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Rising energy costs are a growing concern among mine operators. At sur’ace operations, the size of a dragline, production requirements, pit geometry and layout, and operator skill are all factors in potential energy savings. The following tips are offered as a practical means to conserve energy demand, and can be applied to diesel fuel draglines as well.

Jan 7, 1980

By Leming Ou, Hongqiang Li, Li Zeng, Qiming Feng, Yiping Lu, Guofan Zhang

"The entrainment of sericite, especially in the presence of hydrophobic microcrystalline graphite, leads to the poor flotation selectivity of microcrystalline graphite ore. In this paper, it was attempted to reduce entrainment of sericite, selective flocculation of microcrystalline graphite using polyethylene oxide (PEO) was studied. For the sake of flocculate microcrystalline graphiteselectively, flocculation tests of microcrystalline graphite and sericite single mineral were conducted.To investigate the effect of selectiveflocculation of graphite on entrainment of sericite in microcrystalline graphite flotation, batch flotation tests of graphite single mineral and artificial mixtures were conducted; theflocculationselectivity of PEO of different molecular weight (M.W.) was alsocompared inartificial mixture flotation. Inthe end, the structure of flocs in different particle size was studied by sieve analysis and microscopic observation. The resultsindicated that PEO of molecular weightone million andtwo million could selectivelyflocculate the microcrystalline graphite and reduce the entrainment of sericite at a lower dosage; further increasingof the dosage of PEO(M.W. ?two million) led to hetero-flocculation between graphite and sericiteandmadethe ash content of concentrate increase again."

Jan 1, 2014

By R. V. Ramani

"In this paper, the current status of respirable dust control in coal mine atmospheres is presented. The advancements in the engineering control of dust generation and entrainment, and of reducing the exposures are summarized. The results of the Health Surveillance Program are briefly reviewed. The results of research conducted in the Generic Mineral Technology Center for Respirable Dust are presented. The 1995 NIOSH criteria document on respirable coal mine dust is briefly reviewed. The fundamental scientific and engineering issues in need of research are discussed. A detailed bibliography is attached.IntroductionFor coal mines in the United States, the current permissible exposure limit (PEL) of 2mg/m3MRE-equivalent concentration (an 8-hour TWA concentration measured gravimetrically) was established by Public Law 91-173: the Federal Coal Mine Health and Safety of 1969 (the 1969 Coal Act). This standard is reduced when the respirable quartz content in the dust sample exceeds 5%; the reduced standard in mglm3 is obtained by dividing 10 by the percent quartz. The OSHA and ACGIB PEL for respirable coal mine dust is also 2 mg/m3 , and OSHA PEL for respirable quartz is 100 µg/m3 . The 1969 Coal Act also prescribed two activities in the Coal Mine Respirable Dust Sampling Program and the National Coal Workers' Health Surveillance Program n to control respirable dust in mines, and the coal worker's pneumoconiosis (CWP) among the coal miners.There are three principal methods by which personal exposures to respirable dust are controlled. The first is engineering control where the aim is to reduce the concentration in the mine atmosphere to or below the mandated level. The second is the provision of personal protective devices which allow the miner to work in dusty atmospheres without increasing personal exposure. The third is the use of administrative controls where the miner's exposure is controlled through work schedules and procedures to keep miner exposure at or under the mandated levels. The 1969 Coal Act specifically prohibits the use of respirators in lieu of environmental control. The compliance sampling program essentially does not give any credit to the use of administrative controls."

Jan 1, 1998

By Arthur E. Focke

IF a metallurgist employed in an industry producing mechanical parts or assemblies wishes to make the most of his opportunities he will be concerned with every use of metals in that industry. He will not only take part in the testing and treating of the metals used but will assist in their selection and study their behavior in processing and in service. In addition, he will attempt to develop an understanding of the problems involved in the use of the metals in all plant tools and equipment. Metallurgists that follow this course will soon recognize that frequently too little thought is given to the effect of the design of parts on the way the metal in them is expected to behave in service. He will come to realize that changes in the design of a part will often be much more useful than changes in the hardness, strength, composition, or structure of the metals used in them. Does this mean that a metallurgist is out of place in these industries and that he should leave the field to others or be content to fill only a minor role?

Jan 1, 1947

By J. Ipinza, J. P. Ibáñez, Casas J., S. Cortés

Copper powder generated during the treatment of electro-metallurgical bleeds by reactive electro- dialysis (RED) had totally reduced the content of ferric ions in acidic synthetic electrolytes (Cu (II)- Fe (III) – H2SO4). In batch and columnar experiments 100% of the ferric ions were reduced to ferrous ions with an extremely high kinetics. A preliminary conceptual design for reducing ferric ions based on an integrate RED- Column for treatment of electro-winning bleed system is discussed. This system is able to recover simultaneously sulfuric acid and copper powder, which will reduce ferric ions. INTRODUCTION It is well known the negative effect of ferric ions in the copper electro-winning process. The increase of ferric content in the electrolyte reduces the current efficiency, i.e., there is an increase in the energy consumption, and changes the surface morphology of the copper deposit (Das, Gopala & Krishna, 1996; Vargas & Parra, 2013). The increase of the specific energy consumption due to the loss of current efficiency occurs by the reduction reaction of ferric to ferrous ions in the cathode, at the anode the ferrous ions are slowly oxidized to ferric ions (Shaw, Dreisinger, Lancaster, Richmond & Tomlinson, 2004). To control the level of iron in the electrolyte, bleeds are needed; this bleed electrolyte containing copper, sulfuric acid, cobalt, iron and other impurities normally is waster, which increased the production cost of the plant (Milbourne, 2002; Mckevitt & Dreisinger, 2009). Then, permanent efforts oriented to treat those bleeds to avoid losses of valuables components are made; among them are use ion exchange resins (Shaw et al., 2004; Mackevitt et al., 2009), chemical precipitation (Izadi, Mohebbi, Amiri & Izadi, 2017) and electrodialysis (Cortés, Ipinza & Ibáñez, 2013). The last one allows to the simultaneous recovery of sulfuric acid and copper powder. If one of the valuables obtained by treating the bleed can be used to reduce ferric ion concentration in the electrolyte could be an important asset. This issue at laboratory scale is reported in this work, the use of copper powder, generated by reactive electro-dialysis when treating synthetic acidic electro-metallurgical bleeds, for reducing ferric ions in acidic electrolytes.

Jan 1, 2019

By T. L. Barone, J. R. Patts, L. D. Patts, S. J. Janisko

"Controlling float coal dust in underground coal mines before dispersal into the general airstream can reduce the risk of mine explosions while potentially achieving a more effective and efficient use of rock dust. A prototype flooded-bed scrubber was evaluated for float coal dust control in the return of a continuous miner section. The scrubber was installed inline between the face ventilation tubing and an exhausting auxiliary fan. Airborne and deposited dust mass measurements were collected over three days at set distances from the fan exhaust to assess changes in float coal dust levels in the return due to operation of the scrubber. Mass-based measurements were collected on a per-cut basis and normalized on the basis of per ton mined by the continuous miner. The results show that average float coal dust levels measured under baseline conditions were reduced by more than 90 percent when operating the scrubber. IntroductionAirborne coal dust is a byproduct of coal production, and engineering controls exist to deal with both the respirable dust health hazard as well as the float dust explosion safety hazard. Float coal dust, smaller than 75 µm (0.003 in.) in size, can deposit throughout mine entries and propagate explosions that had been initially fueled by methane gas. The inertization of float coal dust with rock dust helps prevent a potential secondary float coal dust explosion, but a preferable course of action is to significantly reduce the hazard by removing float coal dust from the airstream before it has the opportunity to deposit on the mine’s surfaces.Since 1970, disasters due to explosions in underground coal mines have caused 201 deaths in the U.S. mining industry, including 29 deaths in a single mine explosion in 2010 (Wade, 2010; U.S. Mine Safety and Health Administration, 2015). The U.S. National Institute for Occupational Safety and Health (NIOSH) had initiated a fiveyear research project that aims to investigate methods and technologies to reduce the potential for secondary coal dust explosions by the purposeful capture and/or suppression of float coal dust prior to its deposition on the mine roof, rib and floor (NIOSH, 2013). The project aims to evaluate the efficiency of methods to reduce longwall and belt airway float dust in the general airstream as well as methods to capture it at or near the source. Prioritization is given to longwall sections given the amount of coal produced relative to continuous miner sections, but the research is open to technologies that may be adapted from one method of mining to another."

Dec 1, 2016

By E. Grygiel, J. Haynes, T. McNider

Jim Walter Resources Blue Creek No. 3 Mine was opened in one of the most gassy coal beds in the United States. Although face ventilation requirements exceeded 14,000 cfm (6 .6m3/s) air, continuous miner sections experienced an unacceptable frequency of frictional ignitions. Modifications offered primarily by the U. S. Bureau of Mines such as diffuser fans, water spray fans, and slow speed cutting motors were used with little success. However, laboratory tests conducted at the U. S. Bureau of Mines indicated that an increase in bit attack angle from 50° to 55°-57° significantly reduced the chances of the bit causing a frictional ignition. An experimental miner drum was built using this concept coupled with a new bit designed by the Bureau and manufactured by Hughes Tool Company that better protected the bit steel shank with a carbide cap. It was installed on a continuous miner and placed in an area of the mine prone to ignitions. 50,000 tons (45,500 metric tons) of coal were cut without a frictional ignition. When the miner was withdrawn for rebuild and a machine with an unmodified cutting drum placed in service, two ignitions occurred before 10,000 tons (9,100 metric tons) were mined. Other machines have been rebuilt and are in service, and to date none have been known to cause an ignition.

Jan 1, 1987

By James O. Mawyer

Fuel is a major .cost for power generating utilities. Virginia Power is completing one of the nation's largest coal reconversion programs. As a result, 10 million tons of coal will now be used at six generating stations. Four of these stations are located on naviagable waterways. They consume over half of Virginia Power's coal. Historically, railroads have exclusively served these plants. In an effort to substantially reduce fuel cost, Virginia Power has reexamined transportation logistics and is proceeding with barge delivery. A phased approach was used by Virginia Power for the transportation program. Plant requirements were first identified. Coal sourcing issues were then examined. The concept of intermodal transportation was investigated. The bottom line cost savings was used as the criteria for continuing the project. The results thus far have been gratifying. Virginia Power has begun to implement barge transportation.

Jan 1, 1986

By Martin T

High methane content of the medium volatile metallurgical coal mined from the Coal Basin mines causes very difficult mining conditions. Rapid desorption into the mine ventilation system limits coal production, requires huge fresh air quantities and creates mine safety problems. In workings deeper than 2000 ft (600m) gassy coal and heavy cover create outbursting conditions. Cross-measure methane drainage has reduced ventilation requirements on advancing faces, but degasifica- tion of virgin coal is needed to improve mining Conditions.

Jan 1, 1982

By G F. Johansen

The erratic and localised occurrence of economic gold grades is a common feature of high-nugget effect gold veins. The nugget effect is a consequence of small-scale geologically controlled enrichment, and the inclusion or exclusion of sparse gold particles because of the sampling process. Such deposits do not always contain visible or coarse gold, and can be characterised by fine gold particles. Economic grade accumulations are generally contained within discrete oreshoots, which are surrounded by barren to low-grade material. Problems are often encountered where small sample types (eg drill core or channel samples) often vastly understate in situ grade, due to their general inability to intersect rare gold particles. As a result, the definition of grade and its distribution is often challenging, and leads to substantial resource uncertainty. Proxies, or indicators for grade, can help the geologist gain a better understanding of grade distribution and grade potential. These are based upon geological (eg mineralogical, textural, etc) and/or geochemical (eg specific elemental ratios, fluid inclusion compositions, elemental correlations, etc) criteria. The paper discusses the use and application of such proxies through three case studies.

Jan 1, 2004

Construction workers may be exposed to hazardous dust containing crystalline silica during site preparation when drilling systems are used. The National Institute for Occupational Safety and Health (NIOSH) found that drill dust could be decreased by using wet or dry dust reduction engineering controls, enclosed cabs, and implementing a dust control program.

Jan 1, 2009

Construction workers may be exposed to hazardous dust containing silica when working in enclosed cabs during construction activities. The National Institute for Occupational Safety and Health (NIOSH) found that equipment operator exposure could be reduced by retrofitting air pressurization and filtration systems on existing cabs, using sweeping compounds on soiled floors, and implementing a dust control program.

Jan 1, 2009

By K. Scalise, M. Teixeira, K. C. Kocsis, J. Parrish

"This paper aims to introduce and discuss a newly developed algorithm, which can be uploaded on smart watches and other mobile devices to inform and protect underground personnel working in hot and humid environments. Using this algorithm, the metabolic rate (M) of a worker can be determined in “real-time”. In addition, besides warning signs and alarm signals emitted by the smart watch, the algorithm has the ability to determine work-rest time periods based on the worker’s physiological parameters (e.g. age, height, weight, gender) and the climatic parameters (Td, Tw, flow velocity). This paper also investigates whether a re-designed auxiliary ventilation system can provide appropriate work conditions in the production stopes. INTRODUCTION An underground environment with high temperature and humidity conditions generated from various heat and moisture sources can significantly affect the thermoregulation processes of the human body. This can lead to heat-related illnesses such as heat rash, heat cramps, heat exhaustion, and heat stroke. Heat stroke is a serious illness that carries a high risk of fatality, if the underground workers are not immediately treated and the climatic conditions are not corrected (McPherson, 1993). There are two methods used to control the climatic conditions in underground mines: (1) Using ventilation and cooling systems to reduce the thermal stress on the mine workers, and (2) Reducing the heat transferred to the ventilating air from major sources such as: strata, auto-compression, mining equipment, groundwater, blasting, etc. The heat from strata and auto-compression is transferred to the ventilating air at varying degrees, based on factors such as the virgin rock temperature (VRT), the thermal properties of the surrounding rock formations, and the surface air temperature. However, the use of mining equipment and blasting processes can be managed to reduce their contribution to the mines’ overall heat load. To provide appropriate work conditions, selecting the most suitable cooling method depends on the level of heat to be removed, the location of the problem areas, and economic constraints (Brake & Bates, 2002; McPherson, 1993). Because every mine is unique, it is essential to monitor the climatic conditions to select the most appropriate method of cooling. A majority of the time, simply adjusting or re-designing the auxiliary ventilation system can efficiently remove the heat and dilute the contaminants. This may involve moving the ducting system, changing the size of the duct, changing the size of the auxiliary fan, or switching from forcing to an exhausting fan arrangement. If the required air volumes are higher than the existing primary ventilation system can supply, other measures may need to be taken to increase the airflow delivery. This may include regulating the flow in some areas of the mine to increase airflow to the desired area, adding booster fans, or replacing the primary fans."

Jan 1, 2019

By Orica Chile, Orica Brasil, Orica Brasil Victor Morais, Kinross Paracatu Leopoldo Muñoz, Kinross Paracatu Luis Marinho, Gubio Barsottini, Orica Brasil José Vergara, Lucas Steffen, Orica Brasil Washington Vilas

In drill and blast activities, it has been a challenge to sculpt walls accordingly to what has been designed in state-of-art mining design software. Obviously, the perfection of making neat and smooth walls – using aggressive sources of energy, like explosives – are time-and-money consumable and, sometimes, even unnecessary. But undoubtedly, it is vital to guarantee solid walls, safe operations environment, beyond to avoid ore losses and pit constraints caused by poor rock breakage on detonation. Kinross Gold Corporation owns the biggest Brazilian Gold Mine, located in Minas Gerais state. Morro do Ouro mine has reached over 30 years of operation, and due its mature age, the complex has developed its pits, becoming them deeper and surrounded by high walls.

Feb 6, 2023

By O. Lopez

"Stringent regulations and increased arsenic presence in ore bodies being exploited have created the need for cost effective and environmentally compliant technologies to remove selenium and arsenic from mine waters and metallurgical waste streams. Existing treatment methods have high life cycle costs and/or produce residues that, due to their unknown stability over the long-term, may represent future liabilities. This results in high compliance costs and uncertainties which negatively impact existing operations and projects in permitting. Selen-IX™ is a new ion exchange based process that selectively removes selenium from mine impacted waters down to 1 ppb while producing a stable inorganic iron-selenium product. Results of piloting completed on streams generated from coal and copper-gold deposits are presented along with preliminary equipment sizing and life cycle costs of full scale treatment. An example of a commercially available system for arsenic removal using sulphide precipitation is presented. The benefit of this treatment method is discussed based on recently completed technical feasibility assessment including laboratory testing and preliminary engineering design. INTRODUCTION Selenium Due to the chemical similarity between selenium and sulfur, selenium substitutes sulfur in many minerals that can be found in a wide range of deposits including coal, base metal, precious metal, phosphate, and uranium. One of the main environmental challenges facing the industry in North America today is related to the removal of hexavalent selenium, e.g. selenate, to ultralow levels, typically between 1 to 10 ppb, from large flows of often cold water containing less than 1,000 ppb of selenium. Recent studies commissioned by the industry identified biological selenium reduction systems as the best available technology. Although the biological selenium reduction process is commercially proven in certain applications to remove selenium to ultralow discharge levels, the technology has been primarily applied to relatively low and constant flows of warm water produced by the Flue Gas Desulfurization (FGD) scrubbers in the power generation industry. The wide spread adoption of this treatment method by the mining industry is hindered by high capital and operating costs associated with treating large flows of cold water, lack of data and knowledge about the long term stability of solid residues produced by this treatment, and limited capacity of biological systems to respond to sudden changes in flow and/or mass load of contaminants. Furthermore, it has been reported that reaching discharge limits less than 3 ppb could be a challenge and that polishing treatment for the removal of BOD and phosphate maybe required to avoid the impact of the biological treatment which requires organics and nutrients, on aquatic environment downstream of treatment plants. Alternate treatment systems are being developed to overcome and/or completely avoid some of the challenges of biological systems. One such treatment system is BioteQ’s Selen-IX™ process which is purely physico-chemical treatment system."

Jan 1, 2015

Reduce exposure of longwall face workers to respirable dust generated during the advancement of roof supports. Approach Identify and implement current water-application and improved support-movement practices used to lower support-generated dust. Defining the Problem Bureau studies have shown that on some longwall faces support dust can contribute over 30 percent of the respirable dust exposure of face workers. Conditions contributing to high levels of respirable dust generation during support movement are: depth of cover greater than 1,000 ft; immediate roof consisting of coal top or friable shales; and face-air velocities in excess of 500 fpm. Moreover, at most longwalls, supports are advanced on the intake-air side of the shearer as it travels with the airflow. This places the shearer operators, and in many cases the support movers, downwind of support advance, thus increasing their respirable dust exposures.

Jan 1, 1984

By A. D. Prokop, J. P. Rider

Along with increased production from longwall units has come the likelihood of increased worker noise exposures. In recent years, equipment has become larger, more powerful, and noisier than its predecessors. For these reasons, the Mining Division of the National Institute for Occupational Safety and Health (NIOSH) is investigating worker noise exposure on longwall faces and researching possible solutions to reduce this exposure. Part of this research effort involves studying the effect of covering the underside of longwall shields with acoustical material to reduce reverberating noise along the face. Experiments using acoustical absorptive insulation to cover the undersides of the shields, shearer body, and the shield supports were conducted at the full scale simulated long-wall test facility located at the Pittsburgh Research Center. Sound levels were recorded every 1.5 m [5 fl] along a 15.2 m [50 ft] section of the simulated face for all of the conditions tested. The analysis of the data indicated that a 2.0-3.0 dBA noise reduction was achieved between the shearer drums and a 4.0-5.5 MA attenuation was attained upwind of the headgate drum.

Feb 24, 1997

By John A. Organiscak

The Bureau of Mines evaluated a new dust control technique for longwall personnel required to work at the tailgate end of the face. This technique utilizes a water-powered scrubber to clean a portion of the face air, which is discharged behind a brattice partition at the working area. Laboratory simulation of this system in a wind tunnel resulted in average efficiencies greater than 70 pct with system efficiency directly related to scrubber quantity. Underground evaluations indicated a similar direct relationship between scrubber quantity and system efficiency. Gravimetric measurements of respirable dust made during these underground evaluations resulted in average protection efficiencies ranging from 30.7 to 42.5 pct with increasing scrubber air quantity.

Jan 1, 1983

By Y. Faitakis

In the mining industry, maintenance is a key priority and a major expense. As mining equipment is large in scale, high in cost, and difficult to tow, it is key to maintain equipment on a timely basis. Breakdown in -40°C or away from a maintenance station can cause great costs in repair as well as lost production. It has often been quoted that about 5% of the North American production is lost every year due to unscheduled downtime. About one-third of the downtime is attributable to equipment failures. From this fact alone, it is evident that proper equipment maintenance can add tremendous value to the bottom line. As organizations and equipment become more sophisticated, maintenance expectations begin to evolve. This evolution can be traced through three generations: The first generation (1940?1950): A ?fix it when it broke? attitude prevailed during that time, mostly because the industry was not highly automated. The second generation (1950?1980): Automation and mechanization of the industry increased. The industry now was dependent on machines performing the majority of the work. Preventive maintenance (overhauls at fixed intervals) appeared as the first maintenance practice. Maintenance costs started to rise rapidly. The third generation (1980?): Assets become more complex. Failure modes are better understood and computerized maintenance methods are becoming mainstream. Condition-based maintenance (CBM) starts to gain ground as a cost-effective alternative, replacing the fixed interval overhauls. As corporations amalgamate and market places are becoming more complex, multi-functional teams become responsible for maintenance. At the beginning of the third generation, maintenance organizations began embracing technology to provide efficiencies in maintenance management. A strong push was made to transition from reactive maintenance to proactive maintenance. At the forefront of this push is condition-based maintenance.

Jan 1, 2004

By Y. Faitakis, G. J. Powley, C. Mackenzie

"In the mining industry, maintenance is a key priority and a major expense. As mining equipment is large in scale, high in cost, and difficult to tow, it is key to maintain equipment on a timely basis. Breakdown in -40°C or away from a maintenance station can cause great costs in repair as well as lost production.It has often been quoted that about 5% of the North American production is lost every year due to unscheduled downtime. About onethird of the downtime is attributable to equipment failures. From this fact alone, it is evident that proper equipment maintenance can add tremendous value to the bottom line. As organizations and equipment become more sophisticated, maintenance expectations begin to evolve. This evolution can be traced through three generations:The first generation (1940–1950): A “fix it when it broke” attitude prevailed during that time, mostly because the industry was not highly automated.The second generation (1950–1980): Automation and mechanization of the industry increased. The industry now was dependent on machines performing the majority of the work. Preventive maintenance (overhauls at fixed intervals) appeared as the first maintenance practice. Maintenance costs started to rise rapidly.The third generation (1980–): Assets become more complex. Failure modes are better understood and computerized maintenance methods are becoming mainstream. Condition-based maintenance (CBM) starts to gain ground as a cost-effective alternative, replacing the fixed interval overhauls. As corporations amalgamate and market places are becoming more complex multi-functional teams become responsible for maintenance.At the beginning of the third generation, maintenance organizations began embracing technology to provide efficiencies in maintenance management. A strong push was made to transition from reactive maintenance to proactive maintenance. At the forefront of this push is condition-based maintenance."

Jan 1, 2004