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By B. K. Mishra, R. K. Rajamani, A. D. Joshi

The liners are the most important part in the SAG mill operation. Hence, the liners and their design parameters are primarily studied to see its effect on SAG mill operations. Effective liner designs are directed to reduce downtimes, which is needed for the replacement of worn liners. There exists constant chance of improvement in the capacity of mill by studying the effect of liner design on the charge motion inside the mill. This need is satisfied by three-dimensional discrete element code "Millsoft", which uses Discrete Element Method (DEM) to analyze the motion of charge. This simulation of SAG mill keeps track of all the moving bodies like ball and rock and observes its interaction with liners and lifters. The recent work done on this software helps generating mill to more reality by putting conical wall at feed and discharge end, over the earlier flat walls. Millsoft is an effective tool to watch the change in the motion of the charge due to different types of lifter bars and different design parameters. It was concluded that by simply increasing chord length between the lifters and increasing the face angle of the lifters, capacity of the mill could be increased. On the other hand, this software can also be used to get power draft at the respective mill design.

Jan 1, 2002

By J. T. Ryan, Wayne H. Griffin

Solutions to typical leaky ventilation circuits such as multiple entry headings and ventilation tube or brattice face ventilation are obtained using the discrete continuous simulation language SLAM II. While the continuous aspect of the language allows exact numerical solution of leaky systems, the particular discrete-continuous interface of this language is easily adapted to space varying geometry and flow parameters encountered in mine ventilation. The ease with which this simulation system is adapted to ventilation problems and the availability on personal computers encourage its wider application in the field.

Jan 1, 1987

By Yi Zheng

Under normal circumstances, methane released along a longwall face represents only 10%-20% of the total me- thane emitted from the entire longwall panel. However, there might be a sudden surge of methane at the face which may cause a potential problem because the friction from shearer cutting, support movement, and scraper conveyor dragging can be ready ignition sources. Therefore, to predict the distribution of methane will be critical to prevent possible explosions. In this paper, methane dispersion patterns along a lognwall face are simulated under normal and abnormal conditions. With the simulation of methane released from the face, around shearer drum, and from the broken coal on the conveyor, places with possible high methane content can be identified by different phases of working process and shearer positions. Local ventilation measures are evaluated so precautionary measures can be planned ahead.

Jan 1, 2012

By Alejandro Gutiérrez, David Ahues, Paola Merino, Felipe González

A Discrete Elements Method (DEM) study of load movement within a SAG mill 12,192 × 7620 (40′ × 25′) in normal operating conditions is performed. The purpose is to determine how the geometry of the lifters affects the kinetics of the load inside the mill. Specifically, the changes produced by the incorporation of inclined lifters and spiral or helicoidal pulp lifters to the kinetics are evaluated. Four study cases are identified: first, the base case corresponds to a conventional geometry; the second case corresponds to inclined lifters incorporation; third case corresponds to a mill with helicoidal discharge; and the fourth case corresponds to a mill with inclined lifters and helicoidal pulp lifters. To save computational resources, the water that enters the mill has been modeled by varying the coefficient of restitution. The results of a series of experiments are presented to determine how this coefficient varies when having impacts on surfaces with different liquid levels. A comparative analysis is made of the following variables: mean transport speed and material flow, for normal operating conditions. Taking as reference the mill with straight lifters and radial pulp lifters (case 1), the case with the inclined lifters and radial pulp lifters increases the material discharge flow less to 76 mm of size by 5.1%, and this value increases even more when the helicoidal pulp lifters are incorporated reaching a 58.6%. The most significant change is seen in the flow through the grates and the pulp lifters discharge, which can increase substantially improving the operation.

By Alejandro Gutiérrez, David Ahues, Paola Merino, Felipe González

The semiautogenous grinding (SAG) mill is one of the most important pieces of equipment in the comminution of materials. Its objective is to reduce the size of the ore until the ore can be released and continue on its transformation process. Although it is a simple process that involves impact, abrasion and attrition, its energy consumption is extremely high and inefficient, with no more of 17 percent of the energy supplied going toward size reduction. This gives rise to an important challenge because any improvement generates great economic benefits.

By Husheng Li, Zhongli Wu

This paper discusses the fundamental strategies adopted in the simulation package FIRES developed for ventilation simulation under mine fires. These fundamental strategies include (1) fire characteristic curves specifying the development of a mine fire with time, (2) simulation of fume spread in a ventilation system, (3) determination of the aerodynamic effects of mine fires on flows; and (4) dynamic simulation of flow state under mine fires. The major functions of the simulation package are also addressed. The package has been used to simulate an experiment of mine fire. A comparison is made between the simulation results and the measured data.

Jan 1, 1993

By Ivan V. Klumpar

If components of a gas-liquid stream react with each other and with stationary solids, involving parallel and sequential, reversible and irreversible, and slow and instantaneous reactions, the process can be defined by a set of simultaneous differential rate equations and simulated as multistage semibatch re¬actors. Each stage is divided into finite time increments. Within each increment, even the simultaneous reactions are treated as sequential. The proposed method follows process evolution from non-steady state startup to normal operating conditions. It allows computing byproduct buildup in recycles, tracer response curves and, in case of underground processes, expansion to adjacent parts of the deposit.

Jan 1, 1979

By S. Kenzap, V. Kazakidis

Risk assessment is an essential component of mine feasibility studies. However, it is often challenging to identify the appropriate analysis and derive the required input data. The uniqueness of a mining project and the associated technical issues require customization of the risk assessment approach to meet both requirements and characteristics. The uncertainty driving the operating risk in mine feasibility studies and its assessment through Monte Carlo simulation as a component of a cash flow analysis are discussed in this paper. The paper introduces the use of the analytic hierarchy process for derivation of qualitative input and conducts quantification of the three main sources of operating performance delays, equipment, ground and schedule problems, in a cash flow simulation. A methodology for the assessment of operating risk in mine feasibility studies is presented.

Jan 1, 2011

By A. Henchiri, G. A. Gruber

INTRODUCTION Phosphatic resources may be quantified in terms of ore tons and phosphate analyses; however, to quantify phosphate reserves it is necessary to estimate the tons and quality of phosphate rock that can be extracted from the ore. The yield and grade of phosphate rock that can recovered from sedimentary phosphate deposits are usually difficult to estimate because of variations in stratigraphy and/or mineralogy. Prospecting phosphorite ores for purposes of estimating reserves and preparing mine plans requires considerably more effort than defining ore thickness and P205 content. In Florida, for example, it is standard practice to prospect by core drilling and to subject each strata (split) to beneficiation testing, and to perform detailed chemical analyses on the beneficiated products from each strata. For a completed drilling pattern the area of influence of each hole is 2.5 acres. The number of strata per drill hole typically varies from two to five, and thus complete prospecting of a 40acre tract requires drilling 16 core holes and beneficiation testing of about 48 ore samples. Florida practice is not appropriate for all phosphorite deposits. Functional drill rigs and trained drillers may not be readily available. Water for core drilling may be unavailable and the characteristics of either the overburden or ore may require careful attention and excessive cost to obtain representative core samples. Alternate ore sampling methods include auger drilling, rotary drilling to obtain cuttings, and the excavation of trenches, pits, and shafts. Drill cuttings samples are generally the least expensive to obtain, but they are usually unsuitable for beneficiation testing because of particle size reduction during drilling. Ore samples from surface trenches and pits are expensive and may not be representative of deeper ore. Ore samples from shafts are the most expensive to obtain, but if taken properly they are reliable for use in laboratory and pilot plant testing. Regardless of the prospecting technique used, reliable estimates of the yield and grade of phosphate rock that can be extracted from an ore deposit are required: • to justify capital expenditures for a new mine • for mine design and mine planning • for beneficiation plant design • for production forecasts, quality control, and marketing. This paper describes models that predict the beneficiation response of ores from three phosphate ore deposits. The purpose of these models is to obtain maximum utilization of available prospect data with the least cost. ORE DEPOSITS Simple beneficiation models have been developed for ores from three sedimentary phosphate deposits around the Mediterranean area. The first deposit, herein described as "A" ore, is located north of the Mediterranean Sea. The second deposit, designated as "B" ore, is located east of the Mediterranean Sea, while the third deposit, "C" ore, is located south of the Mediterranean Sea. Ore "C" is from the Sra Ouertane deposit in northwestern Tunisia.

Jan 1, 1993

By Pengfei Wang, Guorui Feng

"With the depletion of easily minable coal seams, less favorable reserves under adverse conditions have to be mined out to meet the market demand. Due to several historical reasons, a large amount of remnant coal was left unrecovered. One such case history occurs with the remnant rectangular stripe coal pillars using partial extraction method at Guandi Coal Mine, Shanxi Province, China. The challenge that the coal mine is facing is that there is an ultra-close coal seam right under it, with an only 0.8 to 1.5 m sandstone dirt band in between the two. The simulation study was carried out to investigate the simultaneous recovery of upper remnant coal pillars while mining the ultra-close lower panel using longwall top coal caving (LTCC). The remnant coal pillar was induced to cave in as top coal in LTCC system. Physical modelling shows that the coal pillars are the abutments of the stress arch structure formed within the overburden strata. The stability of overhanging roof strata highly depends on the stability of the remnant coal pillars. The gob development (roof strata cave-in) is intermittent with the cave-in of these coal pillars and the sandstone dirt band. FLAC3D numerical modelling shows that the multiple seam interaction has a significant influence on mining-induced stress environment for mining of lower panel. The pattern of the stress evolution on the coal pillars with the advance of the lower working face was found. This demonstrates that the stress relief of a remnant coal pillar enhances the caveability of the pillars and sandstone dirt band below them.INTRODUCTIONChina is one of the world’s coal-rich countries. Coal has played a significant role in the growth of China’s economy. Coal reserves have been mined commercially in China for over one hundred years. The demand for coal in China is still going to grow at a relatively high rate (BP Energy Outlook, 2019). Long-term large-scale and intensive coal mining activities have created tension between increased demand and limited resources (Bai et al., 2018). Easily minable coal seams such as sub-horizontal, tabular, and laterally extensive coal seams are being depleted, and therefore the remaining reserves are becoming less favorable. However, in many situations, the coal reserves under adverse conditions have to be mined out to meet the market demand for energy.Due to sedimentary environments and geological conditions, many coal seams are interspersed with sedimentary bands, or partings both within an individual seam and between seams. These bands and partings lead to appearance of ultra-close coal seams, as well as giving rise to considerable variation in their structural and mechanical properties (Ghabraie and Ren, 2016). Difficulties are encountered in the mining of such coal seams. If ultra-close coal seams are mined sequentially, that requires the design of a mining system for each individual coal seam; also, a large number of gateroads have to be excavated, which is not a high-efficiency option. If ultra-close coal seams are mined at a great mining height at once, for instance, using longwall top coal caving—a longwall mining method that is widely used in China for the mining of ultra-thick coal seams—then the location and characteristics of the band would have a significant influence on success of their extraction."

Jan 1, 2019

By K. Biswas, H. C. Lee, S. J. Jung

Ore passes are circular openings excavated in rock for in-mine gravity-transportation of ore. It is a very important component of the overall load-haul system of an underground mine. The function of an ore pass is two-fold: first, gravity-transportation of ore from the extraction level to the haulage level and second, the loading operation at the haulage level utilizing the gate assembly. In reality, like any other system component, an ore pass breaks down either due to a hang-up within the ore pass or due to a failure in the gate structure. The failure of the gate assembly may be attributed to a greater extent to the impact load as experienced by the components of a gate structure as a result of the direct impacts of the rock fragments and to a lesser extent to the static or 'dead weight' loads of the accumulated materials in the ore pass. This paper uses simulations in Working Model® as an aid to investigate the effect of both the impact and static loading on the gate assembly and on the inner-walls of the ore pass. The paper also investigates the impact of ore pass inclination and the presence or absence of dogleg on the static and impact loading of the same.

Jan 1, 2002

By A. C. Smith

Although only used in a few U.S. longwall mines, bleeder-less ventilation systems can be an effective spontaneous combustion control method in mines having a demonstrated history of spontaneous combustion. To provide insights for the optimization of bleederless ventilation systems for U.S. underground coal mines, a computational fluid dynamics (CFD) study was conducted to model the spontaneous heating in longwall gob areas using a bleederless ventilation system. A single longwall panel with a bleederless ventilation system was simulated, and typical longwall mine ventilation data were used in the simulations. The permeability and porosity profiles for the longwall gob were estimated using a geotechnical model and were used as inputs for the CFD modeling. The effects of gob permeability and resistance of the collapsed entries on the spontaneous heating were studied. The effectiveness of using nitrogen injection to prevent spontaneous heating in the gob was also examined.1

Jan 1, 2008

By A. C. Smith

Although it is only utilized in a few U.S. longwall mines, a bleederless ventilation system can be an effective spontaneous combustion control method in mines with a demonstrated history of spontaneous combustion. In order to provide insights for the optimization of bleederless ventilation systems for U. S. underground coal mines, a computational fluid dynamics (CFD) study was conducted to model the spontaneous heating in longwall gob areas with a bleederless ventilation system. A single longwall panel with a bleederless ventilation system was simulated, and typical ventilation data for a longwall mine was used in the simulations. The permeability and porosity profiles for the longwall gob were estimated using a geotechnical model and were used as inputs for the CFD modeling. The effects of gob permeability and resistance of the collapsed entries on the spontaneous heating were studied. The effectiveness of nitrogen injection to prevent spontaneous heating in the gob was also examined. Disclaimer: 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.

Jan 1, 2008

By C. C. Hatch

As part of a general project to simulate a concentrator, the Brenda Mines Limited secondary crushing plant, located near Peachland, B. C., was sampled during the summer and winter of 1975 to develop a digital crushing plant simulator specific to the Brenda operation. The purpose of this simulator was to study the influence of manipulable process variables on important responses and to permit study of alternative circuit configurations if desired. This paper describes the simulation methodology employed and presents the results of a computer study of the secondary crushing plant (1).

Jan 1, 1979

By H. M. Wells

The known high grade mineral re- sources in the United States are fast becoming exhausted; viable new deposits are more difficult to find and more expensive to develop; operating and capital costs have increased to meet more stringent regulatory standards. By contrast, international producers enjoy a cost advantage as a result of higher mining grades, improving technological competence, and more favorable government support. The domestic base minerals industry is finding it more and more difficult to compete in world markets. It has become essentially a marginal industry today. The current philosophy of taxation in the United States has evolved over the past century. The structure of the taxing system is based on the assumption that a firm must be able to pay its tax imposts out of profits. In principle, firms incapable of supporting the tax load should be replaced by others that can do so. This philosophy applies equally well to the mining industry, so long as it remains economically healthy. However, mineral resources are finite. The situation in the domestic base mineral industry has changed fundamentally in recent times. For the reasons given above, much of the industry now cannot continue to compete profitably in the open world market; and there are no known alternative domes- tic mineral resources more capable of doing so. Under these circumstances it is important to consider the effect of taxation not only on profitability, but also on survivability.

Jan 1, 1986

By Gary E. McIntosh

This paper will discuss a U.S. Bureau of Mines project designed to assess and predict the impacts which surface coal mining will have on the regional shallow groundwater systems in the Powder River Basin. The primary objective will be met through the accomplishment of the following: (1) The design and establishment of a regional network for monitoring of shallow groundwater systems in the Basin. (2) Monitoring of the direction and rate of flow, water quality, and aquifer characteristics of the shallow groundwater systems. (3) Development of a regional groundwater simulation model with appurtenant subroutines to determine local effects.

Jan 1, 1978

By T. S. Lundström, B. D. Marjavaara, I. A. S. Larsson

"The flow field in a rotary kiln, used in an iron ore pelletizing process, was investigated using a three-dimensional computational fluid dynamics model. The model is isothermal, downscaled and simplified. The objective was to examine the possibility of capturing the unsteady motion of the flame seen in the real kiln. The results from the simulations were compared with recorded images of the real process. The results demonstrate the possibility of quickly getting an overview of the flow field in the kiln. The main, unsteady behavior of the flame was captured. The model may be used as a tool in the ongoing work of improving and optimizing the pelletizing process.IntroductionThe pelletizing process, in which the crude iron ore from a mine is upgraded into pellets, is a process involving large amounts of hot air flowing in complex geometries. Flow control is a crucial factor in this process to maintain high pellet quality. The rotary kiln is one of the last steps in the pelletizing process, and this is where the pellets are sintered to increase their strength and metallurgical properties. The kiln burner produces a flame that supplies the entire pelletizing process with the necessary heat.Kiln burner flames are large diffusion flames arising from a jet of fuel from the burner issuing into a concentric confining cylinder with a surrounding coflow of air, called secondary air. To enable combustion, the secondary air needs to be entrained into the fuel jet. This mixing of the fuel and air is the slowest step in the combustion process and therefore affects the efficiency of the combustion. The rate of entrainment depends on the momentum ratio between the burner jet and secondary air. The higher the momentum ratio, the faster the entrainment rate and, consequently, the faster is the fuel/air mixing.The kiln of interest in this study differs from kilns used in other industrial processes in both geometry and operating conditions. A distinguishing feature is the large amount of secondary air being induced through the kiln hood and then transported to earlier stages in the process as air or exhaust gas. The secondary air therefore has a substantial momentum, implying that the resulting flow field has a significant impact on the mixing and combustion process in general and the flame shape and stability as well as combustion efficiency in particular. A systematic study of the factors influencing the dynamics of the flow field in the kiln, neglecting the combustion, is therefore justified."

Jan 1, 2016

By C. Bazin

The separation of rare earth elements is a complex process that is industrially carried out using liquid/liquid extraction. Detailed flow sheets of solvent extraction plants for the separation of rare earth elements are rarely available in the literature which limits the opportunity to teach and test the application of data reconciliation, process optimization and control to these types of plants. The basis of a simulator for a rare earth elements separation plant is described in this paper. The simulator is used to adjust the organic phase and stripping acid flow rate in a separation circuit of heavy rare earth elements from light one?s.

Feb 27, 2013

By Etienne Simode

When a fire breaks out in a mine access road, the hot smoke, due to heat transfer with the surrounding strata, progressively cools as it moves forward. Depending upon the resulting temperature distribution, the density of the fluid changes. This change will bring about: Firstly, a variation in the resistance of the roads, a static factor which will affect ventilation flow rates; Secondly, the appearance of extensive aerodynamic driving loads in the vertical and angled roads, a dynamic factor which can have an extensive impact on ventilation. Because of the appearance of combustion and distillation products, the vaporization of water, which wets the timbering and strata, and the expansion of gases, fluid rates can at times be increased tenfold in the area of the fire. These disturbances may cause explosions and ventilation inversions, which fill other working areas with smoke toxic to workers, and which can come up upon rescue teams from behind. Due to the progressive heating of the surrounding rocks, which will slow down heat transfer, these dangerous conditions change over time. At the Lorraine Basin Coal Mines, programs have been set up and employed for the computer simulation of these phenomena over time. They serve to anticipate or to understand such phenomena, the input data being the characteristic parameters of the mine ventilation network, the operating curve of the main fans, and measurements or estimates of some temperatures. Two programs, employed together, have been developed for these studies: One program, called RESO, calculates the distribution of flow rates and pressures throughout the entire network; The other, called FEUMIN, determines smoke temperatures over their entire path.

Jan 1, 1980

By B. DANIEL MARJAVAARA, I. A. SOFIA LARSSON, ANNA-LENA LJUNG

One way to upgrade iron ore is to process it into pellets. The pelletizing process is multifaceted, involving complex fluid dynamics with highly turbulent, high-temperature flow in intricate geometries. This makes it hard to perform measurements during operation, so a useful tool for better process understanding is computational fluid dynamics (CFD), where the challenge is to perform efficient and trustful simulations of complicated problems. A validated simulation model can be valuable for increased process control and development. In this paper, the flow field and coal combustion process in a pilot-scale iron-ore pelletizing kiln is simulated using a CFD model. The objective of this work is to apply a coal combustion model to enable an investigation of thermal effects from the flame on the surrounding flow field.