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By Rex T. Ellington

The fluidized bed is an effective method for investigating retorting phenomena and possibly a commercial means of retorting oil shale. Both were examined by Sinclair Oil Corp. (now part of Atlantic Richfield Co.) in the period 1.965 to 1968. The results of the work show that presence of an oxidizing environment during retorting results in loss of oil yield which indicates that vapor phase oil burns in preference to combustion of coke on spent shale. This has implications for several types of retorts. Correlation of the results of this work with that of other investigators shows that the partial pressure of retorting products in contact with oil shale during retorting has an effect on yield. Consideration of hardware indicates that there are several possibilities for commercial embodiment. As a companion to shaft-type retorts the fluidized bed could have good potential. Realistic assessment of costs suggests that further development may have to await commercialization of another process. The existence of a plant in which to test prototype size would markedly reduce such development costs. Results Preliminary development work with the apparatus was carried out using a fluidized bed of sand, as explained later, with the entire system brought up to temperature and flows stabilized. The shale was injected rapidly in a slug (batch) which had small mass compared to that of the high temperature system to make the reaction approach isothermality with reasonable approximation of instantaneous preheating. Typically, the temperature in the center of the bed dropped from 900°F to 600°F one minute after batch addition. It returned to 750' within three minutes and 900° within seven minutes. Obviously, the bed was quenched but it recovered rapidly. Average bed temperatures of 700' to 1020°F were examined to compare the effect of temperature with published results. Yields In the 700°F range were only 10 to 15%, of Fischer Assay (FA). Above about 950'F, oil yields decreased and gas yields increased. Nitrogen was used first as the fluidizing gas to provide a chemically inert medium. Incept for an insignificant dip at 895"F, Figure 1, oil yield was not affected by retorting temperature in the 800° to 900' range as long as residence time was adequate (16 minutes). At 925°F, the oil yield was some 103% FA. With further increase in temperature, the yield decreased to 86% FA at 1015°F. There is no increase in carbon on spent shale, the lost oil goes to Increased gas make.

Jan 1, 1972

The Ernest Henry copper-gold project is located in North West Queensland, Australia and commenced production in late August 1997. Utilizing a philosophy of selecting the biggest proven equipment available Ernest Henry at full production ¥ill treat 9 Mtpa through a single grinding line over a 15 year mine life. 350.000 tonnes of concentrate a year will be produced, containing 95,000 tonnes of copper and 120,000 ounces of gold. The two mills recently commissioned at the Ernest Henry Copper/Gold Mine are a 10.4m x 5.1m (34 ft x 16.75 ft) SAG Mill and a 6.1m x 8.4m (20 ft x 27.5 ft) ball mill. The mills have a power draw of 11 MW (14745 hp) and 5.5 MW (7373 hp) respectively. While the SAG Mill is not the largest SAG Mill in the world, it is the largest shell-supported SAG Mill in the world. The Ernest Henry mills epitomize the new standard design of large grinding mills. The design was introduced more than 20 years ago and has been further developed from extensive experience with grinding mills, and the need to produce a design, which overcomes the recognized problems of large mills. The result is a design with the potential to be used for mills up to the largest for which machine tools can be found to fabricate and machine them, currently approximately 15m (48') overall diameter.

Jan 1, 1999

By Henry T. Mulryan

The philosophy, strategy and techniques of successful marketing of talc, differ sharply from those applied to most other mined products. Unlike non-ferrous metals, there are no commodity exchanges to facilitate the transfer of goods. Unlike iron ore and some non-metallics, assured markets by means of long term contracts are practically non-existent. Talc must be sold and sold and sold again. The normal channels of talc distribution are almost identical to those used, by the chemical industry. These consist of a blend of producer marketing staff, field technical service, and sales force; and independent chemical wholesalers. Like the term "chemicals", there is tremendous product diversity contained in the rather loose expression "commercial talc". Certain kinds of talc, processed in conventional ways, are regarded as commodities by the consumer. That is, that material from one source or supplier is considered to be effectively interchangeable with those available from a number of other areas and producers. Under such conditions, lowest delivered price, quickest delivery, and best, customer service, are the key factors in a successful sales effort.

Jan 1, 1965

By Ronald L. Wiegel

In the 2000 page Handbook of Mineral Dressing by A. F. Taggart, the subject of material or metallurgical balances is covered in only six pages of eve-straining type. Although Taggart's work was compiled before 1945, and there has been significant progress since then in most areas of mineral processing, the practicing metallurgist's approach to metallurgical balances remains exactly the same as described in those six pages. There are several portions of Taggart's text appropriate to introduce the subject of this paper which I would like to quote: "Milling Calculations. Computations of per¬formance in milling are complicated by the fact that it is a continuous rather than a batch operation, that the quantities of solid materials handled are large and usually mixed with water, hence difficult or impos¬sible to weigh. Fortunately it is possible to determine many facts concerning perfor¬mance without knowing weights, if the value of various constituents is known in some common unit, e.g., the content of some par¬ticular metal or mineral, or of water, or some ingredient soluble therein, or of par¬ticles of a particular size or falling within some particular size range, or the like."

Jan 1, 1979

By J. R. Klaehn, M. Shi, T. E. Lister, L. A. Diaz, J. S. McNally

Since 2019, approximately two dozen international battery recycling companies have been operating at the commercial or pilot scale [1]. However, current process capacity does not exceed 100,000 tons of end-of-life (EOL) lithium-ion batteries (LIB) per year, and the current recycling rate is only about 5% in North America [2-3]. Recycling metals from EOL LIBs is not only essential to waste minimization and environmental stewardship, but also a source of critical materials, which can contribute towards supply chain stabilization. LIB recycling can be roughly divided into three categories: direct recycling, pyrometallurgy, and hydrometallurgy. Direct recycling seeks to retain as much of the manufactured effort with minimum chemical processing [4]. The evolution of battery designs and chemical compositions are challenges to this approach [5-6]. Pyrometallurgical processes are robust and flexible allowing a broad spectrum of batteries with minimum pre-processing requirements. Some of the matrix issues are solved through combustion of some constituents. Smelting is strongly tied to fossil energy and air emissions are a concern. In addition, pyrometallurgical processes are not stand alone, as hydrometallurgical refining normally required to separate and recover the metals of interest (Co, Ni, and Cu) from the produced alloy and Li from the slag [7]. Hydrometallurgical processes can be highly selective and efficient in recovering high purity materials [8]. In general, hydrometallurgical processes are considered cleaner and less costly than high temperature processes [4,9-10]. Extensive chemical consumption and waste generation significantly increase the operating costs and overall environmental impact of the hydrometallurgical processes [11]. Leaching of metals from LIBs is dominated by the mixture of sulfuric acid (1 to 4 M H2SO4) and hydrogen peroxide (1 to 15 wt.% H2O2) [10]. Although organic acids have been tested as lower environmental impact alternatives, the reported pulp density operations are low < 60 g/L [10-11]. For the H2SO4/H2O2 leachates, high leaching efficiencies >90% are reported for Co, Ni, Mn, and Li from cathode materials at temperatures over 40 ⁰C and pulp densities between 30 to 200 g/L [9-10]. H2O2 acts as reducing agent to convert Co+3 and Mn+4 into their soluble forms, Co+2 and Mn+2 [12]. Despite the claims of H2O2 being a clean reducing agent [13], production of H2O2 has significant environmental impacts as determined by life-cycle analyses [13-14]. Moreover, the costs and risks associated with H2O2 transportation and storage cannot be ignored [15].

Mar 2, 2022

By A. S. Azman

In collaboration with Kennametal Inc. and corry rubber corporation, the U.S. National Institute for Occupational Safety and Health (NIOSH) developed a drill bit isolator to address noise overexposures associated with roof bolting machines in underground coal mines. NIOSH laboratory studies confirmed that the drill bit isolator reduces noise during drilling. Field studies were needed to confirm that a noise reduction could be obtained under working conditions and that the device was sufficiently durable. This paper reports results of field tests of the device conducted at five underground coal mines. Noise reduction was assessed by comparing the operator?s noise exposure during drilling with and without the drill bit isolator. Durability was assessed by recording the number of holes and total feet drilled with each bit isolator until either the test period ended or the device failed. The results from these tests showed that the device is an effective noise control in a mine environment. The field-tested drill bit isolators provided a noise reduction of 3-5 db(A). Of nine devices tested for durability, five exceeded 610 m (2,000 ft) drilled and two exceeded 762 m (2,500 ft) drilled before failure. Durability issues found in the field tests led to final production optimizations that have resulted in a commercially available product for drilling with 35-mm- (1.3-in.-) diameter roof bits and hexagonal drill steels.

Jan 1, 2012

By Don Phelps, John Hawley, David P. Field

In recent years observational techniques of tunneling have become increasingly popular methods to facilitate complex underground infrastructure projects. The traditional design and construction management practices developed in Europe have been adapted for application in North America to suit a more restrictive management and legal culture. This paper will discuss three recent projects, the San Diego Mission Valley East Extension, Washington Dulles International Airport People Mover, and the Seattle Beacon Hill Station and Tunnels, with the objective of identifying the challenges of applying observational tunneling methods to established contractual practices in North America.

Jan 1, 2005

By Archie M. Richardson, Carl E. Brechtel, Tom R. Kelly, Frank Feero

Recent work to upgrade the ventilation system for the el Mochito lead/zinc mine in central Honduras is discussed. Network modeling and underground measurements were used to evaluate cost-effective alternatives for achieving satisfactory ventilation in a complex and expanding underground operation. Both interim and long-term solutions were implemented to make mining possible under difficult conditions. INTRODUCTION Mining operations at the el Mochito Mine, located in the central highlands of Honduras, Central America, have been virtually continuous since the opening of the mine in 1948. Initially a high-grade silver mine, the mine has expanded along a westward trend of pipe-like orebodies to a distance of roughly one mile from two centrally located shafts. Production of the relatively large San Juan orebody at the western most extension of the mine (Paddock, 1981) led to the introduction of diesel-powered equipment; however, the ventilation infrastructure was insufficient to meet the needs of mechanized mining. A succession of owners/operators in the 1980s allowed the existing ventilation infrastructure to decay to the point that ventilation in the production areas of the mine was very poor. Environmental conditions in some working areas were not conducive to efficient ore extraction because of high dry bulb temperature, high humidity, and diesel emissions. Upon acquiring the mine in 1990, Breakwater Resources of Tucson, Arizona began an aggressive program to refurbish the mine infrastructure to complete extraction of the San Juan orebody and to allow the extension of the mine another 2500 ft to the west for extraction of the Nacional orebody. The program included increasing the capacity of the main ventilation system. This article presents a case history of the process of upgrading the ventilation system in a mine where extensive old workings cause large air leakage. This process has been one of selecting solutions to difficult technical problems that are compatible with the existing mine infrastructure and economic constraints. The initial ventilation system is described in the background section, along with ventilation projections for the mine expansion. Field characterization of the ventilation system for design verification and fan specification is then discussed. The paper describes a series of interim changes to the system to improve ventilation pending completion of new ventilation boreholes. In addition, the temperature/ heat problems in the mine are described. BACKGROUND Initial Condition of Ventilation System The ventilation system is illustrated in Figure 1, which shows the extent of mining with the main ventilation paths superimposed. Early mining around the two shafts opened up vertical connections (stopes and raises) over the entire 2420 ft (737.6 m) of vertical extent, and mining progressed to the west primarily using compressed air and electric-powered equipment. Since ventilation was not a complex problem in the original mining system, the stopes and interconnecting raises were not sealed. The San Juan orebody was much larger than the silver ore zones mined previously, being primarily zinc and other base metals. Its geometry, size, and grade allowed the use of vertical crater retreat (VCR) stoping with diesel mucking and haulage equipment. Its depth, along with the existence of warm groundwater, resulted in a mine climate problem on the lower levels. To establish a complete ventilation circuit, two vertical boreholes (Bonanza Nos. 1 and 2) had been drilled by previous owners from the surface in the vicinity of the San Juan orebody. The system design called for air to be drawn down the intake shafts, across the lower mine levels to the San Juan workings, then up through the San Juan ramps and ore passes to these two exhaust boreholes (see Figure 1). In practice, however, only the Bonanza No. 1 borehole was drawing air through the desired path. Leakage across the old upper levels from the intake shafts, the Caliche tunnel, and from intervening abandoned stopes and raises supplied most of the air flowing to the base of the Bonanza No. 2 borehole. In effect, there were two ventilation circuits in semi-parallel through the mine, of which only one was delivering appreciable air to the San Juan workings.

Jan 1, 1993

By Steven E. Mischler, Jay F. Colinet

The Mine Safety and Health Administration (MSHA) promulgated a rule in 2014 that required numerous changes in compliance dust sampling requirements for coal mine operators. Two key parts of this rule were the lowering of the respirable coal mine dust standard from 2.0 mg/m3 to 1.5 mg/m3 and requiring operators of underground coal mines to use a continuous personal dust monitor (CPDM) for compliance sampling. The CPDM currently approved for compliance sampling is equipped with a display that provides miners with in-shift information on their respirable dust exposure. The goal was to provide an indication of a potential overexposure and empower the miner and mine operator to implement changes in controls and/or operating practices to prevent an overexposure from occurring.

By Ashley Woodward, S. Katharine Hammond, Mayela Padilla-Salas

This paper presents a scalable framework for worker safety assessments. The paper focuses on uranium mine reclamation in underserved communities, specifically Cove Chapter of the Navajo Nation. By integrating field observations, OSHA data analysis, systems mapping, and a hierarchical occupational health pyramid, this framework identifies site-specific hazards while addressing broader socio-cultural dynamics. The approach improves upon existing safety programs by suggesting actionable, locally sensitive solutions that prioritize higher-order controls such as hazard engineering interventions and administrative controls. This study contributes to enhanced worker safety, efficient environmental restoration, and engagement in marginalized communities with abandoned mine lands.

Feb 22, 2026

By R. A. Allwes

In-plane bending and torsion tests were conducted on full-scale masonry walls to evaluate three post-reinforcement designs. The designs were developed to minimize longwall mine subsidence damage to existing residential masonry foundations. The bending tests show that vertical and horizontal post tensioned tendons significantly increase the resistance of a masonry wall&apos; to in-plane bending. The torsion tests reveal that post tensioned tendons increase a masonry wall&apos;s limit of deformation but do not increase its torsional stiffness. The torsion tests also show that the masonry units minimally contribute to the torsional stiffness of a masonry wall.

Jan 1, 1995

By J. Platt

Debate over acid rain legislation has presented a moving target for coal and utility company planners attempting to figure out how legislation will affect their business environment. In spite of disagreement among experts, the prospect for continued change, and persistent --perhaps even growing --uncertainty, a great deal has been learned about coal market dynamics. This paper reviews progress and describes some of the major problems and controversies.

Jan 1, 1990

By Harold J. Schock

The cases of no auxiliary ventilation and ventilation with tubing were mathematically modeled, using a turbulent dispersion model. The scooptram that is used to load is modeled as a variable-speed, variable-strength source of pollutants moving in and out of the dead-ended drift. Model predictions are compared to experimental measurements. A parametric analysis was performed to determine the effect of exhaust pipe location and time spent out of the drift, as well as to determine if a relationship existed between CO2 and NO levels. It was concluded from this analysis that when modeling a load-haul-dump cycle, it is necessary to use a model that has the capability of predicting changes in source strength as well as source location. It was also determined that four relevant factors include effective heading height, apparent longitudinal diffusion coefficient, transverse concentration gradient at the face, and average dispersion width of the exhaust jet. As these factors change with heading geometry and ventilation configuration, they were determined experimentally, Carbon dioxide was used as a tracer to calibrate the model; since, knowing the fuel flow rate, it is possible to calculate CO2 production. The above four factors in the computer model were calculated using a regression analysis, comparing predicted local concentrations to measured local concentrations. The model was then verified after this calibration process using additional experimental results. With the calibrated model, it is possible to predict pollutant concentrations at any location in the heading using an engine map and the previously calculated flow field. A parametric analysis shows that the exhaust pipe location can have a significant impact on operator exposure to exhaust gases. It was also shown that NO concentration varies directly with C02 levels. Predictions using the dynamic model are contrasted with constant source strength (pollutant flow rate) results. An analysis of these predictions for computing time-weighted average NO shows the dynamic model predictions of operator exposure to this pollutant to be less than one-half of the value predicted using a constant source model.

Jan 1, 1981

By W. Irwin

Global warming hitherto viewed as a distant threat to the environment, is now the subject of fierce goo-political debate. The debate centres around the time frame required to achieve environmental compliance, and the cost implications of meeting that objective. Since coal is the fuel of choice for power generation, the priority objective of energy producers is the pursuit of environmental protection measures that allow coal to be burned without any attendant negative impact on the environment. From an environmental point of view, public attention is today firmly focused on the impact that all industrial activity has on the environment, and coal is singled out from other fossil fuels as being the product of an inefficient smokestack industry. Despite coal&apos;s poor public image it is unrealistic to suggest as some do, that use of this fossil fuel as a primary energy source should be drastically curtailed. Coal which already generates about 35% of the world&apos;s electricity is continuing to increase its share of this rapidly expanding market, and to argue against its use is flying in the face of reality. However, changes are required in the way coal is used in some of the new clean coal technologies, since many include advanced methods of combustion. Indeed changes in the way coal is used is a vital link to the future of coal as a primary source of energy, and increased coal utilization will be directly linked to changes in its use. Discussion of various issues that affect coal utilization are the focus of this paper.

Jan 1, 1998

By K. Luxbacher, A. Haghighat, B. Lattimer

Mine face ignition due to high levels of methane is one of the most common fire incidents in underground coal mines. In continuous miner headings, depending on the magnitude of the ignition or resulting fire, auxiliary ventilation controls may be damaged or dislodged, affecting the ventilation into the area. A computational study was conducted to investigate the effects of different levels of damage to an exhausting ventilation curtain in a continuous miner heading, and the impact on ventilation to the face. The computational fluid dynamics software Fire Dynamics Simulator (FDS) Version 6.0 was used to predict the conditions that develop due to a 200-kW fire in the face following a methane ignition with different levels of assumed ventilation curtain damage. Smoke layer depth, temperature and mass flow inby the last open crosscut were used to evaluate the impact of no damage to the curtain, partially dislodged curtain, and fully removed curtain. As more of the ventilation curtain was damaged, smoke depth and temperature outby the fire increased. With the full removal of the curtain, the smoke accumulated from the last open crosscut to the face, with the ventilation completely bypassing the continuous miner region.

Jan 1, 2016

By Douglas W. Fuerstenau, Pradip Pradip

The design and development of selective flotation collectors has been the key to the remarkable success of flotation in beneficiating complex, difficult-to-process ores. Sustained research efforts in the field over the past hundred years have led to delineating the scientific basis of selective mineral flotation in terms of the crystal chemistry and the surface and colloid chemistry of minerals including their solubility, and the aqueous solution chemistry of added reagents. It is now well-established that the electrical double layer theory (EDL) is the most powerful means of quantifying the relative strength of mineral-reagent interactions in the case of nonsulfide minerals. We illustrate the utility and the power of the EDL in delineating the science underlying selective mineral flotation with the help of a few examples taken from our own work, in particular on the selective flotation of rare-earth minerals (bastnaesite) from associated semisoluble minerals (barite and calcite) using alkyl hydroxamate collectors and the flotation separation of lithium-containing minerals (spodumene) from associated alumino-silicate minerals with oleate (fatty acids). Both of these mineral separation systems are of contemporary research interest and of immense value to the industry today. Recent advances in utilizing molecular modeling computations, particularly in the context of quantifying the effect of crystal chemistry and the relative distribution of adsorption sites available on mineral cleavage planes, are also reviewed.

By S. S. Szoke

The concrete masonry industry, represented by the National Concrete Masonry Association has significantly expanded its markets since the industry&apos;s inception. The concrete masonry industry has developed and refined concrete masonry units by producing a variety of quality products on automated machines. In the sixties, architectural concrete masonry units gained popularity. In the seventies, the concrete paver market expanded. In the eighties, segmental retaining wall units became popular. The industry continues to research and develop new products and applications for concrete masonry to satisfy the needs of designers, specifiers, installers and owners. Both existing and innovative technologies in the concrete masonry industry are discussed.

Jan 1, 1993

By Gary English

"Tunnel safety is evolving as science, engineering and technology make advances. Applicable safety codes and standards simply do not cover all the potentials of design, construction and operation. This paper reviews a series of tunnel projects code gaps in Seattle USA that were uncovered during the design and construction of a new highway tunnel, conversion of bus tunnels to combined road and rail tunnels, new rail tunnels using TBM and NATM, conversion of a road tunnel to light rail, and retrofit of an existing road tunnel to add lanes and improve safety systems. The perspectives of the ‘fire code official’ (Authority Having Jurisdiction) on methods to identify and resolve gaps in safety code and standard regulations, while garnering the consensus of the owner, designer, and contractors are presented. Additionally, the emergency responder command perspective on safe tunnel design, tunnel rescue during construction and operational safety is explained TUNNEL SAFETY EVOLUTION The underground has become nearly the only option to provide essential transportation corridors to continue our economic growth in key global areas. Tunnels are not built on a whim. Often significant portion of a regions wealth are invested to meet current, and hopefully future transportation demands. There are more transportation tunnels being built now than at any time in the planets history. The location of these tunnels is often selected for us based upon regional demand. Most commonly under densely populated urban centers and between populations’ centers to bypass geologic conditions like mountains and water bodies. Tunnels are being built in unforgiving soils, between tectonic plates, in extremes environmental conditions and often, under the very heart of the highest density population centers on the planet. All of these locations can bring with it conditions that challenge our common assumptions about safety. These extraordinary locations and soils create risks for both those constructing the tunnel, and in design engineering to meet the ‘minimum’ requirements at the lowest costs. There is lengthy history of above ground safety. Most countries and major local jurisdictions have adopted, or created safety requirements for the construction of above ground buildings. Through decades of use, these safety requirements have evolved, changed and been expanded to cover a wide gamut of actual and potential safety risks. However, the use of the underground for tunnel transportation corridors has grown exponentially with limited attention to safety requirements."

Jan 1, 2016

By B. G. Kelley

The MIDREX® Direct Reduction Process was developed during the 1960s by the Midland-Ross Corporation, which had pioneered shaft furnace technology and stoichiometric gas reforming for use in processing minerals. In 1969, the first MIDREX® Direct Reduction Plant was built in Portland, OR. Since then, 49 additional modules have been sold in 18 countries. For the last ten years, over 60 percent of the world&apos;s direct reduced iron has been produced in MIDREX Plants. During the quarter century since commercialization, many technical improvements have been made, including larger shaft furnaces, in-situ reforming, greater heat recovery, improved catalysts, and hot briquetting. Midrex continues to enhance the technology in the areas of economy-of-scale, energy efficiency, alternate fuels, and raw material flexibility.

Jan 1, 1998

By Y. Luo

"It is generally known that spontaneous combustion potential is a function of coal rank, with low-rank coals having high susceptibility to self-ignition and high-rank coals having low potential. To establish this functional relationship and use it as an engineering tool to identify the propensity of coal to self-heat, both rank and spontaneous combustion potential should be quantified. ASTM D388 is normally used to classify coals by rank, but this classification system can only serve a qualitative analysis. To classify coals by their potential for spontaneous combustion, the self-heating temperature (SHT) method originally developed by the U.S. Bureau of Mines (USBM) was used by Litton and Page (1994) to correlate coal rank with spontaneous combustion potential. In that method, the SHTs of coal determined by an adiabatic experiment are linked with proximate analysis results through a proposed concept known as the “moist fuel ratio.” This ratio is a function of moisture, volatile matter and fixed carbon, all of which have widely different content percentages in different ranks of coal and have strong relationships with coal rank. However, the method is highly empirical, and there is large standard deviation between experimental data and calculated results. The equation correlating the coal quality parameters to determine SHT should be improved with more experimental data.This paper reports on the development of a new system for predicting the spontaneous combustion potential of U.S. coals, based on coal composition data from the U.S. Geological Survey’s coal quality database. First, the user is provided with a quantified classification of coal rank. Second, based on experimental SHT data covering a wide range of ranks from lignite to low-volatile bituminous coal, the original USBM correlation for predicting SHT is improved for the respective rank of coal. The relationship between the rank and SHT of U.S. coals was developed and plotted. The plot diagram can be used for a quick estimate of the SHT of a U.S. coal and as a cost-effective tool for the initial risk assessment of a new mine development."

Jan 1, 2015