Technical Sessions

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Technical Sessions TECHNICAL SESSIONS MONDAY, FEBRUARY 25 MONDAY, FEBRUARY 25 AFTERNOON AFTERNOON 1:30 PM | ROOM 113 2:00 PM | ROOM 507 Dreyer Lecture: Why Choose Bulk Material Handling: Conveyor Industrial Minerals For A Career Path Maintenance and Safety Recipient and Lecturer: Dennis P. Bryan Chair: N. Madison, Cornerstone Conveyor Engineering, Fayette, AL 2:00 PM Introduction 2:05 PM Constructing Toromoch’s 5.2 KM Conveyor through the Andes Mountains C. Torres and E. Michiels; Maccaferri Mining Solutions, Lithia, FL Constructing a 5.2 KM conveyor has many challenges, combine that with- building it at nearly 5,000m in elevation through the Andes mountains and it can be hazardous. Identifying the structure’s best travel path still required a 250m climb, a 300m decent as well as 7 horizontal turns. This path still left the conveyor exposed to falling debris and ice, the construction of a 20m reinforced slope and a tunnel to allow vehicles to cross the structure. Construction at this elevation is challenging and the weather; wind snow and rain, can be create quite a burden on the installation crews. For the safety and construction timeline experienced crews were necessary to construct various aspects of this project. This presentation will share design and con- struction details on the rockfall protection system, the MSE wall supporting this massive conveyor and the tunnel on this project. 2:25 PM Bulk Material Flowability Testing – What Is It and Why Does It Matter? C. Hartford and T. Holmes; Jenike & Johanson, San Luis Obispo, CA Bulk solids handling systems are often the weakest links in the process plant, and their performance can dictate the performance of the entire operation. Therefore, they deserve special attention. When designing a bin, hopper, transfer chute, or stockpile for a bulk material, it is critical to understand how the bulk solids will “flow” through the system. Flowability is a function of the material and the equipment handling it. A “free-flowing” material placed in poorly designed equipment may have difficulty flowing reliably. Similarly, a material that seems difficult to handle placed in the correct equipment may flow without a problem. When designing a liquids plant, the density and viscosity of a liquid is looked up or tested and used as a design parameter. With bulk solids, the design process is similar except the friction, cohesive strength, compressibility and sometimes permeability need to be measured for the material. It is important for these tests to be run at representative process conditions. Measuring flow properties and applying them correctly will reduce project risk and potentially save a significant amount of capital. 1 SME 2019 ACE | TECHNICAL PROGRAM 2:45 PM The Importance of Being Conservative with the Packing MONDAY, FEBRUARY 25 Ratio in Discrete Element Modeling to Improve the Design AFTERNOON Phase and Simulated Behavior of Transfer Chutes J. Amoroso; Overland Conveyor Co., Lakewood, CO Using discrete element modeling to simulate transfer chutes is an important 2:00 PM | ROOM 711 step towards designing a well-engineered transfer chute. It is beneficial to visualize the material flow through the transfer chutes before fabrication and without building a full scale model. The difficulty with discrete element mod- Coal & Energy: Best of Ground Control eling is understanding what parameters and values to use for the simulated material in order to match the onsite material as close as possible. Onsite tests can be performed on the material to find specific material details which Chairs: M. Murphy, National Institute for Occupational are used to optimize the discrete element modeling parameters. This paper Safety and Health, Pittsburgh, PA will explain how the packing ratio affects other parameters due to the change B. MISHRA, West Virginia University, in particle density. Once the other parameters are adjusted to match the onsite material details, the packing ratio may need to be revised as a result Morgantown, WV of how the simulated material settles. The revolving nature of modifying the packing ratio along with other parameters will be discussed concluding in a conservative packing ratio, not only for simulating material behavior but as a 2:00 PM best practice for designing transfer chutes. Introduction 3:05 PM 2:05 PM Maximizing Conveyor System Efficiency with New Drum Analysis of Coal Pillar Stability (ACPS): A New Generation of Motor Technology Pillar Design Software A. Kanaris; Engineering, Van der Graaf, Shelby Township, MI Z. Agioutantis1 and C. Mark2; 1University of Kentucky, Lexington, KY and 2 Conveyors powered by external motors and gearboxes, along with v-belts, Mine Safety and Health Administration, Pittsburgh, PA chains, couplings & pillow block bearings, often operate with relatively low Thirty years ago, the Analysis of Longwall Pillar Stability (ALPS) inaugurated a efficiency and require regular maintenance. With rising electrical and labor new era in coal pillar design. ALPS was the first empirical pillar design tech- costs, mining & aggregate industries are forced to evaluate ways to minimize nique to consider the abutment loads that arise from full extraction, and the downtime, reduce maintenance costs, increase worker safety and ultimate- first to be calibrated using an extensive database of mining case histories. ly increase profits. New drum motor technology has addressed efficiency ALPS was followed by the Analysis of Retreat Mining Stability (ARMPS) and and operator safety concerns. The drum motor, an internally driven conveyor the Analysis of Multiple Seam Stability (AMSS). Today, these empirical meth- drive, eliminates external components, houses the electric motor & gearbox ods are used in nearly every underground coal mine in the US. However, the inside the drum, increases operator safety, saving space, eliminates sched- piecemeal manner in which these methods have evolved resulted in some uled maintenance, increases longevity and overall efficiency. With v-belts, weaknesses. In certain situations, it may not be obvious which program is chains and couplings no longer required, the internal drive design drum mo- the best to use. Other times the results from the different programs are not tor, has efficiency gains of up to 30% and lower operating costs. Reliability entirely consistent with each other. The Analysis of Coal Pillar Stability (ACPS) & longevity of conveyor drives pose challenges for belt conveyors to operate integrates all three of the older software packages into a single pillar design in harsh & abrasive environments and failure is ground zero for loss of pro- framework. ACPS also incorporates the latest research findings in the field duction. The latest Van der Graaf GrizzlyDrive™ drum motor with IronGrip of pillar design, including an expanded multiple seam case history data base lagging, is developed specifically to operate in these extreme environments. and a new method to evaluate room and pillar panels containing multiple rows of pillars left in place during pillar recovery. 3:25 PM The Different Types of Conveyor Belts Used in Mining 2:25 PM L. Hoggan; Rema Tip Top, Oregon City, OR The Limitations and Potential Design Risks When Mining is a broad term that captures a lot of different products and process- Applying Empirically-Derived Coal Pillar Strength es for extracting the earth’s minerals. There is not just one type of convey- Equations to Real-Life Mine Stability Problems or belt that works well in all mining applications. Learn about the different R. Frith and G. Reed; Mine Advice Pty Ltd, Beresfield, NSW, Australia rubber compounds, types of conveyor belt construction and configurations The paper explores the reasons as to why empirically-derived coal pillar that impact the life, capacity and functionality of conveyor belts around the strength equations tend to be problem-specific, and so should perhaps be mining site. You’ll walk away understanding the terminology and differenc- considered as providing no more than a pillar strength “index”. These include es in specifications, ensuring that you have the knowledge to ask the right the non-consideration of overburden horizontal stress within the mine stabil- questions and make the right purchasing decisions. ity problem, an inadequate definition of super-critical overburden behaviour as it applies to coal pillar loading and the non-consideration of overburden displacement and coal pillar strain limits, all of which combine to potentially complicate and so confuse the back-analysis of coal pillar strength from failed cases. A modified coal pillar design representation and model is pre- sented based on coal pillars acting to reinforce a horizontally-stressed over- burden, rather than suspend an otherwise unstable self-loaded overburden or section thereof, the latter having been at the core of historical empirical studies into coal pillar strength and stability. 2 SME 2019 ACE | TECHNICAL PROGRAM 2:45 PM 3:45 PM What Factors Over and Above Those Included in the Existing Challenges of Mining the First Right-Handed Longwall in Coal Mine Roof Rating (CMRR) Could Also Be Predictive of Pittsburgh Seam Roof Instability in Underground Coal Mines? J. Lu and G. Hasenfus; CONSOL Energy Inc., Southpointe, PA M. Young, E. Holley and G. Walton; Colorado School of Mines, Golden, CO In this presentation, the mining experience and challenges for the first The coal mine roof rating (CMRR) was developed by NIOSH to bridge the gap right-handed longwall panel in the Pittsburgh seam was introduced. The between geological variation in underground coal mines and engineering longwall headgate T-junction experienced very high face convergence (up to design. The CMRR has been widely used and validated in Eastern US coal 2 feet), accompanied by roof sag, floor heave, and rib loading. The headgate mines, but has seen limited application in the Western US. This study focuses convergence was so large that in a few places it threatened longwall retreat, on roof behavior at two Western coal mines. The first mine presents laterally and ultimately required the bottom to be re graded.
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