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By J. G. Groppo, B. K. Parekh

A series of performance studies were conducted using countercurrent column flotation to recover a marketable clean coal product from existing preparation plant fine waste streams. The test work was conducted at several preparation plant sites in Kentucky and Virginia using a 150-mm (6-in.) inside diameter column that was 5.8 m (19 ft) high. Both thickener feed and classifying cyclone overflow with a typical size distribution of 150 µm (100 mesh) X 0 were tested. The percent solids of the column flotation feed varied from 1.5% to 15% while the ash content ranged from about 30% to 60%. The concentrates produced contained 2% to 10% ash with Btu recoveries of nearly 90% using 0.12 to 1.25 kg/t (0.25 to 2.5 lbs per st) fuel oil and 0.12 kg/t (0.25 lbs per st) MIBC. These results were consistent with or better than results obtained in preliminary laboratory scale column flotation evaluation. Test results from seven different seams are discussed as well as scale-up relationships used to design a full-scale installation presently in operation.

Jan 1, 1991

The patterns of flow of reaction gases through the flash furnace at the Kalgoorlie Nickel Smelter were simulated in a 1:20 scale model using a flow of water. Particular features of the flow down the reaction shaft, through the settling chamber and into the uptake leading to the waste-heat boiler were examined. Inferences were made concerning the effects of the patterns of flow on the efficiency of the smelting reaction, on the entrainment of dust by the gas stream and on the erosion of the refractory lining of the furnace. In addition, the effects of geometrical modifications to the arrangement of the concentrate burners and to the profile of the settling chamber were explored by making these changes to the model and observing the resulting variations in the patterns of flow.

Jan 1, 1991

By V. Rajagopal

Corrosion and abrasion properties of a series of chromium-containing cast iron balls with Cr contents ranging from 0 to 29% was evaluated and compared with austenitic stainless steel and mild steel balls. Marked ball wear tests were performed on artificial ore samples consisting of 95% quartzite with either 5% pyrrhotite or 5% chalcopyrite under a nitrogen or oxygen atmosphere. The electrochemical mechanism was investigated by correlating the corrosive wear with the corrosion currents obtained from potentiodynamic polarization curves under abrasion. An offset in their electrochemical activities was observed somewhere between 16 and 26% Cr. In fact, 26 and 29% Cr cast irons showed an excellent corrosion resistance approaching that of austenitic stainless steel. Flotation recoveries were estimated on a 95% quartzite + 5% pyrrhotite sample ground with various cast iron ball materials under an oxygen or nitrogen atmosphere. Electrochemical results are found to be in good agreement with corrosive wear obtained from marked ball wear test and with flotation results.

Jan 1, 1991

By K. M. Kinealy, A. R. Ramsden, D. H. French

A negative correlation exists between sphalerite composition and gold content when gold is transported as Au(HS)2(-); however, there are spatial and temporal differences within a single deposit. A previous model for the formation of volcanogenic massive-sulphide deposits within thermally intensifying and waning hydrothermal sytems in much the same way as is observed around modern sea-floor vents is supported. The results also emphasise that recognition of the mechanisms of gold transport in ancient deposits depends critically on an understanding of their mineralogy and stratigraphy

Jan 1, 1991

By C. -S. Jiang

In most copper refineries, addition agents are added at predetermined rates with no further monitoring of their activity or concentration in the electrolyte. Increasingly stringent cathode quality requirements, and a desire for better process control in tankhouse operations, have recently directed a number of refineries to search for a better addition agent control strategy. Extensive development work has been carried out at the Noranda Technology Centre for the monitor in of glue and thiourea in copper refinery electrolyte using cyclic voltammetry (cv~. Data from both synthetrc and commercial electrolytes are presented, showing the ability of CV to produce reliable and easily identifiable fingerprints of addition agent concentrations in copper refinery electrolyte.

Jan 1, 1991

By M. L. Apel

A conceptual approach to the bioremediation of uranium mill tailings (UMT) is presented., This approach focuses on, biosorption to remediate the. effluent solution and bioleaching remediate the. solid fraction. Comparative biosorption studies were performed with synthetic single metal solutions using a commercially available biopolymer. The maximum rate of metal sorption by calcium alginate was found to be 5.43, 6,39, 6.48, and 9.74 mg dm-3 min-1 for U022*, Ba2+, Cd2+ and Zn2+, respectively. Activation energy (AEa) for barium uptake by calcium alginate beads was determined to be 11.5 kJ, indicating a diffusion controlled reaction mechanism. Thermodynamic values (AG+ AH+ and ASt) of the metal-alginate activated complex, as reported in the literature, were found to be in agreement with those calculated from this research. Results show that this biopolymer can be effectively applied in the removal of select metals prevalent in uranium mill tailing effluents and associated waste streams.

Jan 1, 1991

By M. F. Gleason, S. Burns, J. R. Arnold

In 1986, Gold Fields began negotiations with a large Nevada electrical power utility to supply power for its Chimney Creek mine in northern Nevada. After the long negotiations reached an impasse over various costs associated with the power line, a decision was made by Gold Fields to generate its own power. Self-generation is not uncommon overseas, but it is rare for any but very large or very small operations in the United States. Surprisingly, under certain conditions a mine can generate its own power profitably, and Gold Fields has found that the associated operating and maintenance problems are minimal. The following report details what factors went into this decision and how it works. Hopefully, it can serve as a guideline for those who may find themselves in a similar position. History In the spring of 1986, Davy McKee Corp. was contracted by Gold Fields Mining Corp. to provide design engineering and construction management for the chimney Creek Mine. Chimney Creek is located about 50 mi northeast of Winnemucca, NV in a remote part of Humboldt County. The nearest industry using utility power was the Pinson Mine, about 13 mi from the proposed plant site. The existing electric line was not capable of carrying another mine the size of Chimney Creek, which required 29 million kwh per year. There were three options available to Gold Fields for the power supply: 1 )Power could be supplied by the public utility from a coal-fired plant about 30 mi away by constructing a new line to the mine,

Jan 1, 1991

The Bureau of Mines, with a history of mining research since 1910, still seeks improvement in safety and health along with improvement and competitiveness in the mining industry. Much promise of such improvements lies in new technology, and this is particularly the case in the still growing coal mine sector, although much Bureau research is long term, high risk, aimed at new concepts.The miner's environment is a primary concern, involving technologies of contaminant monitoring and control in high production scenarios. Contaminants arising from diesel use, alternatives to high speed rotary cutting and more efficient dust removal are being addressed, and drilling efficiencies, better monitoring through unitising operations and insitu rock dust monitoring are particular features.

Jan 1, 1991

The Jurassic Walloon Coal Measures crop out over much of the Moreton Basin and contain numerous thin, banded coal seams which have been mined at various locations since the 1870s. Historically most mining has been by underground methods. Increased exploration during the 1970s and 1980s has led to the delineation of significant open cut coal resources and to the development of the Oakleigh, Jeebropillly and Ebenezer open cut coal mines in the Rosewood-Walloon area. Over 2 170 million tonnes in-situ of shallow, high volatile bituminous coal with a mean maximum vitrinite reflectance of between 0.5 and 0.6 have been proven in the Basin.

Jan 1, 1991

By Joni M. Barnes

A strain of Pseudomonas stutzeri isohted from selenium contaminated surface waters, was found to be effective . in reducing selenate (Se04 2) stoichiometrically to selenite (Se03 2 '), which was further reduced to elementaJ selenium (Se0 ). These reactions were concurrent with the microbial oxidation of lactate. In order to assess quantitatively the amounts of seilenate and selenitein solution, improvements to existing analytical methods (ion exchange chromatography and inductively coupled plasma atomic emission spectrophotometry technique) .were made.

Jan 1, 1991

By W. H. Pailes, V. Castranova, K. Van Dyke, J. H. Kang

Recruitment and activation of phagocytic cells after inhalation of occupational dusts has been implicated in the development of pulmonary inflammation, fibrosis, or emphysema. Plateletactivating factor has been described recently as a potent inflammatory agent. The objective of the present study was to investigate if platelet-activating factor might play a role in the inflammatory response of the lung to occupational dusts. In vitro exposure of alveolar macrophages to cotton dust (4 mg/ml), silica (10 mg/ml), or coal dust (10 mg/ml) results in the release of picomole levels of platelet-activating factor with a potency of cotton dust > silica > coal dust. Time course studies indicate that platelet-activating factor release from alveolar macrophages is maximal approximately 10 minutes after in vitro exposure to silica. In vitro, platelet-activating factor is a direct stimulant of polymorphonuclear leukocytes increasing chemiluminescence 2.3 ± 0.3 fold above control. The maximal response occurs in the dose range of 10-10 to 10-7M platelet activating factor. In addition, plateletactivating factor potentiates the response of polymorphonuclear leukocytes to a second stimulant; i.e., chemiluminescence generated from polymorphonuclear leukocytes exposed to plateletactivating factor (10-9M) plus chemotactic peptide (FMLP, 10-9M) is 88 ± 22% greater than the sum of the separate effects of these stimulants. In contrast, platelet-activating factor is not a direct stimulant of alveolar macrophages in vitro, having no stimulatory effect on chemiluminescence or superoxide anion release even at levels of 10-6 to 10-5M platelet-activating factor. However, platelet-activating factor (10-5M) does potentiate zymosan-stimulated activation of chemiluminescence and superoxide release from alveolar macrophages by 117 ± 56% and 30 ± 4%, respectively. In conclusion, these data indicate that exposure of the lung to occupational dusts results in the release of platelet-activating factor which may activate polymorphonuclear leukocytes and potentiate the responsiveness of alveolar macrophages to dust. The net result would be pulmonary inflammation and hypersecretion of reactive species by pulmonary phagocytes which could lead to tissue damage and pulmonary disease.

Jan 1, 1991

By John T. Cantwell

INTRODUCTION The process engineer usually is responsible for the design operating philosophy and/or day-to-day operations of a process. Since instrumentation is an integral part of the operation, it is essential that engineers understand the general capabilities of the different types of control equipment available. Many "noncontrol" engineers have become involved with instrumentation for machinery monitoring and control as well as other plant applications. The advent of the microprocessor has led to significant changes in control, both in systems configurations and man-machine interfaces. Today's concept is called simply "distributed control." What is distributed control? Distributed control is exactly what the name implies; the control system is divided into several functional segments and spread out to cover a process. The systems are distributed for physical, functional, and risk reasons. Before delving further into the specifics of distributed control, let's look at the evolution of control systems to see how we got here. Instruments initially were located near measurement and control points in the field. Operators physically had to go to the instrument to change setpoints or take measurements. As processes became more complex, it became evident that a central control area was required. This allowed an operator to monitor and control many variables. The operator's effectiveness was increased dramatically, which resulted in greater efficiency, better quality control, and lower personnel requirements. At the same time, plants became much larger, control applications became more complex, energy became expensive, and the industry became more competitive. All of these factors placed pressure on process and production engineers to get the most for the money. The result was a continuing push to put more instrumentation into a central control room to maximize efficiency and productivity and minimize manpower. This chapter deals in some detail with devices for measuring physical and chemical properties of coal; devices for measuring the weight and weight-rate of flow of coal; devices for the monitoring and control of conveyor systems, solids inventory, fluid flow, liquid level, density, and specific gravity. These instruments have a multitude of uses throughout a coal preparation plant. The discussions cover advancements in "on-line analysis," nuclear control devices, and distributed control using microprocessors, mainframes, and soft-

Jan 1, 1991

By R. E. Moore

The lining systems currently in use in BOF furnaces, certain steel ladles, and the slag line of electric are furnaces were developed during the late seventies through the mid-eighties using a trial and error method of combining aggregate, carbon sources, additives and binders. They are currently based on magnesia, graphite, metal additives and resin binders, the selections of each being tied to the anticipated intensity of the use conditions. The general functions of the respective constituents are well appreciated, however, there is still a great deal that is not known about how the socalled antioxidants protect the graphite nor how impurities from the graphite and the aggregate enter into the wear processes. In a simplified assessment of wear processes, it appears that if the deoxidized layer can be kept very thin, less than 810 mm in depth, and if the viscosity and quantity of the matrix glassy phases can be controlled to resist erosion of the deoxidized layer, lining life can be maximized for the various applications. This paper will discuss the characteristics of the starting materials systems currently being employed for applications requiring a deoxidation function to realize extended wear. It will not attempt to explain all the complex interrelationships between the respective constituents but will point to the potential for improvements through the use of improved constituents.

Jan 1, 1991

By C. W. Schultz

Introduction The Mineral Resources Institute, The University of Alabama, has for the past three years been engaged in a program to develop a beneficiation system for eastern (Devonian) oil shales. One objective of that program was to evaluate advanced technologies for effecting a kerogen-mineral matter separation. Column flotation was among the advanced technologies selected for evaluation. Early in the program it was shown that column flotation was superior to conventional (mechanical) flotation and to the other advanced technologies being evaluated. The investigation then proceeded toward the further objective of defining the optimum operating conditions for column flotation. One observation made in the course of optimization testing was that introducing the feed into the froth (above the pulp-froth interface) resulted in an improved combination of concentrate grade and kerogen recovery. This observation was reported in a previous paper (Schultz and Bates, 1989). Because the practice of maintaining the pulp froth interface below the feed point is contrary to "conventional" practice, it was decided to subject the observation to a systematic series of tests. This paper describes a recent series of tests and the results that were obtained.

Jan 1, 1991

"Polycom, a new approach to ore processing based on pressure comminution, is obviously a very attractive alternative to conventional processing methods.Since a full-scale pilot plant was commissioned in 1986, more than 125 commercial installations, with capacities up to 1000 t/hr, have gone ahead.Already successfully used in processing cement clinker, limestone, coal, and other minerals, Polycom high pressure grinding results in:o Significantly reduced capital costs, because smaller units can be used m new installations;o Capacity increases of up to 100% in existing facilities; and o Operating economies that include energy savings of 20% or more, and reduced wear parts consumption.1. IntroductionAutogenous or semi-autogenous mills in conjunction with rod or ball mills are used with preference for ore processing. Most ball mills are of closed-circuit design and operate with mechanical classifiers (spiral or rake classifiers) or hydrocyclones. In other words, the ores undergo wet primary grinding, since slurries are required for the downstream separation stages anyway. This paper presents a new grinding system based on high pressure comminution of ores. This grinding process allows:- Energy savings of up to 20 % or more- Capacity increases of up to 100 % and more- Reduction of wear costs- Smaller units for new installation and thus- Reduced investment costsThese advantages are highly interesting for both new installations and conversion projects, particulary in cases where an increasing hardeness of the ore, i.e. rising Bond Work Index, reduces the output of the plants or where the metal assay of the ore decreases and the capacity of the existing systems has to be increased. POLYCOM high-pressure grinding rolls have established themselves with great success already for grinding cement clinker, granulated blast furnace slag, limestone, cement raw materials, coal and other materials.Meanwhile more than 250 high pressure grinding rolls have been installed worldwide. Capacities up to 1.000 t/h with roller diameter up to 2.8 m and drive units up to 2.400 kW are installed."

Jan 1, 1991

By Clark IH

Numerical modelling is an effective aid for the planning and design of underground coal mines. With funding from the National Energy Research Development and Demonstration Program, CSIRO Division of Geomechanics has produced a workstation environment which will allow the Australian Coal Mining Industry access to a wide range of numerical design models. The emphasis is on usability and simplicity and the long-term aim is that the techniques should be used routinely at the mine site, so that, in the future, design of a new underground mine will routinely involve modelling of each proposed layout.Each of the five numerical analysis programs, FESOFt, FLAC, MNLAY, FEBLK and UDEC has both strengths and weaknesses. Some analyses with each program demonstrate areas when; observed in situ behaviour in underground coal mines has been successfully modelled, and the results of site monitoring provide a basis for comparison with the predictions of numerical models.

Jan 1, 1991

By Jay Hilary Kelley

A ventilation system is described using dual aircourses: one zone occupied by working personnel, the other at the active working face. The two zones are separated by a partition or Shroud. The occupied zone to the rear of the face zone is ventilated adequately but with considerably less air because little gas, dust, or fumes are present. The face excavating zone is sealed and maintained at slightly more negative pressure preventing dust and gas generating from within to escape. Explosive mixtures within the face zone is rendered non-explosive by the introduction of inert gas therein. Each zone is vented separately to the outside of the mine. Because less total quantity of air is required for human breathing, etc, the total ventilation system can be drastically reduced in tan capacity, development entries, and air shafts, -- a great savings in costs.

Jan 1, 1991

By P. Massacci

The modelling of phenomena by nonlinear dynamic Systems Theory representations require the specification and identification of suitable models of the phenomenon and the availability of good optimization algorithms to determine the optimal controls. Stochastic disturbances and difficulties of monitoring the process lead invariably, otherwise, to suboptimal performance. It will be shown that an algorithm can be formulated which will simultaneously identify and optimize such a system. The properties of the algorithm will be derived and its convergence to an optimal control proved. Some results of actual applications will be presented and it will be shown how this approach generalizes easily to optimal control of the actual processing system. These results generalize those of optimal learning and input conditioning.

Jan 1, 1991

By Wu Y, Qu Q

The Central Coal Mining Research Institute has developed the MAE acoustic emission monitoring system, the BD4-1 portable acoustic emission monitor and the MRB rock burst monitoring system. In the MAE system there is an IBM-PLAT, a receiver and 16 channels and the investigating range is 100 m. The main functions are detecting acoustic events from the working faces, periodically making statistics, prints, displays and storing of the results, and performing the off-line process such as drawing the curves of acoustic activity. The BD4-1 instrument has four channels, it works for more than 24 hours continuously, and keeps the data for more than 30 days after power tum-off. The BD4-1 is suited to the monitoring for a long or a short time as a fixed point where the system is invalid, especially to the monitoring of the acoustic activity promoted by the blasting. There is an IBM-PC/AT, a receiver and 16 channels spread 10 km in the system MRB. The system could on-line collect microseismic events throughout the whole mine, calculate the source location and the energy, and off-line draw the seismic activity draft of time-based or distribution in space. In practice, the forecasting is successful by using the acoustic emission and microseismic monitoring system and the portable instrument.

Jan 1, 1991

By A. Unal

Barbaro et al. (1990) implemented a tedious study aimed at delineating the short-scale spatial variability of sulfur in a coal seam. It is not possible, however, to extend their conclusions to any other coal seam or use theirs in any other fashion, because the background geology was not presented. Nor were the conclusions accompanied by geological interpretations in the paper. In addition, an unfortunate printing error occurred where the total sulfur (determined by High Temperature Combustion) variogram in Fig.3 was duplicated in Fig. 2 instead of the seam height variogram. A more serious error, however, has been committed in the definition of the variable, seam height. What is defined as seam height by Barbaro et al. (1990) is, in essence, mining height, and is not a regionalized variable that should be studied by geostatistical methods directly. Despite the fact that the variable, seam height, is not defined in the paper explicitly, the following quotation discloses the fallacy: "All roof rock that exceeded 1.8 m (6 ft) from the floor was not taken because the longwall was operated to not mine more than 1.8 m (6 ft) unless the coal seam height exceeded 1.8 m (6 ft)." From this definition, the seam height, and therefore the sampling height, is equal to the actual coal thickness, if the coal thickness is greater than 1.8 m (6 ft). Otherwise, it is equal to the sum of the coal thickness plus the thickness of the roof rock that complements the thickness to 1.8 m (6 ft). In the latter case, the seam height is constant and equal to 1.8 m (6 ft). It is possible to conduct a variogram study on a pool of samples that are realizations of two different variables. But the conclusions derived would not belong to any one of the two variables uniquely and, therefore, do not possess any significance. Geostatistical analysis is irrelevant for the sum of multiple regionalized variables formed by arbitrary selections. In a two¬seam setting, for example, the mining height, as defined by the thickness of one seam at one location and the thickness of both seams at another location (due to quality and/or minimum thickness considerations perhaps), should not be used in the calculation of one common variogram. The two seams should be modeled separately. They can then be combined according to the specific purposes of the study. On the other hand, if a constant is added to a regionalized variable (to incorporate dilution perhaps), the variogram of the new variable will not change. Barbaro et al.( 1990), surprisingly, does not give any geologi¬cal interpretation of their results despite the fact that most of them can be explained by the origins of sulfur in a coal seam. The presentation of the results of a geostatistical study with no reference to the geology of the deposit is uninformative. It may also be misleading for the potential users of geostatistics. It is not unusual to find nuggets of pyrite in coal seams. In such cases, pyritic sulfur will probably display a spatial structure for only a very small distance that will appear in the experimen-

Jan 1, 1991