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By Luthie Els, Chris Coetzee, Roedolf Koekemoer, Casper Els, Olof Vorster, Frank Fereday

Three electric arc furnaces (EAFs) were constructed by Union Carbide at Tubatse Ferrochrome (TFC) in1975. This plant was expanded to four furnaces at the East Plant in 1985 and the gas cleaning system was enlarged without taking flow dynamics into consideration. In order to improve competitiveness, TFC has increased furnace capacity, partially substituted coal for coke, and changed the charge mix. These changes increase the heat and dust load into the air pollution control (APC) system. TFC embarked on a project to improve the APC capacity by: ?Quantifying the required off-gas capacity ?Optimising the aerodynamic flow through the system by means of Computational Fluid Dynamics (CFD) ?Converting the old Brandt Koyo top entry baghouses to bottom entry ?Upgrading the cleaning system ?Installing Gore-tex® ePTFE membrane filter bags The estimation of required off-gas capacity is traditionally done by rule-of-thumb methods such as specific extraction. A more elegant evaluation method was developed for simulating the effects of changes in charge mix on the furnace reaction gas volume and the APC system. Reaction gases are calculated by modelling the reactions taking place in the furnace and off-gas volumes are compared to both fan and baghouse capacity. This enables identification of bottle-necks in the off-gas system. CFD techniques were utilized to evaluate geometric imbalances and propose solutions to ensure optimal use of off-gas capacity. The system modifications were completed over several months and the modified equipment went into service in May2006.

Jan 1, 2007

1. Theory of Wet Dust Suppression Techniques Wet dust suppression is the utilization of a liquid for the control, reduction or elimination of airborne dust, or the suppression of such dust at its source. Effective control involves: a. The confinement of the dust within the dust producing area by a curtain of moisture. b. The wetting of the dust by direct contact between the particles and droplets of moisture. c. The formation of agglomerates too heavy to remain airborne, by combining small dust particles with each other and with the droplets of liquid. From the standpoint of economy, availability and safety, water is the ideal fluid. From the standpoint of effectiveness, however, it leaves much to be desired. As a result, a tech¬nique has been devised in which very small percentages of specially formulated dust control compounds are blended with water to greatly enhance its dust suppression qualities. The terms "dust control compounds, wetting agents and surface active agents" are frequently used interchangeably. Although dust control compounds represent a specific type of wetting agent, a great many wetting agents are far from satisfactory for dust control. "Wetting Agents" is a broad category which covers such items as emulsifiers, solubilizers, detergents, foamers, penetrants, thickeners, etc. Dust control compounds, on the other hand, are carefully formulated blends in which one or more special surface active agents have been incorporated.

Jan 1, 1972

By Leo R. Love

A comprehensive study of the environmental conditions of the area affected by the Colfax and Cheswick Power Stations is of extreme importance to Duquesne Light Company. The residents in the valley where the two plants are located have complained for many years about the emissions from the Colfax Plant which is of the 1920 to 1930 vintage and which has a capability of generating approxi¬mately 200 Mw. They were extremely happy to hear that the Company had plans for shutting it down, however, they were extremely unhappy to hear that we were planning to build another even larger one to take its place in the same vicinity, namely the Cheswick Plant with a capability of 570 Mw. They had visions of a plant twice the size of the Colfax Plant and belching out twice as much smoke. A few of the citizens from that area were most vehement at the public hearings that were held by the Allegheny County Air Pollution Bureau for obtaining an installation permit. With two power plants already existing in that area (Duquesne Light Company's Colfax Plant and West Penn Power's Springdale Plant), the primary concern of the Allegheny County Air Pollution Control Bureau was that the Cheswick Station might increase air pollution levels beyond what they considered to be dangerous limits. It became very evident that the Allegheny County Air Pollution Control Bureau would be extremely reluctant to grant installation and operating permits unless they were satisfied that the new plant would not increase local pollution levels and that we were taking sufficient steps to monitor the emissions from our plants and also the ambient air in the general area. We concluded that an extensive air pollution monitoring program must be conducted in the area to determine the effects of the operation of our plants. The program was conceived with our consultants, NUS Corporation of Rockville, Maryland, and was begun in June, 1968. It was designed to accomplish several things: 1. Determine the effect on the ambient air of the operation of each of

Jan 1, 1972

By S. K. MONDAL, K. K. K. SINGH, S. Singh, R. K. TIWARY, S. K. Chaulya, G. C. MONDAL, R. S. Singh, T. B. SINGH

In this work, a comprehensive field study was carried out to measure the background air quality status and identify the air pollution sources from opencast mines around a heritage site in India. Air quality modeling was conducted to envisage dust concentration due to existing and closed mines in the region. The air quality modeling exercise predicted that particulate-matter levels of PM10 and PM2.5 might increase in the ranges of 3.2 to 23.1 and 2.1 to 8.9 μg/m3, respectively, due to mining activities when some of the closed mines will be operated in the region without controlled emission. The predicted total PM10 and PM2.5 at the selected receptor locations were in the ranges of 86.39 to 194.89 and 34.82 to 99.55 μg/m3, respectively. Adequate measures were suggested to control air pollution from mining activities, and an intelligent dry fog system was designed to suppress dust emission efficiently from mineral processing plants and opencast mines. The developed system has special features for facilitating eco-friendly mining.

By D. Duvris

The main objective of this work was to quantitatively investigate exhaust emission levels, as related to maintenance (service) intervals, during the operation of diesel-powered equipment at an underground bauxite mine in Greece. Such emissions depend on a great number of parameters, including the type (technology) and tuning of the engine, the type of work performed as related to the engine workload, suggested maintenance intervals, the altitude, the temperature and the humidity of the atmosphere of the underground mine, the properties of the fuel, the operator's training and experience level. Necessary ventilation quantities were calculated based on exhaust gas concentration measurements, site specific relationships between pollutants and adjusted air quality indices. Diagrams comparing necessary and recommended air flow for several equipment groups featuring two engine types and for different maintenance intervals are presented.

Jan 1, 1998

Exposure to respirable contaminants in mine atmospheres has long posed a serious hazard to miners. The control of these hazards, some of which can have sudden and catastrophic effects and some others, slow and long enduring consequences, has been a major concern for labor, management and government alike. This concern has manifested itself in four primary mechanisms of control -- (1) regulatory control through minimum standard setting by the passage of mine health and safety laws, (2) engineering control through design and operation of mines according to the best recommended practices, (3) medical control through periodic physical examinations, wearing personal protection devices, etc., and (4) legal and social control through workmen's compensation laws for occupation related health rleterinratinn_

Jan 1, 1988

By R. V. Ramani

"Exposure to respirable contaminants in mine atmospheres has long posed a serious hazard to miners. The control of these hazards, some of which can have sudden and catastrophic effects and some others, slow and long enduring consequences, has been a major concern for labor, management and government alike. This concern has manifested itself in four primary mechanisms of control -- (1) regulatory control through minimum standard setting by the passage of mine health and safety laws, (2) engineering control through design and operation of 'mines according to the best recommended practices, (3) medical control through periodic physical examinations, wearing personal protection devices, etc., and (4) legal and social control through workmen's compensation laws for occupation related health deterioration:-The respirable contaminants in mine atmo¬spheres are toxic and explosive gases, toxic and explosive dusts, diesel exhaust particu¬lates, radon progeny, etc. Perhaps the most important of all these and the most widely occurring in mine atmospheres is respirable dust, an inevitable product of fragmentation, a unit operation fundamental to all mining operations. In fact; the-most serious health hazard for workers in the mining and minerals processing industries is still the exposure to respirable dust, and solutions to the problem of respirable dust disease remain to be found.The 1969 Coal Mine Health and Safety Act and its provisions for the respirable dust standards in underground coal mines are briefly reviewed. An overview of the research accomplishments in meeting the standards is presented. The current state of knowledge on the effectiveness of the standards and the new and emerging problems are discussed. A brief summary of the research programs of the Generic Technology Center on Respirable Dust is presented.In general, underground mines are becoming increasingly safe. The mine atmospheric environment is definitely improving * Professor and Head, Department of Mineral Engineering,-The Pennsylvania State University, University Park, PA for the better. Significant progress has been made in lowering the dust levels in mines. It is generally agreed that mines are less dusty today than they were a decade ago. However, as long as the risks of occupation-related diseases are not completely eliminated, vigilance can hardly be relaxed, and the search for engineering solutions must be intensified."

Jan 1, 1988

By W. Bryszewski

As a result of strategic analysis in respect of the needs for air quality management a new advanced and holistic approach to air quality management process was introduced in the North West Province (NWP) of South Africa. The process is based on the principle of co-operative management. It involves both active participation of all Interested and Affected Parties (I&AP) and the holistic approach to solving problems with the underlying principles of shared ownership and sustainable development. The process consists of the followings phases: ? Industrial process quantification ? Quantification of impacts ? Formulation of the required control measures ? Definitions of certificate conditions ? Implementation of an adequate compliance management system at company level ? Ongoing co-operative air quality and system management with the strategic objective of continuous improvements The system has been successfully introduced in the North Province and proved to be an effective management tool and aids assurance of sustained environmental ability to cope with the pressure of industrial developments. The benefits and effectiveness are discussed using Hernic Ferrochrome as an example. Hernic Ferrochrome is one of the first companies, which successfully implemented this system.

Jan 1, 2004

The air recovery from a flotation cell is the fraction of inlet air which overflows the weir as un-broken bubbles. The air recovery is an important factor in froth phase phenomena; such as gangue entrainment and froth recovery. Increasing the air recovery, results in a higher recovery of attached mineral particles. Air recovery can be measured experimentally on plant using image processing of the top surface of an overflowing froth. The air recovery is directly linked to froth stability and the bursting rate of the bubbles at the froth surface, making it very difficult to predict. Experimental results show a very strong correlation between the superficial velocity of the inlet air and the superficial velocity of the air leaving the cell through the froth surface due to bursting, calculated from the experimentally measured air recovery. This correlation holds over multiple banks from different plants. Development of a power law equation around the inlet air velocity and the bubble solids loading on the froth surface allows the superficial air velocity through the top surface of the froth to be predicted, and from this the air recovery. This model is valid for use when operating beyond the peak in air recovery.

Jan 1, 2014

By P. D. Morrell

Jetbelt is the trade name for the air supported belt conveyor. It does not use troughing rollers. Jetbelt conveyors support the conveyor belt on a thin film of air. The belt rides in a steel trough which has small holes equally spaced along the bottom of the trough. Air comes through the holes under the belt, thereby supporting the belt. The air pressure is provided by a single centrifugal blower that creates very low pressure, between 249 Pa and747 Pa [10" and 30" water column], depending upon the tonnage being conveyed. The volume of air required ranges between .001415 m3/S and .00283 m3/S [3 and 6 CFM] per lineal foot of conveyor. Therefore, depending on tonnage being conveyed, a 304.8m[1000'] conveyor might require as little as 1.415m3/S [3000 CFM] or as much as 2.83m3/S [6000 CFM.]. (See Figure 1) Horsepower requirements can be less than troughing idler conveyors and considerably less than some other forms of bulk conveying. Savings are most significant in horizontal and down hill (regenerative) conveyor designs. Horsepower to lift material, of course, does not change.

Jan 1, 1984

By Veliko Kertikov

Complicated processes of heat exchange and evaporation, leading to changes in the temperature and humidity of the ventilating air flow, take place during the driving of headings. In the case when virgin rock temperature is high, the increase in air temperature and humidity is significant. This causes a deterioration of climatic conditions in the headings. Procedures for predicting the changes in air temperature and humidity are discussed, together with appropriate calculations and computer programmes. Predicted results for example scenarios are used as a background for the selection of approaches and means to improve the climatic conditions in a dead-end heading using auxiliary ventilation.

Jan 1, 1997

By F. H. Wheeler

CONSIDERING the nature of this audience, I perhaps, in addressing you on the subject of air transportation as related to the mining industry, should speak with tongue in check or at least with some reservation. I know full well that many of you, veterans in the great mineral development in Canada, are perhaps more conversant with the overall aviation picture than I, for aviation to you has been the means to an end, and in many instances has been part and ?parcel in the success of your particular projects, in the form of the initial means of transport. I feel, however, that we in this room today have somewhat parallel geographic interests - yours in relation to what is in the ground, mine in the air - and also in the forests and in the streams - aviation, hunting, and fishing - things which have occupied my attention practically all my adult years. In the light of what has gone. before, and in view of present developments, I think you will agree with me when I say that I do not think there could be a more intriguing pursuit than playing a hand in rolling back Canada's tremendous northern frontiers, even if, at this stage, we have made but slight impression on the untold opportunities which lie in our wide-spread, undeveloped areas.

Jan 1, 1956

By Austin Whillier

INTRODUCTION Use of air-cooling or refrigeration equipment in underground mines is needed when conventional ventila¬tion techniques do not maintain acceptable environ¬mental temperatures in working areas. Because refrig¬eration can be very expensive, it should be implemented only after all possible and practical steps have been taken to eliminate or reduce heat sources in the mine. As an example, to prevent the main ventilation fans from contributing heat to mine air, they should be located in the air return and not in the air intake. It is particularly important to prevent any direct contact between hot water and ventilation air, especially in mines which encounter large flows of hot fissure water. Any water hotter than the prevailing wet-bulb temperature of the ambient air must be removed by pipes located as close as possible to the water source. This hot water must not be allowed free contact with the incoming ventilation air at any time during the water's passage out of the mine. Although insulation of the pipes carrying the hot water is seldom necessary, direct contact between the air and the water must be prevented so the warm water cannot evaporate. REVIEW OF COOLING PRACTICES Spot Coolers vs. Centralized Refrigeration To eliminate a few specific hot places in an otherwise cool mine, it is possible to use devices known as "spot coolers." A typical spot cooler that uses chilled water is shown in Fig. 1. These devices consist of self-contained refrigeration units that are often mounted on rail cars for haulage to hot spots. The cooling capacities of such spot coolers usually are limited to about 100 kW or 30 "refrigeration tons." A refrigeration ton represents a cooling rate that produces 1.0 st of ice in 24 hr; that is a cooling rate of 3.517 kW (200 Btu per min). Typically, the electric-power consumption to drive the compressor motor of the refrigeration plant in mines is 1.0 kW per refrigeration ton, corresponding to a coefficient of per¬formance of about 3.5. The principal difference between spot coolers and centralized refrigeration plants is the method of re¬jecting heat from the refrigeration system. Centralized refrigeration plants always discharge heat into the reject or return airflow of the mine; often that is the primary influence in selecting the location for the underground refrigeration plant. Heat from spot coolers usually is rejected into drain water or into air that is not flowing to the location requiring the cooling. As a result, spot coolers remove heat from troublesome hot spots in the mine, injecting that heat-plus the electrical energy used by the cooling unit itself-into other working areas where the ambient conditions are cooler. In effect, this is "robbing Peter to pay Paul." In deep, extensive mines, spot coolers usually pro¬vide only temporary and, over the long term, expensive solutions to localized cooling problems. Centralized re¬frigeration plants are preferred for such mines, with cooling distributed throughout the mine as required. Fig. 2 illustrates a typical underground centralized re¬frigeration plant. Centralized plants lend themselves to improved maintenance at reduced costs while offering the economy of size. Refrigeration plants of larger unit sizes have considerably lower initial costs than smaller unit sizes. The remainder of this chapter is devoted to large refrigeration plants, with no further consideration of spot coolers. Cost of Refrigeration Total Cost: The total cost of refrigeration amounts to about $200/kW of cooling per year (1981 US $). This total cost breaks down into approximately three equal parts: 1) Financial charges, which include the interest and amortization on the capital cost of the initial installation, and the cost of necessary underground excavations. 2) Operating and maintenance costs which include the cost of the electric power to drive the refrigeration plant's compressors. 3) Distribution costs which include costs for pump¬ing, insulated piping, and air-to-water heat exchangers. The local cost of electric power, the number of operating months per year, and the method of refrigera¬tion distribution all contribute to the actual costs in¬curred in a given application. However, the variations usually are limited to no more than ±30% of the $200/ kW per year total cost figure. Cost Per Ton: Refrigeration cost per ton of mineral production can be calculated if the annual production tonnage from the refrigerated section of the mine is known. In most cases, this cost will be less than $1 .00/t. However, in deep mines with high rock temperatures, such as those found in South Africa, the total cost of refrigeration can increase to several dollars per ton of broken rock. Distribution In deep extensive mines, distributing refrigeration often accounts for about half the total cooling costs. As a result, careful consideration and planning must be

Jan 1, 1982

By Dale S. Preece, Ruilin Yang

Shock wave physics is an important part of air-deck behavior since the bulk explosives in the column impart a shock into the air-deck where the air shock then passes through the air-deck at a rapidly attenuating velocity. Through both high-fidelity modeling and shock physics theory it is shown that the resulting pressure in the air-deck is two orders of magnitude less than the detonation pressure of the explosive. The induced air blast reflects from the bottom of the borehole and this reflected pressure, even though doubled, is still approximately two orders of magnitude less than the detonation pressure. Air-shocks will ring back and forth in the air-deck for a few tens of milliseconds while the adjacent explosive column(s) are detonating. Transmission of the initial shock through the air along with reflections is an intensive energy consuming process. Energy balance results in shock heating of the air and a temperature increase. However, the increased temperature of the air is also orders of magnitude less than that of the explosive detonation products immediately behind the detonation front. Replacing high energy explosives with zero energy air-decks in a blasthole will always have a negative impact on the adjacent rock fragmentation and movement.

Jan 1, 2016

By P. Pal Roy, R. B. Singh

"This paper focuses on a number of interesting results to establish the theory and principle of air-deck blasting. It also gives the mechanism of breakage that takes place in air-deck blasting under varying charge load conditions. With these aspects in mind, the mine management can implement this up-coming technology to enhance safety and higher productivity. IntroductionThe method of air-decking has become an increasingly popular technique in production and presplit blasting. In the blasthole, an explosive column is combined with an airchamber. The main aim of the technique is to control breakage through effective distribution of explosive energy and thereby enhance uniform rock fragmentation. An air column lowers the initial pressure of the explosive products and simultaneously increases the time of interaction for the detonation front with the surrounding rock, which enhances rock breakage.To study air-deck blasting, CMRI initially conducted experiments using indigenously developed, low-cost wooden spacers of different sizes and strengths. Air-deck blasting was first tried using these spacers in 1993 at Jambad OCP, ECL and Chasnalla OCP, IISCO. The experiments were extended in 1994 at Bermo Mine, DVC. The results were subsequently published by Pal Roy et al., in 1995. It is worth mentioning that the performance of air-deck blasting during this period was only compared with conventional blasting practices without going into detail of the theory behind the process."

Jan 1, 2001

By C. R. Woodcock, J. S. Mason

In almost any situation where particulate or granular bulk solids have to be conveyed, whether for a distance of a few metres or for many hundreds of metres, a pneumatic conveying system may be considered. Conveying by pipeline is convenient and clean, but running costs may be substantial because of the heavy air consumption and the trend has therefore been towards dense-phase transport in which the ratio of conveyed solids to conveying air is kept high. This paper concentrates on air-float conveying, which can be regarded as an extreme form of dense-phase conveying where the bulk solid is fluidised in a channel and then caused to flow, either by inclining the channel or creating a pressure gradient along 'it. Various designs of air-float conveyor for upward, horizontal and down- ward transport of powders are discussed, with special emphasis on the latter case. In situations where a continuous downward slope can be provided, the combination of air-fluidisation and gravity flow results in a conveying system that, for many kinds of bulk particulate solid, would be hard to better in terms of convenience, reliability and economy. The paper is concluded with a discussion of design features and performance of practical air-gravity conveyors, involving the handling of various bulk particulate solids, both in research and in full-scale industria1 applications.

Jan 1, 1980

By A. H. Bell

The general principles of the gas-lift will not be described in this paper. Only specific details that have not been fully discussed in previous papers, or results that do not fully coincide with conditions previously described, will be dealt with. The principal points to be emphasized and for which supporting data are furnished are as follows: 1. Gas-lift installations usually have comparatively high efficiencies as compared with standard pumping equipment, when reduced to a basis of barrels produced per horsepower installed. 2. Advantages of high-pressure plants from the standpoint of operating efficiency and for the application of the gas-lift early in the life of flowing wells. 3. Evidence of increased ultimate yield through conservation of gas by the gas-lift. 4. Possibility of development of new equipment to increase efficiency of the gas-lift. 5. Indications of the advantages of repressuring as a means of stabilizing gas-lift wells and as a means of increasing ultimate yields. TyPes of Installation The gas-lift installations of the more important companies in California have been of the central-plant type wherever field conditions would permit. This has resulted in greater flexibility and lower installation costs per well than could be obtained with individual well units. In general discussions of the gas-lift method of production, the installation costs are frequently referred to as being too high for economical operation. If the field conditions are carefully analyzed and the plant designed with the idea of obtaining high operating efficiencies, the installation cost per well can be lowered sufficiently to compare favorably with individual well-pumping units, when the operating advantages are considered. Much greater production per horsepower can be obtained with the gas-lift than is possible with pumping equipment. Table 1 shows the unit sizes and costs of gas-lift installations of three companies in the Los Angeles basin. The cost of walking beams, rods,

Jan 1, 1928

By L. A. Schutz

Personnel of the Bureau of Mines have conducted investigations in the principal asbestos mines and mills in the United States, to determine the concentration of airborne asbestos fibers in the workplace, and to establish the exposure of workers to such fibers. 'The surveys were conducted using the sampling and evaluation method recommended by the National Institute for Occupational Safety and Health. The method consists of collecting the air-borne sample on filters and, after appropriate sample preparation, counting the fibers utilizing phase contrast microscopy. The results of the investigation show that fiber concentrations are low in the asbestos mines but high in the asbestos mills, ranging well above 5 fibers/ml of air based on a count of fibers greater than 5 urn in length.

Jan 1, 1973

By J H. J Holtzhausen

Never has there been more focus on the health, safety, and well-being of our employees at the workplace. Ever evolving expectations of individuals, companies and clients are shaping regulatory reviews and advancing standards across the world in the drive to zero harm. The technology is advancing at a rapid pace, which is now allowing continuous real-time monitoring of contaminants to take place in the harshest of environments.

Oct 12, 2022

By J. Partyka, J. S. Stachulak

Dust produced during blasting in a copper/nickel based mine was studied and characterized. A stope utilizing the crater blasting technique, or the vertical retreat mining (VRM method), was examined. Two dust monitors were used to measure an airborne dust produced during blasting operations. The data collected in situ was primarily used to formulate the boundary value problem for a generalized equation that describes the transportation process of airborne dust from all places where dust is produced by the VRM mining method. The field data was also used to define the analytical forms for the initial and boundary conditions, to provide a simple and reliable equation for flow of dust in a stope vicinity, and to identify the non-measurable constants. The effects of the amount of blasting material and of the ventilation system in use on dust concentration are also discussed.

Jan 1, 1995