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By Steve Kral

The coal mining industry in the western United States is seeing the same boom as the rest of the country and the world. Most coal mines in the West are operating flat out as the nation’s appetite for energy continues to grow. And many of the coal mines have either increased their production capacities or are in the process of doing so. However, transportation issues along with environmental restrictions are keeping many mines from expanding even further. Some coal companies held off on further expansion plans until Congress and President Bush could agree on a national energy policy, one that recognizes coal as the nation’s leading source of electricity. In August, Congress passed and the president signed into law such a measure (see Washington Survey, page 7). The legislation includes research funding for clean coal technologies. So western and eastern coal could become even more important in the national energy picture. This is particularly true as supplies of natural gas diminish and the price of oil continues to increase.

Jan 1, 2005

By D. R. Spears

The Bureau of Mines has investigated the fundamental aspects of shear-flocculation using a rapid, in-situ particle size analyzer. Silica was stirred in the presence of an aliphatic amine to determine the effects of collector coverage, stirring speed, and solids concentration on the kinetics of shear-flocculation. The results showed that shear-flocculation is a two-stage process. In the first stage, mean particle size increased rapidly in the first 1-2 min of reaction; in the second stage, an equilibrium was set up between the rate of floc growth and floc decay. Collector dosage affected the position of the equilibrium by altering the number of surface sites for particle-particle attachment. A minimum stirring speed was necessary for shear-flocculation to occur and was dependent on solids concentration and collector dosage. This speed was the minimum necessary for particles to overcome the electrostatic energy barrier which kept conditioned particles dispersed. Larger particles flocculated more rapidly. At very high stirring speeds, large flocs became unstable, resulting in a narrowed particle size distribution in the slurry.

Jan 1, 1993

By J. A. Rusnak, K. M. Mohamed, M. A. Van Dyke, M. M. Sears, G. Rashed

"Researchers from the National Institute for Occupational Safety and Health (NIOSH) recently developed a coal-mass model to realistically simulate the deformation and loading behaviors of the ribs of coal pillars in underground coal mines. The scale-dependent properties (stiffness and strength) of coal material were considered in the coal-mass model. In this paper the orientation of face cleat with respect to driving direction was integrated in the coal-mass model. The controlling parameters (dimensionless coal-mass scale and fracture strains) of the modified coal-mass model were calibrated using a published case study of coal pillar strength. Numerical models with wide ranges of controlling parameters were conducted to simulate the test pillar. The best match between the numerical modeling results and the measured stresses and deformations was achieved by using a coal-mass scale of 30 and fracture plastic shear and tensile strains of 3.25% and 0.325 %, respectively. INTRODUCTION The failure of coal pillar ribs by itself are a major hazard in underground coal mines. Furthermore, failing ribs can indirectly contribute to roof and floor instability by increasing opening widths across intersections and entryways. Over the past decade, rib failures have resulted in 12 fatalities, representing 28% of the ground-fall fatalities in U.S. underground coal mines. Mining depth has always played a very important role in assessing rib stability. Gauna and Mark (2010) completed an analysis of rib fatalities that occurred between 1996 and 2010. One of their most prominent and influential findings was the identification of a relationship among fatalities, depth, and mining height. Therefore, Coal rib stability will continue to be a challenge for future deeper mines in U.S. coal basins. In the past several decades, research efforts have focused on roof support. The current rib control practice in U.S. coal mines is to select rib bolts through a trial-and-error approach (Mohamed et al., 2015a). Rib failure incidents can be can be substantially reduced or even eliminated by adopting an engineering-based coal rib design approach. The factors affecting rib stability in coal mines are numerous and mutually dependent. These factors include but not limited to mining height and overburden depth, interburden thickness for multiple-seam mining, coal strength, cleat density, entry direction with respect to cleat orientation, existence or absence of partings in the coal, percentage of extracted roof and/or floor rock, density of rib bolt support (Mohamed et al., 2015a). Moreover, it is difficult to isolate the particular effect of a specific factor on the overall rib stability. Therefore, a reliable empirical rib design approach is not achievable because it requires a significant number of case histories to be collected in order to have a reasonable range of all of the critical parameters. However, numerical modeling can be a practical tool to assist with rib support design if the modeling is realistic, which can only be achieved through calibration and validation of the numerical model against field data."

Jan 1, 2018

By E. Kurt

The field of percussion rock drilling is subdivided into two areas of application; that which takes place on the surface and that which takes place underground. Surface drills are used in quarrying, highway construction, and maintenance work; underground equipment in mining and tunneling work. Two basic principles are involved in the operation of all percussion drills. First, the principle that reciprocates the impacting piston and second, the principle that causes the drill steel and bit to rotate. The back and forth motion of the piston is accomplished by a self-acting automatic valve that admits air alternately to each end of the piston (Figure 1). Drill steel and bit rotation is imparted by an integral ratchet mechanism (Figure 2) in the so-called "rifle bar" machines (Figure 1) or by a separate pneumatic motor in "independent rotation" drills (Figure 3). While rock drills are subject to all kinds of physical and operational abuse, they are most sensitive to faulty lubrication. Proper lubrication is the single most important factor in the longevity of a percussion drill.

Jan 1, 1970

By B. K. Mishra

Power draw of the mill has been accepted as an indicator of the performance of the mill, yet the problem of predicting power under a given set of mill operating conditions still remains to be solved. In the literature, this problem of predicting power is attributed to a lack of knowledge with regard to the motion of the charge. Here a DEM based model is used to analyze the motion of the charge. The resulting information is used to predict the power draw of the mill. A 16-ft diameter mill is simulated. A factorial design study of the variables-mill speed, lifter configuration and ball size distribution-as independent variables is taken up. The power draw as a response variable is analyzed to establish the best operating condition of the mill.

Jan 1, 1993

By T. Panhorst

Evaluation of through-deck blasthole sample reliability at the Lone Tree gold mine revealed a non-systematic bias in the sampling system. Ore is primarily hosted within the Powerline fault zone. Clay gouge, present in the fault zone and typically enriched in gold content, forms agglomerates during blasthole drilling leading to a segregation error during sampling. Replicated samples split from blasthole cuttings piles show through-deck samples to be either significantly enriched or depleted by 1.5 standard deviations or more from the mean gold content of their respective cuttings pile quality of through-deck samples correlates strongly with quantity of clay present.

Jan 1, 1999

By Gregg R. Bierei

Arch of Illinois is a mining complex comprised of two surface and two underground mines located in Perry County, in southern Illinois. The company a division of Apogee Coal Co. of St. Louis, MO. Arch of Illinois' two surface mines, the Captain and Horse Creek Mines, use large stripping shovels and cross-pit bucketwheel excavators to remove overburden from three seams of coal, the Herrin No. 6, Harrisburg No. 5 and Danville No. 7. All are considered high sulfur reserves. The two underground operations are managed by Arch of Illinois. They are the Kathleen Mine and the newly constructed Conant Mine, which began production in 1991. Both underground mines are continuous miner operations. They mine the No. 6 coal, which is about 1.8 m to 2.1 m (6 to 7 ft) thick. All coal is currently transported by truck to a central preparation plant located at the Captain Mine. This preparation plant produces 27 kt/d (30,000 stpd) of clean coal. Production in 1992 reached 5.9 Mt (6.5 million st) of saleable coal. Of that, about 66% or 4 Mt (4.4 million st) are produced by the surface mines and the rest the by under ground operations. Change is in the wind for Arch of Illinois. In 1988, 100% of all production (6.2 Mt or 6.9 million st) came from surface operations. By 1995, only 38% of production is scheduled from surface mines. And by the year 2000, 100% of production will from underground mining methods. Dwindling low ratio reserves, compounded by increasing environmental and land acquisition costs, coupled with more efficient underground mining equipment, have started an evolutionary trend toward development of underground reserves. For Arch of Illinois to maintain profitability of remaining surface reserves and to compete effectively mining underground, it must improve efficiency, productivity and cost reductions. These efforts are essential for maximizing current surface reserves and to ensure a continued existence in the presence of clean air legislation and the softening of the high sulfur coal market.

Jan 1, 1993

By Dongjie Zhang, Shuxin Liu, Jianduo Wang

Broken rock mass and unreasonable stope structure parameters can cause excessive ore loss and dilution in sublevel caving; this is the main problem faced by caving mining in recent years. This paper proposes a stope structure parameter optimization method suitable for steeply inclined medium-thick broken ore bodies and evaluates the reliability and effectiveness through case studies. To solve the problem of large ore loss and dilution in the high-end wall sublevel caving method of Xilinhot fluorite mine, it is necessary to select proper stope structure parameters. Based on the theory of random media, an end-wall ore drawing experiment was carried out, and the bulk flow parameters needed to optimization of stope structure parameters were determined. In the experiment, it was found the draw-out body of high-end wall ore drawing showed a fine top and a thick bottom; the granular media had good fluidity. The reasonable caving step is determined to be 1.2 m instead of the 1.6 m originally used. Through the optimization experiment of the mining route position along the vein, the study found that the best route position is different with the ore body inclination. When the inclination angle of the ore body was 90°, the reasonable route was located in the center of the ore body. When the inclination angle of the ore body was between 85° and 90°, the route moved from the center of the ore body to the footwall at a rate of 22.5%. When the inclination angle of the ore body was between 80° and 85°, the route moved to the footwall at a rate of 54.8%. When the inclination angle of the ore body is not greater than 80°, the route should be arranged on the boundary of the footwall. Field application results showed the dilution rate reduced by 7.66% and the recovery rate increased by 7.31%. Field test results verify the effectiveness and applicability of the optimized stope structure, which corroborates the effectiveness and applicability of the optimized stope structure.

Mar 10, 2022

By G. E. Wasson

Coal in most refuse ponds including those owned by Consolidation Coal Company can be recovered by froth flotation techniques. Laboratory studies show that the flotation conditions required for coal recovery varied greatly from pond to pond. The variables found to be most important for high coal recovery and low product ash were: a) the amount and type of flotation reagents and b) the degree of conditioning before flotation. Coal recovery at a rate of 0.504 kg/s (2 tons/hr) was demonstrated at a pond site employing a mobile froth flotation unit.

Jan 1, 1988

By Alvaro Veizaga, Samuel Cuellar

In recent years, Industry 4.0 has generated a change in the way companies in various industrial sectors design, produce and deliver products and services, and is focused on the interconnection of systems, the advanced access and management of large amounts of data in real time, and the implementation of emerging technologies such as the Internet of Things (IoT). Artificial intelligence (AI), machine learning (ML), digital twins (DT), robotics, virtual and augmented reality (VR/AR), among others [1]. DTs are accurate and dynamic virtual models that replicate physical systems, where it is possible to simulate and optimize operations before implementing real-world changes [3]. These features make it possible to reduce investment costs, minimize risks and improve strategic decision-making. These benefits are of utmost importance for tailings storage facilities (TSF), since they are facilities aimed at the safe storage of tailings and with the constant need for growth [4]. This paper evaluates the applicability of a DT in a TSF from a conceptual perspective, providing the advantages of its implementation, but also the barriers identified in the industry based on the authors’ experience.

Feb 1, 2025

By Rodney R. Krause

In attempting to tell the general public about the coal industry's land reclamation efforts, we have often said, "We're not doing things by the book, because we're still writing it." Like any good catchphrase, the statement is not only striking but true. It is particularly true in the mountains of Appalachia, where the problems of mining; and of reclamation are made more intense by the nature of the terrain. Mining and reclaiming the land "by the book' --which is to say by the methods of contour mining traditionally used in hill country--hasn't worked too well. So a lot of conscientious coal operators and associations are trying new methods--new ways of mining, new machines for seeding and planting, and new species to seed. Not all their experience can be transplanted to other areas, and of course I don't believe that Appalachia is the only place where new methods are being developed. Nevertheless, there's enough action in Appalachia to make a detailed examination rewarding, so let's focus on the hills to see what's new.

Jan 1, 1970

By T. Guler

Turkey has important celestite reserves in Sivas. These reserves have gypsum and/or calcite as gangue minerals. Celestite-calcite ore cannot be concentrated by gravity methods due to the low efficiency of gravity methods in fine sizes. Research was tried to concentrate celestite to a market grade by flotation. Parameters such as pH, particle size, dosage and types of collector and depressant were examined. Cyanamid A-845 and Na-oleate combination as collector, sodium silicate as depressant, and Aerofroth-65 as frother were found as the optimum flotation reagents. By applying 3-stage cleaning, a concentrate assaying 95,34 % SrS04 was obtained with 84,93 % recovery.

Jan 1, 1999

By R. Gray

"Experience from Australia has identified what is referred to as non-conventional surface subsidence behaviour. This occurs under irregular surface topography, resulting in valley closure, valley floor uplift or “upsidence”, and far-field horizontal movements – even occurring beyond conventional “angle of draw” limits. This paper discusses such behaviour recently observed in Pennsylvania and focuses on the 2005 case of Duke Lake Dam in Ryerson Station State Park. In July 2005, there was a significant increase in water leakage through a number of growing cracks in the dam leading to the dam being breached to avoid an uncontrolled failure. An underground longwall mine was located approximately 900ft to the north, mining at depths of 330 – 720ft. Investigations (including a subsequent ground movement monitoring program) found a range of evidence in the vicinity suggesting that valley closure and far-field horizontal movements may have occurred resulting from the adjacent mining. The paper discusses the phenomenon of non-conventional subsidence behaviour and the Ryerson State Park case study, including an assessment of mining, geology and subsidence impacts and suggested ground behavioural mechanisms. INTRODUCTION Non-Conventional Subsidence The conventional understanding of coal mine subsidence on which most current subsidence understanding and prediction techniques are based, includes the concept of angle of draw which effectively limits the lateral extent of subsidence effects and impacts. Within this zone – above and marginally beyond the boundary of mining – downward vertical subsidence is the dominant component, together with localised horizontal movements towards the mined region, with related tilts and strains. However, more recent experience from Australia over the last two or three decades has identified what is referred to as non-conventional surface subsidence behaviour. This is found to occur in areas of irregular surface topography or variable terrain, and is characterised by phenomena such as valley closure, valley floor uplift or upsidence, and far-field horizontal movements, all of which can occur beyond the conventional angle of draw limits. NSW Department of Planning (2008) defined the conditions for both conventional and non-conventional subsidence behaviour as follows: “The conventional or general model of surface subsidence, which finds worldwide acceptance, is based on assuming the following site conditions:"

Jan 1, 2015

By Ying Lu, Jeffrey C. Johnson, Chen-Luh Lin, Jan D. Miller, Sindhoora Puvvada

The amount of energy used to break rock is of interest in mine-to-mill operations to minimize energy consumption during blasting at the mine site and comminution at the processing plant. In this research, a direct energy measurement was made using high-velocity impact to cause breakage of long granite cores, and to study the energy dissipation along the entire bar length. The results show the formation of three zones of damage — fragmentation, fracture and elastic — that have been characterized in 3D using X-ray tomography. The fragmentation zone of the granite bars was studied in detail to describe the particle size distribution and the particle shape characteristics. The experimental energy dissipation in the fragmentation zone was found to be in close agreement with the expected energy calculated from the Bond work index (BWI) equation [1] when the anisotropic granite particles in the fragmentation zone are defined by length rather than by sieve size. The results increase our understanding of rock breakage and energy consumption and may find future applications in mine-to-mill operations.

By J. J. Harrington

Manufacture and mixing of flotation reagents at the mill site provides an economic and convenient method of maintaining a continuous and fresh supply of reagents for concentrator operations. Kennecott Copper Corporation has designed and built a Reagent Mixing Facility which incorporates new ideas in construction and fail-safe operation at its Nevada Mines Division concentrator. Highly sophisticated automation and instrumentation techniques are combined with safety procedures and equipment that meet and exceed all Federal and State safety requirements. Installation of the facility has minimized hazardous working conditions for the operator, isolated reagent preparation from production personnel and equipment, and reduced the time required for reagent preparation from three shifts to one shift per day.

Jan 1, 1976

By B. Ladanyi

An adequate knowledge of the overall behavior of a rock mass at a given site is fundamental to the satisfactory design of a rock slope. The be- havior is controlled by a variety of factors, in- cluding rock type, geological structure, stress and ground water conditions. There are essentially three lines of approach that may be used to obtain information on the in-situ rock mass behavior for the purpose of the design of a rock slope: (1) Direct measurements of rock mass properties by means ol laboratory and field tests. (2) Evaluation of rock mass properties from a study of slope failure case histories and sta- tistical information on stable and unstable natural rock slopes. (3) Evaluation of in-situ behavior of rock mass by using a physical or mathematical model technique.

Jan 1, 1980

"Above ground, elevated belt conveyors with span >200m between support points can cross valleys, rivers, forests and buildings with minimal footprint. The Cable Bridge Conveyor is a new type of suspension bridge based belt conveyor system that has long span between support points. It combines typical belt conveyor and the improved simple suspension bridge to form a conveyor bridge. The improved simple suspension bridge places a widened bridge deck directly on suspended cables, without the need for high truss towers. The benefits include reduced cost and increase aerodynamic stability compared to conventional suspension bridges. The Cable Bridge Conveyor’s compatibility with current belt conveyors allows the versatility in application. INTRODUCTION Belt conveyor is a ubiquitous material handling system. Conveyors can be placed directly on ground or elevated above ground by support structures. Considerations of cost, design, environment, civil work, safety and process requirements are all factors in choosing the ground based or elevated conveyors (1). The ground based conveyor has the lowest structural cost, where the conveyor is laying on an existing road. Maintenance access is easy and straight forward. Compared to the ground based conveyor, the elevated conveyor can cross existing buildings and structures, give passage to traffic beneath the conveyor, has smaller footprint, and requires less civil work to pass mountainous areas. The drawback of the elevated conveyor is higher structural cost, which can be compared with savings in civil work and other benefits. Conventional elevated conveyors are supported by rigid truss type structures, with typical span of 15m to 25m between concrete support bents or steel trestles. Triangular truss, using steel pipes instead of hot rolled steel sections, is more efficient. The typical span of triangular truss supported conveyor is around 30m to 40m, while the weight is about 10% less than conventional box truss with shorter span (2). Long span elevated structure based on suspension bridge is another step forward in increasing the distance between support bents, reaching 100m~400m and beyond. The very wide distance between support points of an elevated conveyor offers unique benefits. The conveyor can cross rivers, valleys, highways, forests and other obstacles with minimal footprint and reduced civil work. The versatility from long span conveyors makes bulk material transportation over previously impossible terrains now a feasible option."

Jan 1, 2015

By E. H. Ahrens

This paper deals with the daily work of operating geologists and should be of interest to recent graduates. Working with development and production is quite different from exploration and many of the required skills and techniques must be learned on the job. Try to obtain your first position at a mine where good geological work is being done because it is important that you establish a solid foundation by learning valid techniques. Many do not! Those who desire to work in exploration are well advised to spend the initial two or three years at an operating mine where they will deal daily with an orebody during development and mining. Attempt to understand the controls of ore deposition and be interested in all phases of the operation. Learn something about factors which can adversely affect profitability and you will be a better explorationist.

Jan 1, 1983

By Paul E. Scheerer

Synthetically produced magnesium hydroxide serves as the precursor for much of the magnesium oxide produced in the world today. Magnesium oxide, in a variety of physical and chemically reactive forms, is a very important commodity. It is used as the main component in refractories employed in steelmaking furnaces and in many base metal refining furnaces. In the chemical industry, it serves as a raw material in the production of epsom salts, rayon acetate, oxychloride and oxysulfate cements and magnesium sulfonates. It is a minor component in fertilizers and animal feeds. It serves as the starting material for producing fused magnesia, used as an electrical insulator in electric heating elements. It is employed in the magnesium sulfite process for pulp digestion in the paper industry. Additional uses are in SO2 scrubbers, as a neutralizing agent in the tanning industry and as a component in rubber compounding. Magnesium oxide is produced not only from synthetically produced magnesium hydroxide. It is produced from natural magnesites, natural brucites, and natural and synthetic hydro-magnesites. Synthetic magnesium hydroxide, as a starting material provides more control of the chemical purity and chemical reactivity of resulting magnesium oxide products because of the uniform nature, chemical and physical, of the hydroxide that can be produced. Synthetic magnesium hydroxide is produced by precipitation of Mg (OH)2 from magnesium chloride bearing seawater or natural brines through the use of a base such as Ca(OH)2 or NaOH.

Jan 1, 1978

By W. H. A. Timm

Lake Dufault Mines, Limited, is located ten miles north of Noranda, Quebec. Following discovery of a copper-zinc orebody late in 1961, metallurgical investigations of diamond drill core were conducted by Lakefield Research Limited during 1962 and 1963. These were followed by pilot-plant tests in May and June of 1964, utilizing underground development ore. Milling operations commenced on August 16, 1964, and reached rated capacity of 1,300 tons per day by October 1, 1964 (Figure 1). Since that time, tonnage was gradually increased to a maximum of 1,400 tons per day and since January 1, 1968, gradually decreased to the present rate of 1,100 tons per day due to an increase in the hardness of the ore. The ore milled from start-up until January, 1968, was mainly massive sulphides, consisting of a complex mixture of iron, copper, zinc and minor amounts of lead sulphides with important associated values in gold, silver and cadmium (aver- age specific gravity 3.8). From January, 1968, until the present, the ore being processed is described geologically as a boxwork of sulphide stringers of chalcopyrite, pyrite and pyrrhotite and some local dissemination in siliceous rhyolite (average specific gravity 2.9) supplemented by the massive copper-zinc ore. The limited size of the orebody and the mining method employed (open stoping by blasthole and slash and bench methods) would have made grade control from the mine difficult and expensive. It was decided to try to cope with grade variations in the mill. The resulting rapid and wide swings in mill heads, hardness and specific gravity have presented many and varied challenges for the mill personnel.

Jan 1, 1970