Predicting cave initiation and propagation

The most widely used method for predicting the onset of continuous caving is Laubscher's caving chart. A detailed examination of this method was undertaken which concluded that it had limitations which may impact on results, particularly when dealing with stronger rock masses that are outside current experience. These limitations relate to inadequate guidelines for adjustment factors to rock mass rating (RMR), concerns about the position on the chart of critical case history data, undocumented changes to the method and an inadequate number of data points to be confident of stability boundaries. A review was undertaken on the application and reliability of a numerical method of assessing cavability. The review highlighted a number of issues, which at this stage, make numerical continuum methods problematic for predicting cavability. This is in particular reference to sensitivity to input parameters that are difficult to determine accurately and mesh dependency. An extended version of the Mathews method for open stope design was developed as an alternative method of predicting the onset of continuous caving. A number of caving case histories were collected and analyzed and a caving boundary delineated statistically on the Mathews stability graph. The definition of the caving boundary was aided by the existence of a large and wide-ranging stability database from non-caving mines. A caving rate model was extrapolated from the extended Mathews stability graph but could only be partially validated due to a lack of reliable data.

Blast design using measurement while drilling parameters

Measurement while drilling (MWD) techniques can provide a useful tool to aid drill and blast engineers in open cut mining. By avoiding time consuming tasks such as scan-lines and rock sample collection for laboratory tests, MWD techniques can not only save time but also improve the reliability of the blast design by providing the drill and blast engineer with the information specially tailored for use. While most mines use a standard blast pattern and charge per blasthole, based on a single rock factor for the entire bench or blast region, information derived from the MWD parameters can improve the blast design by providing more accurate rock properties for each individual blasthole. From this, decisions can be made on the most appropriate type and amount of explosive charge to place in a per blasthole or to optimise the inter-hole timing detonation time of different decks and blastholes. Where real-time calculations are feasible, the system could extend the present blast design even be used to determine the placement of subsequent holes towards a more appropriate blasthole pattern design like asymmetrical blasting.

Asymmetric blasting: a rock mass dependent blast design method

Blasting has been the most frequently used method for rock breakage since black powder was first used to fragment rocks, more than two hundred years ago. This paper is an attempt to reassess standard design techniques used in blasting by providing an alternative approach to blast design. The new approach has been termed asymmetric blasting. Based on providing real time rock recognition through the capacity of measurement while drilling (MWD) techniques, asymmetric blasting is an approach to deal with rock properties as they occur in nature, i.e., randomly and asymmetrically spatially distributed. It is well accepted that performance of basic mining operations, such as excavation and crushing rely on a broken rock mass which has been pre conditioned by the blast. By pre-conditioned we mean well fragmented, sufficiently loose and with adequate muckpile profile. These muckpile characteristics affect loading and hauling [1]. The influence of blasting does not end there. Under the Mine to Mill paradigm, blasting has a significant leverage on downstream operations such as crushing and milling. There is a body of evidence that blasting affects mineral liberation [2]. Thus, the importance of blasting has increased from simply fragmenting and loosing the rock mass, to a broader role that encompasses many aspects of mining, which affects the cost of the end product. A new approach is proposed in this paper which facilitates this trend 'to treat non-homogeneous media (rock mass) in a non-homogeneous manner (an asymmetrical pattern) in order to achieve an optimal result (in terms of muckpile size distribution).' It is postulated there are no logical reasons (besides the current lack of means to infer rock mass properties in the blind zones of the bench and onsite precedents) for drilling a regular blast pattern over a rock mass that is inherently heterogeneous. Real and theoretical examples of such a method are presented.

Critical comparison of Julius Kruttschnitt Mineral Research Centre (JKMRC) blast fragmentation models

Blast fragmentation can have a significant impact on the profitability of a mine. An optimum run of mine (ROM) size distribution is required to maximise the performance of downstream processes. If this fragmentation size distribution can be modelled and controlled, the operation will have made a significant advancement towards improving its performance. Blast fragmentation modelling is an important step in Mine to Mill™ optimisation. It allows the estimation of blast fragmentation distributions for a number of different rock mass, blast geometry, and explosive parameters. These distributions can then be modelled in downstream mining and milling processes to determine the optimum blast design. When a blast hole is detonated rock breakage occurs in two different stress regions - compressive and tensile. In the-first region, compressive stress waves form a 'crushed zone' directly adjacent to the blast hole. The second region, termed the 'cracked zone', occurs outside the crush one. The widely used Kuz-Ram model does not recognise these two blast regions. In the Kuz-Ram model the mean fragment size from the blast is approximated and is then used to estimate the remaining size distribution. Experience has shown that this model predicts the coarse end reasonably accurately, but it can significantly underestimate the amount of fines generated. As part of the Australian Mineral Industries Research Association (AMIRA) P483A Mine to Mill™ project, the Two-Component Model (TCM) and Crush Zone Model (CZM), developed by the Julius Kruttschnitt Mineral Research Centre (JKMRC), were compared and evaluated to measured ROM fragmentation distributions. An important criteria for this comparison was the variation of model results from measured ROM in the-fine to intermediate section (1-100 mm) of the fragmentation curve. This region of the distribution is important for Mine to Mill™ optimisation. The comparison of modelled and Split ROM fragmentation distributions has been conducted in harder ores (UCS greater than 80 MPa). Further work involves modelling softer ores. The comparisons will be continued with future site surveys to increase confidence in the comparison of the CZM and TCM to Split results. Stochastic fragmentation modelling will then be conducted to take into account variation of input parameters. A window of possible fragmentation distributions can be compared to those obtained by Split . Following this work, an improved fragmentation model will be developed in response to these findings.

Kinetic parameters associated with self-heating of New Zealand coals under adiabatic conditions

Adiabatic self-heating tests were carried out on five New Zealand coal samples ranging in rank from lignite to high-volatile bituminous. Kinetic parameters of oxidation were obtained front the self-heating curves assuming Arrhenius behaviour. The activation energy E (kJ mol(-1)) and the pre-exponential factor A (s(-1)) were determined in the temperature range of 70-140 degreesC. The activation energy exhibited a definite rank relationship with a minimum E of 55 kJ mol(-1) occurring at a Suggate rank of similar to6.2 corresponding to subbituminous C. Either side of this rank there was a noticeable increase in the activation energy indicating lower reactivity of the coal. A similar rank trend was also observed in the R-70 self-heating rate index values that were taken from the initial portion of the self-heating curve front 40 to 70 degreesC. From these results it is clear that the adiabatic method is capable of providing reliable kinetic parameters of coal oxidation.

Pore, surface and fillet moisture in centrifuged beds of coarse coal

The moisture content of the coarse coking coal product from the centrifuges of preparation plants was investigated to evaluate the contribution of three types of water: that held internally in pores, that in fillets at points of contacts between the particles, and the moisture covering the surface. A standardised laboratory centrifuge test was used to measure the total non-centrifugable moisture (NCM) content and also the quantity held in internal pores, called NCMi. The fillet moisture NCMf was estimated by means of a formulation which relies on experimentally measured holdup volumes, supplemented by a physical model. The surface moisture NCMs could then be derived by difference. The NCMf, which depends on the body force, the particle size and the surface tension and contact angle of the liquid, ranges from effectively zero for large particles to 10% for fines. The surface moisture NCMs is of the order of 0.5% for high rank coals and increases to 4.5% for lower rank coals. (C) 2002 Elsevier Science Ltd. All rights reserved.

In situ studies on service life and pick consumption characteristics of shearer drums

Longwall shearers usually suffer from excessive pick and pickholder consumptions and severe wear of the backplate of the clearance ring section of shearer drums. In practice, most of the drums were seen to be withdrawn from the face due to the abovementioned problems, while vane picks and their holders were intact due to the improper lacing design of the clearance ring picks. However, few underground investigations and their results on the effect of lacing arrangement of clearance picks on the service life of shearer drums have been published. Nevertheless, the pick consumption characteristics of shearer drums were not investigated in detail, since these are fewer pick consumptions with shearers when compared to roadheaders. This paper is concerned with the comprehensive in situ trials on the effect of lacing of clearance ring picks on the lifespan of shearer drums, and the pick consumption characteristics of longwall shearers at Cayirhan Coal Mine in Turkey. The lifespan of shearer drums employed with shearers in this mine increased 70 per cent, while the consumption rate of clearance ring picks decreased three fold through using an alternative lacing for clearance picks, indicating the significance of utilizing proper design techniques for clearance ring picks for the service life of shearer drums. Statistical analyses carried out, using the raw pick consumption data, implied that the clearance ring picks experienced much higher loads than vane picks, revealing that special attention must be paid to designing clearance ring picks. An average maximum consumption value of 41 was determined for clearance ring picks, with corner-cutting picks having the most replacements, while it was 35 for vane picks, on three-day based pick replacements.

A statistical approach to predict the effect of confinement on the detonation velocity of commercial explosives

Commercial explosives behave non-ideally in rock blasting. A direct and convenient measure of non-ideality is the detonation velocity. In this study, an alternative model fitted to experimental unconfined detonation velocity data is proposed and the effect of confinement on the detonation velocity is modelled. Unconfined data of several explosives showing various levels of nonideality were successfully modelled. The effect of confinement on detonation velocity was modelled empirically based on field detonation velocity measurements. Confined detonation velocity is a function of the ideal detonation velocity, unconfined detonation velocity at a given blasthole diameter and rock stiffness. For a given explosive and charge diameter, as confinement increases detonation velocity increases. The confinement model is implemented in a simple engineering based non-ideal detonation model. A number of simulations are carried out and analysed to predict the explosive performance parameters for the adopted blasting conditions.