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By Ken J. Richards

Industries dependent on pyrometallurgical processing generally find themselves facing a common set of problems, namely, serious environmental restrictions, heavy capital requirements for new facilities and for plant modernization, the certainty of rapidly escalating fuel costs, and the uncertainty of fuel availability. To remain competitive, it has become clear to industry that a new dimension of attention must be given to assuring the maximum performance from plant facilities already in place and from those that are built in the future. In the last decade or so, in response to these needs, there has been an acceleration in the development of new pyrometallurgical process concepts. Their application, though spotty, is increasing. A common factor in this developing base of technology is the need for effective process control. Digital control is an indispensable element of meeting the challenge. We cannot make the point, however, by looking to a general survey of instrumental control of pyrometallurgical processes. Computer control is in its awkward adolescence. Its application is so new that only isolated applications can highlight the trends. For this reason, the authors have chosen to focus on the nonferrous smelting industry to illustrate the status of pyrometallurgical processing and control. We believe this approach will best meet the interests of most readers of this edition and the background of the authors.

Jan 1, 1979

By Don U. Deere

The tunnel boring machine (TBM) can be a magnificent tunneling device under optimal rock conditions. Such ideal conditions would include good Rock Material Characteristics (compact, uniform; low to medium strength, hardness, and abrasiveness); good Rock Mass Characteristics (few joints and shears; unweathered); and good Geologic Environmental Characteristics (above groundwater level and moderate in-situ stress). Such idealized rock conditions would eliminate support problems, fallout at face and grippers, frequent cutter changes, and water problems. Daily advance rates of 50 m would be commonplace. Unfortunately, nature seldom provides the ideal geologic characteristics. The challenge to the geologist, machine manufacturer, and contractor is to provide equipment and procedures to best handle the adverse geologic features, once identified.

Jan 1, 1981

By Bruce K. Cantrell, Stephen W. Stein, Kenneth L. Williams, David Hassel, Harvey Patashnick

In June 1992, the Mine Safety and Health Administration (MSHA) published the 'Report of the Coal Mine Respirable Dust Task Group; Review of the Program to Control Respirable Coal Mine Dust in the United States." As one of its recommendations, the report called for the accelerated development of two mine dust monitors: (1) a fixed-site monitor capable of providing continuous information on dust levels to the miner, mine operator, and to MSHA, if necessary, and (2) a personal sampling device capable of providing both a short-term personal exposure measurement as well as a full-shift measurement. In response to this recommendation, the National Institute for Occupational Safety and Health (NIOSH), Pittsburgh Research Center, initiated the development of a fixed-site machine-mounted continuous respirable dust monitor. The technology chosen for monitor development is the Rupprecht and Patashnick Co., Inc. tapered element oscillating microbalance. Laboratory and in- mine tests have indicated that, with modification, this sensor can meet the humidity and vibration requirements for underground coal mine use. NIOSH is continuing that effort by developing prototypes of a continuous dust monitor based on this technology. These prototypes are being evaluated in underground coal mines as they become available. This effort, conducted as a joint venture with MSHA, is nearing completion with every promise of success. The immediate benefit of this effort will be to researchers, regulatory personnel, and mine personnel, by permitting evaluation of specific mining practices to see which expose mine workers to excessive dust levels. Using this information, mine personnel can optimize mining procedures to reduce dust exposure. MSHA and the operators will also be able to use the dust concentration data to judge whether dust plan parameters are adequate to continuously maintaining environmental dust levels below the applicable standard. The second development recommended by the Dust Task Group was a person-wearable version of the continuous dust monitor. It will be a monitoring system designed to provide a measurement of worker exposure to respirable dust, both during and at the end of the shift.

Jan 1, 1997

By J. A. Herbst

Successful transitions from micro- to macro-engineering are the keys to effective technology transfer between research and development organizations and industrial end users. At the same time, it has proven to be one of the most difficult tasks that the minerals industry has had to manage. Typically, developers of fundamental information concerning how mineral processing subsystems work have been academics and government scientists. These are the individuals giving the most important input to micro-engineering models that can benefit industrial operations. Publication is the usual route for "attempting" to transfer this technology to the end users. Unfortunately, with such publications, very little direct communication occurs concerning real industry needs or the future steps required to make the particular micro-engineering model useful. In the past, the industry has relied on in-house R&D groups and plant metallurgists to "translate" publications, to provide useful macro-engineering tools for plant applications. To some extent, engineering companies have also been asked to serve this function. However, these firms have been rather ineffective in this area since their conservative nature has caused them to look rather suspiciously at new technology. This approach to technology transfer has worked, albeit clumsily, for the last several decades. This communication system is now on the verge of total collapse due to conditions of the minerals industry. Mining companies can no longer afford the significant overhead expenses of specialized technical staffs. Universities are finding it extremely difficult to interest US students in mineral engineering programs, and funding for such programs is weak. Faculty members involved in micro-engineering research today tend to focus on pure (non-application-oriented) research.

Jan 1, 1992

By A. K. Bakshi

Slurry rheology affects autogenous grinding performance by changing the rock's breakage characteristics. In this study pilot scale batch autogenous grinding was carried out to observe the effect of viscosity on the breakage characteristics of the rocks (the media), and on the overall specific energy consumption. Clay/fines content, and temperature of the initial charge, were varied to alter the viscosity of the slurry. Results showed that at higher slurry viscosity, rocks became more difficult to break, resulting in an overall increase in the specific energy consumption of the mill. Also, it was observed that viscosity had a significant effect on the amount of critical size material present in the grinding circuit, where the critical size material is the material which is too large to be effectively ground in the mill, and too fine to act as grinding media.

Jan 1, 1996

By R. W. Smith, J. Dubel, M. Misra

The bacterium Mycobacterium phlei is highly hydrophobic and negatively charged. It has specificity for selective adhesion to fine coal particles, mainly due to hydrophobic interaction. However, it does not attach to pyrite and ash forming minerals present in the coal matrix. Results have shown that this bacterium is an excellent flocculant for fine coal. Not only, are the coal particles visibly aggregated, but the optical micrograph has shown that the coal particles are held in the aggregate by adhesion and bacterial bridging. With Mycobacterium phlei, the flocculation characteristic of coal is markedly different from that usually observed with synthetic polymeric flocculants. In particular, the entwining characteristics of the long chain molecules of synthetic flocculants are absent in the case of Mycobacterium phlei. Since the hydrophobic interactions between the adhering particles are of greater importance in the formation of particle aggregation, the flocculation process is very selective.

Jan 1, 1994

By Nathaniel Arbiter, Brij M. Moudgil

Separating oil shale from waste material or into high- and low-grade fractions can have a major economic influence on the surface retorting process. Different shale rock components vary significantly in physical and surface chemical properties, such as specific gravity, color, and water wettability. Various techniques that use the differences in one or more of these properties have been proposed to preconcentrate oil shale before retorting. This article discusses some proposed techniques, such as gravity separation, sorting, and froth flotation. Retorting oil shale is the most common method for recovering oil from the rock. This process is accomplished either underground (in situ) or above ground (ex-situ or surface retorting). Both techniques have serious limitations, such as low recoveries in the underground method and the ability to process rich shales only in the above ground retorting method. Also, environmental problems are associated with both techniques. Some of these limitations could be overcome if feed to the retorts is of consistent grade. This could be achieved by selecting appropriate sites for in situ retorting and selective mining for surface oil shale retorting. Both of these, however, would have a serious economic impact on shale oil recovery. Obviously, little control can be exercised over preparing feed material in the in situ retorting process, but beneficiation of oil shale could definitely be advantageous in surface retorting, and should have positive influence on the overall economics of recovering oil from the shales. For example, preconcentration of mined shale could result not only in reduced costs for materials handling, but also in waste disposal costs, since waste characteristics before and after the retorting process are significantly different. Upgrading the oil shale might also allow substitution of alternate technology for retorting as well as extend the process to recover oil from marginal deposits. Also, the separated material may become a potential source for recovering other values from shale deposits. Overall, the incentives for preconcentration are to reduce costs and improve thermal efficiency of the recovery process. Oil Shale Properties Important to Preconcentration Oil shale is a carbonaceous rock assaying 5-30% organic material (kerogen) and 70-95% ash-forming minerals. Kerogen is soft, nonbrit¬tle or semi-brittle material, and generally forms a matrix between irregularly distributed mineral grains. Inorganic mineral mat¬ter-quartz, feldspar, dolomite, kaolinite, dawsonite, and nahco-

Jan 9, 1982

By Robert D. Hansen, Richard R. Klimpel

INTRODUCTION A very important factor in froth flotation is the use of surface-active chemicals to form a froth in which minerals or coals are retained, thus allowing for valuable component enrichment. In coal flotation reagents (frothers) specifically designed to provide an efficient froth are employed. It is this group of chemicals that will be the primary emphasis of this paper. Despite the importance of frothers, surprisingly little systematic scientific work has been performed with the goal of quantifying frother mechanisms and the influence of particles on froth stability. Based on direct experimental observations in both batch laboratory and continuous large-scale flotation cells, the use of a frother significantly increases first, the possibility of a particle- bubble contact, and second, the efficiency of sticking after such a contact. Thus, a major role of a frother is to significantly increase the rate of flotation. This rate modification by a surface-active agent occurs through several observable mechanisms including the formation of a froth of relatively consistent character (bubble size and bubble density) under a variety of operational conditions, an increase in the ability to disperse air in the flotation cell, a reduction in the rate of coalescence of individual bubbles in the cell, and a decrease in the rate of bubble rise to the pulp surface. It will not be the intention of this paper to exhaustively list all frother accomplishments related to research, development and use in coal flotation. Rather, the authors will attempt, based on their experience, to present a technology overview of the role of frothers in the chemistry of flotation as successfully practiced at the industrial level. A very useful framework for flotation is the concept suggested by Klimpel (1984, 1984a) of viewing flotation as a system consisting of three major components: chemistry, equipment and operating variables. This is illustrated in Figure 1. A major point of this figure is that flotation is a highly interactive system with many technical and economic combinations of component settings available to operators to achieve a given goal. Sometimes simultaneously changing various component settings will reinforce a particular attribute. Also various component settings can cancel or counteract each other if changes are not chosen wisely. Thus, coal flotation must be viewed by the plant operator as a complex system with the economic/technical optimization of a given flotation process being directly related to the operator's knowledge of how his particular flotation system behaves as a function of the major control variables he has at his disposal. Typical important component settings in coal flotation are collector dosage, frother type and dosage, air flow rate, feed rate, particle size, pulp density, and the surface oxidation conditions of the coal. Because of the above complexities, it is sometimes assumed (especially in laboratory studies) that the choice of frother type and dosage is not as crucial as some of the other factors such as collector type and dosage (e.g., Leja, 1982). Detailed plant level testing of all of the factors of Figure 1 performed in recent years, Klimpel (1980, 1980a, 1982, 1984, 1984a), Hansen (19861, Klimpel, Hansen and Meyer (1982), simply do not support this assumption. The above testing has shown rather clearly that certain frother chemical structures consistently exhibit predictable performance characteristics in both mineral and coal flotation. In addition, significant changes in both rate and recovery can be expected. In the remaining sections of this paper, the following topics will be covered: requirements of chemicals capable of use as frothers, types of chemicals used commercially as frothers, some general performance characteristics of existing commercial frothers, and recent work in developing new frother chemical structures.

Jan 1, 1986

By D. Malhotra

The effect of some of the reagents, namely hydrocarbon oil, Syntex (sulfated coconut oil surfactant), pine oil, sodium silicate, and lime, used at the Climax mill on the recovery and grade of molybdenite and gangue minerals has been investigated experimentally using factorially designed test approach in the laboratory. The results of the investigation are presented in two dimensional plots. The lower additions of lime (equivalent to a pH of 8 to 8.5) were desirable for maximizing recovery subject to constraints on grade. Higher additions of pine oil improved recovery, but only at the expense of grade. A mathematical model of the objectives of an operating plant was formulated and optimum reagent conditions obtained.

Jan 1, 1977

By S. P. Singh

In order to understand the intricate nature of blast damage mechanism and to counter the associated problems, small scale blasting experiments were performed on hydrostone, concrete and granite. This was followed by a 2.4 m x 2.7 m (8'x 9') drifting operation in a quartzite quarry. Interior as well as exterior damage was assessed by different techniques. On the basis of the experimental results, the effect of explosive characteristics on the damage was examined.

Jan 1, 1992

By W. S. Weldon

The use of spiral separators for the beneficiation of fine coal typically in the size range -2+0.1mm is now well established process technology. Developments during the mid 1980's resulted in the production of cost effective, efficient large diameter coal spiral separators. Recent developments and research have been geared to optimize metallurgical performance, materials handling and equipment geometry of large diameter coal spiral separators.

Jan 1, 1997

By Robert L. Sundeen, Richard V. Wenberg

INTRODUCTION Early rock-bolting practice usually consisted of ran¬domly installing bolts, using hand-held drilling equip¬ment such as air-leg mounted sinkers or stopers. As bolting technology evolved, the practice of installing uniform bolt patterns was developed, utilizing random bolt installation as required within the uniform pattern. The uniform rock-bolting technique, when used as the principal method of rock support, requires drills and jumbos designed specifically for rock bolting. This equipment is similar to conventional face drilling machines, except that the jumbos can orient the drills to obtain any necessary bolting angle; often, this means bolts may be installed at or near perpendicular to the centerline of the drift or stope opening. Fig. I shows a typical rubber-tired rock-bolting jumbo of the type commonly used in drifts and room-and-pillar mining. Modern rock-bolting jumbos are capable of drilling the required holes, inserting rockbolts, and torquing them to proper levels. Jumbos also are available for use with resin-anchored bolts. Probably the most unusual of this type utilizes a rotating bolt turret that carries the rock drill, resin charging unit, and the bolt in a single mechanism. Once the turret is loaded with the resin and bolt, further manual effort is not re¬quired. Drilling and bolt placement are accomplished by the operator from a station remote from the bolt site. Fig. 2 shows this turret device. Roof-bolting jumbos are available mounted on rail, crawler, or rubber-tired chassis. Various types of rock drills are used. Depending upon the type of rock, these may include rotary, percussion, or rotary-percussion drills. Fig. 3 shows a typical rail-mounted jumbo. CONDITIONS INFLUENCING APPLICATION General Rock Conditions Rock-bolting generally is applicable in moderately hard to hard rock. No particular type of rock is ex-

Jan 1, 1982

By R. Flattery, Z. Agioutantis

Coal and rock pillar design is critical not only for mineral extraction but also for the safety of the mine operators. Pillar strength can be estimated through numerous empirical formulas that are available in the literature, which are typically based on a statistical analysis of case study data. The limitation of most of these equations is that they only considered the width to height ratio and in situ rock or coal strength for pillars in horizontal seams. The adoption of such equations to estimate pillar strength in inclined seams may overestimate the pillar strength and ultimately lead to a poor pillar design. This paper will discuss different techniques that can be used to estimate pillar strength in inclined seams as well as present preliminary modeling results for stress redistribution around inclined pillars. Factors in the parametric analysis include pillar shapes, geometry, and seam inclination.

Mar 2, 2022

By R. K. McLimans, C. Knudsen, S. Bernstein, D. Frei

Computer Controlled Scanning Electron Microscopy (CCSEM) is used to analyze indivdual mineral fractions in heavy mineral sands. CCSEM is a fully automated particle analysis technique for the determination of physical and chemical properties of a large number of individual particles. CCSEM enables the precise and accurate determination of the modal abundances of individual mineral fractions (e.g. ilmenite, rutile, zircon, or garnet), their average chemical composition (and compositional variation), as well as their physical properties such as size (e.g. diameter and perimeter length) and shape (aspect ratio and circularity). A unique sample preparation procedure is used to produce representative polished sections from cylinders of raw sand samples such that thousands of grains are present in a polished cross section, but grains are not touching. The combination of this sample preparation technique with CCSEM enables the fully automated analysis of individual grains without the application of de-agglomeration or erosion steps to separate touching particles. Hence, CCSEM yields information representative of the entire area of analyzed grains without systematic bias due to neglect of rim areas by de-agglomeration or erosion steps. Therefore, the resulting data are determined with high accuracy, precision and statistical validity. Because the sample preparation is relatively straightforward, using raw sand samples, and all chemical and physical properties are determined in one analytical session per sample, CCSEM is a powerful cost and time efficient tool for characterizing chemical and physical properties of minerals in heavy mineral sand deposits.

Jan 1, 2005

By D. Dodgen, L. Larrimore

Electric utilities depend heavily on coal as a major fuel source for power generation, annually producing more than 85 million tom of ash, boiler slag and FGD (flue gas desulfurization - "scrubber") materials as by-products. Utilities and others who bum coal have traditionally disposed of these by-products in ponds or landfills. However, in the last 10-15 years there has been a greatly increased emphasis on beneficial utilization of these materials by the producers themselves as well as by customers who purchase the by-products. Regulatory, cost and technical performance issues currently impact the use of coal ash and other coal combustion by-products (CCB).

Feb 24, 1997

By Gordon M. Pugh, David G. Rasmussen

INTRODUCTION Square-set timbering of stopes developed from stull support methods because veins too wide for stulling were being mined. In general, the void caused by the stoping of the ore is filled with a system of interlocking timbers. Timber framework supports the wall rock, the mining operations, and provides access. A timbered stoping method can be used in all widths of veins at any dip. The timbering can be normal and parallel to the planes of the walls or at angles to these planes. Irregularly shaped ore bodies can be worked by timbered methods. Pinching or swelling of the vein will not adversely affect the method. Timbered stoping is especially advanta¬geous where weak ground is encountered in the vein or the wall rock. The ground is unsupported only until timber sets are stood. These stopes can be filled with sand or waste when desirable. The customary method of developing a square-set timbered stope with haulage drifts above and below and timbered raises on each endline is shown in Fig. 1. The drifts are timbered the full stoping length. The raises have two compartments with the manway and timber slide in one compartment and the chute in the other. The drifts and the raises cannot be widely spaced as handling timbers is an important consideration. Stoping can begin immediately above the drift timber and continue in both directions and upward from the raise. Breasting down each blast round for only one timber set laterally is the common practice. The blasted ore falls to a lower floor where it is slushed or trammed to the chute. Drilling can proceed on the upper floor while broken ore is being removed from the stope. As shown in Fig. 2, square-set timbering may be used in cut-and-fill stopes to support the back and walls until fill is added. There are various ways of developing an ore block for timbered stoping. Fig. 3 depicts the situation for the main haulage in the vein with an intermediate drift separated from it by a sill pillar. The ore is slushed into the chute connecting the two drifts. The situation in Fig. 4 is identical to that in Fig. 3 except that no sill pillar is used. In Fig. 5, the haulage drift development is done in the footwall with crosscuts driven to intersect the ore body. The intermediate drift development is above the crosscuts with a minimal sill pillar. The main bottleneck in timbered stoping is in the timbering process. Drilling in the stope is generally held up while timbering is done. Two or three men are re¬quired to do the timbering and an additional one or two men are needed to transport and raise or lower the tim¬ber. Good organization is essential to timbering. Skill must be exercised in standing the timber to support the ground and still maintain good production. COSTS AND PRODUCTIVITIES Development and stoping costs are presented in Tables 1 through 7 for the situations in Figs. 3 and 5,

Jan 1, 1982

By R. Markovic

The objective of this research study was the investigation of heavy metal removal from wastewaters of the "SARAKA" stream by using low-cost materials. These wastewaters flow into Krivelj River and through the network of existing rivers into regional water reservoirs. Sawdust, cardboard and fly ash were used as reactive materials in laboratory studies. Sawdust was obtained from oak and fir-wood while fly ash from heating station Bor, bitter-oak and oak. Experiments were carried out using real Saraka stream wastewaters and the degree of removal for iron, copper, manganese and zinc was investigated. The content of these heavy metals in Saraka stream wastewaters was under the limit of III and IV class of water (Law on Water - Official Register of the Republic of Serbia). Parameters such as flow rate of water, pH and effluent volume, contact time between water and reactive material, etc, were monitored during the experiments. All used materials give satisfactory results for iron and other heavy metals removal; the highest degree of removal was obtained by using fly ash.

Jan 1, 2006

By J. R. Johanson

Many solids processes that look feasible on paper or even in pilot studies become disasters in full scale. Changes in solids flow characteristics from pilot scale to full scale because of larger so lids contact pressures, thermal shocks or unforeseen temperature excursions often cause full scale solids flow problems not encountered in the laboratory or pilot studies. Fortunately, proper applications of solids flow principals and solids flow property measurement at full scale conditions can anticipate the problems and thus provide an accurate basis for full scale design or existing plant modifications.

Jan 1, 1988

By A. K. Sinha

Research shows that continuous mining sections can normally produce around 950 tons per shift in a seam 5 or 6 ft. thick. The shuttle cars as well as the continuous haulage systems are able to match with the continuous miners in capacity. However, in practice both of the two systems seem to be averaging at around 450 to 500 tons per shift in production. Continuous haulage systems are preferred in thin seams particularly where the floor is soft.

Jan 1, 1981

By W. K. Collins, C. L. Dahlin, D. C. Dahlin, W. K. O’Connor, G. E. Rush

Direct mineral carbonation was investigated as a process to convert gaseous CO2, into a geologically stable final form. The process utilizes a slurry of water, with bicarbonate and salt additions, mixed with a mineral reactant, such as olivine (Mg2SiO4) or serpentine [Mg3Si2O5(OH)4]. Carbon dioxide is dissolved into this slurry, resulting in dissolution of the mineral and precipitation of magnesium carbonate (MgCO3). Optimum results were achieved using heat-pretreated serpentine feed material and a high partial pressure of CO2 (Pc02). Specific conditions include 155°C, PC02 = 185 atm and 15% solids. Under these conditions, a 78% conversion of the silicate to the carbonate was achieved in 30 minutes. Process mineralogy was utilized to investigate the appropriate feed characteristics, identify the process products and interpret the mineral dissolution and carbonate precipitation reaction paths. Key words: Mineral carbonation, Carbon dioxide sequestration, Carbonates

Jan 1, 2003