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By A. Broussaud, J. D. McKay

Benefits analysis of adaptive Expert control systems operating at plants in Africa and the United States are presented. Proper statistical tools and techniques are discussed. Technical and practical pitfalls of strategy comparison are also presented and illustrated with from published data. Advantages and disadvantages of a “Pay for Performance” approach to a project are reviewed.

Jan 1, 2001

By Zhenqi Cai, Mike Lichte, Kimberly Kennedy

The Ohio River Tunnel is the first of three combined sewer overflow tunnels to be constructed under Allegheny County Sanitary Authority's Clean Water Plan. The project consists of a total of approximately 5.5 miles of 18-ft and 14-ft finished diameter, segmentally lined deep rock tunnels and smaller diameter dewater and flow connector tunnels, as well as 8 deep flow drop and access shafts varying from 25-ft to 70-ft in finished diameter and 130-ft to 170-ft in depth. This paper describes the project components and the primary engineering challenges faced during design, including tunnel alignments and shaft site optimization with tight right-of-way constraints and multiple railroad and highway crossings. Assessment of tunneling methodology as well as tunnel and shaft designs and constructability included overcoming 5-bar hydrostatic pressure, abrasive bedrock, and the selection of the appropriate support of excavation systems in high-permeability alluvial soils adjacent to the Ohio River.

Jun 23, 2024

By M. Allan Holtz

The shipment of coal, ores, and minerals in bulk form during the winter months presents a difficult problem in emptying rail cars. U. S. Steel Research in cooperation with U. S. Steel Coal Operations bas laboratory tested and field monitored the effectiveness of using freeze conditioning agents (FCA) to minimize the frozen coal problem. This report examines, in an overview manner, our experience after four seasons of treatment using different FCA agents on raw and preparation plant products. Our observations indicate that if an FCA is applied correctly it is effective mineral to mineral. Freezing problems still occur at the interface between the coal and the metal of the car sides and bottoms. Leading chemical suppliers have made positive improvements in their FCA formulations with second and third generation products. Further advances are needed to make chemical treatment for the prevention of frozen coal a real full-proof method.

Jan 1, 1980

By S. B. Patton, T. Novak, R. L. Sanford

A comprehensive approach to the development and organization of an expert system designed to assist electricians in diagnosing electrical faults in mining machinery is discussed. The system includes diagnostic, reference, and tutorial programs. The diagnostic portion of the system is based on a causal-reasoning approach, which is used to establish a hierarchy of symptoms and the subsequent production rules for identifying component-level failures in the motor-control circuit of a shuttle car. With this approach, conclusions are developed directly from knowledge of the circuit and its behavior (in both working and failure modes) based on first principles, rather than the heuristics of a domain expert. The symptoms and their hierarchal structure are formulated by creating "what if' scenarios and performing a qualitative circuit analysis for each fault. Techniques for incorporating interactive graphical displays of the circuit schematic into the diagnostic portion of the system are also presented. Supportive computer programs that provide reference material and tutorials on the circuit are also described.

Jan 1, 1990

By H. X. Li, A. Correa, M. M. Zhang, W. Xuan, M. Andrade

"With increasing demand for steel and depletion of high-grade iron ore deposits, more research efforts are being directed toward extending the life of existing ore reserves and developing technology to treat low-grade iron ore resources. Among all the reported technologies, biotechnologies in mineral processing – specifically bioleaching and microbially induced flotation – have emerged to be considered as low-cost, environmentally friendly potential alternatives to many of the current mineral processing techniques. This paper provides a comprehensive review of current research on the use of microorganisms for iron ore beneficiation and, further, discusses the applicability of bioleaching, bioflotation and bioflocculation for the beneficiation of low-grade iron ores.IntroductionIncreasing global demand for raw materials has led to diminishing resources of high-grade iron ore. As a result, the mining and utilization of low-grade hematite, limonite, specularite, siderite and goethite ores have attracted more and more attention. However, these types of iron ores are of complex paragenesis and fine disseminated grain size, and often contaminated by phosphorus in the form of solid solution. The distribution of phosphorus throughout the iron mineral crystals prevents the effective use of physical separation techniques, and these complex ores are at present largely untapped due to a lack of cost-effective and efficient processing methods. Chemical leaching and roasting-magnetic separation approaches have been mainly tested only on the laboratory scale and are all either cost prohibitive or ineffective when used on low-grade complex iron ores."

Jan 1, 2015

By T. E. Breaux

Repair of large rotating apparatus such as ball mills is uncommon but under certain circumstances is achievable. This paper describes the successful repair of trunion on a 14 foot diameter by 20 foot long ball mill. Diagrams of the repair are included for visual perspective and non-destructive test procedures are outlined.

Jan 1, 1988

By Abhishek Kumar, T. G. Sitharam, Surender Singh

The height of tailings pond (TP) embankments is frequently raised to accommodate the ever-increasing volume of tailings released by the mining industries. Excess pore water pressure (EPWP) may develop during the height-raising operations, which can affect the overall stability of TP. This article presents a detailed stability analysis for the embankments of an existing TP, the height of which was increased twice utilizing downstream (D/S) and upstream (U/S) construction techniques. A rigorous two-dimensional transient fully coupled-stress-pore pressure analysis is performed in the finite element-based package RS2 to examine the build-up of EPWP during different stages of construction. Furthermore, an attempt is made to investigate the feasibility of future height raising, with due consideration given to the influence of embankment raising rates. Results from the analysis show a development of higher EPWP within the tailings deposit in comparison to the embankments of TP, indicating the development of an undrained-like condition. The study further reveals that the development of EPWP is highly affected by the rate at which embankments of TP are being raised. A higher rate of embankment-raising results in the development of greater EPWP in comparison to a lower embankment-raising rate, which may lead to the ultimate collapse of TP. Furthermore, based on the stability analysis, the height of existing TP can be further raised by 4 m (two lifts of 2 m height) utilizing the U/S construction technique. A thorough cost and benefit analyses are however required before implementing the results of the current analysis since the storage capacity of TP is reduced while raising by the U/S method.

May 16, 2023

By S. Simske, K. Boakye, D. Winters

The application of digitization to operations and logistics is commonplace. From advanced data analytics to intelligent networks, digitization offers tremendous opportunities to create value, raise the efficiency of production processes, and reduce emissions. Several manufacturing industries have already implemented solutions to good effect by using digitization. Mining companies, for example, are using historical data about equipment health to predict potential failures, while aeronautics and automotive companies are using robotics and end-to-end digital twins to improve their design and production processes. Not surprisingly, first adopters of digitization in many industries have gained an edge over their competition. The cement and aggregate industry can better manage the enormous energy consumption, rising cost challenges, inefficient uses of raw material, logistic problems, emissions, and overall process complexity that are inherent in their operations by doing the same. This paper presents the results of a literature review and analysis and conveys the challenges for adaptation and implementation of digitization and artificial intelligence (AI) in the cement and aggregate production industry.

Mar 2, 2022

By G. M. Clarke

Minerals are certainly where they are found. The undemocratic distribution of the world's mineral wealth has created an incongruous inbalance: mineral-rich, scarcely populated countries supply highly-populated industrialised countries that in turn consume more minerals than they produce. This has been as much a generating force for colonisation, invasion, and war as religion, political ideals, or megalomania. The Industrial Revolution of the seventeenth century was born in Britain, a country with large domestic resources of coal, iron, lead, zinc, copper, tin, etc., as well as a large population. As consumption outstripped production imports filled the gap, particularly from its worldwide colonies. For example, when Canada was founded in 1867 more than 905 of its investments were British financed, and much of these were mineral-based. The British made similar investments in South East Asia, Australasia, the Caribbean, and elsewhere, as did the other industrialised Western European countries hungry for raw materials. Later the United States emerged as a leading industrial power, again due largely to its abundant natural resources. Consumption soon exceeded production and foreign sources were saught. American business went exploring abroad ant many a mineral resource was developed almost totally on the basis of the US market many .thousands of miles away. Closer to home, Canada was also an obvious target for the US with its rich mineral resource base, small population, and geographical juxtaposition, so much so that about the time of the 1914-18 War the US took over from Britain as the major investor in Canada, and this peaked in 1967 when the US accounted for 80% of the country's foreign investment. After the 1939-45 War Japan joined the ranks of the USA and Western Europe as industrialised powers, and they too searched the world for the deposits lacking in their homeland.

Jan 1, 1981

By Yi Yang, CHENGLONG XU, HAORAN LI, YALI FENG, JINRONG JU

This study presents a method for recovering valuable metals and synthesizing anhydrite from steel slag using sulfuric acid leaching and solvent extraction. The process achieved high leaching efficiencies for V, Ti, Fe, and Mg, and produced anhydrite with 93.09% purity. The leachate was further processed to separate and recover V, Ti, Fe, and Mg using selective stripping and precipitation methods, offering a sustainable approach to steel slag utilization.

Jan 22, 2022

By P. H. S. W. Kulatilake

The presence of discontinuities strongly affects the mechanical and hydraulic behavior of rock masses. Joint geometry networks play a vital role in civil, mining, and petroleum engineering projects associated with jointed rock. The need for a realistic representation of joint geometry in rock masses has been recognized. The first part of the paper shows how to build three-dimensional stochastic joint network schemes and also shows how to perform validation studies for these schemes using joint data from the Stripa mine, Sweden. Due to the existence of complex joint patterns, mechanical behavior of jointed rock masses usually exhibit scale effects and an-isotropic properties. A correct understanding of the mechanical properties (strength and deformability) of jointed rock masses is important for designing and performance estimation of structures build in and on rock masses. Beyond a certain volume, the mass proper-ties of the rock may remain essentially constant with respect to the effect of joints. This minimum volume may be used as the element size to represent the equivalent properties of a statistically homogeneous rock mass volume which contains a significant number of joints. This volume may be termed as a "Representative Elementary Volume" (REV) and may be of great importance for engineering purposes. Investigations are underway at both the 2D and 3D levels to look into the possibility of establishing relationships between REV mechanical properties and joint geometry parameters. Recently developed joint geometry modeling schemes are linked with existing distinct element codes (both 2D and 3D) to create a stochastic/deterministic stress analysis approach in achieving the goal. Results obtained so far in this direction are presented in the second part of the paper.

Jan 1, 1992

By Elizabeth Anne Semon

The marketability of a large volume bulk material is significantly effected by transportation costs. Hence, it is essential for anyone that deals with minerals or mineral wastes to be able to reliably estimate bulk transport costs. The three types of bulk overland transportation modes that will be discussed are truck, railroad, and pipeline. Contract and private carriage are the two types of truck transport generally suitable for movement of bulk commodities. Contract carriers are those transportation firms that service a limited number of shippers and geographic points, and carry a restricted number of commodities. Private carriage consists of control over drivers and equipment by the shipper, ownership or lease of the transport equipment, and shipment of commodities related to the primary business of the shipper.1 A combination of private and contract carriage may also be used. Depending on the size and regularity of the shipment, rail offers single car, multiple car, or unit train service to move bulk minerals. Both long and short distance pipeline transportation has been shown economically and technically feasible for many different solids such as, mine and quarry products, coal, chemicals, copper concentrates, phosphate rock, and sewage sludge. 2

Jan 1, 1973

By M. J. Sapko

The design requirements for mine ventilation seals have undergone a radical transformation in recent years, and these revisions have greatly increased the cost of the seal designs and their construction. For example, in the past two years, new federal regulations have increased the minimum design requirement to withstand explosion pressures from 138 kPa (20 psig) to 345 kPa (50 psig) or 827 kPa (120 psig), depending on whether the sealed mine volume is monitored continuously or not. Moreover, there is still a possibility that under certain conditions (such as detonations) even higher pressure requirements may be necessary. The ability of a monolithic, stand-alone mine seal to reliably withstand the full range of current and future pressures is becoming increasingly difficult and expensive. In an effort to develop a practical alternative, the West Virginia Office of Miners? Health Safety and Training (WVOMHST) and the National Institute for Occupational Safety and Health (NIOSH) have collaborated in a research effort to develop a practical, economic, and safe mine sealing technique that can enable mines seals to meet the full range of new explosion pressure design requirements. The basic idea is to use a barrier of common mine gob and rubble in combination with a conventional mine seal so that the pressure resulting from a gas explosion is reflected, absorbed, and attenuated, so the pressure on the ventilation seal is reduced. This paper discusses some concepts and preliminary test results for a ?Passive Mine Blast Attenuator? (PMBA) that can provide a useful alternative to increasingly larger and stronger stand-alone mine seals. Numerical models and full-scale experiments conducted at the NIOSH Lake Lynn Laboratory Experimental Mine (LLEM) show that the use of a PMBA can signficantly reduce the blast pressure and impulse on conventional ventilation seals. DISCLAIMER: This information is distributed solely for the purpose of pre-dissemination peer review under applicable information quality guidelines. It has not been formally disseminated by the National Institute for Occupational Safety and Health (NIOSH). It does not represent and should not be construed to represent any agency determination or policy.

Jan 1, 2009

By K. L. Hanning

Grinding and classification circuits at Climax Molybdenum Co. are described. Since the installation of a direct digital control computer in 1974, a number of control strategies were developed and evaluated. This paper deals in particular with the practical experience and results obtained in direct digital control of a wet grinding circuit consisting of a ball mill, constant speed sump pump, and hydrocyclones. For this circuit throughput is maximized, while maintaining a desired product size. Product size is inferred from measurement of operating variables.

Jan 1, 1977

By Martin Langenderfer, Catherine Johnson, Alexander Douglas

Mine haul roads degrade rapidly due to extreme loads on suboptimal construction materials. Unmanned aerial vehicles (UAV) are suited to quantify large-area road-network conditions, such as surface roughness, defects and grade to optimize remediation of poor conditions and reduce overall costs. Mine haul roads present unique challenges, such as material type and edge characteristics, to automatic road detection that often fails, requiring manual road input. This research work proposes a new method using the road center determined by the principal curve of a haul truck’s path. Analysis grids were created from this center line. A dense point cloud from UAV photogrammetry was generated and multiple linear regression analysis was conducted on each individual grid. The root-mean-square error in each grid indicates the surface roughness, and the change of slope between grids indicates the road grade inconsistencies. This method was applied to 26 road sections, and the results were validated by images taken from the truck operator’s vantage point. Critical defects were identified including excessive pothole formation, corrugation, depressions retaining water, and narrowing of travel lane. The results demonstrate this is a valid method of road identification and quantification of road defects at a mine site.

Apr 1, 2024

By Robert W. Lawson

INTRODUCTION The two basic types of mine-air compressors are the positive-displacement compressors and the dynamic compressors. Positive-displacement compressors con¬fine successive volumes of air within a closed space and increase the pressure by reducing the volume of that space. Reciprocating and rotary compressors operate on this principle. Dynamic compressors utilize an impeller to acceler¬ate the air, with the increased air velocity converted to pressure through a stationary diffuser. Centrifugal compressors and turbocompressors operate on this principle. Reciprocating Compressors Reciprocating compressors include both single-stage and multistage units. For mine service the most com¬mon is the two-stage intercooled compressor having an atmospheric pressure intake and a discharge pressure of 689 to 861 kPa (100 to 125 psi). The cylinders of a reciprocating compressor may be either single acting or double acting. In the single-acting cylinder, compression occurs on only one side of the piston, while, in double¬acting cylinders, compression occurs on both sides of the piston. Fig. 1 shows a cross-sectional view of a typical two-stage double-acting water-cooled reciprocat¬ing compressor. Fig. 2 illustrates the sequence of opera¬tions occurring in the cylinder of a reciprocating com¬pressor. Most modern mine compressors are double acting and are driven by electric motors. Induction motors are used on low-powered compressors, and synchronous motors are used on larger compressors. Steam-driven compressors once were common and still are applied where a reliable source of low-cost steam is available. For this type of compressor, steam is a desirable power source since a governor that senses the discharge pres¬sure can be used to control the steam inlet. This can be used to regulate the compressor speed to compress only air sufficient to meet the mine's requirements (up to the capacity of the unit). Unlike a constant-speed electric¬driven compressor, no other regulation is required for the cylinders of a steam-driven unit. Rotary Compressors Rotary compressors include sliding-vane, liquid¬piston, two-impeller straight-lobe or cycloidal, and helical-lobe units. Each of these has specific advantages and applications. Of these, the helical-lobe or "screw" compressor has the greatest application for supplying "100-lb air" [689 kPa (100 psi) ] to small- and medium¬size underground mines. Fig. 3 illustrates the operation of a sliding-vane compressor. Fig. 4 illustrates the operation of a helical lobe or screw compressor. Fig. 5 illustrates the operation of a two-impeller straight-lobe compressor. Fig. 6 illustrates the operation of a liquid¬piston compressor. Centrifugal Compressors Centrifugal compressors deliver 0.94 m3/s (2000 cfm) or more of air, and they are best suited to supply¬ing large volumes of compressed air for base loads. The efficiency of a centrifugal compressor declines rapidly when its operation deviates from its design point. If the power cost is not a critical consideration, a centrif¬ugal compressor is attractive as a result of the low initial and installation costs and the high degree of reliability. Fig. 7 illustrates a typical four-stage centrif¬ugal compressor, and Fig. 8 is a cross section of this type of unit. COMPRESSOR SELECTION The process of selecting a compressor requires sev¬eral considerations, including the capacity, the control system, the location, the power supply, and the cooling provisions. Compressor Capacity To determine the required capacity, the total air quantity and pressure requirements must be calculated. The air consumption of various tools, as listed in Table 1, must be included in this calculation. Some of the other considerations include: 1) The correction factor for altitude, as listed in Table 2, must be included in the calculation. While pneumatic tools require additional compressed air as the altitude increases, the compressor produces less. 2) A correction factor must be incorporated for the use of multiple tools. Table 3 lists appropriate correc¬tion factors for rock drills.

Jan 1, 1982

By R. B. Elver

The level of steel consumption per capita is one of the principal indicators of a country's standard of living. It is no coincidence that the materially advanced nations possess viable iron and steel industries to provide a reliable and economic source of steal for the manufacturing industries. No other metal is as dominantly important in manufacturing as steel. The blast furnace - steel furnace complex based on coking coal, ferrous scrap and iron ore - continues to be the principal steel-producing method. Less important is the electric furnace method based on scrap, In recent years, there has been considerable interest in the many direct reduction processes that are not dependent on coking coal but usually produce a product for further refining in steel furnaces. No matter which series of processes are used, iron ore is essentially the only source of virgin iron units. Thus, to such a vital and capital-intense industry as steel, access to a relatively inexpensive, long- term supply of iron ore is essential.

Jan 1, 1964

By L. Yan, D. Yantek

Federal regulations require refuge alternatives in underground coal mines to sustain life for 96 h while maintaining an apparent temperature below 35 °C (95 °F). Research by the U.S. National Institute for Occupational Safety and Health (NIOSH) has shown that heat and humidity buildup is a major concern with refuge alternatives because they have limited ability to dissipate heat, and high internal air temperature and relative humidity (RH) may expose occupants to heat stress. The heat transfer process within and surrounding a refuge alternative is complex and not easily defined, analytically or experimentally. To investigate heat and humidity buildup in refuge alternatives, NIOSH conducted multiple in-mine, 96-h tests on a 10-person tent-type refuge alternative, a 23-person tent-type refuge alternative and a six-person metal-type refuge alternative. The results show that when moisture was introduced to represent perspiration and respiration from miners (wet tests), the average temperature at midheight increased by 10.5 °C (18.9 °F) and the RH approached 88 percent for the 10-person tent-type refuge alternative; the average temperature at midheight increased by 9.4 °C (16.9 °F) and the RH approached 94 percent for the 23-person tent-type refuge alternative; and the average temperature at midheight increased by 7.7 °C (13.9 °F) and the RH approached 95 percent for the sixperson metal-type refuge alternative. For the dry tests, where no moisture was introduced, the average internal temperature increased by 12.6 °C (22.7 °F) for the 10-person tent-type refuge alternative, by 10.3 °C (18.5 °F) for the 23-person tent-type refuge alternative and by 8.4 °C (15.1 °F) for the six-person metal-type refuge alternative. These results may provide refuge alternative manufacturers and mine operators with guidelines and considerations for evaluating temperature profiles for portable refuge alternatives. The information may then be used to make decisions on occupancy ratings and heat mitigation strategies based on the thermal environment in which the refuge alternatives will be installed.

Jan 10, 2018

By Lynn B. Hales, Randy A. Ynchausti

Expert supervisory control strategies have been used for many years to improve operating revenues in comminution circuits. Typical improvements in capacity range from four to eight percent. Several case studies of results will be presented as well as a general discussion of the technologies used to achieve the improvements. Crushing. SAG milling and ball milling circuits will be discussed.

Jan 1, 1997

By C. Okrusch, C. Roos, M. Akers, S. Rosenthal

Modern mining consistently faces controversy. Public sentiment impacts the permitting and development of mines, so a quality public relations (PR) program for mining companies may improve society’s impression of the mining industry. Developing mines face more permitting challenges than operating mines, which stems from a lack of societal trust given the history of mining and its impact on the environment. Two case studies were selected based on the type of public controversy they face to demonstrate how pervasive permitting issues are in industry. Both Pebble Mine, owned by Northern Dynasty Minerals (NDM), and Black Butte, owned by Sandfire Resources America Inc (SRA), experienced difficulties with their water permitting due to potential risks their mine developments posed to local fish populations. Pebble has, to date, failed in all of their attempts to become permitted due to concern for the water and the fish. Black Butte dealt with the same problems, on a smaller scale, but was able to become permitted. These two mines will be discussed in detail including local history, mine setting, mining history in America, prevalent culture groups, technology development, and intercultural communication competence (ICC). The mining industry needs to evaluate its ICC skills since ICC directly determines the effectiveness of PR. Based on Barna’s Stumbling Blocks for intercultural communication, methods for improving the mining industry’s PR will be suggested in the hope of easing the permitting process for future mines by developing ICC.

Mar 2, 2022