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By Donald D. Gullickson

The entire system is built around pre-designed and pre-engineered modules which are assembled to meet the metallurgical and production parameters of the project. The carbon vessels are the key to the flexibility of the system. The vessels are made of a coated mild steel, which allows the carbon vessels to be used in the adsorption, desorption and acid wash cycles. In the adsorption mode, the solution is pumped up-flow through four (4) vessels in series at 250 gpm fluidizing the carbon bed. When the carbon in the lead vessel is loaded, it is disconnected from the adsorption circuit via rubber hoses with quick-disconnect fittings. The second vessel is then made the lead vessel and a stripped carbon vessel is added to the end of the adsorption circuit.

Jan 1, 1998

By T. M. Yegulalp

Geometric programming is a mathematical optimization technique, first formulated by Zener [1], for dealing with certain types of functions which typically arise in engineering design problems. The theory provides algorithms for finding the optimal solution, existence theorems by which one can show that a particular design is possible or not; and characterization theorems that especially make possible to obtain the relationships among the optimal design parameters at optimum. It has been demonstrated [2] that this technique can be applied to several design problems in chemical, electrical and mechanical engineering. Design problems in mining, metallurgical and mineral engineering have many aspects similar to that of other engineering problems. Thus it is only natural to consider geometric programming as a potential tool for solving certain optimization problems in mineral industries.

Jan 1, 1974

By Jue Kou, Lei Yu, Bern Klein, Lusheng Zhou, Chunbao Sun, Genzhuang Li, Reem Roufail, Amit Kumar

Magnetic liners can improve the performance of ball mills by increasing grinding efficiency, extending service life, and reducing maintenance costs. Despite their importance, the fundamental understanding and the quantitative investigation on the effects of the magnetic liners has not been addressed in the literature. This paper addresses this gap by studying charge motion, and how the use of a magnetic liner affects the breakage mechanism of the mill, using discrete element method (DEM) modeling and the Hertz-Mindlin contact model with relative velocity dependent (RVD) rolling friction. Charge motion was modeled under different mill speeds. Compared to conventional steel and rubber liners, the charge motion in the magnetic liner mill was predominantly cascading. Quantitative analysis of the energy dissipation within the mill was conducted to investigate mill breakage. Regardless of speed, over 50% of the total energy dissipation in the magnetic liner mill was in the form of abrasion and attrition. The results highlighted the appeal of magnetic liners in secondary and regrinding application, where abrasion and attrition are considered more efficient in the fine material breakage, and where impact is ideally minimized to reduce mill wear. A number of experiments were conducted to assess the effect of different model parameters on the performance of the magnetic liner mill. The highest abrasion/attrition intensity was observed with high values of the model parameters namely the restitution coefficient, static friction coefficient, and rolling friction coefficient.

By J. K. Pandey, ebashish Mishra, D. P. Mishra, N. K. Mohalik, S. K. Ray

The increasing demand for coal and depletion of shallow depth reserves are pushing towards deeper mining. In deeper coal mines with multiseam workings, the problem of ventilation surges many folds primarily related to air quantity requirement, heat, humidity and spontaneous heating/fire in goaved (gobbed) out areas. The paper describes the design of a new approach to improve the ventilation system of a real-life deep underground coal mine with multiseam workings. For this, the ventilation problem of one deep underground coal mine 6&7 pits Bhutgoria Amalgamated Colliery of Tata Steel Ltd. with multiseam workings has been studied in detail to determine an appropriate solution. A ventilation survey of the mine and computer simulation of the ventilation network has been carried out to reach a practical solution. Ventilation survey results have been analysed to develop a representative ventilation network of the mine for both qualitative and quantitative analysis. Further, computer simulation of the ventilation network of the mine has been performed to virtually verify the application of a highcapacity booster fan in the present ventilation circuit without disturbing the vulnerable areas. Field validation is also carried out after the implementation of the solution in the mine to determine its efficacy. Thus, the findings of this paper can be directly applied for the installation of booster fans to achieve the required air quantity in deep underground coal mines with multiseam workings having spontaneous combustion liabilities of upper seam goaved out areas.

Jun 2, 2022

By Xiaochun Xiao, Xin Ding, Yishan Pan, DI WU, Xiangfeng Lv

Rockburst is a sudden disastrous instability of coal mass that poses a serious threat to underground exploitation of coal resources; therefore, approaches of prediction and control methods are valuable for improving mining environments. The mechanical properties and bursting liability of coal with drying, under-saturated, and saturated moisture content under uniaxial compression are investigated, and the charge induction signal during coal deformation both in the laboratory and on-site is recorded in this study. The presence of water reduces the cohesion and increases the internal stress caused by non-uniform deformation of minerals, resulting in the strength, elastic modulus, and bursting liability being weakened. The charge induction precursor main frequency band is 1–100 Hz and belongs to the very-low-frequency signal regime, and it indeed varies with the loading stage, leading to specimen failure owing to changes in amplitude and continuity of the charge pulse in both the time and frequency domains. Water inhibits the richness of charge induction and reduces the bursting liability, and the earlier the precursor appears, the more total charge emerges. Moreover, measurement results indicate that the amplitude and continuity of the charge pulse decrease over a longer time, as recorded in a coal seam with water injection, further verifying the weakening of the coal dynamic characteristics. Charge induction can be a valuable tool with which to obtain the precursors for rockburst and to aid the evaluation of water injection.

Dec 26, 2022

By J. Rostami, J. Brune, S. Slouka

Respirable dust poses long-term health issues to personnel working in mining and civil projects where mechanized mining and tunneling machines are used for hard rock excavation. Machines, such as longwall shearers, roadheaders, or continuous miners, use consumable picks to cut rock. However, rock dust is generated in the work environment each time the pick tip contacts the rock surface. Additionally, the generated dust can be reintroduced into the air further down in production, such as at transfer points. The purpose of this study is to characterize respirable dust particles generated at the pick tip at two stages of pick wear: new and moderately worn. Understanding dust characteristics in terms of concentration, size distribution, and particle shape throughout the life-cycle of the pick will provide a basis to mine and tunnel operators for changing out picks to mitigate dust generation at the source. This paper discusses the dust characteristics generated from preliminary full-scale cutting tests in a laboratory of an igneous rock block cut with conical picks at new and moderately worn levels of wear. The moderately worn pick generated a size distribution that favored smaller particle sizes compared to the new pick. The moderately worn pick also generated more overall dust, as the concentration level in mg/m3 was over double the amount of the new pick. Lastly, both picks generated particles that had similar aspect ratios and roundness measures.

May 18, 2022

By Michael A. Trevits

A mine fire represents one of the most dangerous and challenging safety issues facing underground mine operators. Given the right circumstances, a mine fire can occur at any location in the active or abandoned mine workings, can quickly grow beyond control, and threaten the welfare and livelihood of the entire underground workforce. The National Institute for Occupational Safety and Health (NIOSH), in partnership with the Mine Safety and Health Administration (MSHA), has been conducting an in-depth program of research addressing mine fire prevention, early and reliable fire detection, and mine fire suppression technologies. One portion of this program is focused on understanding the characteristics of mine fire combustion products and flame spread through large scale deep-seated (firmly established) fire tests and use of computational fluid dynamics (CFD) modeling. In this study, two deep-seated fire tests were conducted; one fire consisted of coal material and the other utilized the two most abundant fuel sources found in a coal mine: coal and wooden cribbing blocks. The fires were burned to completion while the combustion products were collected and analyzed. In addition, an array of thermocouples was placed within the body of the material to measure flame spread rate. The coal fire test information was then used to develop a CFD model of the fire. This paper describes the fire tests, provides insight into characteristics of flame spread, and presents the CFD modeling work results.

Jan 1, 2009

By E Marambio, R Brändle, G Fischer, G von Rickenbach, L Burgos, R Luis Fonseca

Ground support systems must provide safe and effective designs for underground excavations under high stress conditions. These systems must be capable to resist dynamic impacts and yielding during the loading process. In this context dynamic testing of the reinforcement and retaining elements that compose the ground support system are required to study and improve the behaviour of these elements under dynamic load events. During the last years, Geobrugg has been working on the improvement of retaining products by testing them in a large-scale impact test facility located at Walenstadt, Switzerland. The test facility is composed of a double level platform with a square-shaped pyramidal trunk geometry, in the upper level housing a loading mass that drop from a height up to 5m. The loading mass is guided by one central steel pipe, and the impact occurs in the sample to be tested located at the lower level in a slab with an area of 3.6m × 3.6m where the ground support system is installed. During the last years, this innovative facility has been used to test several configurations of ground support systems. The results of these tests have enabled to improve the understating of the behaviour of ground support systems under dynamic loads. In this manuscript, the arrangement, measurement, results, and the preliminary analysis of a single impact dynamic test performed during 2021 of a ground support system with a high-tensile steel wire mesh MINAX 80-4.6 is presented.

Apr 26, 2022

By Reed S. C. Rogers

The most widely used machines for grinding coal to the sizes prescribed for the pulverized coal firing of furnaces, boilers, and kilns are the vertical ball-race, roller-race and roller-bowl types of mills. However, the increased use of coal has led to an increased use of tumbling ball mills for coal grinding. Specifically, air-swept ball mills are now a part of many dry pulverized coal firing systems, offering the advantages over vertical mills of lower maintenance costs and the ability to handle strong or abrasive (high ash) coals. The current use of wet ball mills is to prepare coal-water slurries for direct combustion, although in time they may also find routine application for preparing slurry feed for coal gasifiers. In either application, wet ball mills ofer the advantages that coal grinding and wetting can be accomplished in a single step, and that the mills are readily used with fine wet screens to assure top size control in the slurry product. The simulation of tumbling ball mills with mathematical models has reached a fairly advanced stage, but the concepts have been applied only recently to coal grinding. As this paper will demonstrate, however, significant progress has been made in the use of models in ball mill circuit design for coal grinding. Included is a description of the techniques used for simulation, recommended parameter estimation methods, and demonstrations of process engineering calculations for large scale coal grinding circuits.

Jan 1, 1986

By Edgel P. Stambaugh

Oxides are important for use in the production of metals, ceramic hardware, paints, permanent magnets, magnetic recording tapes and many other uses. In some of these applications, particle morphology, degree of crystallinity, purity, and homogeneity are relatively insignificant, while for other uses, these same properties are of critical importance. Many conventional processes are based upon recovery of the oxides from aqueous solutions by processes which include neutralization, evaporation of solvent, and precipitation of a complex salt. Consequently, many of these techniques lead to oxides of low quality. There is a growing demand for oxides of high quality, i.e., materials with narrow particle size distribution, controlled particle morphology, high purity, few structural defects, and high degree of crystallinity and homogeneity. This demand has prompted industry to search for new approaches for the manufacture of these special materials. One new approach for preparing high quality oxides is hydrothermal precipitation. This process has been used for preparing simple oxides such as ZrO2; mixed oxides such as ZrO2-SiO2; and complex oxides such as BaTiO3. These oxides were prepared in a high state of purity with a high degree of crystallinity and., in many cases, without the addition of precipitants. Many impurities- that are normally precipitated by conventional methods such as neutralization present no problem since they remain in solution. Nature of the process and its applications are discussed in this article.

Jan 1, 1977

By David M. Kjos

Large diameter autogenous and semi-autogenous grinding mills represent the primary thrust of the expanding grinding technology. In spite of initial difficulties, large autogenous and semi-autogenous mills have reached an acceptable level of technology which provides the mineral engineer with a reliable, low cost means of ore comminution. A successful milling installation begins during the design stage of the grinding mill and the plant it is to be installed in. This is particularly true in autogenous and semi-autogenous mills. Critical mill and plant design factors should be considered while the mill and installation are still only ?paper.? Various current liner designs will be discussed ranging from lifter bar/plate to integral types. Modes of operation such as "high-low" will be considered. Liner maintenance procedures ranging from laydown area in plant design, proper mill shutdown methods, to installation and bolt tightening complete the equation to yield optimum performance possible for any particular grinding application. The objective of this paper is to discuss trends in wear materials, designs and operating practices, and provide some guidelines for good practice as we move through the 1980's. We will put together concepts that relate to the designs, materials and applications so that higher performance can be obtained by the operator for his specific application. The concepts are shown as being in series because they are dependent on each other to achieve the desired performance.

Jan 1, 1985

By Biswajit Samanta, Pranjal Pathak

A multimine mineral value chain (MVC) consists of multiple mines in the upstream supplying raw materials to multiple destinations in the downstream. The short-term mine production scheduling problem of a multimine MVC aims to determine the optimal extraction sequence and destination allocation of blocks from all the mines collaboratively to meet the quality and quantity requirements of all the processing plants in each period, subject to all relevant technical and operational constraints of the mining system. It is carried out at shorter scales of days/weeks/months under the purview of long-term production scheduling. An optimal short-term production schedule for MVC involving multiple mines that share the same infrastructure (processing units, stockpiles and waste dumps) requires coordination across the network of mines. Optimizing the short-term production schedules independently at each mine fails to capture the benefit of collaboratively generating schedules for all the mines, resulting in suboptimal schedules. Additionally, in short-term production scheduling, the operations are modeled in greater detail with additional decision variables and constraints to model the more complex multimine MVC situations. This makes the large-scale instances of the problem computationally intractable for standard mixed-integer programming (MIP) solvers. This work presents a customized genetic algorithm (GA)-based heuristic approach to obtain near-optimal solutions to the industrial-scale instances of the short-term production scheduling problem of multimine MVC within a reasonable computation time.

Oct 1, 2022

By J. A. Herbst

Fine coal cleaning by froth flotation has become common practice in the U.S. with more than 80,000 tons treated in this way per day. In spite of this large tonnage, developments in the automatic control of coal flotation circuits have lagged significantly behind those for mineral systems. One reason such developments have been limited is that instruments have not been available for the on-line measurement of carbon or ash and another critical variables in coal slurries. A second reason is that the influence of the operating variables on coal flotation has not been completely understood. During the last few years some of the required instrumentation has been developed and an improved knowledge of the flotation process itself has occurred through mathematical modeling; as a result certain control strategies for coal flotation are beginning to emerge. This paper attempts to evaluate several control strategies using a detailed flotation dynamic simulator, DYNAFLOAT. After constructing a process matrix for the system of interest, promising alternatives for linking manipulated and controlled variables have been analyzed. In order to develop combined grade and recovery control strategies, the authors found it necessary to construct a grade/recovery map with the aid of the simulator to drive the system to known final, feasible grade/recovery operating conditions. Finally, an advanced strategy which uses an on-line model to identify disturbances and take control actions is proposed.

Jan 1, 1983

By Panshi Xie, Yingyi Zhang, JIANJIE DUAN, Shenghu Luo

The most important safety aspect associated with great mining height in steeply dipping coal seam mining is the stability and control of the roof. When soft coal and hard gangue make up the immediate roof of a working face, the soft-coal interlayer plays a significant role in gangue damage and can cause problems such as roof collapse in front of the support, collapse of partial area supports and other problems that can affect the stability of the supports and the surrounding rock system. This study found that the first weighting step of a multigangue roof is larger than that of a nongangue roof, but periodic weighting steps are similar. The overburden collapse height is lower in a multigangue roof than in a nongangue roof due to the buffering and supporting function of the collapsed gangue. Failure of the coal interlayer is the key factor in the collapse of multilayer gangue. The limited load of the interlayer and maximum resistance of the support is concluded by the hard gangue and soft coal interlayer mechanical model. The maximum resistance of the support increased with the dip angle of the seam and burial depth. Certain measures are proposed to control the stability of the gangue roof, including zoning control of the mining height and resistance and advancing the support while maintaining roof contact, thus ensuring the integrity of the support and surrounding rock system.

By H. Colijn

The trend in the coal industry for many years has been to make everything "bigger and faster" This also held true for loading and storage facilities. Where once a million ton per year mine was rare, three to five million ton per year mines are not uncommon today in the bituminous industry. This greatly increased production, made possible through mechanization, required greatly improved loading facilities just to get the coal away from the mine. Also, there is a trend toward combining production from more than one mine and cleaning it in a single preparation plant. In addition to increased loading capacity, this frequently necessitates raw coal storage and blending facilities. The development of the unit train, more than any other factor, has contributed to the widespread construction of storage and high-speed loading facilities for clean coal. In the export market, the construction of ever larger coal bulk carriers has contributed to a need for faster and larger loading facilities at ports. The present engineering and construction cost of these larger facilities make it essential that the flow and handling properties of the particular coals are fully known. These properties can be measured well in advance and the proper design criteria established. This eliminates costly surprises later on during start-up and operations. This paper will review coal and coal refuse properties, such as shear strength, cohesion, friability, and the flowability of coal and how they affect the design criteria of storage silos.

Jan 1, 1979

By Y. Yu

Florida phosphates ore typically processed by reverse flotation with an intermediate acid-scrubbing step. A single-reagent flotation process, using fatty acids or amines as the collector, would eliminate the intermediate scrubbing step plus an additional flotation step. This would not only simplify the process flowsheet but would also result in reduced reagent costs. The potential of single-reagent flotation of Florida phosphates using fatty acids as the collector is examined in this study. Introduction The beneficiation scheme now used for Florida phosphates involves the following three steps (Smith, 1976: Lawyer et al.. 1978, 1984: Moudgil et al, 1976, 1979, 1986, 1987): •rougher flotation of fluorapatitc particles using a fatty acid-fuel oil mixture as the collector. •scrubbing of fatty acid, and •cleaner flotation of silica particles using amine collector. Several attempts have been made to simplify the process flowsheet by floating either apatite or silica (not both, as is the current practice). However, single-reagent flotation schemes have had limitations in meting the concentrate-grade requirements of the phosphoric acid plants. In this study, an attempt was made to use a minimal amount of the fatty acid-fuel oil collector to obtain an acceptable grade (rougher) concentrate. Invariably, the recovery in such cases is expected to be lower than in the conventional rougher-flotation step. Therefore, scavenger flotation of tailings with additional fatty-acid collector was conducted to improve the phosphate recoveries.

Jan 1, 1997

By Nathaniel Arbiter

The development of flotation machines since the first industrial use of the process can be divided into three stages. The first, up to about 1930, was marked by diversity in the means for contacting floatable mineral with the air/ water interface and for generating the interface, as well as in cell design. By 1927 Taggart (1) could list 170 patents covering flotation cells, and he mentioned dozens which were or had been in operation. He divided cells into eight categories according to design, type of separating interface, and where in the cell and how separation took place. These were: (1) Film or skin flotation with wet or dry oiling of surfaces; (2) pulp body process with bubbles generated chemically by pressure reduction, by vacuum or by boiling; (3) agitation-froth processes involving local supersaturation with air; (4) bubble column; (5) pneumatic; (6) cascade; (7) subaeration; and (8) combination and miscellaneous types and processes. Most widely used then were the agitation-froth, sub- aeration, pneumatic types. By 1943 a significant reduction in categories had occurred to the two main divisions of mechanical and pneumatic cells according to whether agitation and aeration were (a) by an impeller with or without compressed air, or (b) by compressed air alone. Cells at that time were still relatively small; the Morenci Concentrator completed in 1942 used 432 1.7m3 (60 cu ft) Fagergrens for roughing 45,000 and later up to 55,000 t/d.

Jan 1, 1979

By John D. Batty

With the emergence ofbiooxidation as a viable process for the pre treatment of refractory gold ores, so have the number of publica­tions on this topic increased dramatically. To a novice in the field of biooxidation, the infonnation presented is often confusing and sometimes even incorrect. Infonnation has also been published that is misleading in that it highlights a particular feature of a process that is either totally irrelevant or of no consequence to the ultimate goal viz. achieving the maximum economical gold recovery. To assist a potential user of biooxidation in evaluating the available published infonnation some guidelines or considera­tions for some of the more important aspects are given, as well as some extracts from publications that demonstrate the manner in which information has been presented.

Jan 1, 1996

By Earl Sackett

In its 110-year history as a mining camp, the Boleo copper district of Baja California has weathered significant changes in its operation, ownership, and profitability, despite an inhospitable environment and unique ore body. For some 65 years, under the operation of Compagnie Boleo, the area ranked as the second largest copper producing district in Mexico, with over 560 km of underground workings. As its ore grade-and profitability-declined, operations continued sporadically and with varying degrees of success. Today, operations at Boleo are maintained -despite the economics -while work is underway to devise a viable metallurgical process. Lab tests on a hydrometallurgical method look encouraging and, though this may end the district's days as a mining camp, the feasibility of the process may result in an 18-kt/d full-scale operation.

Jan 7, 1980

Acid Mine Drainage (AMD) is the most serious environmental problem facing the Canadian Mineral Industry today. Acid Mine Drainage results from oxidation of sulphide minerals (e.g. pyrite or pyrrhotite) contained in mine waste or mine tailings. It is characterised by acid effluents rich in heavy metals that are released into the environment. A new acid remediation technology is presented in this paper by which metallurgical residues from the aluminium extraction industry are used to construct permeable reactive barriers (PRB) to treat acid mine effluents. It describes column tests performed to simulate a PRB using Bauxsol?, a chemically and physically treated bauxite refinery residue, as a reactive material. This experimentation shows promising results for the Bauxsol? PRB method in neutralizing pH and removing metals from acidic mine effluents.

Jan 1, 2006