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By B. Ballard

Engineers at a West Virginia coal preparation plant owned by one of the nation's largest coal producers sought a fire suppression system for the plant's MCC and cable spreading rooms. Officials considered the traditional options of water-based sprinklers, dry chemical, and clean agent systems; however, each of those options presented challenges. Sprinklers can damage electrical equipment, proper delivery of the agent and adequate coverage/protection can be an issue with dry chemical systems, and clean agent systems require room integrity. An alternative to traditional systems was discovered in the Victaulic Vortex Fire Suppression System. The first hybrid inert gas/water mist system (FM 5580), Vortex adequately addressed these concerns. The system, which deploys a high-velocity, low-pressure mixture of water and nitrogen, is not damaging to electrical equipment and extinguishes fires in open, ventilated areas. This is one of the first installations of the Vortex system in a prep plant, and is a compelling example of how new technology can overcome the challenges of traditional technologies. The paper will detail plant specs, situation, and system evaluation, selection, and configuration.

Feb 23, 2014

By O. C. Carter, B. J. Scheiner

The Bureau of Mines is investigating the effects of rainfall and gypsum/cooling pond water on the rate of metal and nonmetal ion mobility through phosphogypsum stacks located in central Florida. Since leachate contains metal and nonmetal ions that have the potential for migration into surface and groundwater, laboratory column leach tests were conducted. Synthetic rainwater was passed through the column and metal and nonmetal ion migration was monitored. Similar experiments were conducted using a number of synthetic solutions which simulated a number of different compositions of gypsum/cooling pond water. Results indicate that within the first five pore volumes most of the mobile metals and nonmetals were removed.

Jan 1, 1992

By M. Niinae, Y. Nakahiro, K. Yamaguchi, T. Wakamatsu

The rare earth magnet has a good performance and the production is increasing year by year. Two types of rare earth magnets are presently made as industrial products. One is a Nd-Fe-B intermetallic compound magnet and the other is a Sm-Co alloy magnet. The mixed scraps of Nd-Fe-B intermetallic compound and Sm-Co alloy are sometimes produced in the step of production. Therefore it is desired that a recycling system of mixed rare earth magnet scraps should be established. In the present study, hydrochloric acid leaching of the oxidizing roasted products of Nd-Fe-B intermetallic compound and Sm-Co alloy and solvent extraction of metals such as Nd, Sm, etc. are tested to obtain the fundamental data for the hydrometallurgical treatment of the mixed rare earth magnet scraps.

Jan 1, 1995

By J. A. Lombardi

"EXECUTIVE SUMMARY The use of membranes for the treatment of Acid-Mine-Drainage (AMD) water has been a 35 year mining industry quest that has only recently produced commercial scale Zero-Liquid-Discharge (ZLD) plants. The process of development of the membrane treatment of AMD has been defined by the water treatment industry’s efforts to control gypsum scaling of the membranes, an artifact of the concentration of calcium and sulfate ions on the concentrate or “brine” side of the membranes. Improved anti-scalants, changes to membrane surface geometry and a lowered permeate flux rate were all part of solving the calcium sulfate (gypsum) scale formation problem. Whether used singly or as part of a multi-stage membrane treatment process, the production of “left over” membrane concentrate or brine, in any volume large or small, was a second barrier to adoption of the method by the mining industry. The two identified “final brine” treatments were a) solar evaporation ponds and b) mechanical evaporators. Brine disposal by solar means is typically site limited to flat terrains or high net evaporation locations. Mechanical evaporation-crystallization is applicable at all sites but, typically, at onerously high ownership and operating costs. Miwatek, a South African water treatment start-up, has entered the mining AMD ZLD marketplace with two new, pilot-scale tested, processes, both of which are predicated on the innovative treatment of a reasonably concentrated AMD and neither of which produces a final brine that requires disposal. In the Miwatek Brine Treatment, MBT, method the membrane brine is caustic pH adjusted and de-calcified precedent to passage through a second membrane plant. The caustic is generated on-site by a lime treatment of the second-membrane concentrate. The first- and second-stage permeates are blended for discharge. The process usually yields no “final brine” for disposal. In the Miwatek Ettringite Treatment, MET, method a low pH first-stage membrane brine is lime treated in two or three steps in the presence of aluminum in a way that metal hydroxide and calcium sulfate solids are formed and purged from the system. Sufficient aluminum is often present in the feed water to, with judicious recycling, enable operation of the lime-aluminum treatment without the purchase of outside aluminum reagent. The first-stage membrane permeate is blended with the lime-aluminum treated membrane concentrate for discharge. The indications are that the method can comfortably meet the low 250 -500 ppm SO4 discharge water quality standards that have most recently been proposed in South America. The process yields no “final brine” that requires disposal. Projected own-operate costs for the MBT and MET systems are less than the estimated costs for all identified alternative treatments."

Jan 1, 2015

By Charles E. Joachim

Current Army tunnel destruction criteria (1) are based on limited nuclear-explosive (NE) and high-explosive (HE) test data. The PILE DRIVER (2) and HARDHAT (3) events investigated tunnel and support system response where yields were relatively large and tunnel diameter small compared to typical underground openings and localized stress fields of low yield weapons. Some limited tunnel destruction information was obtained from underground events of the PLUMBBOB and HARDTACK II Series (4). These events used access drifts which were designed to be self closing at the weapon point. The limited NE data are augmented by HE results from the Underground Explosion Test (UET) Program, a series of model and prototype-scale experiments in granite and sandstone (5). Weapon standoff distances (charge c.g. to tunnel wall) were at or near the maximum for major damage. Limited tunnel destruction was produced by a series of hasty and deliberate tests (6) on abandoned railroad tunnels in basalt. Additional HE data were obtained from model tests at the Waterways Experiment Station (WES) (7) using 2.1 MJ (2 lb) TNT charges and tunnel diameters varying from 3 to 17 cm (1.2 to 6.6 in). Recent laboratory scale HE experiments (8) conducted at the WES under the ESSEX program investigated the effects of tunnel diameter, standoff distance, charge confinement, material strength and to a limited extent, tunnel spacing and liner strength variations on tunnel damage. This paper summarizes the analysis conducted to develop predictions for the effects of low-yield nuclear weapons against tunnels and underground openings in rock.

Jan 1, 1979

By K. Verghese

Neutron capture prompt gamma-ray analysis provides the best method for on-line analysis of the elemental composition of large volumes of bulk material. This paper summarizes the Monte Carlo models which simulate the radiation transport within two such analyzer systems; namely, the borehole configuration and the conveyor belt configuration. The models are useful in the design optimization of the analyzer systems, in minimizing the amount of experimental calibration data for calibrating these analyzers, and in investigating the detection sensitivity for different elements. The computational scheme in these models is made extremely efficient by the use of various powerful variance reduction methods and by efficient data management. Experimental verifications of the two models carried out in the laboratory indicate very good agreement with the Monte Carlo results.

Jan 1, 1984

By J. Alton Burks, Roy C. Bartholomae

The chain conveyor is utilized extensively in underground mining to convey raw ore, especially coal. It is estimated that several thousand loading and continuous mining machines rely on this type of conveyance. Although the chain conveyor is both efficient and highly reliable, its use is generally associated with the production of noise levels that often exceed 105 dBA at the operator's position. Thus, it is one of the most significant contributors to the occupational noise problem experienced by miners in the underground coal mining environment. Conventional engineering noise controls that result in an average reduction of 4 dBA have been previously designed and implemented. However, a novel solution involving a change in conveyor operation has been proposed that takes advantage of two aspects of conveyor noise: 1) conveyor noise has an approximately cubic dependence on conveyor chain speed and 2) due to the damping provided by coal, a full conveyor is 5 dBA quieter than an empty one. An engineering analysis has shown that a significant reduction in the operating noise level of a typical continuous miner can be achieved through the use of an adjustable speed drive automatically controlled by a coal loading sensor that maintains a full conveyor at all times. The potential reduction depends primarily on the mining conditions (coal seam thickness and the presence of either rock or water) and varies from 7-18 dBA. Other benefits to be derived from the use of a variable speed drive include reductions in power consumption, dust, and maintenance costs.

Jan 1, 1992

By Gaither H. Kitchell

Introduction Fire assaying is an ancient method of determining the amount of gold and silver in geological materials. Today's commercial, mining, school, and private fire assaying laboratories still use this basic assaying method. One of the primary reagents used to collect gold and silver from the ore is litharge (PbO), or lead oxide. The Federal Occupational Safety and Health Administration's (OSHA) and the Nevada Division of Occupational Safety and Health's (OSH) have a lead standard. It states that a person exposed to airborne lead at concentrations greater than 50 µg/m3 (1.4 µg per cu ft) of air over an eight-hour period has gone beyond the permissible limit for health safety. It is not uncommon to get airborne lead concentrations of 1400 µg/m3 (40 µg per cu ft) in the flux/sampling area or 900 µg/m3 (25 µg per cu ft) around the gas/ electric furnaces during the fusion and cupelling phases. Therefore, any individual working in these areas for more than 30 days per year without proper protection is a likely candidate for lead poisoning. Lead In A Human Lead enters the body as a toxic substance by breathing it into the lungs and upper respiratory tract and by getting lead particles into the digestive system through ingestion. Smoking, eating, drinking, chewing tobacco and gum, or wiping a lead-contaminated hand across the mouth are all potential ways forgetting lead into the body. Lead taken in large quantities can actually kill a person in a matter of days. This is rare, however. The real hazard of lead overexposure is for the unsuspecting person who works in an unsafe lead environment for months or years. This individual can slowly receive damage, sometimes permanent, to the central nervous system, gastrointestinal tract, kidneys, blood, gums, and reproductive system. Safe Blood-Lead Level The Lead Standard states that the maximum safe blood-lead level is 40 µg/100 g (40 µg per 3.5 oz) of whole blood. It recommends 30 µg/100 g (30 µg per 3.5 oz) if a person is of child-bearing age. People not working around lead products normally have a blood level of less than 10 µg/100 g (10 µg per 3.5 oz). A person not adequately protected can exceed 40 µg/100 g (40 µg per 3.5 oz) in a few weeks by fire assaying only 100 samples per day per week. Studies show that some individuals have developed lead-related diseases with blood-lead levels less than 80 µg/m3 (2.3 µg per cu ft). Lead Poisoning Symptoms There is a long list of symptoms associated with lead poisoning. The most common are: a prolonged, sweet, metallic taste in the mouth; loss of appetite; anxiety and irritability; weakness and dizziness; nausea and tremors; and insomnia. Preventive Measures Based on the lead standard, a number of preventive measures can be taken to ensure that fire assay laboratory personnel frequently exposed to lead are protected against overexposure. First, the actual lead concentration within the assaying area should be determined. In Nevada, one can contact the Department of Industrial Relations, Division of Occupational Safety and Health for assistance in monitoring any laboratory. The agency will also recommend ways to protect against lead. This agency does the monitoring and provides an educational class on lead safety. This type of agency can be found in other states. Commercial consulting firms are also available, but they are expensive. Regardless of the technique used to determine lead concentrations, it is most likely that the average fire assay area exceeds the 50 µg/m3 (1.4 µg per cu ft) lead concentration limit. This is considered unsafe.

Jan 8, 1985

By Robert A. Jankowski, Jonathan Kelly, Edward F. Divers

Results for the first underground test of the ventilated drum in a U.S. coal mine are presented. Tests were conducted by the Bureau of Mines through a contract research program with Foster-Miller, Inc., to evaluate dust control effectiveness in a western mine and for gas control in a full scale laboratory facility. The ventilated drum is designed to reduce the amount of dust from cutting by drawing dust-laden air from the cutting zone through twelve water- powered "dust capture" tubes built into the shell of the shearer drum. High pressure water up to 1 12.48 kg per cm2 (1,600 psig), released from sprays, induces maximum airflow of 1.89 m3/sec (4,000 cfm) from the face side of the drum and provides cleaning for respirable dust and improved methane dispersion. At the gob side of the drum a deflector plate, attached to the cowl arm, turns the water spray and a proportion of the cleaned air back into the cutting zone. More than 50 ventilated drums have been installed to date in England, and their tests carried out on fixed height and single-ended ranging drum shearers have shown reductions in respirable dust of 60-80 pct, as compared with conventional wet cutting. The U.S. test on a double drum shearer showed slightly lower reduction.

Jan 1, 1987

By E. Sirolli

In recent times, with rare exceptions, most economically viable ore discoveries have been large, low-grade and located in remote parts of the world. Mining companies have often shown to be incapable of mitigating their social and economic impact on local communities. Sustainable development and relations can be achieved by implementing bottom-up methodologies to the top-down tools already in use by mining companies. In order to magnify the importance of enterprise facilitation as a primary method for community development, data from 25 years of community based work around the world was used. Results highlight the need for a grassroots approach to local economic and community development, which focuses on the creation of a parallel economy in communities. Using solely top-down methodologies for developing community relations is shown to be a limited resource for mining companies. There are fundamentally two dangers for mining companies: alienating the local population, resulting in militancy and lengthy legal battles to obtain a license to operate; and, being accountable for building social and economic infrastructure that are not the company?s responsibility.

Jan 1, 2012

By W. E. Horst

Historically, research organizations have made significant contributions to the development and commercialization of new chemical products for the mining industry and examples of commercial results are cited With the recent demise of research organizations within the mining industry and dynamic changes in the industry, the supporting role of R&D groups has become limited or non-existent. Cat- reduction requirements and new raw-material sources offer future opportunities for R&D organizations to continue their effective participation in the commerical development of new chemical products. Potential areas of interest for future process applications are reviewed.

Jan 1, 1986

By D. R. Willmer, E. J. Haas

"DISCLAIMER The findings and conclusions in this paper are those of the authors and do not necessarily represent the views of the National Institute for Occupational Safety and Health. Reference to specific brand names does not imply endorsement by the National Institute for Occupational Safety and Health. ABSTRACT This study analyzed the publicly available health and safety policies of 26 mining companies to determine the quantity of health and safety (H&S) practices that mining companies encourage in relation to the Plan-Do-Check-Act cycle. A thematic content analysis of the policies identified elements and practices within the text. On average, companies communicated information on about 7 elements (range 1–14, standard deviation = 3.49) and discussed 15 practices (range 2–34, standard deviation = 9.13). The elements in which companies highlighted the most practices were risk management, emergency management, leadership development, and occupational health. A discussion of the policy trends shows areas that mine sites can improve upon within their Plan-Do-Check-Act cycle, in addition to encouraging the use of both leading and lagging indicators to manage health and safety performance. INTRODUCTION Mining companies and their employees are expected to identify and manage risks at their worksites to ensure the health and safety (H&S) of everyone at the site. The primary mechanism in place to control these risks is a company’s health and safety management system (HSMS) (Boyle, 2012). Broadly, an HSMS is a set of standard, interrelated, and interacting elements used to promote and achieve occupational H&S goals (ANSI/AIHA Z-10, 2012; BS OHSAS 18001, 2007). The practices conveyed within an HSMS are expected to minimize incidents, injuries, illnesses, and even save worker lives (Alsop and LeCouteur, 1999; Arocena and Núñez, 2010). In the United States, both the Occupational Safety and Health Administration (OSHA) and Mine Safety and Health Administration (MSHA) regulate and encourage aspects of an HSMS (US Federal Register, 2011, 2010). Many HSMS documents (i.e., Chemical Industries Association, 1995; Health and Safety Executive [HSE], 1995; International Labour Office [ILO], 2001) attribute the source of their basic management system to Deming’s Plan-Do-Check-Act (PDCA) model of continuous quality improvement and organize their practices within this cycle (Johnson, 2002). The PDCA cycle is a well-adopted approach in health and safety management and promotes continuous learning and adaptability (Robson et al., 2007)."

Jan 1, 2018

By Rocky Gunderson

When operations begin early next year at the $100-million Port Kembla coal loading facility in New South Wales, Australia, a sophisticated computer system, directed by two of Hewlett-Packard's HP1000 mini-computers, will perform a number of functions ranging from monitoring and reporting arrivals and departures to maintaining a library of events for up to one year. The three-processor HP1000 system configuration, valued at $215,000, is one of the largest single orders, in terms of dollar value, ever submitted in Australia for Hewlett-Packard's line of engineering and manufacturing minicomputers. The processors will be linked in a fully "backed-up'' configuration using Hewlett-Packard's fourth generation distributed networking system, DS/1000-IV, making the system one of the most sophisticated in Australia. Interfaced to a number of weightometers and programmable logic controllers (PLCs), the computers will be the heart of a coal inventory system for the facility which, in its first phase, will be capable of handling more than 13.5 Mt/a of coal. The computers will report on all plant functions, including conveyor belt and water spray operations. Specifically, the system will: • Monitor and report all coal movements related to road and rail deliveries, dispatches from ship loaders, and interstockpile transfers. •Maintain a ''running log" of all events pertaining to overall plant operations, such as conveyor starts and stops and anti-pollution spray activation. • Accept and maintain plant data entered manually or acquired automatically from various remote locations via either visual display units (VDUs) or PLCs. • Maintain complete historical records of all transactions and related plant events for up to one year. • Provide a facility for stockpile management, modeling-type programs, and training or other simulation activity. The facility was designed with the following characteristics in mind, based on an analysis of requirements for an automated coal loading operation that would optimize productivity and be flexible to change and grow with facility needs and changing technology: • Continuous Operations-Due to the need for continuous plant logging and control, the overall facility will be capable of uninterrupted, 24¬hour operation. • Handling Current and Projected Workloads-The facility will be capable of not only handling current workloads, but also any additional workloads required during future coal loading operations. • Expansion-The facility will be capable of expansion, for a minimum cost, at any time with minimum disruption in operations. • Single Source of Supply and Maintenance-The facility will be supplied and maintained by one supplier, through hardware and software maintenance support contracts. System Configuration Two HP1000 minicomputers, each with 500K bytes of main memory, will be front-ended by a pre-processor with 256K bytes of main memory. These three systems, active, backup, and front-end, will be interconnected into a triangular array, as shown in the accompanying diagram. Under normal conditions, the front-end will transmit plant status data to one of the main systems, whose primary function will be to monitor coal flow and maintain a relevant dialogue with operators. The front-end, therefore, handles all communication with the plant PLCs, effectively removing this overhead from the current plant monitor (either of the two main systems). The front-end pre-processes and post-processes all information flowing from the plant monitor to the PLCs and vice versa, thus effectively handling all communication between the two units. A second main system will handle reporting, administrative, and modeling functions, and will also be capable of performing both front-end and monitoring operations. Linking all

Jan 11, 1981

By G. A. Perry

Cyprus Sierrita is a major producer of copper and molybdnum from its Sierrita and Twin Buttes open pit mines south of Tucson, Arizona. Both pits were started in the late 60's and are in excess of 1500 feet in depth. Sierrita has utilized a Cat 992C Remote Controlled Loader since January 1993. The loader was justified to increase SAFETY and PROFITS at Sierrita. It has exceeded all expectations. As of June 1993, it had produced additional profits totaling more than $1,500,000.

Jan 1, 1994

By H. R. Manouchehri

The responses of calcite, feldspar, and quartz minerals In a laboratory free fall electrostatic separator, before and after tribocharging with stainless steel, PVC, and copper plates, have been investigated. The effect of H3BO3 and BaCl2 chemicals pre-treatment on the electrical properties of the minerals is examined. The changes in the electrical properties are discussed with the determined charge, dielectric constant, and electrical conductivity of the mineral samples. Electrical properties of the minerals and their responses to the electrical field during separation, after tribocharging and chemical pre-treatment, are explored for the need to characterize the electrical behaviour of the minerals.

Jan 1, 1998

By Gregg Wilkerson

The Blind Springs Hill pumice beds are located 5 miles southwest of Benton, California in the foothills between the Benton Mountain Range and Blind Springs Valley. The best exposures of the pumice are in an area 0.75 miles west of Blind Springs Hill. The pumice is Quaternary ejecta material which came from the rhyolitic volcanoes in the Glass Mountain-Volcanic Tablelands area of Mono County. The pumice beds occur in two distinct layers separated by an unconformity. The upper layer is 0 to 11 feet thick and consists of coarse subangular pumice fragments, some of which are over 1.75 inches in diameter. The lower bed is medium to coarse grained with subangular fragments up to 1.0 inch. The lower bed is 0 to 9 feet thick. Overburden at the Blind Springs Hill deposit varies from 0 to 15 feet. There are approximately 1 million cubic yards of material in the deposit that can be mined. The size distribution in the deposit is mostly fine with only 10.6% of the pumice fragments being over 0.5 inch in diameter, the minimum size needed for stone-wash or acid-wash applications. Suitability of pumice for the textile industry is quantified by standard 15-minute abrasion and absorption tests. In the Blind Springs Hill deposit, the plus 0.5 inch fraction has an abrasion loss of 33% which is too high for stone-wash application but it has an absorption capacity of 36% which makes it suitable for acid-wash applications in the textile industry. The abrasion and absorption properties of this deposit are within the range of those which have been measured for other pumice deposits within the United States.

Jan 1, 1995

By G. K. Wilson

This paper will discuss some of the more important aspects to be considered when selecting pumps for mill discharge, cyclone feed or other severe-duty applications Included will be the selection of the pump based on such factors as particle size, particle distribution, head, flow, temperature and pH Other specifics to be covered: The relationship of impeller speed, head and wear factors as they affect pump performance and wear life; the importance of selecting a pump whose performance curve best suits the application; and how the addition of service factors applied to the actual operating conditions can lead to severe operational problems such as premature wear, pump running out on curve, and exceeding horse power limitations.

Jan 1, 1996

By J. Felipe Costa, Andrew H. White, Marcot T. M. B. Vilhena

Ordinary kriiing (OK) is an interpolation algorithm mostly used in earth sciences applications where it provides satisfactory results. Robust kriging (RK) is an alternative algorithm which at- tempts to minimise the problems caused by the existence of outlier values within a given data set. Robust kriging essentially consists of an editing step prior to running the traditional OK method. This study compares the interpolation results obtained by OK and RK. Two data sets were used. The first data set consists of 140 samples mimicking a drilling survey named cluster.dat. An additional feature of this sample data is that its parent population, the reference data set, is available, thus permitting direct quantitative assessment of the effectiveness of a given estimation technique. The second data set consists of a grid sampled at 1x1 m. The estimates obtained by OK and RK using cluster.dat were compared to the reference data set. RK provided better results in terms of quality of the estimates than OK

Jan 1, 1996

By Ian H. Clark

A series of numerical experiments were performed in order to elucidate the stress distribution, fracture strength and mineral liberation potential in single specimens of rock during crushing. Fracture strength was shown to reduce under eccentric loading conditions. Similarly, the presence of inclusions, both hard and soft, reduced the fracture strength. The predicted crack paths indicate that mineral liberation is unlikely to be preferential.

Jan 1, 1992

Power consumption of stirred media mills has been studied by an approach developed from work on stirred reactors. Relationships between torque required to rotate both disc and pin impellers immersed in dense particulate media as a function of speed, impeller and tank dimensions, and other relevant variables are evaluated. Data collected during numerous different experimental conditions are analyzed. The results can be summarized and presented in the form of characteristic plots, general equations and dimensionless group correlations involving power and modified Reynolds numbers. Special attention is directed towards the rheological properties of the media, which is considered as non-Newtonian liquids and hence, the equation of power law liquids is employed. Procedure for estimating parameters of effective viscosity and scale-up guidelines with respect to power consumption are put forward.

Jan 1, 1994