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By Steve Kral

U.S. mines are among the most efficient, productive and safest in the world. Much of that efficiency is due to the high-technology equipment and processes available to the industry. The U.S. mining industry can produce more material now with fewer people than it could a few decades ago. And that material can be produced more safely. However, the workforce is growing older and fewer young people are filling the holes created by retirements. Even though mining is one of the highest paid occupations in the United States, young people believe they can find jobs that pay almost as well without the risks and the often remote locations associated with mines.

Jan 1, 2002

By D Cliff, B Belle

Trigger action response plans (TARPs) are inherent to managing multiple hazards such as high gas content with multiple coal seams, high spontaneous combustion propensity, heat and ventilation. TARPs aim to provide assurance and guidance when the situation deviates from the original plan or there is a change in conditions that could be hazardous. Over the years, learnings from various incidents have continuously required coal operations to revisit the TARP trigger values that were based on historical data or guidance values from the industry. In most cases, the background to the basis of TARP statistical data (ie average, maximum, hourly or daily for the monitoring or sampling location) is unknown. The introduction of real-time monitoring devices to monitor gases and airflows has provided greater understanding of the hazard scenarios and their controls. This paper analyses the carbon monoxide data from operating longwall mines and compares these with the historical trigger values to understand the changes and identify improvement opportunities while setting trigger levels in the TARPs. As an example of setting trigger values, those used during the sealing of a panel are explored in terms of setting values based upon the sampling location and the level of risk. It is envisaged that the learnings shared herein will further enhance the understanding and management of multiple hazards in Australian coalmines.CITATION:Belle, B and Cliff, D, 2015. Improved trigger action response plan development based upon mine-specific data, in Proceedings The Australian Mine Ventilation Conference, pp 73–78 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By M. E. C. Snyman, N. Naudé

"Coal fines produced during processing are difficult to dewater and result in a lower quality product and consequent lower value. A South African coal mine experiences severe difficulties with belt filter dewatering operations due to the presence of fines reporting from the thickener underflows. Plant 2 currently handles super-fine particles of size -34 µm and has low belt filter efficiency: excessive moisture retention lowers the product quality and strains downstream processing. It was necessary to determine an alternative method for dewatering these fines. Blending of fine material with coarser material was proposed as a solution. The effect of coal particle size and layering during ultrafines belt filter dewatering was evaluated using various blends of the fine Plant 2 material with coarser Plant 1 material. The best layering arrangement of the two materials and its optimum blend required to achieve reduced filter cake moisture content was determined in practise using a vacuum filter to simulate belt filtration. A blend of the two materials gave improved dewatering efficiency for the belt filters compared with that of the Plant 2 material alone. The best layering configuration was with Plant 2 material at the bottom and Plant 1 material on top. The optimum blend for industrial applications comprised 48% fines from Plant 2. IntroductionFines are produced during the processing of coal. It is estimated that 2 to 3% of run-ofmine coal reports to the ultrafine portion (-100 µm) (le Roux, 2005). The particle size of coal is inversely proportional to the amount of water adsorption, so smaller particles adsorb more moisture. Moisture removal requires either mechanical processes or thermal drying: mechanical processes are less expensive, but the fines still have high moisture retention. Discarding of fines leads to economic losses, so it is essential that they be dewatered so that they can then be sold as a product: fines need to be treated for both resource management and conservation reasons (Kenney, 1994). Removal of free surface moisture from ultrafine coal particles using a belt filter therefore remains a process that needs to be continuously improved. Ultrafine coal originating from a thickener underflow is known to be difficult to dewater owing to factors such as filter cloth blockage and moisture retention due to clogging. Mixing of finer and coarser materials has been proposed to deliver better dewatering efficiency and improved the quality of the recycled water (Kenney, 1994)."

Mar 1, 2019

Increase the safety of underground mine workers by minimizing hazards associated with rerailing mine cars after derailment. Background and Approach A serious operational problem in underground mines is the task of rerailing mine cars. Current rerailing practices are not only hazardous but are inefficient as well. Most methods involve pulling the derailed car back onto the track with a locomotive. This causes damage to the road bed and is not effective on curves or in situations where the car's wheels are too far from the rails. Jacks, wooden props, and pry bars are also used to raise or lower cars back onto their tracks but methods involving these tools require much strenous manual effort by mine workers, thus posing possible serious injuries. The problem is further compounded by the cramped, narrow confines of the underground mine environment which allows no space to permit use of cranes or other surface railroad rerailing techniques. The Bureau of Mines, aware of these problems, investigated improvements in current underground rerailing methods. Through a cooperative effort with Hoesch MFD, a system was designed and modified that can be easily carried into the mine by workers and quickly assembled at the derailment site. The system is hydraulically and pneumatically powered rather than reliant upon manual operation.

Jan 1, 1986

Since 2001, the Hybrid Stress Blast Model (HSBM) project members have developed a software suite to model the complete blasting process from non-ideal detonation to muck pile formation. To preserve the physics and improve solution time, the breakage engine uses a combination of analytical models and 2D axisym-metric finite differences to model near-field crushing, coupled to 3D discrete lattice fracturing and distinct element numerical methods to model throw and muck pile development. The model has been validated by comparison with laboratory and field tests in kimberlite. Multiple blasthole simulations are used to demonstrate how changes to blasting parameters can influence downstream efficiencies. Case studies of wall control blasting show that the presplit design must balance the two opposing effects of increased damage with increased charge and decreasing attenuation of the seismic waves with decreasing charge. Modelling of decoupled explosives needs further development. Reducing the charge towards the back of the trim blast results in a much more significant decrease in back damage than altering the timing. The model demonstrates how separation along the weaker planes in a jointed rock can coarsen the fragmentation, leading to inefficient beneficiation, and extends the damage to a distance of at least twice the burden behind from the blasthole, severely compromising the wall stability.

Jan 1, 2012

By N. Barton, E. Quadros

This paper addresses the prediction of groutable joint apertures, grout penetration limitations, and possible grout take volumes per cubic metre of rock, as a result of 5 to 10 MPa pre-injection pressures ahead of tunnels. Joints are obviously opened more than in the preceding Lugeon tests, and many rock mass properties can apparently be improved if stable micro-cement based materials are used. Cet article concerne la prédiction des ouvertures des fractures injectables, les limites de pénétration du coulis et les volumes injectés par mètre cube, d’après les résultats des injections à l’avant tête des tunnels sous pressions de 5 à 10 MPa. Evidemment les joints s’ouvrent plus que dans les essais Lugeon précédents. Maintes propriétés du massif peuvent apparemment être améliorés si l’on emploi des coulis a base de micro-ciment stable. Die Publikation widmet sich der Prognose injizierbarer Kluftöffnungen, Grenzwerte für Injektionsreichweiten und erreichbarer Injektionsvolumen pro Kubikmeter injizierter Fels, durch die Anwendung von 5 bis 10 MPa Vorinjektionsdrücken vor der Tunnelfront.Die Klüfte werden offensichtlich weiter geöffnet als in den vorhergegangenen Lugeon Versuchen und mehrere Felsparameter können durch die Verwendung von stabilisierten Micro-Zement basierten Injektionsmaterialien verbessert werden.

Jan 1, 2003

By Bruno A. Fichna

Longwall mining offers low cost potential for coal with high capital investment. As opposed to two shifts-per-day operation in most long- walls, Saarberg Mines in Germany increase utilization of capital by operating their longwalls around the clock. Differentiation between capital and operating costs, corrective maintenance versus preventive maintenance, improved roof conditions, and economical life of equipment was investigated. A surprisingly high degree of improvement was attained. Capital costs at Saarberg longwall coal mines have been reduced through a step-by-step research and trial program. This reduction was particularly influenced by the high performance pilot longwalls at the Ensdorf mine. The following presentation shows data and figures of those longwalls. End results were 40% reduction in capital costs, which could contribute favorably to investment decisions in the coal industry in a supply side economics environment.

Jan 1, 1982

At Namdeb, submerged beaches are earmarked for sampling and future mining and various sampling configurations are tested for optimality through the use of spatial simulations. For the creation of these virtual orebodies, basic statistics and variograms are needed, but in this specific instance no data exists from which the necessary parameters can be determined. The best that can be done is to use proxy data from onshore beaches, with adaptations where needed. The reworking of raised beaches during periods of rising and falling sea levels in some cases destroyed the internal beach structures, and it is very difficult to determine the variograms. A method is proposed whereby simulated annealing is used to adjust the sample locations to align the data pertaining to beach crests or cliff lines, thus improving the variogram structure along the shoreline in the direction of the highest geological continuity.

Jan 1, 2014

By S W. Kingman, D Whit, I S. Lowndes

The use of compressive crushing equipment such as gyratory crushers within minerals processing plants can potentially generate large quantities of dust. Remedies to this problem include the retrofitting of shrouds, enclosures, local exhaust ventilation (LEV) systems and water suppression systems. The single or combined application of these systems must be optimised to ensure they operate efficiently. It is desirable that the future design planning of such facilities include integrated dust suppression and/or removal systems to ensure material delivery rates are maintained and the welfare of the workforce is protected. The characteristic release of dust and the disturbance to the surrounding ventilation airflow is investigated by the construction and solution of computational fluid dynamic (CFD) models validated by data obtained from scale experiments. A 3D computational model was constructed using the FluentTM CFD software to represent the background ventilation regime within an underground crushing installation. The falling ore is represented as a continuum granular fluid falling under gravity from the raised bed of the dump truck. Transient path lines are computed to simulate the updraft airflow generated by the tipping process and indicate the dispersion path of any entrained dust. The relationships between the falling ore material, the displaced air and the shear induced flow are determined by an analysis of the computed volume/mass flow rates predicted across the crusher opening. An analysis of the airflow patterns predicted by the CFD simulation models indicates strong shear flows induced between the tipped material and the surrounding airflow in the vicinity of the crusher during tipping, and a strong influence of the background ventilation regime on the path taken by this shear flow. Scale experimental studies were conducted to characterise the induced shear flow and visualise the potential entrainment and transport of dust. An analysis of these experiments is presented.

Jan 1, 2005

By Robert A. Jankowski, J. Drew Potts

The Bureau has identified several ventilation techniques and a water spray application for reducing auger mining dust levels. The dust control methods all work by improving air quantity or flow patterns at the face. Section airflow is maximized by reducing air leakage between entries. Sealing stoppings with brushed- on mortar, containing fiberglass additives, reduces leakage. Heading airflow is maximized by properly installing the brattice curtain and keeping the area between the curtain and rib free from obstructions. The brattice curtains should be hung at least 1.7 m (5.5 ft) from the ribs in 7.9 m (26 ft) wide entries and kept less than 4.6 m (15 ft) from the face. A tight curtain seal is created by using the mine air pressure to force the curtain against the timbers, roof and floor of the mine. Using both a blowing curtain and an exhausting curtain will isolate some face workers from dusty air. The Bureau designed, auger clearer spray system, can be used to force heading air across the active face. Laboratory tests indicate that the auger clearer spray system can increase face velocities by more than 0.5 m/sec (100 ft/min), while using less than 0.13 l/sec (2.0 gal/min) of water.

Jan 1, 1989

Reduce the dust levels to which jacksetters and helpers on auger mining sections are exposed by identifying viable, effective methods for control-ling respirable dust on these sections. Approach The Bureau of Mines con-ducted laboratory tests and respirable dust surveys to identify the factors that distinguish clean auger mining operations from dusty ones. Study Results Results of the Bureau's study revealed that ventilation is the most important element of auger mining dust control. The four must important venitilation parameters are airflow, curtain configuration, curtain setback, and curtain installation.

Jan 1, 1988

By G. G. Garrett, J. A. Peters, J. V. Bee, M. W. Atkinson

The development of steels with improved abrasion-corrosion resistance for use in underground components in South African gold mines is described in terms of design, manufacture, and performance. Based on the concept of microstructural design, new compositions were formulated to provide the optimum structures and properties. Extensive laboratory tests were conducted, and an industrial melt was produced. The resultant materials were tested for fabricability and machinability, and various components were manufactured. According to the preliminary operational results, these alloys exhibited outstanding performance in wear-plate tests, and are very promising for general application in underground components.

Jan 1, 1987

By Jerry R. Riding

Metallurgical process methods have seen dramatic improvement over the past fifty years. As these improvements have come about, more and more emphasis has been placed on obtaining accurate and rapid analysis of the metallurgical processes. Well-defined conventional laboratory analysis procedures which have proven to be reliable were developed early in the mineral industry's history; however, these conventional procedures, which have not changed appreciably in fifty years, have the serious drawback that they are too slow to be of appreciable value in automatic control of the processes. For example, the assay results normally become available to a mill operator from eight to twenty-four hours after a sample is taken. Since the desired mineral separation can only be made while the minerals are in the flotation circuit, conventional assay results provide information similar to postmortem reports. Consequently, using conventional procedures, the mill is operated with information from an earlier period of time, which may not reflect current conditions. In recent years there has been a steady increase in the volume of required samples. At the same time, labor, material, and overhead costs have continued to rise causing the cost per assay to reach an alarming level. This rising cost per assay, plus the increasing demand for rapid analysis necessary for control, has caused the mining and metal processing industries to look toward other techniques to solve these problems As a result, X-ray fluorescence which can provide on-stream analysis necessary for control, as well as perform numerous laboratory assays at lower cost and at a much greater speed than conventional methods, has gained wide-spread attention. In addition, multichannel X-ray fluorescent instruments are now available which have been perfected to the point where the analysis of the most important chemical constituents is available within one minute after a sample is presented to the X-ray analyzer. Because of these obvious advantages, extensive use is being made today of X-ray analysis in the mining industry to analyze slags, ores, and mineral content of rocks. The results are used to make quick decisions for both mining and beneficiation of metals. For example, X-ray systems which provide rapid on-stream analysis of the slurries at desired points Fn metallurgical processes have recently been developed. The successful application of these systems has moved the milling process a step closer to fully automatic control.

Jan 1, 1969

By B. G. Cousins, L. Racine, R. S. MacPhail

"FLEX 31 is a chemically enhanced sodium isopropyl xanthate that has shown improved collection properties over SIPX for copper-bearing and copper-activated minerals. Characteristics such as improvement of recoveries with lower dosages and high pyrite and pyrrhotite rejection capabilities have all been exhibited by FLEX 31.The most improved results have been seen insphalerite flotation. Plant trial work carried out in the zinc circuit at the Louvicourt Concentratorin northern Quebec has produced data showing superior grade and recoveries from rougher concentrates that previously had not been attain-able with other reagents effectively. The improvement over SIPX adds up to an almost$1,000,000 annual improvement on the mine’s bottom line at present zinc prices.IntroductionSodium Isopropyl Xanthate (SIPX) is one of the most popular flotation chemicals on the market today. Somewhat more specific than amyl xanthates, SIPX is used in a variety of ores like copper/zinc, lead/zinc, arsenopyrite/pyrite, and many others (Melis et al., 1991). An investigation carried out by Tennants Research Technology Applications (TRTA), a division of Charles Tennant & Co. (Canada) Ltd., produced a chemically enhanced SIPX that has shown all the advantages of normal SIPX along with improved recoveries of copper and copper activated minerals. The new product has been named FLEX 31. Currently, FLEX 31 is manufactured at the Prospec Chemicals, another division of Charles Tennant & Co. (Canada) Ltd.A large amount of laboratory testing pro-grams have been carried out with FLEX 31 todate (MacPhail and Cousins, 1995; Cousins and MacPhail, 1996). One of the minerals that has a defnite affinity to improved fotation is sphalerite (ZnS). Once activated with copper sulphate, sphalerite has produced some of the most spectacular test work when FLEX 31 is compared directly to SIPX. Plant trials of FLEX31 at Aur Louvicourt Inc. carried out in 1995show that FLEX 31 is far superior to SIPX for activated sphalerite flotation."

Jan 1, 1997

By Robert MacPhail, Louis Racine, Bret G. Cousins

"Sodium Isopropyl Xanthate is employed in a wide variety of sulphide flotation procedures due to the specificity over other xanthates and the cost savings over other sulphide collectors such as thionocarbamates, xanthogen formates and dithiophosphates. An investigation carried out by Tennants Research Technology Applications (TRTA), has produced a chemically enhanced SIPX that has shown all the advantages of normal SIPX along with improved recoveries.Currently, FLEX 31 is manufactured at the Prospec Chemicals xanthate plant in Fort Saskatchewan, Alberta, Canada. Prospec, founded in 1983, produces approximately 4500 tonnes of xanthates per year and is presently undergoing expansion to produce approximately 6000 tonnes. The proprietary process for FLEX 31 is a new addition to plant operations that include the production of xanthates, thionocarbamates and xanthogen formates.This paper will cover the testwork on the zinc flotation circuit at the Louvicourt Mine in Val d'Or, Quebec. This testwork indicated that FLEX 31 could replace SIPX due to the ability of the FLEX to improve zinc flotation kinetics without adversely affecting final concentrate grade. FLEX has presently replaced SIPX in the zinc circuit at Louvicourt.BackgroundThe Louvicourt deposit is hosted by greenschist facies Archean volcanic rocks located in the southeast portion of the Abitibi Greenstone Belt. In the Val d'Or area, the volcanic rocks form an east-west striking, steeply dipping and south-facing sequence composed of thick mafic and ultramafic flows of the Lower Malartic Group.The joint venture has three partners-Aur Louvicourt Inc. (30%), Novicourt Inc. (45%) and Teck Corp (25%). Aur Resources holds 30% interest through Aur Louvicourt, a wholly owned subsidiary and is the operator of the project. Novicourt Inc. is 60.9% held by Noranda.Approximately 75% to 85% of Louvicourt's revenue comes from the sale of copper; 10% from gold (in the copper concentrate); 7% from zinc and 3% from silver (also in the copper concentrate) The copper at Louvicourt is fairly ""fast floating"". About 60% of the copper in the ore can be concentrated in the first flotation cells with feed grades of approximately 4% copper.The initial testwork and pilot trials had indicated that it would be difficult to achieve zinc grades over 52% and recoveries would have to be kept at a level amenable to salable concentrate grades. The actual mill results, with a fine regrind, achieved zinc grades of 55% to 56% at about 75% recovery."

Jan 1, 1996

By Sanggono Adisasmito

"The quality of the higher education in Indonesia is being improved by implementing a program financed by the World Bank under a project named QUE (Quality for Undergraduate Education). The investments are provided to selected study programs through a competitive selection process. The grant finances staff development, the purchase of equipments, textbooks, consumables, technical assistance, and incentives for outstanding faculties such as teaching grants, project grants, lecture note awards, and educational policy studies. These additional investments are provided to produce chemical engineering graduates that will compete beyond the national market.Chemical Engineering Department of Institut Teknologi Bandung in Indonesia has been selected to receive the QUE grant beginning the year 2000 and ending the year 2004. The department is actively involved in the mineral processing issues, particularly in the aspects of energy supply and the environmental protection. The activities are distributed in different laboratories and areas of expertise, such as: thermodynamics and utility systems, process equipment, chemical reaction and catalysis, microbiology and bioprocess engineering, process control, ceramics, as well as polymer and membrane technology. The main objectives of the QUE project are to improve the undergraduate program in the following aspects: Relevance, Academic atmosphere, Institutional management and commitment, Sustainability, as well as Efficiency and productivity, or abbreviated as RAISE. At the end of every fiscal year, the progress of the program is evaluated to measure the effectiveness of the project.The achievement of the QUE project objectives were assessed using performance indicators developed during the program design. There are six indicators to measure the performance of the individual program of study, such as: (1) Admission Test score, (2) average students' Grade Point Average (GPA), (3) average graduates' length of study, (4) graduates' waiting time before getting first job, (5) Test of English as Foreign Language (TOEFL) score, (6) Graduate Record Examination (GRE) score. Essentially, the RAISE evaluation criteria will be used to perform three main functions, such as (1) to measure the achievement through the six quantitative performance indicators, (2) to support the progress of evaluation and reporting throughout the implementation of the program, (3) to provide a universal framework for qualitative evaluation."

Jan 1, 2003

By Ernesto de la Torre, Karla Velín, Alicia Guevara

"The following study shows the improvement and simulation of a gold recovery plant of 24 t/day of capacity by gravity concentration, flotation and leaching. The ore processed had grades of 6 g/t Au, 15 g/t Ag, and 0.69 %Cu with the mineralogy consisting of 2 %chalcopyrite, 12 %pyrrhotite, 7 %plagioclase and 50 %quartz. The recovery process starts with crushing the ore followed by grinding it further in a ball mill. The ground ore is then concentrated in a Falcon centrifugal concentrator with concentrate being processed by amalgamation process. Gravity tails are sent to a flotation circuit where the copper minerals and some gold are concentrated. Lastly, the flotation tailings undergo cyanidation for gold recovery. Currently, the overall recoveries are 82.8 %Au, 49.6 %Ag and 99.1 % Cu. The optimization was developed in the laboratory using a Wilfley table by gravity concentration. Flotation tests in the laboratory were performed using potassium amyl xanthate and pine oil. Lastly, cyanidation was then performed on the flotation tailings. The results showed the optimum concentration of sodium cyanide in cyanidation is 2 g/L, which produced an increase in gold recovery from 30% to 44%. The reduction of diameter particle from 132 to 80 µm also produces an incremental recovery of gold and silver from 11% to 21% Au and 0.4 to 3% Ag in gravity concentration. Likewise in the cyanidation the recovery of gold and silver has shown a rise from 44 to 62% and 8 to 32% for Au and Ag respectively. However, the flotation method the gold recovery is reduced from 68 to 30% Au by reducing the particle size. Computer simulations using the programs, Moly-Cop and ModSim were performed to determine optimum parameters for the recovery of precious metals at the gold recovery plant."

Jan 1, 2014

By M Darby, B Burdett, F Lovell

The results of the process control improvement project aimed at improving the quality of Australian Bulk MineralsÆ (ABM) iron ore pellets produced by four vertical shaft furnaces are very positive. These results are achieved through process stabilisation and optimisation, improvement in process monitoring and taking early corrective actions when operating variables were outside the target ranges. A number of benefits are obtained from this project. These benefits include: More consistent and improved pellet quality. The average cold compression strength (CCS) value of pellets produced during the eight-month trial is 260 kg/pellet, which is 16 kg/pellet higher than that produced during the 12 months prior to the trial (244 kg/pellet). Reduction in the heat input by eight per cent, from 727 MJ/tonne to 668 MJ/tonne. Reduction in bentonite rate by six per cent, from 7.1 kg/tonne to 6.7 kg/tonne. Increase in the furnace throughput rate by four per cent and additional production of 10 000 tonnes per annum through process stabilisation. Better understanding of the process behaviour. This knowledge is valuable not only for setting the target operating conditions but also for developing the ABM expert system to control the process.

Jan 1, 2005

By M. J. Swan, W. C. Foshee, R. R. Klimpel

The large volume of water used in coal preparation plants makes water recycling a necessity. Economical cleaning of dirty water usually requires flocculation with an efficient organic polyelectrolyte. This paper discusses identification of optimum flocculant systems. Supporting laboratory data with on-site tests and full-scale field trails supplies information necessary for matching the polymer to the plant.

Jan 1, 1983

By W. C. Foshee

The large volume of water used in coal preparation plants makes water recycling a necessity. Economical cleaning of dirty water usually requires flocculation with an efficient organic polyelectrolyte. This paper discusses identification of optimum flocculant systems. Supporting laboratory data with on-site tests and full scale field trials supplies information necessary for matching the polymer to the plant.

Jan 1, 1979