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By John G. Whellock

Over the last decade new constraints have emerged in the metallurgical industry which challenge the very basis of design and construction of smelters and refineries. The hackneyed designs of the past will not now serve the revised objectives of: - minimal cost of ownership - improved productivity - reduced energy consumption - greater flexibility in feed or product - minimized recycle loops and by-products - more stringent environmental control The impact of these constraints has been channeled constructively into process intensification - exemplified at the large scale by the introduction of flash smelting technology and at the smaller scale by the application of rotary process vessels and converters for augmented heat and mass transfer. The design of successful process plants depends on the understanding of the unit operations and their interactions which is the discipline of systems engineering. With the advent of increased process intensification the importance of a systems approach to process design and implementation becomes paramount. This paper describes the systems approach with specific reference to medium scale projects in the primary and secondary metallurgical industry.

Jan 1, 1985

By C. Allen, H. Zhang, L. Falk

Shock loss occurs when there is a change in the area of a drift or airflow direction. These shock losses accumulate throughout the ventilation system and will increase the mine resistance as underground development deepens or becomes more complex. Hence, shock losses should be carefully considered when establishing the resistance through a series of branches as they can be a significant contributor to the estimated mine resistance. Using computer software to simulate a ventilation system is common but applying reasonable shock loss factors in the software is not a simple or direct process. Determining shock loss values includes the consideration of historical measurements, application of factors and formulas from literature based on the geometry and complexity of junctions, and the geometry variation at different locations. For example, the shock loss at the bottom of a ventilation raise can consist of a 90° bend and a sudden area change. This paper presents an approach for estimating shock loss factors near raise junctions using computational fluid dynamics (CFD). Current and future work will also be compared with field measurements. Results from this approach are compared with software defaults as well as classical techniques in published literature and standards.

Sep 1, 2024

By A. Juganda, Jr. Bogin, S. Saki, R. Gilmore, J. Brune, J. Grubb, S. Lolon

"In longwall mines, atmospheric or barometric pressure fluctuations can disturb the pressure balance between the gob and the ventilated working area of the mine, resulting in a phenomenon known as “gob breathing”. Gob breathing triggers a gas flow across the gob and the working areas and may result in a condition where a methane accumulation in the gob flows into the face area forming an explosive mixtures. This paper discusses results of Computational Fluid Dynamics (CFD) modeling carried out to analyze this phenomenon and its impact on the explosive mixture development under a bleeder-ventilated longwall gob panel scheme. Modeling results indicate that the gas inflow and outflow across the gob and the formation of Explosive Gas Zones (EGZs) are directly affected by the barometric pressure changes. Methane gas and EGZs in the gob expand out toward the face and bleeder entries during the falling barometric pressure. Where methane zones interface with mine air, EGZ fringes may form along the face and in the bleeder entries. When the atmospheric pressure increases, an ingression of oxygen into the gob is observed that can also increase EGZs in volume. The findings from this study help assess the methane ignition and explosion risks associated with fluctuating atmospheric pressures. INTRODUCTION Methane explosions continue to be a daunting risk for underground coal miners, although the number of related fatalities and injuries in the U.S. coal mining industry has steadily decreased since the establishment of the U.S. Bureau of Mines in 1910. Still, the consequences of a methane explosion are often disastrous with multiple fatalities and property damage often leading to permanent shutdown of the mine. Methane is formed during the coalification process and is released from the coal seam to the mine atmosphere when the coalbed is disturbed by mining or natural causes such as earthquakes. If not properly diluted by appropriate mine ventilation, this methane may accumulate in the active mine workings and gob areas. Researchers at the Colorado School of Mines have developed numerical models showing how and where explosive methane may accumulate in gob areas. Historical mine explosions appear to show a connection between mine explosions and fluctuating barometric pressure as a result of stormy weather. McIntosh (1957), Boyer (1964), and Kissell et al. (1973) studied the influence of barometric drops on major coal mine disasters in the United States prior to 1970. Their statistical analyses found that a majority of these disasters occurred in the fall and winter months when the barometric pressures were influenced by unstable weather conditions and noted increased methane content in the mine workings during times of falling pressure. Studies conducted by Fauconnier (1992) and Hemp (1994) found similar connections between methane explosions and barometric pressure fluctuations in a majority of gas explosions in South African mines. Ten out of twelve major mine explosions with five or more fatalities in the U.S. after 1970 were found to have occurred during the months of November through April when barometric pressure swings were more abrupt and intense (Lolon et al., 2015)."

Jan 1, 2016

By J. C. Fox, V. L. Ketellapper

The Summitville Mine, located in the mountains of Southwest Colorado, is an abandoned gold mine. From 1984 to 1992, Summitville was mined for gold using an open pit heap leaching technology. During this period, the volume of acid mine drainage released from the mine significantly increased. This was attributed to the development of the mine pits, the waste rock piles, the heap leach pad, and increased discharges from the drainage adit. The release of this acid mine drainage resulted in the destruction of the aquatic ecosystem for more than twenty miles downstream of the mine. Beginning in 1993, plans were implemented to reduce the amount of acid mine drainage released from the mine. The majority of this work has been completed at the mine. This work includes removal of the Cropsy Waste Pile, closure of the Heap Leach Pad, and revegetation of disturbed areas. Significant improvements to water quality downstream of the mine have occurred resulting from mine reclamation. Aquatic life has returned to portions of the previously mining impacted areas. This study discusses the actions taken to reduce the amount of acid mine drainage generated at the Summitville Mine, the costs of these actions and the resulting reduction in metal loadings. Over 250 samples taken at over 10 locations since 1993 form the basis of this evaluation. Copper loading is analyzed as an indicator of the effectiveness of the actions taken.

Jan 1, 2002

By L. Neuman

Reclamation and permit applications for mines tend to be very detailed and complicated documents. Depending on its complexity, the application may have to be reviewed in detail for water quality, water quantity, wetland and upland habitat, wildlife issues, waste disposal, historical and archeological significance, other environmental factors, and financial surety sufficiency. To reduce review time and cut costs to the applicant, this paper identifies the most common mistakes that can lead to delays in the application process.

Jan 1, 2004

By G. A. Hope, K. Watling, R. Woods, I. Chandra, I. M. Ritchie

This paper presents two aspects of gold leaching research and development. The first section of the paper covers the development of innovative gold leaching processes. The research in this area has concentrated on the development of new thiosulfate leaching systems which use Fe(III) stabilized by ligands as the oxidant in place of copper(II)+ammonia. The second section will cover the development of innovative techniques such as surface enhanced Raman scattering (SERS) to study the leaching of gold in cyanide solutions. It will be shown that the use of in-situ SERS yields information which cannot be obtained using other methodologies.

Jan 1, 2005

By Peter Maltby

A $20M pressure oxidation facility is under construction at the Nerco Con Mine, Yellowknife. Plant commissioning will start in the third quarter of 1992. Roasting of arsenical auriferous concentrates prior to 1970 left 45,000 tons each of highly toxic gold-bearing arsenic trioxide sludge and roaster calcine at the minesite. Safe disposal of these wastes has been a high priority. In 1983 an arsenic trioxide plant was built by the former owner to re-treat the sludge and to sell the product. Due to a poor market and high operating losses, the plant was closed by Nerco in 1989. Mine production in the future will revert increasingly to refractory ore as a replacement for free-milling ore which has been the mill feed since the roaster was shut down. With this fact in mind, Nerco management saw the potential of a proven process to recover the gold from a combined feedstock of refractory flotation concentrate, sludge, and calcine waste. A further requirement was the stabilization of all the arsenic as an insoluble ferric arsenate. By the end of 1989, after the completion of a literature search and a study of process economics, pressure oxidation was selected. Extensive bench and pilot plant work was completed in 1990 and early 1991 to develop the process parameters and to complete environmental testing of the autoclave products. Management approval for construction of a pressure oxidation facility was made in December 1990. Plant capacity is 96 tpd requiring a 40 tpd VSA oxygen plant on site. Detailed engineering began in March 1991. The pressure oxidation building was completed by the end of 1991. The autoclave arrived on site and was mounted on its foundation in December 1991.

Jan 1, 1992

By Boleslav Taraba, Antonín Taufer

Thermovision monitoring of surface temperature has been examined for the purpose of detection of spontaneous combustion of early stage. Measurements were carried out in bituminous and subbituminous coal mines. It was found that surface temperature heterogenities can be considered as common phenomenon in mine openings. However, the most of the observed temperature heterogenities were not connected with coal spontaneous combustion of early stage. These, so called [non-spontaneous combustion] temperature heterogenities in surface of mine openings were found to be caused by: l. Different conditions of heat transfer between opening surface and air stream; 2. Low temperature (natural) oxidation of coal; 3. Dissipated heat loses of working machine. Sites of early stage spontaneous combustion of coal were characterized by: 1. More significant, local rise in surface temperature comparing with low temperature coal oxidation; 2. Evolution of carbon monoxide with local concentration near the surface of such site more than about 15 ppm (bituminous coals) or 30 ppm (subbituminous coals). INTRODUCTION Mine fires are a serious hazard to life and result in a considerable loss of coal reserves. Thus, great attention is paid to investigation of new methods enabling already early detection of self-heating of coal. The earlier a fire is observed, the easier would it be to deal with. Detection methods used in coal mines are mainly based on: 1. [Mine air analysis]. Changes in composition of mine air are examined. Products of spontaneous heating of coal, not being present in mine air under normal conditions, are considered as indicators of anomalous behaviour of coal (carbon monoxide, unsaturated hydrocarbons) (Mackenzie-Wood and Strang, 1990). 2. [Temperature measurements]. Sites of higher temperature level comparing surroundings are looking for underground using various direct or indirect methods of temperature measurements. This paper summarizes experience from thermovision monitoring, as one of the latest indirect temperature measurement technique, used for the purpose of early detection of self-heating of coal in mine openings. INFRARED THERMOVISION Infrared thermovision device of AGEMA Infrared systems AB (Sweden) was used for the in situ measurements. The constant value of emissivity factor, 0.95, was pre-set as the most probable level of emissivities of coal and rocks in mine conditions.

Jan 1, 1993

Fundamental results obtained from research on the properties of the edge surfaces of kaolinite particles (~500 nm) are reported. Of particular significance was the development of the experimental protocol. Well-ordered kaolinite edge surfaces were prepared as an epoxy resin sandwich structure having layered kaolinite particles in the center of the epoxy resin sandwich. Images of the sectioned kaolinite edge surfaces were examined by atomic force microscopy (AFM), and the average thickness of kaolinite particles in this study was determined to be 38.3 nm ± 11.7 nm. Furthermore, the surface charge of the kaolinite edge surfaces was evaluated with a super sharp Si tip. The point of zero charge (PZC) of the kaolinite edge surface was determined to be below pH 4, in contrast to the traditional view that the edge surfaces of kaolinite particles may carry a positive charge at pH 4. This lower PZC of the kaolinite edge surface was attributed to the lack of isomorphous substitution in the silica tetrahedral layer when compared to the PZC for the muscovite edge surface. Our results are consistent with the particle aggregation and flotation behavior of kaolinite, and should provide the basis for improved flotation strategies leading to the efficient recovery and utilization of mineral and energy resources.

Feb 23, 2014

By Barbara Maren Winkler

For mine production problems in mines with varying qualities, both open pit and underground, the linear programming method (LP) has been used successfully. By this method it is possible to keep the total production blend for each period within a required range of qualities while optimizing objectives like production costs, net return, ore grades, other qualities, or a combination of these. Technical restrictions like constrained capacities can be added to the model. This makes LP a flexible and powerful tool for mine production planning. Practical experiences have shown the major influence fix costs have on the actual economic result of a planning decision. It can be proven that fix costs cannot be included in LP models. We describe a way to address this fix cost problem by using mixed integer linear programming (MILP) as an extension to LP in the optimization of a mine planning problem. This raises the issue of complexity. We discuss the computational complexity of the resulting models and the enhancement of model flexibility for the user of a planning system. We demonstrate the method embedded in a practicable everyday planning system for a complex underground coal mine. By computational examples we show how the method improves the economical results of the planning.

Jan 1, 1996

By C. F. Lee, Bezalel C. Haimson

A 300 m deep test hole at Ontario Hydro's Darlington nuclear plant site, 65 km east of Toronto, was used to determine the state of stress in the Paleozoic limestones (O-22O m depth) and the Precambrian granitic gneiss (220-300 m). The results of the hydrofracturing measurements indicated a state of high horizontal stress along the depth of boring and a consistent orientation of principal stresses in each geologic unit. These results were confirmed by a borehole TV camera survey, and by overcoring tests. The magnitudes and orientations of the measured in situ stresses were used in a feasibility study of siting an underground nuclear plant, and in particular in the geotechnical design of proposed reactor caverns in Precambrian rocks. Their implications on cavern stability under operational and accident conditions were analytically studied, taking into consideration the potential superposition of thermomechanical stresses under loss-of-coolant condition, and the possibility of thermal spalling in the host rock.

Jan 1, 1979

By I. Iwasaki, T. Fujuita

The removal of phosphorus from steelmaking slags is essential for recycling such slags to blast furnaces for recovery of their manganese, iron, and lime contents. Phosphorus is mainly concentrated in the dicalcium silicate phase of the slags (Fujita and Iwasaki, 1988, 1989; Suito, et al., 1977). Slow-cooling of steelmaking slags in an air atmosphere increased the grain sizes of constituent minerals; however satisfactory magnetic separation results could not be attained because of the close association of a strongly magnetic ferrite phase with dicalcium silicate (Fujita and Iwasaki, 1988). Curie point of the strongly magnetic ferrite phase in the slow- cooled steelmaking slags was investigated and an attempt was made to separate the phosphorus-bearing dicalcium silicate phase in ground slag pulps heated to a temperature exceeding the Curie point. Materials and methods Slag samples, heated to its fusion temperature of 1370°C and slow-cooled in an air atmosphere, were ground dry to -90 µm (about 170mesh) in a ring grinder. The ground sample was pulped to 1% solids in distilled water using 1 kg/t sodium hexametaphosphate as a dispersant and separated in a Sala high gradient magnetic separator, Laboratory Model 10-15- 20B, using a 100-mesh expanded metal matrix and 300 m/h flow rate.

Jan 1, 1990

By Alfred C. Maevis

On October 27, 1972, ground was broken for the first section of the Second Avenue Subway, a two track underground rail system that was to extend from the south end of Manhattan at Broad Street, north to the Harlem River at 126th Street, a distance of eight miles. This ground breaking was the culmination of 67 years of planning for an east side subway in Manhattan. Following the successful opening of New York City's first subway on October 1904 there was a mass planning for additional subways throughout the City. In 1905 approval was requested of the Board of Estimate for a First Avenue route and Third Avenue route. The Third Avenue route was approved but when action was not taken to start construction, the approval in accordance with the conditions under which it was given was withdrawn. Further reports and plans for an east side subway, usually to be constructed on Third Avenue, were issued in 1920, in 1922, in 1924, etc. Those of us who had worked on the Sixth and Eighth Avenue subways in the thirites and early forties left to join the armed services of World War II in the expectation that we would return and start work on designing and constructing that east side subway. The reason that much of the thrust in those years was to construct on Third Avenue was that there was a Third Avenue "EL" and business interests of the City were in favor of its demolition. This demolition was accomplished in 1955 so one of the incentives to construct on Third Avenue was removed; but an east side subway was always part of the master plan of the City.

Jan 1, 1976

By S. Page, R. Bhaskar

The development is described of a real-time tracer gas sensing system for use in fell-scale laboratory studies of air flow behavior around mining machines. A semiconductor sintered tin-dioxide gas sensor is used for gas analyses. A data acquisition and analyses software specific to the sensor characteristics was also developed as part of the system. The system permits the study of transient behavior and assists in obtaining a better understanding of the movement of air around mining machines and in the study of the effect of potential airflow modification devices on the dust exposure of face personnel. It seeks to replace the current method of using a centralized infrared gas analyzer that polls several sampling points using an array of solenoid valves and gas line purgers. The polling results in a significant time lapse between the first and the last set of readings. The system described in this paper has the advantages of real-time sampling and safe operation.

Jan 1, 1992

By F. F. Aplan, S. Chander, A. R. Alaboyun

Several aspects of the capture of hydrophobic dust particles by droplets in sprays have been studied. The particle capture depends on several sub-processes involving collision, adhesion and engulfment. The collision events between dust particles and a single droplet were observed with a high speed motion analysis system to determine the influence of a surfactant on the capture process. In the adhesive process it was observed that the dust particles are collected at the surface of the water droplet to produce a rigid film at high dust loadings. In the presence of the surfactant, however, the particles were engulfed inside the droplet keeping a fresh surface on the droplet available for capture of more particles. A theoretical analysis is presented to take into account the role of contact angle on the penetration of particles into droplets. A significant increase in collection efficiency was observed with decrease in droplet size.

Jan 1, 1991

By M. J. Virnig, C. P. J. Van Vuuren, A. J. Botha

The Zadra, AARL and organic elution processes and variations of them are presently widely used to recover gold from activated carbon. Despite this the study of the kinetics of elution have received relatively little attention. It is the aim of this study to investigate the rate processes taking place during elution in both inorganic and organic solutions. Batch adsorption and elution rate and equilibrium experiments were performed. The spatial concentration of gold inside carbon particles at various stages of the adsorption and elution processes were measured with a scanning electron microscope using an image analyzer to control and manage the micro-analysis data. The activated carbon particles exhibited film and intra-particle mass transfer rate- controlled behaviour during adsorption in a caustic aqueous solution at 95°C. Elutions in the aqueous caustic acetone solution at 30°C and the caustic aqueous solution at 95°C were unaffected by change in stirring rate. Elution was modelled by desorption reaction rate-control at the outer surface of the carbon particle. Adsorption and elution isotherms under duplicated solution conditions showed reasonable agreement for the inorganic solution and a large disparity for the organic solution.

Jan 1, 1993

By L. M. Chan, D. H. Carlson, J. H. Johnson

This paper discusses laboratory evaluation of a tailpipe emissions measurement apparatus (EMA) developed by Michigan Technological University (MTU) under contract to the Bureau of Mines. The apparatus dilutes diesel exhaust and measures the concentrations of diesel particulate matter (DPM), CO, C02, NO and NO2 at known dilution ratios. The EMA was evaluated by side-by-side comparison of its measurements with those by laboratory grade instruments. During the preliminary laboratory evaluation concentrations of DPM, CO and CO2 were measured. The concentrations of CO and CO2 measured by the EMA were usually within ±14 pct of laboratory-measured values for CO and ±20 pct for CO2. EMA DPM concentrations correlated well (r = 0.96) with the laboratory values, but were 29 pct lower on average. The CO and C02 differences were observed to be related to the method of calculating the EMAs' dilution ratio and the difference in DPM concentrations is attributed to thermophoretic and/or condensation losses related to the EMA's unheated sample probe. Preliminery analysis of data obtained with a heated sampling probe and modifications in the sampling procedures have indicated reduced variability in DPM and in the calculated dilution ratios.

Jan 1, 1991

By R. A. Paul

The requirements for water inflow control for the Chicago Intercepting Sewer System are stringent. This posed special problems in grouting the bored and conventionally mined tunnels, shafts and chambers of the system. In adapting conventional grouting techniques to the specific problems encountered in the system's pilot project, numerous field procedures were developed. Careful preand post-grout testing and evaluation identified the most efficient and economical of these procedures. As an example of some of the conclusions reached during the project it was found that the mineralized groundwater in the Chicago area tended to reduce the efficiency of the grout holes, thus limiting their useful life. Pressure washing to remove natural fillings was a critical factor in achieving a permanent grout seal. The value of relatively thin lubricating grout mixes was definitely established. Although not an ideal situation, satisfactory results could be obtained by manifold grouting several grout holes simultaneously if done within specific limits of hole groutability, location and numbers. Caulking proved to be a primary controlling factor in achieving acceptable results. To achieve such a high degree of water inflow control requires close supervision by experienced personnel. "Temporary grouting as a construction expedient" produces seepage conditions which are extremely difficult to treat.

Jan 1, 1974

By Jerry Luttman, Mark Dubay, Anvesha Dogra, Elizabeth Dwyre, Wei Hu

The I-75 Modernization Project (Segment 3) just north of Detroit, MI is being delivered as a Design-Build-Finance-Maintain (DBFM), which is a Public Private Partnership (P3). The project includes design and reconstruction of 5.5 miles of freeway, including a depressed section with a 20,630-ft long, 14.5-ft inside diameter, up to 100-ft deep stormwater tunnel, multiple drop shafts, and a pump station. The project also includes a maintenance term of 25-years. This is the first time MDOT has used a P3 delivery method for a major highway and tunnel project. This paper describes the development of the P3 documents, including performance-based tunnel and shaft technical requirements, and the approach to project risk management, financing, and insurance coverage.

Jun 23, 2024

By Neal Rackstraw, Mamo Meaza

Washington Metropolitan Transit Authority Section E8a consists principally of twin tunnels 1,713 meters (5,620 ft) long, excavated to a diameter of 6.35 meters (20.83 ft) using an open face shield, with a primary lining of four unbolted precast concrete segments expanded at the crown, and a full circle unreinforced concrete final lining with a finished tunnel diameter of 5.08 meters (16.67 ft). The tunnels, constructed in Cretaceous age sediments, are mostly in stiff to hard clay except for a few areas along the alignment that contain dense to very dense fine sand in the upper portion of the tunnel that created a mixed face condition. At two locations unexpected heavy water inflows produced very serious problems in both tunnels. Water flows in the interface area were generally more than 378.5 1pm (100 gpm) and reached as high as 2,649.5 1pm (700 gpm) in the mixed face ground. The nature of the tunnel inflows, the consequences, and the corrective measures adopted will be the subject of this paper.

Jan 1, 1991