Search Documents

By W. Cholewa, T. S. Golosinski, J. Wedzicha

"Power requirements of belt conveyor drives are usually estimated based on the calculated belt tension which equals the sum of unit resistances to motion which the belt has to overcome. In most situations, the value of various unit resistances can be accurately predicted using published information (5,6,8,12). A simpler approach calls for use of standard formula and tabulated values of related factors which reflect various features of both the conveyor and the transported material (2,3,7) . None of these approaches is reliable when materials with unique properties are conveyed, nor if applied to conveyors working in extreme climatic conditions. Such is the case of oil sand mines in northern Alberta.There the bitumen content of oil sand causes it to behave in a unique manner. Furthermore the conveyors operate year around, with winter temperatures often lower than - 40°C. It was the objective of presented investigations to quantify the power requirements of conveyors, and related resistance to motion for the conveyors used in oil sand mines during winter operations.The other objective was to quantify the drive power requirements of oil sand conveyors during start-up. These requirements are usually much higher than those during norm al operation, and their quantification is of paramount importance for operation of large conveyors."

Jan 1, 1992

By F. P. Schwarz

Even in an otherwise care-fully done sampling procedure, reducing subsample weight, or splitting, when the grain size of material is too large commonly generates significant error. Such error can be estimated from the standard deviation of differences between values of PAIRED ASSAYS. Samples from split-ting steps immediately before comminution, and showing a restricted range of grade, generate paired assays. Splitting steps characterized by relative standard deviations exceeding 16% generate nonrepresentative data. Such steps should be redesigned to optimize reliability of assay-dependent studies. A sampling scheme can be graphically characterized, and then redesigned as appropriate, using a SAMPLING NOMOGRAPH. Use of the nomograph avoids continued replication of assays. Generally at a splitting step, excessive error can be reduced by comminuting more material. Unnecessary effort can be mitigated by comminuting less finely and/or by splitting to a smaller weight.

Jan 1, 1992

By Yael Miron

Two recent unplanned detonations occurred during blasting operations in sulfide-bearing ores in a Nevada gold mine. Other premature detonations have also reportedly occurred at other Nevada, California, and Arizona operations within the past few years, with increasing frequency. Unplanned or premature detonations can be extremely hazardous to life and can cause extensive property damage. A miner was injured in one of these occurrences. This report, by the U.S. Bureau of Mines, is intended to acquaint personnel involved in such mining activities with the basic causes for these accidents. These causes include the exothermic oxidation of pyrite (FeS2) and formation of ferrous sulfate (FeS04), the exothermic and energetic reaction of the ferrous sulfate with ammonium nitrate-fuel oil (ANFO)-based explosives, and the associated elevated temperatures that can set off detonators and explosives in the boreholes. Recommendations for safe operation by the Mine Safety and Health Administration, the Bureau, and the mine involved with the recent incidents include monitoring temperatures in the blast holes, analyzing for sulfate and ferrous ions, and limiting the time between loading and firing in accordance with conditions in the blast holes. Other procedures for safe operations should fit specific conditions in, the mines.

Jan 1, 1992

By J. L. Parks

Designs, installation procedures, and performance characteristics of martensitic cast steel concaves are reviewed. Longer wear life, fewer pieces to install, and eliminating the need to scarf joints are the principal benefits of using martensitic steel to replace austenitic 12% Mn (Hadfield's) steel, the traditional concave material for large gyratory crushers. Installation procedures that reduce the risk of breakage are described. Operating practices that affect concave performance are also discussed.

Jan 1, 1992

By Richard M. Levine

Now that the former Soviet Union has divided into 15 countries, it is necessary to analyze separately the industrial mineral position of each of these countries. Industrial mineral data The former USSR was one of the world's largest producers of industrial minerals and had some of the world's largest reserves. Production and reserve figures, however, must be qualified. Even when these figures were reported by the Soviets, it was not clear that the production figures were for products that would be equally marketable in a competitive market economy. The reserve figures are based on the Soviet system of reserve classification, which is not directly equatable with the US Geological Survey and US Bureau of Mines classifications of economic reserves in market economy countries. The Soviets reserve classification system, in terms of which reserve figures will be given, is based on the reliability of the quantity of the material in place. The Soviet system assigns each occurrence to one of seven categories A, B, C1 and C2 are considered reserves; P1, P2, and P3 are considered resources. Mining in the former Soviet Union was authorized on the basis of the reserves in place in categories A, B and C, which had to be in prescribed ratios. However, the categories A, B and C do not necessarily correspond to Western concepts of material economically exploitable under present market prices with existing technologies.

Jan 1, 1992

By E. M. De Souza

"A scientific testing program, sponsored by the Mining Industry Research Organization of Canada (MIROC), was undertaken on the surface and underground facilities of Inca's Crean Hill Mine to investigate the effectiveness of using dry drilling with a dust control system.The surface test work consisted of the monitoring of advance rates and bit life white a series of 165 mm holes, wet and dry, were drilled at both mine air (0.69MPa) and high pressure air (1.72MPa). The results, based on statistical evaluations of field data, indicated that penetration rates can be increased by an average of 24% when drilling dry with high air pressure and by approximately 27.5% when drilling dry with mine air as compared with wet drilling under the same conditions. Dry drilling also has the effect of reducing button wear by approximately 69% using high pressure air. The underground test work employed a dust collection system developed for use with large diameter holes (165 mm) and high pressure drilling. The testing program has indicated that an average increase in penetration rate of 35% can be achieved when dry drilling in rock (waste) and of 49% when dry drilling in ore with high air pressure. Although preliminary dust monitoring did not indicate any appreciable increase in dust concentration during dry drilling, further dust monitoring is still required.A comparative cost analysis has indicated the potential for reduction in drilling costs when dry drilling is utilized. Further testwork is to be conducted to develop a reliable dust collection system for underground production."

Jan 1, 1992

By N. Agron-Olshina

The application of the QEM*SEM image acquisition and analysis system to the measurement of the mineral matter in coal and the materials in fly ash is described. A new sample mounting technique was developed using iodinated epoxy to provide a backscattered electron contrast between the coal, the mounting medium and the mineral matter. Several comprehensive and detailed species identification programs for silicate minerals and materials were developed to analyse the 1000 count x-ray spectra used for the measurements. Case studies are presented to demonstrate the capabilities of the new technique to distinguish different coals and fly ashes by their mineral and material composition rather than by conventional chemical analysis. Applications of the new technique are aimed at demonstrating that composition and size distributions obtained from OEM*SEM measurements can be used: 1. to characterize coal with respect to combustion problems in power stations, 2. to characterize coal for fine coal cleaning, 3. to characterize fly ashes in relation to problems such as erosion in combustion systems and the ease of precipitability in dust collection facilities, 4. to refine the classification systems used in marketing coal for pulverized fuel firing and fly ashes as a component of cement and building materials.

Jan 1, 1992

By Philip E. J. Green

Two of the cornerstones of total quality management, the use of statistical and problem solving tools, and the involvement of employees, are directly applicable to environmental protection. The reduction in variation decreases the chances of violations and mishaps. Involving employees in minimizing environmental impacts is critical. One mistake, even with the best technology, and your plant can be shut down, customers lost and fines and penalties imposed - your reputation and the environment damaged. Proven strategies for involving employees in environmental protection, and over-coming the frequently strong differences of opinions about what constitutes environmental protection, will be discussed.

Jan 1, 1992

By Charles L. Kimbell

In 1988, the aggregate value of total world international export trade in mineral commodities was estimated at nearly $542 billion in current (1988) dollars, which was about 8.6% above the 1987 level, but still 23.7% below the record high set in 1980. Comparable comprehensive data for 1989 were not available in time for inclusion in this chapter, but 1989 returns for developed market economy countries only were 1 1.8% above those for 1988. These countries accounted for about 50% of the total mineral commodity export trade in 1988. It would be unsound to utilize the overall 11.8% growth rate for mineral commodity export trade for these countries to extrapolate the growth in total world mineral commodity trade because these developed market economy countries account for substantially different shares of the five major mineral commodity groups listed in table 2. Specifically, developed market economy countries in 1988 accounted for 56% of world export of ore, concentrate, and scrap, 74.7% of world exports of iron and steel, 71.7% of world exports of nonferrous metals, and 57.8% of all exports of crude nonmetals, but only 26.6% of world exports of mineral fuels. Moreover, even within each of these groups, the actual product mix included in developed market economy country aggregates differ from that in developing market economy country aggregates and in centrally planned economy country aggregates. Nonetheless, an increase of 9% to 12% in the value of world mineral commodity export trade seems indicated by available returns.

Jan 1, 1992

By Summers D. A.

A mining machine has been designed and fabricated to mine coal from room and pillar operations combining high pressure waterjet cutting and mechanical fragmentation. Waterjets are used to slot the coal face with an advancing plow wedge then breaking out larger coal pieces. The machine has the following advantages: - simply built around a disassembled longwall chock and gathering arm loader apron; - few moving parts which are simply and inexpensively maintained; provides immediate roof support in the face working area; - coal produced is larger, with resulting lower preparation cost; - no dust is generated; - risk of spark generation is virtually eliminated.

Jan 1, 1992

By J. Boitano

This paper discusses the study, design and implementation of the new gas handling system for the Caletones Smelter of Cbdelco..Chile. A discussion on design conditions for a Mure Sulphuric Acid Plant using Teniente Converter.gases.is also included. The old system which started to be modified in 1985 and relied on natural draft and used balloon flues, resulted in a limited .gas handling capacity for operation under Mure process conditions. This system also caused excessive fugitive gases in the smelter working areas. The new system permits handling of process gases from the higher capacity Teniente converters installed in 1987-1989 Improving the gas handling of the reverberatory furnaces and Peirce-Smith converters as well as the environmental conditions of the smelter. This system utilises improved converter gas hoods, evaporative cooling and electrostatic precipitators gas cleaning, and is based on natural draft.

Jan 1, 1992

By Elaine Ellingham, Francis T. Manns

"The Orostar and Scadding were two small gold mines owned and operated by Orofino Resources Limited. Conventional statistical treatment indicates an identical arithmetic mean grade of 0.22 oz/T Au for both mineable reserves. Further, the deposits are both shown to have cut weighted average reserve grade of 0.21 oz/T. Orostar mined out at 0.206 oz/T and Scadding at 0.156 oz/T Au. The combined exploration and development database contained 1394 fire assays, more than enough for statistical confidence in a normal distribution. Therefore this study was initiated to determine, if possible, why the mill head grades were lower than the averages and to experiment with several methods to determine whether a reliable statistical mill head grade estimation method would emerge. Despite the identical reserve grades, distinct differences in the grade distribution histograms are present. By studying the arithmetic and log-normal grade distributions, with some attention to South African practices, this paper reports on those differences which may account for the considerable divergence in the mill head grades. Furthermore, this study casts considerable doubt on the industry standard method of cut weighted averages.The global mill head grades of the two deposits have been derived from the arithmetic average grades by graphic means. This precise method of mill head grade prediction, if applied to complex orebodies, could permit selective grade control and result in direct cost savings by allowing the operator to detect false value stopes, benches or levels and emphasize reliable regions of not only gold mines, but also uranium or base metal deposits."

Jan 1, 1992

By J. C. Cawley

Improvements in today's maintenance practices are mandatory as more complex and productive machines evolve in the mining industry. By keeping machine reliability high through improved maintenance procedures, overall mining costs can be reduced. The Bureau of Mines is investigating diagnostic maintenance systems for underground mining machinery. A hydraulic expert diagnostic system and an electric motor predictive diagnostic system have been designed and installed on a Joy 16CM continuous miner. An electrical diagnostic system has been designed and installed on a Joy 14CM continuous miner. Each system is functionally described and the relative merits of expert diagnostic systems versus algorithmic diagnostic systems are discussed.

Jan 1, 1992

By Gary K. Elliott

Many industrial processes generate hot waste gases which contain particulate pollutants. Conventional clean-up techniques suffer limitations either because collection efficiency is low or because the gas must be cooled before treatment. thereby increasing costs and preventing energy recovery. The application of increasingly stringent environmental legislation to the non-ferrous metallurgical industry is presently illustrating these conventional technology limitations. Low density ceramic media allow filtration to ta,ke place at 'high temperatures and are now rapidly becoming accepted In many industries. This paper reviews experiences with a proprietary low density ceramic filter element. CerafH. It includes consideration of the structure, composition. typical operating and case studies with particular reference to non-ferrous metallurgical furnace applications.

Jan 1, 1992

By J. Hupka

Some aspects of kerosene penetration into tar sand have been investigated. The natural tar sand porosity was measured and used to analyze the performance of the hot water process. Subsequently, pretreatment experiments, using 20 kg tar sand samples (Asphalt Ridge and Whiterocks, Utah), and kerosene as a diluent were carried out at the expected summer temperature (26°C) and the expected winter temperature (-14°C). The natural tar sand porosity accessible by diluent has a crucial impact on the reduction of bitumen viscosity, and influences the penetration time required for successful bitumen separation from tar sand by hot water processing. Thus the tar sand porosity is an important variable which determines appropriate operating conditions. Experimental results indicate that diluent penetration into the Asphalt Ridge tar sand (high porosity) is almost complete after 30 min, whereas for the Whiterocks tar sand (low porosity) the penetration process is much slower, and still not complete after 15 hours regardless of the ambient temperature.

Jan 1, 1992

By Miguel N. Herrera, Abbas H. Mirza, Fiona M. Doyle

The standard test methods used to determine the pyrite content of coal and mineral wastes, and their propensity to release acidic drainage, are critically reviewed. In addition to analysis of total sulfur by combustion, test methods using selective oxidation of pyrite by HNO3 and H2O2 are available. The oxidation kinetics of pyrite vary appreciably from sample to sample, and it is difficult to ascertain whether complete dissolution has occurred in heterogeneous materials. The reliability, reproducibility and suitability of different standard test methods were studied, using well characterized ore and coal pyrite samples. The kinetics of pyrite dissolution were also investigated. The results are discussed in terms of the fundamental chemical and physical characteristics of each sample, and the implications for waste characterization are considered.

Jan 1, 1992

By Richard S. Kunter

Artech Recovery Systems, Inc has developed a low pressure and temperature? leach process called the "Cashman Process" to extract metals from arsenical flue dusts and residues and fix the arsenic in an environmentally stable form as ferric arsenate (scorodite). The process was pilot tested at Hazen Research in an integrated plant including continuous recycle from August 1989 to October 1989 during which several tons of flue dust were processed. Based on this pilot program, the process was deemed technically feasible and produced commercially salable products. Residues from this pilot program were subjected to a long-term stability test jointly designed by PTI environmental services and the USEPA. The process, its versatility, and the nature of the products is discussed in some detail.

Jan 1, 1992

By David J. Dunn

Materials related problems at mines can be big ones - like a newly completed 1 -m (3.5ft) water pipeline burst during initial filling, grinding ball consumption at double the typical norms on startup of a new semiautogenous grinding (SAG) mill circuit or 30 open-pit haul trucks in the shop for new bed liners after less than a year’s service. Materials engineering provides solutions to these kinds of equipment problems by selecting good materials and designs, by trouble-shooting service failures and by maintaining high quality in vendor-furnished materials and components. Materials with good properties, correctly made and fabricated, correctly installed in mining and processing equipment, produce ore and final products reliably and efficiently. Materials engineering, applied during design phases, specification writing, and receipt and installation of materials, ensures that equipment will have the best possible shot at performing up to expectations. Good calls on materials properties - specifying state-of-art materials produced by competent manufacturers - help mine managers to reduce downtime and mining and processing costs. Materials that are improperly made or specified can make a mining operation less efficient or, possibly, uneconomical.

Jan 1, 1992

By Hendon G. W, Carr F, Jiang Y

A vast majority of the operating longwall sections use shield-type face supports to provide ground control in the United States. As a co-operative research program between the University of Alabama (UA) and Jim Walter Resources, Inc.(JWR), a joint research program is underway to study interaction of shields with surrounding rock masses. A series of analyses on the response of shields are performed using monitored data at a longwall face in a deep coal mine. In this paper, various effects of parameters, such as leg pressure, setting load, developing load, maximum loading rate, pressure in capsule, and convergence between canopy and base, are discussed and recommended as stability indices. A microcomputer program is being developed for instantaneous interpretation of the shield monitored data, and for giving warnings of potential problems. The preliminary results define the effects of the setting load, developing load, and rate of developing load or leg closure rate. The objective of the study is to understand the shield characteristics and their interaction with surrounding strata in real time, then develop a reliable program for maintaining longwall stability.

Jan 1, 1992

By Kenneth L. Driggs

The Environmental Protection Agency's Clean Air Act of .1970 provided the driving force for the current Magma Smelter configuration. The historical and technical perspectives of those process developments are reviewed. Innovations in procedures and equipment have allowed compliance with the requirements of the regulating authorities. The wet scrubbing of converter gasses and the monitoring of converter operations by a controlling foreman are two of the major contributors to these successes. The Clean Air Act Amendments of 1990 have posed many new concerns for all U.S. industry, including the few (seven) primary copper smelters remaining. Future concerns include tightening the sulfur dioxide ambient standard from the current three-hour averaging period to one hour"

Jan 1, 1992