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It is widely accepted that particles stabilise flotation froths and that stable froths result in improved flotation performance. Predicting the effect of particle addition on froth stability is, however, challenging. Dynamic surface tension measurement using maximum bubble pressure presents an attractive technique to investigate the effect of surfactant and particles at the air-water interface. The range of bubble lifetimes that can be studied (typically 0.1 to 60 s) is analogous to variations in air rate in flotation cells, and the corresponding changes in surface tension give an indication to the diffusion and adsorption rates of particles at the interface. In this paper, we use dynamic surface tension measurements to investigate the effect of particles on bubble surfaces at the microscale and link this to bulk froth stability measurements carried out using a froth column. Using the maximum bubble pressure method, the results show that the addition of particles results in lower surface tension, both at the dynamic (i.e. short) bubble lifetimes and towards equilibrium (i.e. 60 s bubble lifetime). This corresponds with the bulk froth stability measurements, where the three-phase system yielded more stable froths than the surfactant only system. Furthermore, increased particle loading at the air-water interface, whether through higher surfactant concentrations or lower air rates (longer bubble lifetimes), gave lower surface tension and higher froth stability. This demonstrates the link between bubble loading and froth stability. It is proposed that the maximum bubble pressure technique can be used to predict froth stability for two- and three-phase systems, enabling the effect of particle loading to be accounted for and quantified. Moreover, the technique has the potential to allow rapid determination of particle and surfactant diffusion at the air-water interface and prediction of the corresponding effect on bulk froth behaviour.

By Kritika Baxla, M. Mustafa Kahraman, Frank A. Drews, Yaxue Wang, Joel M. Haight, Kody Powell, Mohit Sobalkar, W. Pratt Rogers

In the opinion of these authors, technology alone can never give an organization an edge over competitors or provide an industry step change. However, history has shown that technology applied with correct logistics and strategy makes a significant difference. Never has the minerals industry faced such daunting challenges and been in such need of a step change. Application of autonomous systems has been steadily increasing in the minerals industry. Automation technology has changed the mining value chain from exploration to mineral processing and refining. The future state will only see additional in-roads of automation into more processes and the whole system design. To better understand the near-future potential of automation, it is useful to explore and review the current state of automation in minerals development. A review of the state of automation research is given. The review will consider three critical areas: automation technology, system’s engineering and management processes around automation, and the role of human factors engineering in automated and semi-automated systems. The review ends with a discussion on the social and political risks of automation in terms of shared value and sustainable development.

By TUIJA MONONEN, LUDGER BENIGHAUS, VIRGINIA DEL RIO, CHRISTINA BENIGHAUS, SARI KAUPPI, JUHA M. KOTILAINEN, JAVIER GÓMEZ, JARI LYYTIMÄKI

This article presents results from a comparative case study focusing on newspaper coverage of mineral exploration and mining in three European countries representing different geological and socioeconomic contexts. The results show that regional newspapers in Finland, Germany and Spain report about mining issues relatively intensively even in the absence of major accidents or other media events causing peaks of attention. The tone of the articles is generally neutral to positive toward mining activities. Common themes include mining revival, mining events and social interaction, history of mining, and damages related to mining. Past, present and future employment opportunities related directly or indirectly to the mining sector are key storylines. Contrary to some expectations, the regional-level debate was not dominated by a long-lasting confrontation between the mining industry and its adversaries spearheaded by environmental nongovernmental organizations.

By Jacob Carr, Chenming Zhou, Nicholas Damiano, James Noll, Jingcheng Li

Machine-related injuries are one of the major safety concerns in underground coal mines. Severe injuries and fatalities occur when a miner is struck, crushed, or pinned by mining equipment such as a continuous mining machine (CMM), shuttle car, or a scoop. Proximity detection systems (PDSs) have been applied in mining to reduce these types of injuries and fatalities. All of the PDSs that are currently approved by the Mine Safety and Health Administration (MSHA) for use in underground coal mines are magnetic-field based and could be affected by metallic objects such as trailing cables. Researchers from the National Institute for Occupational Safety and Health (NIOSH) investigated the influence of trailing cables on the performance of PDSs. In particular, the magnetic field coupled from proximity system generators to a de-energized trailing cable was characterized. The results show that significant energy can be coupled from the proximity system generators to a trailing cable when there is a closed loop in the cable. The effect on PDS performance from the magnetic field radiated around an energized trailing cable was also quantified for different current amplitudes in the cable. It is shown that the magnetic field caused by the electric current in the trailing cable mainly consists of a 60-Hz signal and its harmonics which causes little interference to the PDS. The results presented in this paper can help PDS manufacturers to design better systems that are more immune to these effects.

By Andrew B. Cecala, Emily J. Haas, Jay F. Colinet

A sociotechnical system (STS) creates a framework that allows an examination of how social and technical factors affect organizational outcomes within a specific environmental context. STS has been rigorously studied with a primary research focus addressing worker-technology interactions. Although these interactions are important, the social processes and interactions that occur whenever any technical or environmental change is introduced into the system have been undervalued. If social processes are better understood, mining organizations could efficiently prepare and stabilize for such changes. With this goal in mind, we sought to extend STS theory through applying principles of meta-design to analyze the results of two case study interventions. Specifically, we studied the impact of an unregulated dust control technology (the Helmet-CAM) and a regulated dust control technology (the Continuous Personal Dust Monitor) on factors within an STS including employees’ knowledge of, communication about, and use of technology to mitigate respirable dust sources. The results are presented in a way that first, addresses the overarching principles of meta-design STS including organizational participation, flexibility, and communication and second, examines how technology implementation processes differ when the organization is complying with a formal, higher-level requirement. Results show that a prominent focus on the social factors within an STS framework could help reduce unpredictability on the technical side and may improve communication within the system to help reduce adoption time, especially if and when accompanying a new, formal work process.

By Guowen Dong, Qiyong Li, Qiang Li, Tiejun Chen, Zhihong Wu, Junying Wan

In order to search for a more economical and effective roasting additive for extracting vanadium from stone coal and solve the question of the disposal of PVC waste, PVC waste was proposed as a novel roasting additive to enhance extraction of vanadium from stone coal and realize the comprehensive utilization of resources. By adding this roasting additive, the leaching rate of vanadium reached 94.5% under the conditions that the PVC waste addition was 10 wt%, the roasting temperature was 800 °C, the roasting time was 1 h, the sulfuric acid concentration was 15 vol%, the liquid-to-solid ratio was 1.5 cm3 /g, the leaching temperature was 95 °C, and leaching time was 4 h, which increased by 8.4% compared with that of blank roasting. The thermodynamics calculation showed that the decomposition reaction of mica was performed easier with the participation of HCl produced by pyrolysis of PVC. Meanwhile, The SEM-EDS and aperture test analyses demonstrated that more cracks and voids appeared in the roasted sample by roasting with PVC waste, which could facilitate the release and extraction of vanadium. Additionally, the TG-DSC analyses indicated that PVC could provide large amounts of heat for the roasting process to promote the decarbonization and roasting efficiency of stone coal because of its high calorific value.

By Tyler Acorn, Brandon Wilson, Jeff Boisvert

Scenario-level uncertainty is a representation of large-scale differences encountered when considering ultimate mining pits optimized over various subsets of stochastic realizations. Accounting for scenario-level uncertainty allows mine plans to be assessed against several probabilistic subsurface interpretations. Scenario-level uncertainty is found through clustering stochastic geostatistical realizations and optimizing final pits across the realizations in each cluster. Where these pits are geometrically different, plans for each scenario differ. Knowing these differences allows the value of each planning alternative to be assessed based on the value and relative probability of each scenario. These results also facilitate the use of formal decision-making frameworks for planning, leading to optimization that better represents the full statistical characterization of the deposit. An example utilizing this approach evaluates both infrastructure placement and drilling program requirements. In both cases, scenario-level uncertainty improves initial plans by limiting opportunity costs and identifying additional potential.

By Diler Katircioglu-Bayel

This study aims to investigate the effect of combined mechanical and ultrasonic milling on the size reduction of talc. Firstly, the talc sample was wet ground in a stirred media mill for five different times (30, 60, 90, 120, and 150 min), and the optimum result was subsequently achieved with treatment by ultrasonication. The effects of amplitude (20, 35, and 50 μm), solid content (2.5, 5, 7.5, and 10%), and sonication time (60, 120, and 240 min) on the sizes of the final product were investigated. The pre-milling by wet grinding caused a decrease in the grinding resistance of talc. Sequential ultrasonic treatment, which was applied to the talc sample, generated smaller particles in comparison to those acquired by stirred media milling alone. Experimental results were assessed based on the product particle size (d10, d50), reduction ratio, and specific energy consumption. Submicron particles prepared by ultrasonic treatment were perfectly stable compared to stirred media milling alone as investigated in terms of particle size. In addition, the effects of mechanical and ultrasonic milling on structural properties of talc particles were characterized by XRD analysis.

By Maurício Covcevich Bagatini, Maycon Athayde

Nowadays, the HPGR (high-pressure grinding rolls) is an intermediate step between filtering and balling in the most modern iron ore pelletizing operation. The operation debottlenecks filtering process and reduces pressure over the typical milling process to control particle size to the balling. The present study evaluated aspects of microwave application to the iron ore concentrate fed to HPGR in a bench scale unit. Iron ore concentrate was irradiated varying the microwave exposure time and grinding efficiency was evaluated. The moisture influence in the HPGR efficiency was also assessed. The pellet feed blaine surface area (BSA) improved by 300 cm2/g and % < 325# fraction by 3%. Scanning electron microscope (SEM) images show the formation of micro-cracks onto the particle surface induced by microwave; the effect observed helped improve the milling process performance, in addition to the moisture reduction observed due to the temperature increase.

By Hamed Khodadadi, Hamid Ghadiri

In this study, a fuzzy logic self-tuning PID controller based on an improved disturbance observer is designed for control of the ball mill grinding circuit. The ball mill grinding circuit has vast applications in the mining, metallurgy, chemistry, pharmacy, and research laboratories; however, this system has some challenges. The grinding circuit is a multivariable system in which the high interaction between loops, the variation of the system parameters with time, and time delay are some of the problems that pose a challenge. Since the controller parameters are determined offline in classic PID control, these gains are unchangeable and cannot overcome the mentioned challenges in this system. Hence, a fuzzy logic self-tuning PID controller, which is a combination of fuzzy logic and a conventional PID controller, is proposed to control the grinding system, especially in the presence of model mismatch and disturbances. In addition, in order to solve the system challenges, a multivariable control approach based on an improved disturbance observer is proposed to suppress the effects of the disturbances. The most important feature of the algorithm proposed in this paper as the combination of fuzzy logic self-tuning PID and improved disturbance observer is its ability to eliminate system interaction, attenuate internal and external disturbances, and compensate the effect of system uncertainty on the performance of the ball mill grinding circuit. Simulation results in the cases of the set-point change in particle size and circulating load in the presence of model mismatch and external disturbances confirmed the controller performance compared to other controllers.

By Chen-Luh Lin, Jan D. Miller, Sindhoora Puvvada

The depletion of good-quality phosphate resources, coupled by a need to supply acceptable products at a rapid rate, while meeting the specifications of fertilizer chemical plants, is of significant concern to the phosphate industry, particularly the production of concentrates with tolerable dolomite content. Tremendous efforts have been made in the past to develop an efficient and economical process that can effectively reject dolomite. However, dolomite removal continues to plague the phosphate industry due to several process-specific challenges being encountered with various beneficiation technologies. In this regard, detailed characterization of phosphate reserves is crucial to understand textural limitations and help design appropriate strategies to achieve quality products. In this paper, the development of procedures to establish dolomite rejection/francolite recovery curves for gravity preconcentration of pebble phosphate from Central Florida is described using high-speed X-ray computed tomography (HSXCT). The developed procedure is illustrated with the analysis of high MgO pebble phosphate samples (10.39 mm × 1 mm) received from South Pasture and Four Corners locations operated by the Mosaic company. The rejection/recovery curves were calculated for each sample for five different particle size classes to observe the trend in rejection/recovery with variation in particle size. In order to evaluate the reliability of the HSXCT data, analysis using the high-resolution X-ray computed tomography (HRXCT) technique was performed on one particular sample (FC-3-1). Finally, to assess the separation efficiency, the HSXCT and HRXCT rejection/recovery curves obtained were compared to experimental gravity preconcentration results reported in the literature. In this way, liberation limitations for gravity preconcentration in the processing of pebble phosphate have been established based on X-ray computed tomography analysis.

By M. K. Mohanty, H. Akbari, L. A. Ackah

Dry separation was the predominant method of coal cleaning in the United States from the 1930s to 1980s. The application peak of dry separators for cleaning raw coal was in 1965, when about 23.1 Mt of cleaned bituminous coal was produced. The main advantage of dry coal cleaning is the elimination RIWKH GHZDWHULQJ VWDJHV DQG VLJQL¿FDQWO\ UHGXFHG moisture in comparison to wet processing. In addition, developed dust control systems have made dry cleaning method an environmentally friendly process. The largest air-based coal cleaning plant was built in Pennsylvania in 1968 and could clean 1,272 t/h of raw coal sized smaller than 19 mm. This was followed by a decline in dry coal cleaning to less than 3.6 Mt in 1988. Some of the main reasons that shifted coal operations IURPGU\WRZHWSURFHVVLQJZHUHWKHQHHGIRUPRUHHI¿FLHQW separations with lower density cuts, increase in raw coal surIDFHPRLVWXUHVSHFL¿FDOO\LQXQGHUJURXQGPLQLQJWRFRQWURO GXVW ¿QHUSDUWLFOHVL]HUHTXLUHPHQWV LQFUHDVHLQ¿QHVLQUDZ coal from underground mines, and health and safety concerns related to dust and noise (Arnold, Hervol and Leonard III, 1991; Miller, 2011).

By Andre Vien, Frank Laroche, David Di Sandro

Back in 1994, Claude Bazin presented a novel method for linking size data from milling models to the feed input of flotation models. It was achieved with the simple addition of a metal/mineral distribution—size distribution relationship. This allows grade and recovery predictions from a varying mine plan via product size distribution predictions. This paper presents a case study where this elegant method has been used to build a very powerful forecaster at a process plant, built from historic operating data. The methodology has been used by this operation to forecast production on a quarterly, annual, and life-of-mine basis since the late 1990s. It has been upgraded several times to incorporate new drivers as the complexity of feedstocks has increased over the years.

By S. K. Sahoo, S. K. Sharma, A. Yadav, B. Behera, G. S. P. Singh

A field representative modeling of the gob behavior is critical for the understanding of the associated mechanics of strata behavior in longwall workings. The findings of theoretical models and laboratory tests on the simulated gob material have shown the strain hardening behavior of the gob material. The double-yield material model, which is a built-in constitutive model in FLAC3D, has significant potential to simulate the gob compaction process as it represents materials which undergo irreversible compaction in addition to shear yielding. Apart from this, several researchers have attempted using modified elastic model or applied nodal force in reaction to the strain in the gob area as per the well-known theoretical relations to meet this requirement. Although these models can simulate the mechanical response of the gob for subcritical and critical extraction widths, they do not apply to supercritical extraction width as the gob stress may exceed the in situ stress level in such cases. For overcoming these limitations, a standard approach has been developed and validated in this paper, which can be used for simulating the gob behavior in supercritical longwall workings as well. The complete study is divided into two stages wherein the laboratory scale compression test on the simulated gob material has been numerically replicated to develop preliminary confidence followed by a parametric study of the double-yield constitutive parameters for a rational estimation of their values in different conditions. The calibrated model has been used for verifying its results by plane strain modeling of two different longwall workings, using well-established empirical and analytical findings and field observations. The approach suggested in this study can be used for the efficient modeling of the gob behavior of longwall panels under varying geo-mining conditions without compromising the accuracy of the numerical model. The meticulously validated model can be helpful in rational estimation of stress redistributions around the gob area apart from load transfer on the barrier pillar.

By Eti Purwaningsih, Widi Astuti, Erik Prasetyo

Selective-reductive leaching of manganese from low-grade manganese ore using tannic acid as a reductant in acidic media was demonstrated by XRD, SEM-EDX characterization, and batch leaching studies at room temperature. The pH change in the liquid phase before and after leaching revealed that selectivity of manganese over iron was due to the hydrolysis of iron. The acidity in the liquid phase during leaching was dictated by two mechanisms: proton-consuming reaction (manganese oxide reduction by tannic acid) and proton-producing reaction (ferric ion reduction by tannic acid to produce ferrous ion). Based on the leaching studies, the more prevalent reaction between these two was determined by initial leaching conditions: tannic acid concentration, sulfuric acid concentration, liquid-solid ratio, temperatures, and agitation time. Kinetic studies revealed that maximum recovery was attained within 6-h agitation, which indicated a product layer diffusion process.

By Roland W. Merwin

The Bureau of Mines has studied the possibility of using the heap leaching process for treating the gold ores in the sedimentary beds of northeastern Nevada. This paper summarizes all available information on the technical and economic feasibility of heap leaching oxidized ores from these beds, past industry application of vat leaching, results of recent Bureau of Mines and industry tests on heap leaching ores from this region, and requirements for planning the proper application of heap leaching. Preliminary tests on representative samples of ores from the region show that a satisfactory recovery of gold can be obtained by heap leaching the ores with cyanide at a relatively coarse size. Significant deposits of gold ore occur in sedimentary beds of various locations over an extended area 40 miles wide and 200 miles long in northeastern Nevada. The area is centered 40 miles west of and runs parallel to the leading edge of the Roberts Mountain thrust fault system, a prominent geologic feature in the area. The general locations of past and present gold mining operations are shown in figure 1. (slide 1)

Jan 1, 1969

By F. Ames Smith

Offshore oil and gas production operations have moved from water depths of about 50 feet in 1948 to the present record depth of 340 feet. Although mobile drilling rigs are widely used for exploratory drilling, most development drilling and production operations have been conducted above water from the decks of fixed, bottom-founded platforms. Increasing water depths have caused problems associated with design and construction of these platforms and with laying of pipelines, but not so much with other activities. After a platform is installed, drilling, production, and maintenance operations are similar to those onshore and are relatively unaffected by water depth. Events of 1968 indicate that offshore production may soon extend into much deeper water. These events include leasing of Santa Barbara Channel acreage in water depths over 1500 feet, and the successful drilling of a wildcat well in 1300 feet. Designs have been developed for platforms suitable for installation in water over 600 feet deep, and studies suggest they may be used in some areas to water depths of 800 to 1000 feet. Buoyant towers can probably support above-surface platforms in water 1000 feet and deeper. Although the cost of either of these platforms will be high, once installed they will permit relatively low-cost development drilling and production operations compared with estimates for subsea production systems. In some cases, savings in development drilling costs alone could pay out the platform investment.

Jan 1, 1969

By James A. Hartlage

Work on the design of Kelex 100 was initiated several years ago at the Research Laboratories of Ashland Chemical Company. The effort was specifically directed toward the synthesis of an organic molecule which would strongly and selectively chelate copper ions in acidic solutions and form an oil soluble complex which would be stable in contact with an aqueous phase having a pH of approximately one. This publication describes efforts to establish data which could be used to estimate the economic utility of the new reagent. For helping to accomplish these ends, the author wishes to acknowledge the assistance of Mr. A. V. Henrickson of Hazen Research, Inc. for gathering a portion of the data presented here and to thank the copper companies who supplied leach solutions for studies described in this paper.

Jan 1, 1969

By Clarence O. Babcock

Model pillars of limestone, marble, sandstone, and granite, with length-to-diameter ratios of 3, 2, 1, 0.5, and 0.25 (0.286 for granite), were broken in axial compression to determine to what extent an increase in end constraint increased compressive strength. Radial end constraints of 13 to 23 percent of the average axial stress in the pillar, produced by solid steel rings bonded with epoxy to the ends of dogbone-shaped specimens, increased compressive strength somewhat above that of cylindrical pillars without ring constraint. However, when the results were compared with those obtained by other investigators for straight specimens of several rock types taken collectively, with L/D ratios greater than 0.5, the resulting strengths were not significantly different. Thus, the amount of end constraint produced by the solid steel rings was about the same as that produced by the friction from the steel end plates. In other tests a radial prestress of 3,000 psi or 5,000 psi was applied prior to axial loading by adjustable hardened steel rings to increase the constraint above that obtained for the solid rings. The average radial constraint stress, expressed as a percentage of the average axial pillar stress at failure for the 3,000 psi prestress, was 54.3 percent for limestone, 40.3 percent for marble, 44.7 percent for sandstone, and 23.4 percent for granite. The average radial constraint stress, expressed as a percentage of the average axial pillar stress at failure for the 5,000 psi prestress, was 74.2 percent for limestone, 51.2 percent for marble, 61.6 percent for sandstone, and 29.7 percent for granite. These constraints increased the compressive strength significantly above the strength of straight specimens and solid-ring constrained specimens. These results suggest that large horizontal stresses in orebodies mined by the room and pillar method should increase the strength of the pillars and allow an increase in ore recovery by a reduction of pillar size when major structural defects are absent.

Jan 1, 1969

By John G. Holmes

The generation of low cost power is but one phase of the TVA program for regional development. During the 36 years since TVA began, growth in its generation of electric power has necessitated a shift from a predominantly hydroelectric power system to a combination steam and hydroelectric system. The addition of steam-electric power plants to TVA&apos;s generating system was necessitated by the rapid increase in the traditional and defense demands for electric power in the 80,000-square-mile area served by TVA, the need to firm up the hydroelectric power, and the fact that all available sites for sizeable hydroelectric projects had been developed. At present TVA owns and operates 40 power plants--29 hydroelectric and 11 steam-electric plants. The total generating capacity of the hydroelectric plants is 3,105,430 kw, and the capacity of the steam plants is 13,951,135 kw. This provides a total generating capacity of 17,056,565 kw for the plants operated by TVA. Individual capacity of the 112 hydroelectric units ranges from 10,000 to 67,500 kw, and the individual capacity of the steam-electric units now in operation ranges from 60,000 to 950,000 kw. In addition to this generating capacity, TVA distributes the power from 6 U. S. Army Corps of Engineers hydroelectric plants on the Cumberland River. These plants contribute an additional 725,000 kw. Also, under an agreement with the Aluminum Company of America, TVA directs the stream flows and generation of their 423,715-kw system on Tennessee River tributaries and shares with Alcoa in the increased generation resulting from this coordinated operation.

Jan 1, 1969