Search Documents

By Ralph Bernstein

The processing of earth observation sensor data by digital technology is almost two decades old. Only recently, however, has this technology become practical and economical. The reasons for this are interesting to analyze, and they provide some insight into what the future may bring. Some of the earlier activities and their limitations, current systems and their applications, and future technology direction are summarized.

Jan 1, 1979

By D. K. Dysinger

The U.S. Bureau of Mines investigated leaching of chalcopyrite with sulfuric acid-oxygen under conditions anticipated during in situ leaching. A central composite experimental design was chosen to study oxygen pressures of 150, 300, and 450 psi, leach temperatures of 35?, 65°, and 95° C, oxygen-to-chalcopyrite mass ratios of 0.5, 1.0, and 1.5, leach times of 8, 16, and 24 hours, initial acid strengths of 0.6, 1.2, and 1.8 g H2SO4/g chalcopyrite and pyrite to chalcopyrite mass ratios of 0, 1, and 2. The leaching kinetics were consistent with the shrinking core model. A quadratic response surface model was used to determine linear and interaction effects of the design factors on rate constants from Arrhenius correlations.

Jan 1, 1993

By Thomas Kuhn, Carsten Ruehlemann, Christina Heller, Anna Wegorzewski

The commercial extraction of metals from manganese nodules on an industrial scale requires more than 50% of the investment necessary to realize manganese nodule mining. This is mainly due to the fact that a completely new metallurgical processing scheme for the extraction of both base metals (Ni, Cu, Co) and high-tech metals (Mo, Li, Ga) has to be developed and upgraded to industrial scale. There are a number of conventional processing technologies that combine hydro- and pyro-metallurgical approaches such as the INCO and CUPRION processes which have been developed in the 1970s and 1980s. Today, new approaches based on selective leaching with chelating agents and bioleaching try to minimize energy consumption and waste production. All of these extraction methods require knowledge how the metals are structurally bound in the manganese oxides. In this contribution we will review the current knowledge about the mineralogy of iron and manganese minerals in the different marine oxide deposits, present our results, and discuss the possible consequences for metal extraction.

Sep 1, 2014

By S. Frimpong

Cable shovels are used for primary excavation in in-situ and/or pre-fragmented formations in surface mining operations. Poorly fragmented hard rock formations and random occurrence of hard boulders in soft formations cause extreme variability of material diggability, resulting in varying shovel stress loading. The stress loading of a shovel’s front-end assembly could result in fatigue failure. Conventional design process, which uses physical shovel simulation studies, is very costly and time consuming for achieving statistically significant results. In this paper, rigid and flexible multi-body dynamic theories are used to develop component stress loading and deformation models of the cable shovel, and solved in the ADAMS/NASTRAN/FLEX environments. Detailed simulation experiments are carried out to examine the performance, reliability, durability and efficiency of the P&H 4100A under varying in-situ formation conditions. The results show areas of high stress fields with a maximum stress of 313.31 MPa at node 441 within the hoist rope. The reliability of the results is confirmed by comparing existing test data. The study is significant because it provides a solid foundation for further study of failure life analysis of the cable shovel components.

Jan 1, 2007

By Tony S. Calayag

Throughout the mining industry today, new bearing materials - ZA* high-performance zinc-aluminum alloys - are reducing costs of maintaining and rebuilding a wide range of equipment. As replacements for bronze bearings, installed in original equipment at the plant or during maintenance and repair operations in the field, the zinc alloys frequently provide better or equal performance at lower cost. The ZA Alloys The ZA alloys are a family of three high-performance zinc-aluminum alloys that compete in cost and performance with cast iron aluminum and bronze. The growing number and uses testifies to the versatility of these alloys and is encouraging their consideration in a wider range of applications. The ZA alloys are referred to as ZA-8, ZA-12, and ZA-27, the numbers corresponding approximately to the percentage of aluminum each alloy contains. ZA-8 is a permanent-mold casting alloy and is usually selected for decorative purposes; ZA-12 provides both performance and cosmetic benefits; ZA-27 offers the greatest functional strength. The term high performance ZA alloys distinguishes them and their improved engineering properties from traditional zinc die casting alloys. Maintenance Savings At its mine in Timmins, Ontario, Kidd Creek Mines Ltd. operates over 40 Joy VCR- 150 crawler-mounted air-powered rock drills. Most of the drill components undergo severe stress as the drill batters through the under-ground rock. As the components wear, the drill bits wobble; when the wobble becomes excessive, the drills are rebuilt. In the gear train, which rotates the drill steel, there are three planetary gears with - historically - bronze bushings. Since the planetary gear bushings are wear items, they are routinely replaced during overhaul. The bronze planetary gear bushings (three bushings per assembly) were replaced up to five times annually. With 43 drills in use, bushing consumption approached 600 per year. At the manufacturer's replacement part cost, the 600 bushings and gears would cost more than $20,000 a year. Even though a major saving was achieved by having the bronze bushings manufactured locally, the 600-unit annual usage provided ample incentive to investigate other ways of lengthening drill life and reducing the part costs. One approach was to consider using a bushing material that offered good bearing properties, but was lower in cost. About three years ago, ZA-12 zinc-aluminum casting alloy, costing less than half as much as bronze, was evaluated and selected for testing. One hundred ZA bushings were manufactured and placed in service as the drills came in for rebuilding. At the next rebuild the "drill doctor" (drill maintenance mechanic) noticed that, although the bronze bushings were completely destroyed, on occasion the zinc alloy bushings were not. In addition, he noted that some of the ZA bushings showed less wear than the bronze bushings. Because the bushings were changed routinely during each overhaul, the actual operating life of each bushing was not determinable. Therefore, it was not possible to statistically compare the life of the ZA bushing against the bronze. However, the desired life of the part was from overhaul to overhaul. So the ZA alloy obviously met the objective, giving equal or better life than bronze at a significantly lower price. Based on the favorable results of the testing under actual operating conditions, Kidd Creek maintenance personnel decided to switch permanently to the ZA bushings for rebuilding the VCR-150 rock drills. Original Equipment Application As one of the leading companies marketing the ZA alloys, as well as a zinc -copper-silver mining company, Kidd Creek is interested in developing applications for the alloys by original equipment manufacturers such as joy Manufacturing. Kidd Creek marketing representatives provided joy with information on the Timmins mine tests, along with ZA-12 bushings for evaluation and testing. Based on this information, joy installed ZA bushings in 12 new VCR-150 units and delivered them to customers for use in such areas as granite quarries and copper, lead, zinc, and limestone mines. During the following year, joy engineers closely monitored repair reports to verify the performance of the ZA part. The engineers' findings convinced them of the advantages of ZA-12. As a result, joy now uses ZA-12 bushings in the manufacture of its VCR-150 air tools. Advantages for Casters and Users In the foundry, the new alloys have proved their castability and profit potential in sand and metal permanent-mold processes, as well as the new graphite permanent-mold gravity casting process. The energysaving, pollution-free and ease-of-machining benefits they offer are important to all of these processes. Most recently, the high-performance alloys entered the arena of cold-chamber die casting, where they provide properties beyond those of

Jan 7, 1983

By Timothy Batchler, Khaled Mohamed, Morgan Sears

The National Institute for Occupational Safety and Health (NIOSH) initiated a testing program to assess the effects of lateral loading on various standing supports used in underground coal mines. This study is not intended to endorse a particular type of standing supports nor to provide a comparison between different types of standing supports. This paper aims to measure the lateral loading capacity of two types of standing supports and evaluate how it affects their vertical loading capacity and yielding mechanisms. The study utilizes the Mine Roof Simulator (MRS) at NIOSH Pittsburgh. Type-1 support is characterized by telescopic tubes made from ASTM A-513 steel with a specified locking mechanism, and Type-2 support comprises a single component constructed from ASTM A500 Welded Grade C pipe. Vertical load tests were carried out to assess the designed performance of Type-1 and Type-2 props. Type-1 props demonstrated a "constant yielding" behavior, achieving an ultimate capacity of up to 140 kips. Type-2 props showed a "load shedding" behavior, reaching peak verti- cal loads of up to 191 kips. Buckling analysis revealed that Type-1 props were not designed to buckle, and Type-2 props failed due to buck- ling rather than material yielding. Under vertical pre-loading, lateral loading tests showed that Type-1 props can withstand about 9 kips, and Type-2 props can withstand about 10.79 kips of lateral load. This represents roughly 6% of their vertical loading capacities. Testing props under lateral loads in addition to their intended vertical loads showed that the lateral loads could influence their loading mechanisms. Type-1 props did not exhibit the expected "constant yielding" behavior under lateral load but instead showed "load shedding" decreasing their rated vertical capacity by 70%. At high vertical pre-loading, Type-2 props demonstrated "constant yielding" behavior instead of the anticipated "load shedding," leading to a 60% reduction in their rated vertical capacity. These findings provide valuable insights into the behavior of these props under different loading conditions, aiding in their efficient use and design in underground mining operations.

Jun 25, 2024

By Charles Merguerian

In medium- to high-grade metamorphic terrains such as found in New York City(NYC), rock mass texture and mineralogy are important factors in predicting TBM penetration destiny. Integration of data from over two decades of traditional field and tunnel mapping suggest that hard-rock TBM penetration in the NYC area depends upon textural, mineralogic, and structural control. The bedrock of NYC consists of many different lithologic units of varying age, composition, texture, and metamorphic grade including many varieties of intrusive rock. In addition, brittle faults of numerous orientations cut the polydeformed crystalline bedrock, producing zones of highly fractured and disturbed ground and high water inflows. Pre-bid compilation of published bedrock data, drill core analysis by geologists to establish lithologic and mineralogic trends, integrated surface geologic mapping along a proposed alignment, and targeted petrographic and geotechnical investigations to characterize the rock mass conditions together constitute an important prelude to successful subsurface bidding and tunneling. A carefully planned program of as-built geological mapping, structural analysis, fracture class mapping, and monitoring of machine performance data provide important information for adjusting to changed conditions. In complex terrains, a clear understanding of the structural geology of any proposed tunnel line is the simplest and most cost-effective method to mitigate losses encountered during TBM tunneling.

Jan 1, 2005

By J. H. Daniel, S. Krzemien

Partners In Economic Reform, Inc., established a Polish-American Mine Center in Katowice, Poland, in 1996 to improve working conditions in the minerals industry. The program was based on the experience of mining companies, government, and labor in the United States, and was executed by a Coordinating Committee headed by the Center Director and Polish leaders from industry, State, labor, and academia. The cooperation among all parties has enabled safety and health issues to become part of industry restructuring with impressive initial reductions in coal mine fatalities. Existing work practices and attitudes of labor and management were assessed in coal mines throughout the country. Promotion, Rules, and Job and Task Analysis were identified as the areas requiring the most improvement, and are part of a post-graduate Safety Management program. Demonstration projects included measuring dust levels, using safety glasses, and promoting hazard awareness. Improved labor-management relations increased cooperation allowing for effective transfer of technology. Results can also be applied to improve the working environment of the manufacturing sector also undergoing restructuring.

Jan 1, 2001

By W. L. Jacobsen, T. L. Dyer

Cortez Gold Mines completed a feasibility study for a new openpit gold mine in north central Nevada. The production schedule calls for a peak in material movement. This schedule is based on current operational efficiencies and equipment parameters observed at the company’s existing openpit operation. To mitigate risks of over/under predicting production, simulation modeling was used to validate the loading and haulage requirements during the peak production period. The advantage of simulation is the ability to provide a realistic model of a mining operation based on scheduled and unscheduled random events during the period under analysis.

Jan 1, 2007

By H. E. Rojas

The primary objective of most comminution operations is liberation; however, mill performance is generally quantified in terms of particle size. Only recently has the use of image analysis equipment made it possible to quantify mill performance on the basis of liberation. In this investigation, a series of tests were carried out to study the effect of mill operating parameters on the liberation of sphalerite from a sphalerite/dolomite ore. The parameters studied included mill rotational speed, mill loading and ball size. The results of this work appear to indicate that sphalerite liberation is improved under conditions that promote impact breakage, while dolomite breakage is enhanced under attrition conditions.

Jan 1, 1990

By Harald F. Solberg

A preliminary study of the performance of a 4-inch Krebs cyclone at near rope conditions and different feed slurry temperatures was completed. Results suggest that temperature influences the x50c size which, in turn, did not depend upon spigot diameter. The bypass correction to a reduced efficiency equation incorporating the concept of a critical size xo was a function of fractional water recovery to underflow and may depend on feed size and feed percent solids. Further experimentation is required to develop an accurate model at near rope conditions.

Jan 1, 1981

By J. Boldy

The discovery of the Delbridge massive sulphide deposit in the Noranda district of Quebec resulted from an appreciation of the significance of a mercury leakage halo as a litho-chemical pathfinder to blind ore, coupled to its location relative to a geologically inferred ore-bearing horizon within complex volcanic stratigraphy. Systematic sampling of micro-fractures present in outcrops delineated a diagnostic anomaly, drawing attention to an area considered prospective for buried ore. The massive sulphide deposit was subsequently found to be blind and topped at the 110 metre level.

Jan 1, 1984

By W. K. Connor, O&apos

The Bureau of Mines is investigating the Co and Mn resource of the West-Central Arkansas District, including field investigations, mineralogical characterization, beneficiation, and hydrometallurgical tests. The deposits occur within the Ouachita Mountains and are con-trolled structurally, occurring along the axes of anticlines making up the mountain ridges. Brecciated novaculite is cemented with a mixture of Mn oxides, primarily cryptomelane and psilome-lane. Cobalt is concentrated within a particular Mn oxide phase, lithiophorite. Chemical analyses on head samples reported up to 25 pct Mn and 0.17 pct Co. Magnetic separation yielded products with up to 41 pct Mn and 0.22 pct Co at recoveries of 95 pct Mn and 93 pct Co.

Jan 1, 1991

By E. Fregeau-Wu

To recycle steelmaking slags for their iron, manganese, and lime contents, removal of the phosphorus-bearing dicalcium silicate and calcium phosphate is essential. Slow-cooling of slags was necessary to promote the sufficient grain growth to achieve liberation. In-situ grain size distribution determination showed that a high soaking temperature, a long soaking time, a very slow cooling rate, and the addition of fluorspar were shown to promote grain growth. High gradient magnetic separation on slow-cooled slags removed much of the dicalcium silicate. Liberation modelling was used to discuss the breakage and beneficiation characteristics of the slow-cooled slags.

Jan 1, 1992

By Peter C. Finlayson

Rapidly rising gas and oil prices and the falling quality of coal is forcing energy users in many parts of the world to consider the application of low grade fuel, particularly coal, for steam raising and power generation. However, the use of such low grade coal is normally resisted by the consumer because of operational problems associated with high ash content, sulfur emission and, in some instances, slagging problems caused by low melting temperature constituents in the ash. Recently developed technology involving 'fluidized bed combustion' offers a potential solution to these operational problems. Much of the early work was conducted in Britain, where rig tests were commenced during the early 1960's. This has led on to the successful conversion and operation of a fluidized bed fired industrial boiler at the Renfrew works of Babcock & Wilcox Ltd. Orders for the first commercial boilers incorporating this technology have recently been announced. Significant development work on fluidized combustion is now being undertaken in various parts of the world, in particular North America, Germany and Japan, and the first large scale units are under construction or being commissioned. This paper concentrates on the development of the technology in Britain, outlines the reasons for applying fluidized bed combustion and de-scribes its application at atmospheric pressure for steam raising and at elevated pressure for power generation . Coal Processing Consultants is a Partnership between the National Coal Board and Babcock & Wilcox Ltd. of Britain and has been established in order to provide technical advice and economic evaluations on all aspects of coal processing and utilization. In view of the involvement of its Parents in the development and exploitation of fluidized bed combustion technology, Coal Processing Consultants has been retained by clients in various parts of the world to provide expert advice on the application of fluidized combustion for particular coals and project situations.

Jan 1, 1978

By Michael Lenz

Predictive maintenance technologies including vibration analysis, tribology, infrared thermography, ultrasonic detection, and electrical measurements have been applied to large electric mining shovels. The predictive program was initiated on the P&H Model 2300 and 4100 electric shovels. The utilization of these technologies has shown the potential for improving electric mining shovel availability and minimizing maintenance costs. Predictive technologies provide the tools to assess machinery condition. Availability is enhanced by the condition based planning of component replacement. Maintenance costs are minimized by focusing resources through condition based prioritization.

Feb 24, 1997

By G. J. Joy

Although rates of pneumoconiosis in coal miners have declined substantially in the United States since the passage of the Federal Coal Mine Health and Safety Act of 1969, new cases continue to occur, including cases of rapidly progressive disease. In contrast, Australia?s underground coal mining industry has reported few new cases of pneumoconiosis for over twenty years. Mortality from Coal Workers? Pneumoconiosis in official health statistics and the prevalence of pneumoconiosis among miners screened in x-ray surveillance programs are also lower in Australia. To understand this disparity, the National Institute for Occupational Safety and Health was requested by both industry and labor stakeholders to examine this issue, with the ultimate aim of reducing the rate of pneumoconiosis among United States coal miners. A number of factors, including coal dust exposure, silica exposure, and coal rank were examined as potential contributors to the above observed differences. Comparison of coal rank data from each country did not show any significant differences. Air sample data from the coal mining industries in both countries show that coal dust levels in Australian mines are somewhat higher than those reported in similar U.S. mines; however, quartz exposure for Australian miners is lower than for many U.S. miners. Assuming that quartz is contributing to the greater number of cases of advanced pneumoconiosis in the U.S., more effective dust control measures, as well an independent exposure standard for respirable quartz in coal mining, need to be implemented to prevent this potentially disabling condition.

Jan 1, 2011

By V. Rajaram

The oil shales located in the Appalachian Basin cover an eight-state area of the eastern U. S., and are referred to as Devonian (black) shales. These shales have been exploited for their gas potential for several years. The Institute of Gas Technology (IGT) has conducted research since 1972 on the production of shale oil from the Devonian shales, and this resulted in the development of the HYTORT process. This process demonstrated that the yield from the Eastern oil shales can be greater than the value indicated by the Fischer assay method. IGT estimates that 423 billion barrels (67.3 x 109 m3) of oil could be recoverd by HYTORT processing of surface-minable eastern U. S. shales. Recently American Syncrude Corporation and Southern Pacific Petroleum N. L. have proposed oil shale projects in Kentucky. This paper will describe the surface mining and retorting techniques that have been studied for exploitation of the Devonian shales, and enumerate the problems that have to be overcome before commercial production can be realized from these shales.

Jan 1, 1983

By J. Devon, D. L. Ewart

Long-term coal mining plans are often based on attainment of an average cost of coal. This is achieved by blending low- and high-cost coal production. Coal that is beyond the economic limit of the reserve is mined in a misguided effort to improve reserve recovery. Long-term contracts should be least cost-based and generate the best net present value from the economic reserve within the context of a rational mine plan. The selected economic reserve should he mined on a low- to high-cost basis to benefit from the time value of money.

Jan 1, 1996

By James R. Taylor

24.1-BASIC PRINCIPLES JAMES R. TAYLOR The basic principle involved in maintenance is protection of a company's investment through the care and upkeep of machinery and equipment, buildings and properties. Maintenance is justified through making available to the maximum extent possible the facilities, machines and services required by the operating and production departments in their function of insuring optimum return on investment. As the size, cost and complexity of the equipment used in modern mining and related industries increase, operating and production personnel become proportionately more dependent upon maintenance engineering for its contribution to the overall profit picture. A greater part of the total cost now is charged to maintenance and the maintenance group becomes a major company unit. Basic maintenance concepts have changed very little over the years, but the advances in methods and technique have brought about tremendous challenge and have in consequence assumed a greater influence and importance. The older "sledge- hammer" methods have given way to engineered and scientific systems, while the accelerating development of intricate equipment and machinery, and the instrumentation essential for control, demand an ever-increasing upgrading of maintenance personnel. Regardless of this growth in importance, cost and complexity of the maintenance function, it is important to remember that it is not an independent and self-sufficient unit, but is a necessary facet of the entire plant operation and is subject to the company's total production effort. As one part of a team, maintenance is successful only when functioning cooperatively wit11 the other departments it serves Close collaboration in all areas served by n maintenance group is essential if it is to function fully to protect the company's investment, whether the assets are in machinery, materials or people. 24.1.1-MAINTENANCE SCOPE Maintenance functions may be grouped into the two general classifications of primary and secondary. This grouping constitutes a basic division although, in practice, the scope of the maintenance activity varies in each mine or plant and is subject to differences in size and type of operations and company policy, plus the influence of precedent, which may be sectional or industry-wide. The primary functions supply the justification for the maintenance engineering department. while secondary functions are variable according to plant conditions and needs. The primary functions may be categorized as follows: 1. Maintenance of existing machinery and equipment. 2. Maintenance of existing buildings and grounds. 3. Inspection and lubrication of equipment and machinery. 4. Utilities generation and distribution. 5. Alterations to existing equipment and facilities. 6. Installation of new equipment and facilities. 7. Instrumentation.

Jan 1, 1973