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By A. Sullivan

Success in mining demands the creative application of equipment, systems and processes to the unique needs of each mineral deposit, market and, though often overlooked, the culture of the individual business. In recent years, domestic coal mining companies have become more attentive to the contribution safety and loss control programs have on their financial results. Although most have adopted fairly conventional safety programs, some have created systems and processes tailored to their unique circumstances. While each coal mining business must consider the typical risks inherent to our industry, excellence in safety is most likely achieved when a safety program is customized to meet the needs of the individual business.

Jan 1, 2000

By Dwight R. Coles

The solving of complex metallurgical flowsheet calculations by hand is, at best, a tedious job which often proves that engineers, too, make mistakes. The high cost and long lead time associated with manual flowsheet solutions have led several organizations involved in research, development and construction of extractive metallurgical processes to search for computerized systems which will solve flowsheet calculations. Although design flowsheet programs have been developed by the chemical industry, the ability to solve flowsheets involving particulate solids is usually overlooked. A new computer applications system has been developed at Fluor Mining and Metals which has been designed to accommodate the type of design flowsheets required by the minerals industry. By employing the sequential modular computation technique, a library of metallurgical pro- cessing routines may' be accumulated which are used by a universal executive system. This technique enables rapid solution of new process) .flow- sheets with only a minimum of additional programming effort. The implementation of the FLEXMET flowsheet solution system is the subject of this paper. Some of the major features of the system which are examined include interactive input data handling, automated flowsheet calculation order arrangement, flexible accomodation of unit operations models and advanced management of recycle and specification control calculations.

Jan 1, 1982

By A. J. Abraham, K. E. Seitz, J. D. Humphrey

Caterpillar has led the way for sound reduction in off highway trucks (OHT) used for mining. In 2000 Caterpillar introduced the 793CXQ sound reduction OHT (Figure 4) to meet local noise level demands in the Hunter Valley near Sydney, Australia. The sound level of the mining equipment in the Hunter Valley is being reduced to pre-serve the quality of life for the residents of the area. To meet the levels established required a major redesign of the 793C, as a result the sound power level was reduced by 9 dB (A), which is a less than 1/8the original sound level.

Jan 1, 2004

By John R. Gaines

I am not a member of AIME, and this is my first annual meeting. As a lifelong member of the non-ferrous metals industry I have enjoyed listening today to speakers point with pride and view with alarm the public relations activity or lack thereof in the halls of government, as well as at the grass roots. There is much to be alarmed about, to be sure, but also some accomplish¬ments to be viewed with pride. Other speakers have given a broad overview of our industry's relations with their several publics. I will be specific about two incidents in which The Anaconda Company faced the loss of confidence of a large portion of its publics: the nationalization of our properties in Chile in 1971 and the closing of our under¬ground mines in Butte, which was announced last October. If I have a minute left over, I will speak about our concern for the loss of confidence in business institutions which has been re¬vealed in recent public opinion polls.

Jan 1, 1975

By Harold D. Taylor

Lognormal grade distributions are definitely the rule rather than the, exception in many types of deposits, including precious metals, uranium, and many others. The "normal theory" geostatistical techniques do not work well in these situations because the occasional high grade values, perhaps several orders of magnitude larger than the median, can overwhelm the rest of the data, resulting in variograms and Kriged estimates which are unrealistic or even ridiculous. Robust techniques for variogram modeling have been proposed, and truncation of high sample values can produce more reasonable Kriged estimates, but the technique of working with log transformed data appears to be the best method of handling lognormal data. This paper will discuss primarily the two parameter lognormal case, with some discussion of the three parameter lognormal, but no discussion of other methods of transforming data, such as disjunctive Kriging.

Jan 1, 1982

By Steve Kral

Not too many years ago, mining was in one of its cyclic down-sides. This forced mining companies into some innovative thinking to bring down the costs of production. And they have. Mining equipment and processing plants have become more efficient, mostly due to technological advances. The mining industry is now in a boom period, one that some analysts believe can sustain itself. But even with higher commodity prices, sky-rocketing energy costs and the costs associated with environmental and reclamation regulations have not allowed all mines to reach their full profitability potential.

Jan 1, 2006

By Albert W. Evans

Introduction Engineering Health and Safety is concerned with the understanding of the complex interplay between the risk of injury with technological ,environmental, individual, organisational and legal factors. With this understanding, the design and decision making processes can be balanced with the other objectives of industry and employment to arrive at solutions which place appropriate controls on technology and other aspects of human activities to prevent disease and injury to personnel in the coal mining industry and the design of safe production machinery and ancillary equipment. Advances in the detection and diagnosis of causes of diseases and the need for engineering health and safety in the coal mining industry has increased the need for appropriate education and training. Hazards arise in many forms; exposure to toxic chemicals, escape of radio - active materials, explosion of pressure vessels, contact with moving machinery, exposure to dust, environmental dangers such as excessive noise, high temperatures and manual handling etc. As technology advances, these dangers become more complex and less clearly defined and less easily perceived. Consequently, the ways of controlling the dangers also become more complex and wide ranging. The need to educate and train people in coal mining applications of engineering health and safety has been enhanced over the last five years and courses should be established to fulfil the need for competent people to deal with the problems which modern coal mining technology creates together with the legislation that governs engineering health and safety and to carry out research and development work in the coal mining industry. Industrial Involvement The engineering health and safety experts must be prepared to take a more active part in monitoring conditions that exist in the mining industry, and not design from information obtained from the mechanical, electrical and hydraulic expertise and off-the-shelf components from other industries. Surveying and control of the operating environment must be essentially the concern of the engineering health and safety experts and, whilst it is not possible to create a perfect environment for each machine, every effort must be made to minimise failures and hence plan for designs which will maximise

Jan 1, 1986

By W. J. Nelson

Detailed underground geologic map- ping at a scale of 1:1200 has been carried out at the Crown II Mine of Freeman United Coal Mining Company, which operates in the Herrin (No. 6) Coal Member. The roof sequence, upward from the coal, includes (1) soft, medium- to dark-gray shale; (2) hard, black, fissile shale; (3) argillaceous nodular-bedded limestone, and (4) fine-grained, shaly, water-bearing sandstone. The first unit is highly lenticular, and any or all may be missing at a given locality. The sand- stone has a sheet facies and a channel facies. The Herrin Coal is eroded in channels near the Crown II Mine. Structural features mapped at Crown II include normal and strike-slip faults of small displacement, "slips" and clay dikes, and limestone "bosses." Less stable roof and wet con- ditions are encountered where the limestone is thin or missing or where it is broken by natural fractures or by artificial openings that inter- sect the water-bearing strata above the limestone. Geologic mapping of the underground workings has allowed us to predict faults, fracture zones, and channels ahead of the face for this mine. Some lithologic and structural patterns apparently are random and cannot now be projected. Conventional exploratory drilling is entirely inadequate to map faults or lithology of the roof, but it does indicate the range of lithologic variability, which can be used to project needs for roof sup- ports. Drilling also is useful In locating channels and in mapping regional variation in thickness and facies of the sandstone.

Jan 1, 1980

By F. Stanley, A. Noble, G. Luttrell

"The supply chain for coal-fired power stations involve a multi-stage network of mining units, preparation plants, blending facilities and transportation systems. Attempts to optimize the supply chain have historically been difficult due to the lack of communication/coordination between the various groups involved in coal production, transportation and utilization. In light of this issue, a new approach for globally optimizing the coal supply chain called Micro-Price Optimization has been developed to simplify the optimization problem and to provide coal producers with fundamental insight needed to improve the profitability of their operations. This fundamental concept assigns unit values to each particles (or groups of particles) passing through production units. Optimization occurs whenever the maximum tonnage of positive value particles are recovered and passed to market, while the minimum tonnage of negative value particles are recovered. Elements considered by the concept include factors such as target boiler cost/efficiency, waste disposal costs, coal quality parameters, emission penalties, transportation charges, or other quantifiable impact factors. This article reviews the basis for the micro-price concept and provides a detailed industrial case study involving the determination of optimum coal qualities that need to be supplied by mine operators to feed a coal-fired power station. INTRODUCTION The performance of coal preparation plants have long been known to play an important role in determining the overall profitability of mining operations. This significance is due to the fact that the misplacement of just 1 ton/hr of clean coal to reject resulting from poor plant performance can represent nearly $300,000 per year in lost revenues for a mine producing a steam market coal (i.e., 1 ton/hr x $50/ton x 6,000 hr/yr = $300,000/yr). This loss can be even more pronounced, occasionally approaching $1 million per year for each 1 ton/hr of misplaced clean coal, for operations producing high-quality coking coal products sold into the premium metallurgical market (i.e., 1 ton/hr x $150/ton x 6,000 hr/yr = $900,000/yr). Detailed economic studies indicate that improvements in plant yield resulting from increases in organic efficiency have one of the largest overall impacts on mine revenue when compared to other cost centers within the mining operation. One of the first studies to show this important financial impact was reported by Norton-Hambleton Consultants (Norton, 1979). Their study indicated that an unfavorable change in plant efficiency was second only to coal transportation in terms of its impact on profitability, while an unfavorable change in the cost of underground mining was a distance third. This longstanding realization has continued to provide a strong financial incentive for coal producers to optimize the separation efficiency of their coal processing and blending operations."

Jan 1, 2015

By Gary W. Hausler

Bergbau AG Niederrhein, a subsidiary of Ruhrkohle AG; Essen, Germany, is working coal mines on both sides of the Rhine River. The Prosper Mine in the City of Bottrop has a production of about 13,000 tons per day and has been in operation since the turn of the century. Mining has moved to the north as coal deposits south of Bottrop are exhausted. To facilitate ventilation, material handling, and transportation new shafts are being constructed in the northern coal fields. The Prosper 10 shaft is being sunk to develop the Prosper - Haniel coal field which has reserves of 280 million tons. In October, 1976 Bergbau AG Niederrhein awarded the shaft sinking contract for the 1047 m deep, 8 m inside diameter Prosper 10 shaft to Gewerkschaft Walter; Essen, Germany. Construction costs will amount to about 40 million DM with construction completion scheduled for 1981. GEOLOGY The shaft, located near the town of Kirchhellen north Bottrop, is being sunk in the Grafenwalder Horst between two faults on the south west flank of the Kirchheller Anticline. 270 m of upper cretaceus sands and marls overlay sandstone bedrock at the shaft location. The upper 124 m of this section contain highly saturated sands interspersed with marl. In order to successfully sink the shaft through this section, ground stabilization by freezing was used.

Jan 1, 1979

By S. J. Jung

The stability of underground openings for deep mines is critical, since incorrect orientation or geometry of shaft, stope, and accessways often results in the failure of openings due to high stress concentrations. Current state-of-the-art procedures for the design of underground openings are largely based on rules of thumb, experience, and trial and error. Rules of thumb are invariably based on the past experience of the designer and may not remain optimal as the depth and complexity of mine workings increase. Often, as conditions change, and as the interaction between geology, in-situ stress conditions, and mine openings grows more complex, the cost of maintaining structural integrity becomes prohibitive. Existing design procedures for deep mines are rapidly becoming inadequate as mines are worked at greater depths. For example, in the Coeur d' Alene Mining District, several million dollars are spent for inspection, repair, and maintenance on a regular schedule, largely as a result of inadequate design. In these types of situations, it is of critical importance that a new design methodology be developed for the layout and design of underground openings.

Jan 1, 1994

This paper presents a virtual prototype for the stress analysis of cable shovel components based on combination of flexible and rigid body approach. The general mechanical system of the cable shovel is modeled as a multi-body system with rigid and flexible bodies. The relevant theories applied for the dynamic model are described in terms of Lagrangian multi-body dynamics and finite element method. A virtual prototype of the cable shovel is built in the Automatic Dynamic Analysis Mechanical System (ADAMS) environment, which allows visualizing the motion of general mechanical system and analyzing the dynamic stress of structural components of the cable shovel. An example is given to perform dynamic stress of durability analysis for the boom and handle. Attention of this study is devoted to the mechanisms of damage of the cable shovel and also the critical high stress areas. Keywords: Cable shovel, Von Mises stress, Virtual prototype simulation, Stress virtualization.

Jan 1, 2009

By P. C. Thakur

Frictional ignitions (also called face ignitions) is defined as the rapid oxidation of a mixture of methane and air with a visible flame that could last from a few seconds to several minutes. These ignitions have a potential to turn into a mine explosion and eventually a large-scale mine fire. Over the last 22 years, U.S. coalmines have had 1566 frictional ignitions. There were no fatalities but serious injuries have occurred. Every effort, therefore, should be made to prevent frictional ignitions. The preventative measures fall under four categories: (a) degasification of coal seams prior to mining, (b) adequate ventilation, (c) wet cutting or water-jet assisted cutting and (d) machine design to minimize ignitions. The paper discusses each of these techniques in detail.

Jan 1, 2006

By M. J. Farrell

Mining is a significant emitter of greenhouse gases and is the focus of increasing attention from green groups and regulators. Miners need to know their own carbon emissions and how they compare with the rest of the industry. Miners and mining companies need to know where they fit in the emissions curve. Who is in the bottom quartile? This article is based on research report data from minecost.com and Metalytics Pty Ltd which detail the specific carbon dioxide emissions for 208mines producing 90% or more of western world copper, zinc, lead and nickel in 2007. The copper and nickel mines also include Norilsk in Russia, KGHM in Poland and Kazakhmys in Kazakhstan. This is the first time that such information has become available.

Jan 1, 2009

By A. Eccles

Phase designs are the foundation upon which all open pit mine sequence optimizations and budgets should be built. Unfortunately, at times, mine engineers skip the step of developing realistic pit phase designs - designs that include access ramps and mineable widths. Without mineable phase designs, their optimized schedules are based on theoretical pit shells or ?quick-and-dirty? plans with no ramps. The output from such optimizations is almost always overly optimistic. Without mineable designs, the production estimates are misleading, because they overestimate ore, and underestimate waste stripping requirements. Worse yet, when plans are not based on realistic phase designs, they can point to exactly the wrong decision in feasibility studies (i.e. ?go? when it should be ?no-go?). This paper discusses the importance and features of good pit phase design, and demonstrates the pitfalls of relying on optimized production sequences that are not based on properly designed pit phases.

Feb 27, 2013

By William E. Hole

The sand and gravel industry provides an enormous quantity of materials vital to the maintenance of low-cost construction. There has been little effort to conserve this valuable natural resource. In fact, existing regulations which affect sand and gravel operations act more to waste these materials than to conserve them. Another factor affecting the industry is new legislation requiring the reclamation of worked-out pits. Although such legislation creates many administrative headaches for a sand and gravel operator, there exists the possibility through such legislation of gaining some conservation measures that could be helpful to the industry.

Jan 1, 1974

By Hal McVey

"Philosophy" addresses the definition and assigning of importance to the marketing of by-products. Two examples, one in metals and the other in industrial minerals, explore prime product to by-product relationships. Relative revenues from all products illustrate the importance of by-products to economic feasibility. "Mechanics" takes a broad view of the types of marketing organizations that are applicable to individual circumstances in the marketplace. In-house marketing as well as agents, merchants and trading companies are outlined and discussed. Philosophy Definition Of Terms Philosophy Definition Of Terms The definition of terns for a paper such as this is generally a necessary but not-very-interesting exercise. However, in simply trying to clearly define the term "by-product" some interesting relationships between products arise and the line of demarcation between "product" and "by-product" often becomes obscure. The search for that distinction represents the philosophy portion of the title. A couple of definitions of philosophy can even help to set the tone for what follows. According to Webster, philosophy is : 1 Pursuit of wisdom. 2. A search for a general understanding of values and reality.

Jan 1, 1983

By D. R. Bomberger

An automatic microscope has been developed to .measure the size and populations of macerals and minerals in fine coal particles. Differentiations are made on the basis of reflectance. This study is concerned with the size distribution of pyrite inclusions. Most fine coal cleaning processes do not remove pyrite as completely as a straight density separation. Consideration of the pyrite size distribution is suggested as a more accurate method of predicting sulfur reduction by a cleaning process. Analyses of float-sink results and Deister Table operation in terms of pyrite particle sizes are made. Other potential applications of automatic microscopy are also discussed.

Jan 1, 1963

By Robert M. Cox

The principal factor that must be determined for the effective design of a coal mine roof bolt support system is the maximum stable tension that can be developed with a given bolt assembly in a particular roof rock. There are four basic types of roof bolt anchorage techniques available: (I) the splitwedge; (2) mechanical expansion units; (3) resin point anchors or grouted expansion units; and (4) the cone shell which is placed in a reamed hole. A study of this problem has been made which includes theoretical analyses, laboratory experiments and field tests. A static free-body analysis of each of the anchorage techniques has provided formulas for predicting the anchorage capacity for a particular rock from the results of standard pull tests. The formulas also provide an insight into the anchorage mechanism of technique and allow for a comparative evaluation of the methods for design purposes. The theoretical analyses also indicate clearly the pertinent variables affecting the anchorage mechanism of each method.

Jan 1, 1977

By William F. Riggs

The characteristics of frothers can often be determined by the proper selection of various chemical groups. There are three basic groups utilized in the application of frothers. These are alcohols, polyglycol ethers, and polyglycols. Some of the chemical groups are separated in subgroups. Each chemical group provides particular characteristics which affect load support, bubble diameter, water retention, air dispersion, and kinetics of froth formation. These chemical groups may be preblended in various percentages to optimize frother characteristics for a particular ore deposit.

Jan 1, 1986