News serves as a forum for the was a great opportunity presentation and discussion of to expand knowledge facts, ideas and opinions pertaining on many fronts relating to the interests and technology to mining and ground of the Environmental Division. water resources. We got Accordingly, all material published to hear presentations of herein is signed and reflects the Brazilian mining compa compaindividual views of the authors. It is not an official position of SME or nies on their ARD pro prothe division. Comments by readers grams. South American will be referred to the division for participants got to hear response. The division chair in 2010 more about the GARD is Anne Williamson. Guide and what the

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Global Alliance is doing worldwide.” It was good for the South American participants to hear of the issues in North America, as they have many of the same environmental issues as mines in North America. However, as Vasconcelos pointed out in his presentation at the symposium, Brazilian and other South American countries’ regulations lag those in the United States by almost 20 years. This lag time allows South American countries to learn from development and regulatory experiences in the United States, Europe and Canada. In addition to the short course and the symposium, Chatwin and Verburg, as members of the ADTI, met with representatives of the Executive Committee of the South American Network for Acid Prevention (SANAP). Juliana Esper of Kinross Gold, German Vinueza of Vale and Flavio Vasconcelos expressed their plans to expand SANAP to Chile and Peru and discussed the need for collaboration and strengthening ties within the Global Alliance. Later, the ADTI members interacted with other members of SANAP, including academics, regulators and other stakeholders that had been instrumental in organizing SANAP. Chatwin and Verburg also exchanged ideas with Juan Ramon Candia and Carmen Gloria Duenas of Fundacion Chile, who are leading the Chilean National Program on ARD Prevention and are organizing SANAP in Chile. Later, the groups from Brazil and Chile met to develop the details of the SANAP organization and rotation of the chair position between their countries and Peru. The group also toured the closed Vale openpit iron ore mine, which is proceeding with reclamation. While the mine is very close to Belo Horizonte and high-rise office buildings are within 4.83 km (3 miles) of the pit, much of the land surrounding the mine is held as a nature preserve. Because of its proximity to Belo Horizonte, Vale is planning to develop some of the adjacent land for housing and commercial building. The company plans to use the pit lake for recreation. Chatwin expressed his pleasure with the strength of the SANAP organization. “SANAP not only has a core of committed individuals, but it has a broad range of stakeholders, including mining companies, governmental agencies, consulting firms and academics. I think that SANAP will be a very strong and successful member of the Global Alliance.” The Global Alliance is a group of regional organizations founded in 2003 to promote the prevention and mitigation of ARD, SD and ND through collaborative research, technology and information transfer and facilitation of partnerships. It currently has eight members with the addition of Chinese Network for Acid Mine Drainage, the Indonesia Network for Acid Drainage and SANAP during the last year. The addition of these organizations to the previous members of the Global Alliance — the Australian Center (continued on page 60) Mınıng engıneerıng

AUGUST 2010

SME News

In the Aggregate

(continued from page 56) edition of Industrial Minerals and Rocks (1975) provided a lengthy discussion of environmental considerations for the aggregates industry. High interest rates in the early 1980s depressed the housing, steel and automobile markets. Aggregate production plunged 32 percent over the next three years, rivaling the decreases during the Great Depression and the period following World War II. Granite was shipped from Scotland to Houston in August of 1986. The economic success of the transoceanic shipment was due, in part, to the vessels backhauling petrochemicals and other products. The transoceanic shipments of aggregates from Scotland to the United States were abandoned, in part, because of large increases in transoceanic rates. However, U.S. imports from Canada and Mexico have taken their place. The fifth edition of Industrial Minerals and Rocks (1983) reiterated the problems of encroachment and the necessity to adequately address environmental issues. The savings and loan crisis led to a sharp recession in 1990-1991 that severely impacted the real estate sectors of the economy. New housing starts dropped more than 40 percent from 1.8 million per year to 1 million between 1989 and 1991, which led to a 13-percent decrease in aggregate production. During 1994, aggregate consumption passed 2 Gt/a (2.2 billion stpy) for the first time. The sixth edition of Industrial Minerals and Rocks (1994) discussed envi-

ronmental controls and concerns of crystalline silica and asbestos. The crash of the dot.com bubble, combined with fear stemming from the Sept. 11 attacks against the World Trade Center Towers and the Pentagon, caused the early 2000s recession. This resulted in reduced spending, an economic slowdown and a slight reduction in aggregate production. The aggregate industries moved toward implementation of sustainable aggregate resource management during the early 2000s. The seventh edition of Industrial Minerals and Rocks (2006) included a chapter dedicated to sustainable mineral resource development, and the National Stone, Sand, and Gravel Association endorsed sustainability. The mid-2000s housing boom, spurred on by readily available mortgages, created an unprecedented demand for aggregate. Production peaked at a record 3.1 Gt (3.4 billion st) during 2006, having surpassed 3 Gt/a (3.3 billion stpy) for the first time. The late 2000s recession was started by the collapse of the housing market, which has been linked to unsustainable mortgage lending practices. By the end of 2009, aggregate production had fallen to 1.88 Gt (2.06 billion st), the lowest production in 17 years and nearly 50 percent below its 2006 high. The first quarter of 2010 shows a slowing of the decreases in U.S. aggregate production. This will be newsworthy if the trend continues for the second and third quarters of 2010. n

Membership Kenneth Abbott, Tucson, AZ Siddhartha Agarwal, Fairbanks, AK Hamid Akbari, Carbondale, IL Paul Ampey, W. Palm Beach, FL Laurence Andrews, Orland Park, IL Sampurna Arya, Lexington, KY Doug Backstrom, Virgina, MN Parker Backstrom, Virgina, MN Brett Beranek, Gladstone, MI Leonardo Borrher, Lakewood, CO Nick Bozek, Smock, PA Alex Broda, Calgary, AB, Canada Wally Chen, Seattle, WA Michael Cherry, Sacramento, CA Raymond Cousineau, Vancouver, BC, Canada Jeffrey Covington, Golden, CO George Daily, Columbus, OH Daniel DeAntonio, Reading, PA Andrejs Delle, Rockaway, NJ Bryan Feathers, Newburg, WV John Gakos, Secaucus, NJ Thomas Gillespie, Bethlehem, PA Wesley Gilmer, Clairfield, TN Russell Hager, Pueblo West, CO David Haug, Whittier, CA John Hawley, Los Angeles, CA Jamie Howard, Blacksburg, VA Gary Irwin, Portland, OR Hamid Javady, Markham, ON, Canada Elizabeth Keefner, Soda Springs, ID Petr Kocandrle, Plzen, Czech Republic Vincent Krause, Whitestone, NY Gerhard Lang, Ettenheim, Germany Richard Larsen, Imlay, NV

AUGUST 2010

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Roger Nelson, Seattle, WA John Newsome, Columbus, OH Rick Odle, Rensselaer, IN Anthony Palladino, Akron, OH Suresh Parashar, Abu Dhabi, United Arab Emirates Brandon Rampersad, Chaguanas East, Trinidad Thomas Reardon, W. Palm Beach, FL Reg Ryan, Raleigh, NC Ryan Scalise, Glendale, AZ Jason Schneider, Republic, WA Daniel Scholz, Folsom, CA Linda Semenya, Safford, AZ Masni Shabri, Morenci, AZ Shun Myung Shin, Daejeon, Korea Lori Smith, Middlemount, QLD, Australia Mark Smith, Greenwood Village, CO R. Craig Smith, Reno, NV Shawn Smith, Waterflow, NM David Snyder, Pittsburgh, PA Steven Soldatek, Lewiston, ID Alana Stern, Tempe, AZ Aaron Stewart, Casper, WY Lodewicus Steyn, St. Augustine, FL John Stine, Arvada, CO Peter Stone, Melbourne, VIC, Australia I. Nengah Sugita, Phoenix, AZ Vinsensius Agus Supriyanto, Yogyakarta, Indonesia Jerry Szpak, North Royalton, OH Robin Taggart, Ballymoney, United Kingdom Stanberg Tallman, Bellemont, AZ Ali Tarokh, Socorro, NM

Mark Terry, Atlanta, GA Clayton Thayer, Grants, NM Mike Throckmorton, Denver, CO John Town, Las Vegas, NV Juergen Triep, Hollywood, FL Ken Vallens, Cypress, CA Matthew Veenstra, Seattle, WA James Vesey, St. Petersburg, FL Silvia Vidal, La Paz, Bolivia Gregory Villa, Ontario, CA Karthik Viswanathan, Bloomington, MN Javier Vizcarra T., Lima, Peru Joseph Walsh, Tempe, AZ Peter Wang, Lynnwood, WA Dallas Ward, Duncan, AZ Jason Warren, Burnaby, BC, Canada Eric Wasmund, Burlington, ON Larry Wetzel, East Pittsburgh, PA Brett Whitford, Sparks, NV Arlene Willmann, Belleville, IL Buddy Wilson, McCalla, AL Sena Wiraguna, Tempe, AZ Micheal Wirthlin, Salt Lake City, UT Stephan Woll, Lima, Peru Tom Wood, Littleton, CO Christy Woodward, Denver, CO Emily Wortman-Wunder, Littleton, CO Steve Wortmann, Slatington, PA John Yao, Los Angeles, CA Yaw Yeboah, University Park, PA Suheyla Yerel, Bozuyuk, Turkey James Young, Phoenix, AZ Gregory Zekoff, Peoria, AZ Osvoldo Zubieta A., La Paz, Bolivia n www.miningengineeringmagazine.com

SME News

Obituaries

IRVIN C. SPOTTE

JOHN LaMOTTE SHAW

An appreciation by James H. Justice

rvin C. Spotte died Nov. 5, 2009 in Ft. Myers, FL. He was 99. Spotte was born in Centralia, IL on May 26, 1910. He graduated from the Missouri School of Mines in 1933 with a B.S. degree in metallurgical engineering. He played varsity football, served as an ROTC cadet and was an active participant in the Prospector’s Club. After graduation, Spotte worked as a mining engineer for an iron mining company in the Philippines. Immediately after Pearl Harbor, he joined the U.S. Army in the Philippines where he was commissioned in the Corps of Engineers building air fields. He was captured during the Japanese invasion in April 1942 and spent the rest of the war in northern Japan at the Sendai #6-Hanawa prisoner of war camp. This camp was a 1,300 year-old copper mining operation owned by Mitsubishi. The prisoners were the work force. Captain Spotte was one of 494 survivors of this camp. Much has been SpOttE written about the horrible treatment of prisoners at the camp, but Spotte never related his experiences with anyone. His decent treatment of others who worked under him later in life was a reflection of this experience. After the war, Spotte returned to the coal industry, working his way through the ranks to vice president of Philadelphia and Reading Coal and Coke. He then moved to Kentucky with Princess Coal as general superintendent of its David operation. At David, he was instrumental in the development of low 71-76 cm (28-30 in.) seam conventional mining equipment manufactured by Joy in the early stages of coal mine mechanization. He then became vice president operations and developed organizations at the newly acquired Sycamore Coal. Spotte left Princess to manage mines near Richwood, WV, then moved on to Clinchfield Coal at Dante, VA as operating vice president. Clinchfield Coal was acquired by the Pittston Co. and, in 1969, he became president of the Pittston Coal Group. He led the expansion of Pittston Coal through the acquisition of several coal companies including Jewell Valley, Eastern Coal, Ranger Fuels, Laredo Coal and Sewell Coal. Spotte was best known for his motivational, lead-byexample style, which he developed during his military experiences. His ability to communicate with the hourly work force by visiting them underground and learning of their problems made him respected by all. He made it a part of his schedule to go underground and visit the preparation plants at one operation each day treating each worker as a critical part of the operation and encouraging them to work safely. He was instrumental in the expansion of Pittston’s production capacity by separating each production center into divisions. He organized each division so that there was accountability in operations through a single manager, safety (continued on page 60)

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ohn L. Shaw died Jan. 28, 2010. He was born Nov. 24, 1923 to G. Robert and Helen Shaw in Cleveland, OH and grew up in Verona, NJ. He studied electrical engineering and graduated from the University of Wisconsin. He served in the U.S. Navy Air Corps as a radar officer during World War II. After post-graduate work at the University of Wisconsin, Shaw joined Inco’s New York office. He invented a method of prospecting for nickel from the air. As head of geophysical research for Inco, he and his family spent ShAw the next 10 years based in Copper Cliff, ON, Canada. Much of this time he was in the Northwest Territories, Ungava and Australia. He operated the equipment on the discovery flight of the giant Thompson, Manitoba nickel orebody. He then went to Huntington, WV to organize a technical service and marketing department to promote the use of and service nickel alloys for aircraft engines, nuclear, oil and chemical plants, and electronics. He was granted several alloy patents including one that does not allow ice to form on transmission lines. In 1967, Shaw moved to New York to determine the feasibility of mining nickel deposits three miles deep in the Pacific Ocean. Inco Ocean Mining was established in Bellevue, WA in 1971. In 1974, he organized a four-nation joint venture company — United States, Canada, West Germany and Japan. Ocean Mining Inc.(OMI) conducted a pilot mining test 1,288 km (800 miles) south of Hawaii. He was president and general manager of the operation. OMI was the first to successfully mine the deep ocean in bulk quantity. As an Inco vice president, he moved back to New York to plan and execute the reorganization of rolling and forging mills in the United States, Canada, the United Kingdom and Japan. Shaw retired from Inco and moved back to Bellevue in 1982 to be executive vice president of International Submarine Technology (IST), a company formed by former Inco OMI employees. IST built side-scan sonar for mapping the bottom of the ocean. The company was sold to Honeywell in 1988, at which time he retired to gardening, computer programming and letterpress printing. During his career, Shaw was a delegate to the United Nations, a professional engineer and an advisor to the U.S. State Department, the University of Washington Oceans Department and the Atomic Energy Commission. He was active in the Boy Scouts, the Lutheran Church, several engineering societies and was a director of the Offshore Technology Conference. Shaw is survived by his wife of 65 years, Ann Axness Shaw; four children, John Shaw, Brian Shaw, Jocelyn Shuman and Sarah Newsum; nine grandchildren; one greatgrandchild and two sisters. n Mınıng engıneerıng

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SME News

personal News

SRK Consulting welcomes three new employees. BRUCE KENNEDY (SME) is a principal mining engineer in the SRK Tucson, AZ office. He has more than 36 years of mining industry experience in openpit and underground mine engineering and operations, as well as in oil and gas permitting. Kennedy is a professional engineer in Mexico and has KENNEDy worked in Chile, Peru, Canada, Mexico and the United States. ERIC OLIN (SME) is a principal process metallurgist in the Denver, CO office. Olin has more than 30 years of experience in consulting, plant operations, process development, project management and research. Olin has held general management and plant superintendent positions for several gold and base metal mining operations. His international experience includes posts as project manager in China, India, Jordan and Turkey. FERNANDO ROOlIN DRIGUES is also joining the Denver

office as senior mining engineer. He will use his strong mine planning abilities and expertise in Vulcan 3D software to benefit metalliferous and stratigraphic clients. Rodrigues’ focus is on openpit mine design, mine scheduling and scheduling optimization, using his facility with production statistics, engineering studies, fatal flaw and due diligence reports. He is rODrIguES fluent in English, Spanish and Portuguese.

Environmental Division News

could be done properly with no production goals in order to produce a safe and competent work force. Spotte also introduced a comprehensive maintenance program that included equipment component change-out and repair and equipment rebuild and upgrade at a central shop plus comprehensive equipment maintenance records at the mines. Some would agree that Spotte never did retire. At 75, he started and operated Sun-Glo Coal in Kentucky until its reserves were depleted. He also continued to offer consulting services to the industry until his death. Spotte was the recipient of the Eavenson Award in 1980 “for his leadership and dedication in improving coal mine production by motivating people and for his wisdom and integrity shown in the integration of people and machinery to achieve this improvement.” Spotte should also be remembered for his endeavor to develop and promote coal industry leaders — Robert Quenon, Ray Bradbury, Gene Mathis, Tom Garges and John Grubb. All those who worked for Spotte in the coal industry will never forget his knowledge and exemplary leadership. He is survived by his two daughters, Sarah Marie and Anna Ruth, and his brother Walter. n

(continued from page 57)

for Minerals Extension and Research, ADTI in the United States, Mine Environmental Neutral Drainage in Canada, the Partnership for Acid Drainage Remediation in Europe and the Water Research Commission of South Africa — has resulted in a very broad and strong network. The Global Alliance has been instrumental in supporting INAP in the development of the GARD Guide. Currently, the global alliance is supporting the promotion and use of the GARD Guide in their respective regions. For example, ADTI has presented papers and short courses on the GARD in Nevada, Wisconsin, Utah, Colorado, Arizona, Washington DC and other states. This regional commitment is a key to the successful implementation of the GARD Guide throughout the United States and globally. The Environmental Division of SME and ADTI are confident that the partnership with SANAP and other environmental organizations in South America will strengthen and prosper during the future years. n

Obituaries

(continued from page 59) through a division director who reported to Spotte and had inspectors making daily mine safety inspections. Coal preparation for the entire coal group was organized as a separate division with a manager that reported to Spotte. Any new idea that would enhance safety, production and labor relations would be shared with his managers in those meetings. Spotte also was responsible for developing training programs. Training mines were set up where the training 60

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P&H Mining Equipment has named JEFF ROSCHYK (SME) to lead its global customer support program as vice president, aftermarket parts and service. He joined P&H in 1997 as general manager of MinePro Services’ operations in Nevada. Roschyk has been vice president, marketing and product development since 2007. The Minerals Advisory Group, a mining consultancy, has appointed DONALD A. SCHULTZ, P.E. as a principal of the company. Schultz has extensive experience in the mining industry. n

SME Foundation

(continued from page 53) the education of our future industry leaders through this scholarship fund, please note your wishes on a check payable to SMEF and send it to SME, attention: AnnMarie Estrada, 8307 Shaffer Parkway, Littleton, CO 80127-4102. As the endowment grows, the number and dollar amount of scholarships we are able to award each year will grow as well. n www.miningengineeringmagazine.com

New Media Going for Gold 2010, by Jack H. Morris, published by the University of Alabama Press, www.uapress.ua.edu, ISBN-13: 978-08173-1677-8, pp. 416, 53 illustrations, $27. A new book on the history of Newmont Mining Corp. details the evolution of the company that gave birth to the modern gold industry. Morris, a former Wall Street Journal reporter and former vice president of investor relations at Newmont, recounts the prowess and challenges faced by one of the world’s oldest mining companies. Sensitive about objectivity, he insisted on working at arm’s length from Newmont, which exercised no control over the content of the book. Going for Gold: the History of Newmont Mining Corporation is for history buffs, gold bugs and students of finance and industry. Morris traces the company’s history from its turn of the century creation by a wealthy Wall Street executive to its leadership in every facet of modern mining. Along the way, Newmont has survived dramatic encounters with corporate raiders such as T. Boone Pickens and Jimmy Goldsmith, an epic battle with the French over control of South America’s largest gold mine, issues with the Indonesian government and, at times, unrelenting pressure from anti-mining activists. The book also provides an insider’s look at Newmont’s acquisitions, such as Santa Fe Pacific Gold, Franco-Nevada and Normandy Mining, while also exploring the issues that twice prevented a merger with Barrick Gold. The discovery of submicroscopic gold at Carlin, NV in 1963 earned Newmont a permanent place in mining history.

Bucyrus Drills 2010, by David M. Lang P.E., published by Icongrafix, P.O. Box 446, Dept. BK, Hudson, WI 54016, phone 800-2893504, e-mail info@iconografixinc.com, www.iconografixinc. com, ISBN 13: 978-1-58388-253-5, 128 pp., 200 photographs, $34.95. Bucyrus Drills, Drilling the Earth for 75 Years, presents a 75-year progression of the Bucyrus drill line in 200 black-and-white and color photographs. Photos of people and machines aptly illustrate the mud, sweat and gears. The book begins with a concise history of the trade and offers an in-depth description of the principles of drilling.

Whether digging holes for water, oil or rock blasting, the humble drill rig has greatly increased the pace of modern development. Bucyrus started building drill rigs in 1933 after buying the manufacturing rights to the Armstrong drill brand. It eventually paid $551,000 in royalties, although it had paid only $89,000 for the initial manufacturing rights. The author goes on to detail other lore in this new book, aimed at mining and construction equipment enthusiasts. Lang is director of engineering for Bucyrus International, which still manufactures drills for mining and construction.

The Riches Beneath our Feet: How Mining Shaped Britain 2010, by Geoff Coyle, published by Oxford University Press, 198 Madison Ave., New York, NY 10016, phone 212-726-6430, www.oup.com/us, 288 pp., 30 illustrations, ISBN13: 978-0-19-955129-3, £20. Geoff Coyle, a former mining engineer, sketches the story of how mining has shaped Britain since the flint mines of the Stone Age, which still exist. And in that 4,000 year period, the country’s miners produced colossal amounts of copper, tin, lead, zinc, iron, a lot of silver, some gold and smaller amounts of just about every other metal from arsenic to uranium. Coyle’s account is wide ranging, involving stories of the mineral wealth of Britain and its exploitation from simple quarrying to the advent of mass production. There are tales of the miners’ lives and the great mining families, as well as accounts of the miners’ work, the conditions in the mines and mining disasters. The author weaves his personal experiences into the story of industrial history, geology and technology. Each chapter highlights one of the main mining fields and explores the mineral in question, its use and how technological changes affected the mining techniques. n www.miningengineeringmagazine.com

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AUGUST 2010

New Products BinMaster develops high temperature probe

he BinMaster SHT, or super high temperature vibrating rod, features a newly developed piezo system built specifically for higher process temperatures up to 482° F (250° C). The durability of the SHT is due to the unique design of the patented, reinforced membrane and the new piezo system that features a standard insulation tube that insulates the electronics from excessive heat. The SHT features BinMaster’s unique stainless steel, single-rod probe design. This prevents bridging and buildup of material on the sensor, unlike tuningfork designs that can cause false alarms. Other standard benefits include a switch-selectable, high-low, failsafe function that switches the device to an alarm condition when the power supply fails and an auto-sensing power supply compatible with up to 250 V ac/ dc. The SHT features easy installation and setup and requires no calibration.

EG Electric Corp. has added two energy-efficient motors to its line — the Quattro and the W22 Super Premium. The Quattro, a line-start permanent magnet motor, is a hybrid model that features a three-phase distributed winding in the stator operating at IEC established IE4 efficiency levels. The motor operates at synchronous speed regardless of the load, providing no I2R losses in the aluminum cage. The Quattro has a low bearing temperature, the same frame size as an induction motor and a synchronized, inverter-driven, multi-motor operation. No feedback device is required for precise speed control and no special protection relays are needed. The W22 Super Premium is the most efficient model in the W22 product line. The motor is two efficiency bands over premium motors and operates with low noise levels and high torques. The engine has a 1.25 service factor through the 447T frame size.

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www.weg.net/us

The device is constructed of stainless steel, and the electronics are mounted inside an IP66/ IP67 aluminum enclosure for advanced protection.

Two new electric motors available from WEG

The W22 Super Premium motor offers maximum efficiency and exceeds NEMA Premium levels with 20 percent fewer losses.

Flexterra growth medium is 99 percent erosion-control effective

rofile Products has introduced its new patent-pending Flexterra high-performance, flexible growth medium (HP-FGM). Flexterra HP-FGM offers a 600-percent greater initial seed germination and more than a 250-percent greater biomass than its predecessor. It also offers more than 99 percent erosion control effectiveness immediately upon application. Plus, it is totally biodegradable. The original Flexterra FGM, introduced in 2004, set the bar for controlling erosion and establishing vegetation on severe slopes. It outperformed rolled erosion control blankets and led a movement toward more cost-efficient and effective hydraulically applied techniques. Because Flexterra HPFGM is hydraulically applied, it has no nets or threads to

AUGUST 2010

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endanger wildlife. Flexterra HP-FGM consists of recycled and phyto-sanitized wood fibers and biodegradable crimped interlocking fibers. Micro-pore particles optimize water and nutrient retention while increasing wet-bond strength and increasing resistance to sheet flow. Its nontoxic biopolymers and water absorbents further enhance vegetative establishment. Tests following EPA protocol confirm the product is completely safe for aquatic and terrestrial life forms. It immediately bonds to the soil surface to reduce turbidity of runoff for up to 18 months. www.profileproducts.com www.miningengineeringmagazine.com

New Products Mining engineers solve optimization problems with NAG

GeoPro LBS offers two-way global satellite messaging

ining engineers who wish to solve difficult optimization problems for minerals and metals processing can get step-by-step instructions on how to select the best-suited local or global optimization routines from the Numerical Algorithms Group (NAG) library decision trees for optimization. NAG, a not-for-profit numerical software development organization, devotes significant resources to continually advance methods for solving optimization problems and similar computational challenges. The NAG decision trees are part of the documentation for one of the most rigorously tested and documented sets of optimization routines and other mathematical and statistical algorithms in the world. The NAG library of routines, including the optimization chapters, can be called from diverse environments such as C++, Fortran, Matlab and R. Many of those who use NAG’s routines as the building blocks of their applications rely on the knowledge base in NAG’s exhaustive documentation as a part of the “future-proofing” of their application development investments. The decision trees, which are a feature of this documentation, are especially useful in helping new and experienced users to select the appropriate routine for the problem at hand.

eoPro LBS has introduced a comprehensive workplace safety two-way messaging and monitoring solution. GeoPro is a rugged satellite text-messaging device with an integrated global positioning system coupled with a secure, hosted web application. Key features of the messenger device include two-way text messaging, up to 160 characters, and a rugged design with a covered emergency button. The system offers remote workers two-way, global text messaging between GeoPro users and other e-mail and mobile phones based on the Iridium satellite network. The web application includes a secure, browser-based access to emergency, check-in, tracking and waypoint functions. This allows employers to respond to emergencies, mitigate risk and increase overall productivity with a complete 360° view of the remote field from any web browser.

www.nag.com

www.geoprosolutions.com

GeoPro was field tested with government, industry and partners around the world.

Joy Mining Machinery ships its 200th 7LS shearer

oy Mining Machinery has manufactured its 200th 7LS model shearer and shipped it to the Shaanxi Coal Group in China. It has shipped 200 7LS shearers globally and there are 90 shearers now in China. Capable of single-pass mining the thickest extraction in excess of 6 m (20 ft), the high-performance shearer incorporates a powerful haulage unit with JNA memory cut controls. Using the JNA memory cut, the system permits the shearer operator to create an initial cutting profile or template under manual control, and the machine then automatically replicates the profile on subsequent cuts until conditions change. The operator then updates the profile by manually cutting a new pass. This higher level of automation improves machine efficiency and better control out-of-seam dilution from the roof and floor. This results in cleaner product and lower machine maintenance cost while reducing operator exposure to dust and noise. The major elements of a Joy longwall system are a shearing machine, an armored face conveyor, roof supports, a stageloader, a crusher and a mobile belt tailpiece. Joy manufactures these individual elements and provides www.miningengineeringmagazine.com

professional project management to incorporate them into an integrated system. Joy delivers that system on time, to specification and on budget. n www.joy.com

The Joy longwall system.

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AUGUST 2010

Web Directory THE BEST IN MINING PRODUCTS AND SERVICES BETE Fog Nozzle, Inc.

Manufacturers of spray nozzles for fire protection, conveyor and truck washing and dust control.

Email: sales@bete.com

www.bete.com

Call & Nicholas, Inc.

2475 No. Coyote Drive, Tucson, AZ 85745

Email: cni@cnitucson.com www.cnitucson.com

Cognis Corporation

Mining Chemicals Technology Solvent Extraction Reagents 2430 N Huachuca Drive, Tucson, AZ 85745

www.cognis.com

Dawson Metallurgical Laboratories, Inc.

an FLSmidth Company Minerals processing testing & consulting Telephone: (801) 596-0430 Email: SLCDawsonLabs@FLSmidth.com

www.flsmidthminerals.com/dawson

dnh search - Headhunters

P.O. Box 277, Cambria, CA 93428 Telephone: (805) 203-5878 Fax: (805) 203-5887

dhanak@dnhsearch.com www.dnhsearch.com

Downer EDI Mining Mineral Technologies

Leaders in fine mineral gravity separation with Reichert spirals. Reading magnetic separators & Kelsey Centrifugal Jig. Telephone (fax): (904) 827-1694 (1695)

E-mail: pbarkermdmtusa@aol.com www.mineraltechnologies.com.au

EarthRes Group, Inc.

Mining engineers and professional geologists, Mine exploration, permitting, planning and design, Hydrogeologic studies and compliance assistance

www.earthres.com

FMC Technologies/ Material Handling Solutions

Syntron® and Link-Belt Material Handling Equipment. Tupelo, MS Telephone: (800) 356-4898

www.fmctechnologies.com/materialhandling

GIW Industries, Inc.

“The Experts in Slurry Pump Design” 5000 Wrightsboro Road, Grovetown, GA 30813 Telephone: (706) 863-1011

www.giwindustries.com

Your one source for the world’s largest installed base of original equipment including: Crushing, Grinding, Classifying, Flotation, Thickening, Clarifying, Filtration, Pyroprocessing, Material Handling, Parts & Service. Telephone: (801) 526-2000 or (610) 264-6900

www.flsmidthminerals.com

Mixing Consulting; Audit, Optimize, Design Mixers, Copper & Nickel SX, Solvent Extraction, Biooxidation, Gold CIP/CIL, Agitated Leaching, and Autoclaves

www.postmixing.com

Prep Tech, Inc.

Cyclones, spirals, flotation, filter press, magnetic separators 4412 Rt. 66, Apollo, PA 15613 Telephone: (888) 447-7737

www.preptech.com

Hitachi Construction

and Mining Products Hitachi hydraulic excavators and haul trucks have built an excellent reputation for high productivity, low maintenance costs, and long-life reliability.

Richwood

www.hitachimining.com

Conveyor Belt Cleaners, Conveyor Belt Material Containment, Conveyor Pulley Lagging, and Conveyor Belt Protection. Rely on Richwood Toll Free: (800) 237-6951

ITT Water & WasteWater USA Flygt Products

Schaeffler Group USA, Inc.

Pumps, mixers, monitoring and control products, pre-engineered, self-cleaning fiberglass pump stations. 1000 Bridgeport Ave., Suite 402, Shelton, CT Telephone: (203) 712-8999

www.flygtus.com

J. H. Fletcher & Co.

Roof drills, long hole drills, mobile roof supports, prime movers, scalers, jumbos and other specialized underground mining equipment. Telephone: (304) 525-7811

www.jhfletcher.com

Luff Industries Ltd. - Canada

Manufacturer of quality conveyor components. Idlers, Pulleys, Impact Beds, Accessories. The most dependable conveyor products available! Toll-Free: 1-888-349-LUFF (5833)

www.luffindustries.com

Marshall Miller & Associates, Inc.

FLSmidth

Post Mixing Optimization and Solutions

International Engineering Consultants ENERGY / ENVIRONMENTAL / ENGINEERING / CARBON Locations in KS, KY, LA, NC, PA, TN, VA, WV Telephone: 276.322.5467

Email: corp@mma1.com

www.mma1.com

www.richwood.com

E1 spherical roller bearings, split spherical roller bearings, TAC11, seals, dragline, shovel and motorized wheel bearings. www.fag.com

Skelly and Loy, Inc.

MINING ENGINEERS AND ENVIRONMENTAL CONSULTANTS 449 Eisenhower Boulevard, Suite 300 Harrisburg, PA 17111 Telephone: (800) 892-6532 or (717) 232-0593

www.skellyloy.com

TESSCO Technologies

TESSCO is a value-added supplier of MSHA-approved products for wireless two-way communication from leaky cable, antennas, broadband wireless radios, power supplies and custom enclosures.

www.tessco.com

Vibra-Tech/GeoSonics

Blast Consulting & Seismograph Manufacturing Allied Companies with 80 years experience. Telephone: (800) 992-9395 / (800) 233-6181

www.geosonics.com www.vibra-tech-inc.com

Naylor Pipe Company

Manufacturers of Spiralweld Steel Pipe and Fittings 4” to 102”, #14ga. to 1/2” wall. Telephone: (773) 721-9400 Fax: (773) 721-9494

www.naylorpipe.com

AUGUST 2010

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www.miningengineeringmagazine.com

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J. DAVID LOWELL PROFESSIONAL PROGRAM IN MINERAL RESOURCES FALL 2010 COURSES Credit or Non-credit • Non-credit Cost: $500

• September 24-25 Introduction to Engineering Contract Law Introduction to the basics of contract formation, risk allocation and management, applied to a representative cross section of contract types.

• October 1-2 Modern Corporate Organizations in the Mineral Industry Introduction to the key issues in setting up and managing effective mining organizations and will provide insight into the role of boards of directors and senior management of such companies.

• November 12-13 Basic Concepts in Mineral Economics Overview of the field of mineral economics, what it holds in common with other areas of economics, and the special requirements of the mineral resources sector. For the MEng degree, if you work for a company that has a business presence in Arizona that employs engineers, you are considered an Arizona resident and eligible for the resident tuition rate. Courses available on-site, live via video conference, live and on-demand internet streaming. Registration form, course syllabi, instructor biographies, and required textbooks can be found at: http://www.geo.arizona.edu/imr/events/fall.html

For more information contact the Lowell Institute for Mineral Resources 520·621·5292 www.IMR.arizona.edu pbosco@u.arizona.edu www.miningengineeringmagazine.com

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AUGUST 2010

Professional Services

ALASKA

COLORADO GROSVENOR ENGINEERING COMPANY

ON-LINE EXPLORATION Services, Inc.

• Geological & Mining Consultants • Complete Services for the Mining Industry James Adler, CPG Kerry Adler, CPG Kevin Adler, PE 11900 Industry Way, Unit M-10 Anchorage, Alaska 95515

Phone: (907) 345-4815 Fax: (907) 345-1987

N E VA D A

709 West Littleton Blvd Suite 206 Littleton, Colorado 80120 Office (303) 798-0181

David E. Krebs, P.E. President

Underground Mining Contractor

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NV License 46158 • CA License A-723890

www.magmineserv.com

R Squared Incorporated

Sacrison Engineering

Environmental and Engineering Services

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Mine • Geological • Hydrological • Environmental • Maintenance

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ILLINOIS Carlin Trend Mining Supplies & Service

Grouting Systems

369 5th Street, Elko, Nevada 89801 (775) 778-0668 carlintrend@frontiernet.net Geological Consulting - Claim Staking - Soil Sampling Mineral Surveys - Mine Hazard Fencing Geology & Drafting Supplies - AutoCad & GIS Temporary Employees in all Fields

ChemGrout systems offer you the widest selection of mixers, pumps and power options.

PHYSICAL RESOURCE ENGINEERING, INC. MINING, ROCK & CIVIL ENGINEERING • SURVEYING REMOTE SENSING • MICROPHYSICS • MAPPING • CONSTRUCTION MATERIALS INSPECTION & TESTING • STRUCTURAL ENGINEERING

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P E N N S Y LVA N I A

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EAVENSON, AUCHMUTY10/12/07 & GREENWALD A Professional Corporation

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LOUISIANA

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Engineering Afﬁliate of METALOCK® CORPORATION

1:53:02 PM

Mining Consultants Our 90th Year Three Church Street P.O. Box 529 Tel 724-942-5894 Lawrence, PA 15055 Fax 724-942-5897

Engineered Casting Repair Service, Inc.

MINERALS ADVISORY GROUP R&D Research, Development and Testing Services

Martin C. Kuhn, PhD., P.E. Peter J. Crescenzo, P.E. James F. Minno, VP Operations One W. Wetmore Rd. Phone: (520) 887-7357 Suite #207 Fax: (520) 887-7420 Tucson, AZ 85705 E-mail: office@magintucson.com

Analysis and Repair of Cracked and Eroded Ball and SAG Mill trunnions Phone 225-791-8900 • Fax 225-791-8965 email: metalock@eatel.net You Know It’s Cracked - How Do You Fix It?

KENTUCKY

SLIM HOLE LOGGING SPECIALISTS SLIM HOLE LOGGING SPECIALISTS COMPLETE LOGGING SUITES COMPLETE LOGGING SUITES

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DARCO ENERGY MANAGEMENT CORPORATION (Appraisal of All Mining Assets)

EnvironmEntal EnginEEring and SciEncE

Roger Daugherty, President Certified Senior Appraiser

CALIFORNIA

TerraMins, Inc.

Consulting Mining/Economic Geologists Dinah O. Shumway California Registered Geologist

Doug Shumway

Mining Engineer / Registered Environmental Assessor 12277 Apple Valley Road, #184, AppleValley, CA 92308 760-285-5801 TerraMins.com

AUGUST 2010

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••ABHTV BH GYROSCOPE ABHTV • BH •GYROSCOPE ••HP FLOWMETER • IMPELLER FM HP FLOWMETER • IMPELLER FM • COLOR BH VIDEO • COLOR BH VIDEO INDUCTION ••INDUCTION • FLUID CONDUCTIVITY • FLUID CONDUCTIVITY THERMAL • RESISTIVITY/S.P. ••THERMAL • RESISTIVITY/S.P. SONIC • CALIPER ••SONIC • CALIPER

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Effective Technical Solutions for the Mining Industry • • • • • • • •

Beneficial Reuse Industrial Minerals Valuation Multi-Site Environmental Management Systems Groundwater Modeling Hydrogeologic Investigations Mining & Mineral Processing Management Mine Design and Permitting Dewatering Studies

Pipersville, PA

Toll Free (800) 264-4553 www.earthres.com

www.miningengineeringmagazine.com

Professional Services

TEXAS

U TA H

LM GOCHIOCO & ASSOCIATES Inc. Coal & Mining Geophysical Technologies

Detecting and imaging geologic anomalies, old mine works, abandoned mines & wells, seeps, and other environmental, exploration, mine safety, & permitting challenges.

GEOLOGICAL DATA SERVICE • Resource Management • Property Valuation • Project Management • Exploration • Geology • Data Maintenance • Mapping Servicing: • Coal, Trona, Limestone and other minerals • Coal Methane Specialists 49 East Gordon Avenue 801-288-8919 Phone Salt Lake City, UT 84107 USA 801-288-8917 Fax geodrill@burgoyne.com Partnering with Mentor Consultants to offer PC/Cores, since 1994

• New Business Development • Domestic & International Joint Ventures • CBM and UCG

(832)647-0867, Fax (281)579-6308 • Houston, Texas, USA Email: geophy6@hotmail.com; lmgochioco@gmail.com www.geonanotechnology.com

US GENERAL

Professional Services Directory $250 for One Full Year! mcginnis@smenet.org 303-948-4243

US GENERAL

Nearly FREE Stress Relief

P.O. Box 10080 • American Canyon, CA 94503 707-553-2772 • sfmicro@earthlink.net

PETROGRAPHY ORE MICROSCOPY PROCESS MINERALOGY

Since 1969

SKELL Y AND LOY SKELLY ENGINEERS-CONSULTANTS

Harrisburg, StateCollege, College, Harrisburg,Pittsburgh Pittsburgh and and State PA PA Morgantown, WV • Raleigh, NC • Hagerstown, MD Morgantown, WV • Hagerstown, MD Phone (800) 892-6532 or (717) 232-0593 Phone (800) 892-6532 or (717) 232-0593, Fax (717) 232-1799 Fax (717) 232-1799 www.skellyloy.com www.skellyloy.com “ We the Mining MiningIndustry Industry Worlwide” “WeServe Serve the Worldwide”

F.M. LOCOTOS CO., INC. Mine and Roof Control Products

Complete line of Bolts, Plates, Resin, Mats Washers, Stratascope, and Specialty Items On-site Testing and Evaluation (412) 257-8730 • Fax (412) 257-8738 • (866) 279-6507 www.fmlocotos.com

CONTINENTAL PLACER INC. Geologic and Environmental Consultants Brent Tardif, Senior Vice President 2 Winners Circle • Albany, New York 12205 (518) 458-9203 • www.continentalplacer.com

EXPLORATION / EVALUATION • ENVIRONMENTAL PERMITTING • MARKET STUDIES • MINERAL APPRAISALS • EXPERT TESTIMONY • QUALITY & QUANTITY STUDIES • ACQUISITION DUE DILIGENCE • COMPUTERIZED MINE PLANNING • TOTAL BUSINESS VALUATIONS

ATLAS EQUIPMENT Co. Call 1-800-Meta-Lax

ENGINEERING TO THE MINING Subsidence INDUSTRY

Foundations Refuse Disposal Site Development Slope Stabilization Ground Improvement

412-856-9440

Visit Us at www.Meta-Lax.com

Slurry Pumps 206-315-2950 • www.atlaseqco.com

The Warman® AH Pumps and parts are inter-changeable with the Battle Mountain pump Horizontal fully lined and Vertical Cantilever for harsh abrasive service.

Bonal Technologies’ patented Meta-Lax process is the Effective Consistent Fast Alternative to Thermal Stress Relief.

Harrison Western Construction

www.harrisonwestern.com 800-638-8793 Experience, Integrity, Performance Mine Development Underground Mine Construction Mine Rehab & Repair

www.dappolonia.com

Weir Minerals provides the best slurry and minedewatering solutions for virtually any application, anywhere in the world. www.weirminerals.com www.miningengineeringmagazine.com

SCHURER.indd 1 Irrigation & Liquid Handling Solutions

Phone: 800-246-3685 E-mail: irrigate@schumacherirrigation.com Website: www.schumacherirrigation.com Since 1956

Pipe • Hoses • Fittings

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AUGUST 2010

Professional Services

US GENERAL

ABRESIST® Fused Cast Basalt Linings for hydraulic & pneumatic conveying systems

Wear resistant material 40-500 mm internal diameter for pipes & bends Hoppers, chutes & cyclones

A Kalenborn Company

Abresist Corporation Toll Free: 800-348-0717 Fax: 888-348-0717 E-mail: info@abresist.com

www.abresist.com

Mine Ventilation Services, Inc. 1625 Shaw Avenue, Suite. 103, Clovis, CA 93611 Tel: 559 452 0182 - Fax: 559 452 0184 Web: www.mvsengineering.com

We Specialize in: • Mine Ventilation Surveys • Computer Modeling for Future Designs and Efficiency & Optimization Studies • Software for Mine Ventilation & Cooling, Mine Fire Analysis • Ventilation & Software Training Programs • Diesel Particulate Matter (DPM) Analysis & Control

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Software Available from MVS: VnetPCTM 2007 VnetPCTM 2007 en Español ClimsimTM MineFireTM DuctSimTM

Full Service DPM Laboratory!

M V S

DAWSON METALLURGICAL LABORATORIES, INC. An FLSmidth Company

Process Development Testing Precious Metals • Base Metals • Industrial Minerals

Philip Thompson, Director

2030 North Redwood Road, Suite #70 Salt Lake City, Utah 84116 Phone: 801-596-0430 • Fax: 801-596-0425 email: SLCDawsonLabs@FLSmidth.com

CHAPMAN, WOOD & GRISWOLD, INC.

Consulting Mining Engineers and Geologists

Feasibility • Valuations • Worldwide Experience Metals • Industrial Minerals • Uranium 4015 Carlisle Blvd. N.E., Suite C Albuquerque, NM 87107• Ph(505) 883-0220

I N T E R N AT I O N A L

QSP Packers, LLC Quality - Service - Price

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AUGUST 2010

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Toll Free: 1-888-572-2537 Fax: 253-770-0327 Email: info@QSPPackers.com Or visit our WEB SITE: www.QSPPackers.com Prompt Shipping in US & International Usually in just one day!

GeoTDR, Inc.

Mine subsidence risk assessment, slope stability

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Page 1

POCOCK INDUSTRIAL, INC. SPECIALISTS IN SOLIDS / LIQUID SEPARATION CONSULTING • TESTING • EQUIPMENT SALES

INTERNATIONALLY RECOGNIZED EXPERTS IN: • Gravity Sedimentation (Thickening & Clarification)

METALS, MINERALS, COAL AND OIL SANDS CONSULTING SERVICES

• Filtration (Pressure and Vacuum Applications)

WWW.MARSTON.COM 314.984.8800

• Solids/Liquid Separation Systems Optimization

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• Mixers • Vacuum Filters (Drum, Disk & Belt) Glenn Welch • Mike Empey • Michael Wirthlin Nick Newton • Ben Pocock 6188 South 300 West Salt Lake City, Utah 84107, USA

www.TechnoMine.net

Front End Engineering • Bankable Feasibility Studies Resource and Reserve Estimations Due Diligence • Expert Witness Mine and Plant Optimization Advanced Control Systems Salt Lake City, Utah - USA 801•944•1382 Office 801•733•6053 Fax Brazil Branch Office, Belo Horizonte, MG 55•31•9131•3474 Office

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AUGUST 2010

Professional Services

I N T E R N AT I O N A L

SRK Consulting Engineers and Geoscientists

RESOURCE GEOLOGY, DUE DILIGENCE, ENVIRONMENTAL PERMITTING, GROUNDWATER STUDIES, AND DESIGN ENGINEERING Global Experience Global Solutions

Material Handling and Transportation Mine Engineering and Design Mining Feasibility Studies Reserve Evaluations Backfill Planning/Post-Mine Topography Design ! Mine Permitting ST. LOUIS, MO 314.781.7770

SHERIDAN, WY 307.673.1644

CALL & NICHOLAS, INC.

Rock Mechanics

Slope Design

Geological Engineering

2475 N. Coyote Drive (520) 670-9774 Tucson, AZ 85745 Fax: (520) 670-9251 email: cni@cnitucson.com Website: www.cnitucson.com

www.cdgengineers.com

International Manufacturer, Distributor and Service Group for Specialty Mining and Tunneling Equipment

Your source for mineral processing equipment WEIR

Weir International, Inc. Mining, Geology and Energy Consultants

Providing mining, geology, geotechnical, operational, environmental, training and engineering services worldwide.

Chicago Corporate Office Tel: 630-968-5400 Fax: 630-968-5401 e-mail: weir@weirintl.com www.weirintl.com

Language Solutions for your Global Market

Specializing in technical projects in 100 languages Including: *Brazilian Portuguese *Russian *Chinese language@horizontranslating.com Kanab, UT USA www.horizontranslating.com Ph (435) 644-2728

• Equipment Cost Calculator • Coal Cost Guide • Mining Compensation Reports

www.CostMine.com

www.mpiinc.info Crushing Performance • Evaluation Plant Design and Efficiency Studies

Jerry Motz

Consultant-Crushing

KCA

Kappes, Cassiday & Associates

Specialists in the Testing and Field Application of Heap Leach and Cyanide Technology Since 1972 7950 Security Circle, Reno, NV 89506 Phone: (775) 972-7575 Fax: (775) 972-4567 www.kcareno.com e-mail: kca@kcareno.com AUGUST 2010

• Linear Screens • Paste Thickeners • Thickeners • Vacuum Filters

• Mining Cost Service

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• Buoyant Media Clariﬁers • Carbon Retention Screens • Heavy Duty Drives • Horizontal Belt Filter

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801.265.1000 westech-inc.com

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5446 S. 20th Street Milwaukee, WI 53221

Tel. 414-281-8432 jcmotz@yahoo.com

Tel: +1 509 328 8023 Fax: +1 509 328 2028 info@costmine.com

CostMine Division - InfoMine Inc. 2010 www.infomine.com

M I N I N G S O F T WA R E

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WINBELT

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Mining Technical Systems Analysis www.miningsoftware.com Contact: Betty Gibbs GIBBS ASSOCIATES P.O. Box 706, Boulder, CO 80306 (303) 444-6032 mining@miningsoftware.com

www.miningengineeringmagazine.com

Index of Display Advertisers

MINING ENGINEERING

AUGUST 2010

American Peat Technology LLC

Cytec Industries Inc

Grieve Corporation

International Society of Explosives Engineers

Jennmar Corporation

Liebherr France SAS

McLanahan Corporation

Back Cover

Metso Minerals

Inside Front Cover

Miner Elastomer Products Corporation

Naylor Pipe Company

Ontario Government

Sioux Corporation

Stedman Machine Co Inc

Strata Safety Products LLC

Weir Minerals North America

Wirtgen America www.miningengineeringmagazine.com

OFFICIAL PUBLICATION OF SME

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Hooper Jones Central, NW U.S. 847-486 -1021 • Cell: 847-903-1853 Fax: 847-486-1025 hooperhja@aol.com Marsha Tabb East, South, West U.S. 215-794-3442 • Fax: 215-794-2247 marshatabb@comcast.net Lewis Bonder Canada 514-485-3083 • Fax: 514-487-0553 lbonder@miningpublications.com Patrick Connolly U.K. and Europe 44 1702-477341 Fax: 44 1702-477559 patco44uk@aol.com Gunter Schneider Scandin. / Europe 49 2131-511801 • 49 2131-4038973 info@gsm-international.eu Johanna McGinnis Asia, Russia, Ukraine Africa, Middle East Latin America, Australia 303-948-4243 • Fax: 303-973-3845 mcginnis@smenet.org Mınıng engıneerıng

AUGUST 2010

The Drift of Things

Material ME readers count on S

Steve Kral, Editor

o, you have reached page 72, the last page of this month’s Mining Engineering magazine. You have seen the magazine’s new look and, hopefully, found it more appealing to the eye and easier to read. This redesign has been several months in the making. It took much discussion, and some disagreement, but the ME staff believes it has found a look that is more modern, more in tune with the 21st century. Despite the disagreements (friendly, to be sure) concerning type sizes and fonts, headline sizes, colors and even the use of that mug to the left (I was against it), the editors and production staff never lost sight of Mining Engineering’s purpose — to bring SME members the best technical information available and coverage of the global mining industry. While the look of any magazine is important, readers, especially ME readers, are not going to be fooled by warmer colors or more eye-catching photos. Content still rules. And SME’s flagship publication will continue to carry the best in technical papers and features, relevant news from around the world, technology-related articles that are useful to the mining professional and updates on what SME is doing to help its members grow professionally. The ultimate judge as to how well the staff did, of course, is the reader. And we encourage you to let us know what you think.

New mines in the making

While reading the Industry Newswatch section, the reader probably noticed a handful of items relating to new mine development and expansions — Coeur d’Alene Mines finally beginning production at its Kensington Mine in Alaska, Farallon Mines building a second mine at its Campo Morado property in Mexico and Xstrata spending $1.47 billion to expand at Tintaya, thus extending the mine’s life. And those were just the items we had room for. In addition, two feature articles in this month’s issue deal with two of the major companies plans for new copper mines, one in 72

AUGUST 2010

Mınıng engıneerıng

Indonesia and the other in the United States. P.T. Freeport Indonesia, a unit of FreeportMcMoRan, is building its newest mine at its Grasberg complex. This is a region that has been mining copper and gold for about 30 years and, by reading the feature article on page 20, will likely be mining copper and gold for at least another 30 years. The DMLZ Mine is expected to begin production in 2015 and eventually ramp up to its peak production of 29.2 Mt/a (32.2 million stpy) of copper ore. Reserves currently stand at 501 Mt (552 million st), grading 0.89 percent copper, 0.74 g/t (0.022 oz/st) gold and 4.4 g/t (0.13 oz/st) silver. Located at 1,400 to 1,800 m (4,600 to 5,900 ft) below its original surface, the DMLZ Mine will be one of the world’s deepest caving operations. Now to the United States, a country not known for approving very many new mining operations. Those who have been involved with the domestic copper industry for some time no doubt remember the Magma Mine near Superior, AZ. Today, Rio Tinto is attempting to bring the mine back to life, only with a new name. Rio Tinto, through its Resolution Copper subsidiary, is spending a lot of money trying to bring the Resolution copper mine (the old Magma Mine) back into production. ME’s Emily Wortman-Wunder (page 33) reports that the company already has about $500 million invested in the project, and it has not even received the right to mine yet. However, Rio Tinto is doing an admirable job of paving the way for mining — the way it should be done. Resolution Copper is spending most of its time, and a fair amount of money, building relations with Superior residents. It is addressing early on potential environmental and social impacts of the Resolution Mine. And, while there is opposition to the mine, a majority of the town’s population seems to be in favor of it. The project still has some major hurdles to overcome before mining can begin. Among them is a proposed land exchange between the company and the federal government. That issue is currently before Congress in the form of an omnibus land package. That could be decided this year. Most anything involving public land in the United States is an uphill battle. But, hopefully, Congress sees the benefits of the mine and approves the exchange. n www.miningengineeringmagazine.com

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oCtober 10-12, 2010 • WeStin ChiCaGo river north hotel, ChiCaGo, illinoiS

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