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By U. Srivastava

In the processing of manganiferous ore, it is useful to control whether the manganese (Mn) goes to the iron product to produce ferromanganese, or to the slag for extraction as a high Mn product. This can be done by manipulating the thermodynamic conditions for manganese oxide(MnO) reduction to control whether it remains as MnO or converts to metallic Mn. Results are presented showing that during production of iron nuggets, reduction of manganese oxide (MnO) can be controlled by changing the furnace temperature and reductant composition appropriately.

Jan 1, 2010

By S. Paul Singh

"The long-term viability of seismically active and/or deep mining operations hinges upon the industry's ability to maintain profitability in a climate of increasingly difficult conditions, escalating operating costs and fluctuating metal prices. Within this context, it is prudent to explore mining techniques that could provide means for safer and more profitable extraction of seismically active and/or deep seated deposits that are vital to the long term survival of the industry.The first step was to examine Penetrating Cone Fracture (PCF) and other relevant concepts with the objective of semi-continuous mining in deep underground hard rock mines. This was followed by an assessment of the current conventional drilling and blasting practice. Thirteen blasts were monitored in five different seismically active workings of an operating deep mine. The main concerns during the current drill and blast practice were identified.On the basis of the literature review, three short round blasting techniques were short listed for further review. These techniques were evaluated based upon the available literature and discussions with the persons associated with their applications. Justification, requirements and major challenges for the application of short round blasting have been discussed in this paper. Suggestions for improving the current drilling and blasting practice have also been outlined.INTRODUCTIONRock fragmentation is the key to mineral excavation and production. Increasing working depths, environmental concerns and trends towards continuous mining necessitate the development of new and improved rock breakage methods.The excavation of hard rocks is still dominated by the sequential routine of face preparation, drilling, charging explosives, blasting, ventilating for fume and dust removal, mucking and roof support. Worse still, drilling and mucking require specialized equipment that fills the end of the heading so that no other operation can be performed and the equipment must be removed from the face to protect it from fly rock."

Jan 1, 2010

By A. C. Smith

The U.S. Bureau of Mines conducted a study to evaluate the effect of underground mining conditions on the activation of automatic sprinkler heads. Sprinklers were exposed to liquid fuel fires in a rectangular tunnel at airflows of 0, 45, 90, 150, and 250 m/min to determine the effect of ventilation and fire size on the time to activation. As the airflows were increased, the time to activate the sprinklers for a given fire size increased. Also, as the fire size increased, the activation time decreased. Temperature profiles of the tunnel showed that the maximum temperature near the roof was shifted downstream as the airflow increased. Experiments to determine the effect of rated activation temperature and response time index (RTI) value on activation time showed that the time to activate increased with increasing activation temperature, and decreased with decreasing RTI value. Exposure to the mine environment showed little effect on the activation times in large-scale experiments, and no significant effect in laboratory experiments. The results showed that airflow can have a significant effect on the activation times of automatic sprinklers. This needs to be considered in the design of effective sprinkler suppression systems for ventilated areas.

Jan 1, 2010

By Thomas M. Barczak

This U.S. Bureau of Mines report describes methods to enhance the capacity, stiffness, and timber utilization of wood crib supports. Since stiffer supports minimize strata deflections that contribute to roof instability, efforts to maximize crib stiffness while maintaining stability through a wide displacement range should be a design priority. The stiffness and capacity of conventional crib designs, employing alternating layers of wood timbers that are loaded perpendicular to the grain, can be increased by increasing the interlayer contact area or by using higher strength wood. Contact area can be increased by using wider timbers or employing more timbers per layer. Concepts that provide parallel-to-the-grain timber loading will provide substantial increases in crib stiffness and capacity. Two concepts that utilize this principle are examined: (1) an original South African design that constructs wood cribs from preformed layers (mats) of timber where short blocks are oriented vertically between horizontal slabs; and (2) a design that employs full lengths of timber placed vertically in the interior of a conventional crib structure. These designs also provide more efficient timber utilization by providing greater support capacity per volume of wood used in the crib construction.

Jan 1, 2010

By M. J. Beus

Researchers at the U.S. Bureau of Mines have developed personal-computer-based data acquisition, instrumentation, and mine visualization and modeling techniques to evaluate a mine accessway in a deep hard-rock mine in northern Idaho. These techniques were applied to a mine shaft in a large silver mine that has been in operation for many years. A very deep, rectangular, timber-supported shaft extending to depths exceeding 2.3 km (7,500 ft) had been deforming continuously as a result of nearby mining, resulting in operational problems. Preliminary visual observations and rock and support monitoring confirmed that severe diagonal distortion was occurring. Extensive field measurements and data analysis confirmed initial observations, provided insights into the cause of deformation, and defined a general approach to structural modeling. Computer analysis of the problem was initiated by developing a three-dimensional model of the terrain. This represented a volume of rock approximately 80 km3 (40 x 1010 ft3) and an area on the surface surrounding the mine 9 km2 (3 square miles). Based on this model, a three-dimensional, finite- element analysis was conducted to establish boundary conditions for sequentially more detailed two- and three-dimensional submodels of the shaft area. Results from the computer study are being used to develop new approaches to mine design and to provide design guidelines for deep mine accessways subject to severe rock-mass loading conditions.

Jan 1, 2010

By W. G. Pariseau

The U.S. Bureau of Mines has been conducting a series of rock mechanics investigations at the Lucky Friday Mine in the Coeur d'Alene Mining District of northern Idaho. The present study uses rock deformation measurements to validate and calibrate a geomechanical model of the experimental Lucky Friday underhand longwall (LFUL) stope on the 5,100-ft level of the Lucky Friday Mine, Mullan, ID. The calibrated three-dimensional, finite-element model and measurements of rock mass displacement show a correlation of 0.795. The calibration reduces rock mass modulus to 14 to 17 pet of laboratory values and rock mass strength (with an energy rule) to 37 to 41 pet of laboratory values. This model suggested that stress-related ground control problems would be encountered west of the stope where the vein makes a right-angle turn and then splits. Rock burst activity was concentrated in this area during mining of the LFUL stope.

Jan 1, 2010

By L. Martins

To increase zinc recovery in the concentrate, this investigation performed mineralogical characterization, dispersion studies, bench and pilot-scale flotation experiments and an industrial flotation trial. The objective was to verify the flotation behavior of the silicate zinc ore (calamine type) in the presence of slimes, with the aid of dispersing agents. Characterization studies identified the major minerals in the flotation feed as hemimorphite (calamine), quartz and dolomite. Dispersion tests showed that enhanced dispersion of the particles in the pulp in the absence of reagents occured at a pH range between 8.5 and 12.0. Bench-scale flotation experiments were planned using the statistical tool of complete factorial design at two levels, replicated once. These experiments showed, and were confirmed at the pilot-plant scale, that higher doses of sodium sulfide and polymeric dispersant combined with sodium silicate favored a higher metallurgical recovery. At 6,800 g/t (218 oz/st) sodium sulfide and 6,992 g/t (224 oz/st) polymeric dispersing agent combined with sodium silicate, a zinc grade of 38.4% in the final concentrate was achieved, at an average metallurgical recovery of 72.4%. The industrial trial confirmed the pilot scale results, leading to zinc recovery of 76.1% and a 37.3% zinc grade in the concentrate. Key words: Froth flotation; Flotation reagents; Flotation depressants; Zinc/ zinc ores

Jan 1, 2010

By Huimin Lu, Min Li, Jinghua Zou

"Zeolitic imidazolate frameworks (ZIFs) are new type of porous materials, form inerratic polyhedral in three-dimensional with large cages and small apertures, and appear structural diversity. Their hole size can be adjusted. These materials have high selective adsorption capacity to carbon dioxide. In this paper, zeolitic imidazolate frameworks were synthesized by solvothermal synthesis method with dimethylformamide (DMF) as solvent and structuredirecting agent, divalent metallic ions as cation, and imidazole as ligand. The crystals were characterized with XRD, SEM for their crystal structures and physical properties, the adsorption of the crystals for carbon dioxide was also tested, and the result suggests that these porous materials have a capacity of 1.35ml/g for storing carbon dioxide at 273 Kelvin under ambient pressure.IntroductionGlobal warming caused by the increase of carbon dioxide in the atmosphere has become one of the main environment problems, contemporary research has focused on ways to slow or stop this trend. CO2 capture has attracted attention due to the potential to trap and sequester large amounts of CO2 from concentrated sources such as power plants [1]. Traditional technologies in capturing CO2 include absorption by aqueous amines [2]. However, utilization of this process is energy intensive and expensive. Carbon dioxide storage materials investigated so far can be divided into two categories: chemical storage adsorbents and physical storage media [3]. The first kind of materials can chemically adsorb carbon dioxide within their structures and need thermal energy to release the adsorbed carbon dioxide. The examples of the chemical adsorbents include aqueous amines, gas-hyperbranched aminosilicas [4]. The physical adsorbents store carbon dioxide by physical adsorption of carbon dioxide at elevated pressure and release the adsorbed carbon dioxide at low pressure. The physical adsorbents that have been investigated for carbon dioxide storage include zeolites, carbonaceous materials and other porous materials. Until recently, a new type of microporous material, known as zeolitic imidazolate frameworks (ZIFs), has been reported as promising adsorbents for carbon dioxide storage [5 ~ 10]."

Jan 1, 2010

By A. G. Belova

With the federal climate change legislation in progress, there is a need for demonstration-stage technologies aimed at providing clean energy from coal. Our research aims to experimentally illustrate the feasibility of capturing CO2 on a novel sorbent system from a gaseous stream. The gas is then released resulting in a regenerated sorbent and a pressurized stream of pure CO2 to be used for storage. The proposed sorbent is a ceramic honey-comb structured monolith coated with CaO supported on a high-surface area alumina. CaO is a natural acceptor of CO2 and our design ensures the physical stability and chemical reactivity of CaO over a large number of CO2 capture/release cycles. Furthermore, the use of the monolith ensures a uniform flow through the reactor, minimizes pressure drop across the reactor, and maximizes the surface reactive area. In this paper, we will present the results from a flow-through laboratory-scale reactor that establishes the efficiency of the proposed system to capture CO2. Future applications of the reactor include integration within the new-generation coal gasification power plants, such as IGGC, as means of providing decarbonized electricity.

Jan 1, 2010

By Essie Esterhuizen, Michael M. Murphy, Chris Mark

"The response of the surrounding rock mass to the creation of mining excavations determines the ultimate load on a pillar support system. In conditions where the ground is relatively soft and weak, the full overburden weight can be transferred to the pillar system. However, in stiffer and stronger rocks, a greater portion of the overburden load is transferred to the unmined coal barriers or abutments, and the pillar stress is reduced. This paper makes use of numerical models to examine the interaction between typical pillar systems and the surrounding rock mass for weak and strong geological conditions at various spans and depths of cover. The concepts of structural failure and functional failure of pillars are used to assess pillar performance when pillars are deformed beyond their peak resistance. The results show that the span-to-depth ratio is an important factor in determining the pillar stress and the ultimate deformation of pillars. The ultimate pillar strain appears to be closely related to the functional success of pillar systems.INTRODUCTIONThe National Institute for Occupational Safety and Health (NIOSH) was requested by Congress to study the safety of retreat pillar mining following the Crandall Canyon Mine disaster that took place near Price, Utah in August, 2007. As a part of this study, an investigation was made to better understand how the rock mass responds to the creation of mining excavations and how the loads are distributed among the pillars and the surrounding abutments or barriers. The outcome of these investigations contributed to the development of a modified loading model for the ARMPS-2010 (Mark, 2010) method ofretreat mining pillar design.Structural and Functional Failure of PillarsPillar design is typically conducted by estimating the pillar strength and stress, and then sizing the pillars so that an adequate margin of safety exists between the expected strength and stress. The pillar strength can be defined as the maximum resistance of a pillar to axial compression (Brady and Brown, 1985). If a pillar is loaded beyond its peak strength, load shedding or yielding can occur, and the pillar is considered to have failed as a structure. Structural failure generally refers to a loss of loadcarrying capacity."

Jan 1, 2010

By Bolger Witthaus

"High performance production under challenging geological conditions is a product of several parameters. Main factors are the technical equipment and the knowledge in processing. The design and the support system of maingates must also be taken into consideration. The extraction of seams in German underground hard coal mines of RAG in a range of heights between approximately 1.1 and 4.0 m ( 4 and 13 ft) is done by plow and shearer technology. A complete system for quality management of production is required. The process examination of processes begins with procurement of the equipment. Education and training of the engineers and specialists, as well as for the miners are requirements for success as well.This report gives an overview of RAG measures for achieving high performance. Starting with examination of the processes accompanying procurement of equipment, the following important elements are described. Standards in education and training, technical design and elements of automated processing using stateof- the-art in control systems are critical to this system.The application of automation plays a decisive role in modem coal mines. The latest development in German coal mines is the fully-automated shearer system for longwalls. This helps to enhance safety, particularly in difficult ground conditions, by removing the shearer and shield operators from the immediate mining activity.INTRODUCTIONLongwall mining in carboniferous strata in Germany faces various challenges. Different longwall systems are used to mine up to 24 seams, each with a thickness between 1.1 m (3.6 ft) and 4.0 m (13 ft). High stresses due to a depth of up to 1,400 m (4,593 ft) requiring pillars between the panels, require special systems for roadway development, roadway support and reinforcemen.t as well as for longwall advance operations. Two main types of equipment for extraction are shearer and plow systems. While shearers are utilized for seam thicknesses above approximately 1.8 m (6 ft), plow systems can be used for smaller seam thicknesses between 1.8 m (6 ft) and approximately 1.0 m (3 ft)."

Jan 1, 2010

By C. L. Karr

U.S. Bureau of Mines (USBM) research has shown that fuzzy logic and genetic algorithms (GA's) have great potential for industrial process control. A technique has been developed by the USBM in which GA's are used to substantially reduce the time needed to design fuzzy logic controllers (FLC's).This technique shows promise as an efficient, robust approach to developing control systems. The research described in this report is twofold. First, the basic approach to developing an FLC using GA's is presented. The GA-designed FLC is developed for a specific physical system, a pH titration system. Second, empirical results are presented in which variations in the FLC implementation are compared. Specifically, the effects of altering five aspects of the pH FLC are considered: (1) membership function form, (2) number of fuzzy classes, (3) the center-of-area method, (4) implication operator, and (5) fuzzy rule form. Results indicate that (1) the technique in which GA's are used to design FLC's is effective, and (2) when this technique is used, variations in FLC implementation have little effect on FLC performance in a chosen control problem.

Jan 1, 2010

By J. S. Gomer

The U.S. Bureau of Mines conducted Cu exchange tests for six common clays under simulated in situ leaching conditions. Regression equations were obtained from the data expressing the Cu exchange capacity as a function of Cu concentration, pH, and temperature. Using these equations, an analysis was made of the impact each clay could have on overall Cu recovery. The results suggest that Ca and Na montmorillonite clays could have a major impact on Cu recovery and that attapulgite and illite clays could have a smaller, but still significant, impact. Kaolinite and ripidolite clays pose little threat to loss of Cu from in situ leaching solutions.

Jan 1, 2010

By Andrew Theobald, Peter Dare-Bryan, Trevor Byers

The use of advanced modelling techniques and the timing flexibility of electronic initiation systems allows for unprecedented control over blast outcomes as shown in several complex blasting problems experienced by the open pit operation Xstrata Ernest Henry Mine (EHM) in north-west Queensland, Australia.

Jan 1, 2010

By G. Walsh, L. Wolkovitch, A. Savage, V. Romero, T. Zimmerly, G. Imahara, J. Hyneman, K. Byron, D Tapster, S. Belleci, J. Metzger, M. Stanley

Testing was conducted at the Energetic Materials Research and Testing Center for the MythBusters on three separate occasions. This testing included (1) an experiment designed to create diamond from graphite using the shock and pressure of a detonation, (2) the flattening of a car using a steel plate driven by a rocket sled, and (3) the bifurcation of a car also using a rocket sled. All tests were successful; diamond was produced following the detonation of ANFO, and extracted from a graphite / cobalt matrix. A plate was accelerated to 646 mph (1040 km/hr) using a two-stage sled system loaded with 5” (12.7 cm) high velocity aircraft rockets (HVAR) into a car, which was subsequently demolished. Finally, a steel wedge was pushed to 541 mph (871 km/hr) by a one stage sled using HVAR rockets, and was able to cleanly cut a target car in half.

Jan 1, 2010

By M. Rodgers

Dow Water & Process Solutions (DW&PS) was approached by ASARCO Inc. to attempt to recover cobalt and copper from their copper solvent extraction (SX) raffinate. Cobalt is added to many copper electrowinning tankhouses to help to prevent lead electrode corrosion. With cobalt?s high price this can be a large expense. ASARCO has ore that contains a small amount of naturally occurring cobalt. Currently they have no way of capturing this high value metal from their leach or raffinate streams. DW&PS has some chelating resin technologies that should be able to help solve this problem.

Jan 1, 2010

By G. Jalkanen

Dealing with a trend in inverse distance estimation, IWD, is presented. A measurement is proposed to be consisted of a portion due to a mean and a portion due to a residual. The procedure consists of de-trending the measurement via a linear or nonlinear regression. Residuals are computed, and IWD parameter estimation is conducted on the residuals. Estimation at un-sampled points is then computed by estimating the mean and adding on the estimate of the IWD on the residual. A possible BOXCOX transform is also proposed.

Jan 1, 2010

By Laxman S. Sundae

In the vast majority of American coal mines, roof bolt holes are drilled dry, mainly because of mine operator concern with the spent water creating adverse working conditions. Wet drilling, however, can increase drilling rates and the effective lifetime of the drill bits used. This study, carried out as part of an ongoing cooperative research program between the U.S. Bureau of Mines and the University of Missouri-Rolla, shows that the large volumes of water conventionally used in wet drilling are not necessary, and the performance benefits from wet drilling can be achieved with total volume flows on the order of 0.4 L per hole. This conclusion is validated based on the measured respirable dust generated in drilling Berea sandstone. The results are confirmed using a variety of bit shapes, which are also shown to have a significant effect on penetration rate.

Jan 1, 2010

By Ben Mirabile, Alan Campoli, Rodney Poland

"The majority of U.S. underground coal mines use some form of cable bolt as supplemental support to a primary roof bolting system. Many coal operators employ the high load capacity of non-tensioned cable bolts, cable roof trusses, or solid bar trusses in an attempt to suspend the primary bolted horizon to overlying strata. However, in cases where many discontinuities exist in the roof strata or where pre-existing fractures are present, these passive supplemental support systems often cannot adequately control roof deflection. This paper examines the application of tensioned cable systems to minimize roof deflection in very laminated and fractured strata. Three underground case studies are presented to demonstrate the application of tensioned cable bolts. The first case study involves the rehabilitation of a longwall head gate in the Eagle Seam with highly laminated and fractured sandstone. The second case study examines the recovery of a longwall face in the Alma Seam. The final case study addresses rehabilitation of a longwall head gate in the Pittsburgh No. 8 Seam that was developed in a sandstone channel margin area and subjected to horizontal stress concentration.INTRODUCTIONDuring the previous decade, Jennmar Corporation has recognized coal operators' increasing interest in tensioned cable bolts. The majority of these tensioned cable bolt systems have been applied in adverse roof conditions including broken ground, high horizontal stress areas, and highly laminated roof strata. In most cases, qualitative data on roof conditions after application of tensioned cable bolt support indicate successful implementation of these systems. The qualitative evidence suggests that the combination of high load' capacity and applied tension provides superior supplemental roof support in adverse roof conditions. This research aims to quantify the effects of applied tension to cable bolts. This paper will review the types and installation of tensioned cable bolt systems, present initial laboratory test data, discuss successful case studies, and propose an instrumentation system for quantification of tensioned cable bolt performance."

Jan 1, 2010

By Xuan Li

Aluminum slag is generated when aluminum metals are recycled through a smelting process in the presence of salt. There are small amounts of aluminum metals trapped in the aluminum slag. This research aims at evaluating the use of aluminum slag as an expansion agent for the production of lightweight concrete by taking advantage of the residual aluminum metals in the slag. The research identified key elements of producing lightweight concrete products through utilizing various mixture components including sodium hydroxide (NaOH), lime (CaO), cement, and gypsum. The volumetric expansion rate was investigated and the density and strength of the products were determined. The results show that aluminum slag can be utilized for the production of lightweight concrete products.

Jan 1, 2010