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By J. Philip Bromberg

The 1977 Clean Air Act Amendments will have a large effect on the coal-fired segment of the electric utility industry. Since electric power generation constitutes by far the largest single use for coal, this legislation has the potential to greatly affect future patterns of coal utilization in the U.S.A. The inability to depend exclusively upon low sulfur coal as an exclusive mode of compliance with New Source Performance Standards may greatly lessen projected demands for low sulfur coal by eastern utility boilers. The requirements of the legislation is discussed with particular reference to the needs of the electric generating industry, along with the technologies available for complying with the Act.

Jan 1, 1978

By R. C. Klimpel

Size reduction of material in aqueous pulps by the use of tumbling media overflow discharge mills is an important and common unit operation in industry. There also has been extensive attention given in recent decades on developing a more fundamental understanding of the breakage processes involved, especially in ball mills. These studies have mostly emphasized the use of size-mass balance or population balance approaches for quantifying the analysis and design of size reduction circuits, ego Austin, et al (1984).

Jan 1, 1989

By M. A. Reuter, N. J. Bartie

Metals make modern societies function, and increasingly, various high purity precious and special metals endow sustainability-driving technologies with specific functionalities. These metals become heavily intertwined within products, complicating end-of-life treatment. To counteract the resulting downcycling and potential depletion of scarce resources, maximising both the quantities and qualities of materials recovered during primary extraction and recycling, processes should be a priority in the pursuit of sustainable circular economy. Adopting a process simulation approach; a digital twin for the life cycle of cadmium-telluride solar photovoltaic (CdTe PV) modules was created. The system comprises an integrated metallurgical production system that produces, among others, cadmium, tellurium, selenium, zinc, copper, and lead, all of which are required to manufacture PV modules. System-wide resource efficiency and environmental impacts are assessed using exergy analysis and life cycle assessment, respectively. Simulation of this large and complex product life cycle at a high level of detail allows for the evaluation of potential system-wide effects of various production, recycling and residue exchange scenarios aimed at maximising the sustainability of the entire system. It diminishes the need to make arbitrary choices about allocation methods for the distribution of environmental impacts in multipleoutput production systems. Furthermore, it demonstrates the key importance of metallurgy in achieving circular economy. Keywords: Circular economy, sustainability, simulation, metallurgy, CdTe photovoltaics, life cycle assessment

Jan 1, 2020

By Shailendra Chawla, Ashok Jaiswal, Sonu

Side spalling/skin failure occurs due to the high-induced stress in underground structures. In such cases, rock bolting or other support systems are being used to control the skin failure or spalling of the pillar. The nature of these support systems is passive, which acts during the deformation. These support systems restrict the displacement considerably of the side/or roof surface of the excavation. Ultimately, it improves the stability of the structure because of the increment in residual strength of rock mass. It is noted that these passive support systems give very low confinement in the range of 0–0.015 MPa at the onset of failure. As the level of confinement will be very low and dependent with progress of failure, triaxial test was not found practically suitable. Thus, an alternative procedure of testing has been proposed. In the procedure, sides of sample have been restricted little bit by using adhesive tape. It provides the limited boundness on the lateral direction (LBLD) of rock specimen. The uniaxial compression strength (UCS) test has been performed on 30 numbers of cylindrical rock specimens using the servo-controlled stiff testing machine. Specifically, two rock types (medium-coarse–grained and coarse-grained rocks) were studied in terms of stress–strain behaviour so that a full residual strength envelope for each specimen was obtained. This study reveals that the residual strength of limited confined rock specimens has been significantly increased as compared to unconfined rock for both groups of rock types. The average residual strength of LBLD specimens of fine-grained rock and medium coarse-grained rock has been increased around 12 times, and five times as compared to unconfined rock, respectively. The average peak strength of LBLD rock specimens has been increased in the range of 30.5 to 48.6% for coarse-grained rock. The results of this study have been presented in terms of peak strength, residual strength and Young’s modulus of rock, and the post-peak failure behaviour of rock specimens was also critically analysed through a stress–strain curve.

Mar 21, 2024

By Phillip B. Messersmith, Emmanuel P. Giannelis

"A versatile in-situ polymerization approach is described for the synthesis of polymerceramic nanocomposites consisting of two-dimensional layers of mica-type silicate (MTS) within polymer matrices. Functionalized, organically modified mica-type silicates (OMTS) were used to promote delamination/dispersion of the host layers and initiate polymerization of organic rrionomer. Epoxy nanocomposites prepared in this manner exhibit substantial modulus reinforcement at low silicate loadings. The water vapor permeability of the poly(?-caprolactone) nanocomposite containing 4.8% silicate by volume was reduced by nearly an order of magnitude compared to pure poly (?-caprolactone).IntroductionPolymer matrix nanocomposites are a relatively new class of materials with dimensions typically in the range of 1-100 nm.1 In general, because of the ultrafine phase dimensions involved, nanocomposites exhibit new and improved properties when compared to their micro- or macrocomposite counterparts. We as well as others are currently investigating the design, synthesis and characterization of polymer-ceramic nanocomposites. Our effort, in particular, has focused on the use of mica-type silicates (MTS) with various thermoplastic and thermosetting matrices.2-5MTS's belong to the general family of 2: 1 layered silicates. Their crystal structure consists of layers of two silica tetrahedral sheets fused to an edge-shared octahedral sheet of either aluminum or magnesium hydroxide. Stacking of the layers leads to a regular van der Waals gap or interlayer.6 Isomorphic substitution within the layers generates negative charges that are counterbalanced by cations residing in the interlayers. Although the natural forms of MTS's usually contain hydrated Na+ or K+ ions, ion exchange reactions with organic cations (e.g. alkylammonium ions) can render the normally hydrophilic MTS's organophilic."

Jan 1, 1994

By Turgut Yalcin

"In this study, potential benefits of focculant usage were explored in the processing of mill tailings by hydrocyclones. Tests conducted on copper-nickel mill tailings have demonstrated that, under suitable conditions, flocculation could significantly enhance solid-liquid separation in hydrocyclones. For example, at a feed pulp density of approximately 9%, focculant-assisted hydrocyclone produced an underflow with over 98% solids recovery, compared to a recovery of less than 53% with conventional hydrocyclone. However, feed pulp density was found to be a critical factor, and tailings with pulp densities of greater than about 15%required a two-stage hydrocyclone operation where the focculant-assisted hydrocyclone was employed at the second stage to process the overfow of a conventional hydrocyclone.The underflow and overflow products obtained from the focculant-assisted hydrocy-clone may be discharged into tailings dams in the same manner as those produced by gravity thickeners. The focculant-assisted hydrocy-clone would, however, provide a higher throughput."

Jan 1, 1996

By Wern-Ping Nick Chen

Durability risks for underground facilities can be underestimated during design phase as compared to well-known geological risks. However, unclear durability requirements can result in construction schedule delay and change orders. Unlike bridges or buildings, a unified underground durability code or standard does not exist. This paper will provide a durability approach for underground facilities, including degradation modes, mitigations, and compliance measures during construction. In addition, this paper will address how to clearly specify durability requirements in a contract document to reduce disputes during construction and discuss key durability tests that are time consuming and will impact construction schedule if not timely planned.

Jun 23, 2024

By Tom Watts

This paper will focus on the design, manufacture and use of pump safety systems on MMUs (Mobile Manufacturing Units – Bulk Trucks) with progressive cavity pumps. The practice of pumping bulk blasting agents is highly regulated and the explosives manufactures have done an excellent job of hazard and operability studies allowing criteria to be established for the safe pumping.

Jan 1, 2009

By W. P. DYKEMA

This report gins the results of a study conducted hy the Ilnreau of Mines for the purpose of informing the petroleum industry on the recent progress in the de,·elopment nncl application of the absorption process for recO\·ering gasoline from natural gas. The work has been undertaken entirely with regard to plant practice and for the purpose of describing the features and the operation of units of the plants now in use, the improvements that have been made, and the reasons for any ehanges eontemplated by the engineers in eharge· of the plants studied. Throughout the United States the impro,·ements in the absorption process that are under consideration by engineers not only widen practice so as to include gases at all pressures and percentages of gasoline content, but seem to be dewloping definite standards as to dimensions of towers, l"elocities of flow, saturation of oi~ areas of eooling surfaces, and quantities of menstruum to be circulated. Although perfect practice has by no means been attained, the writer belie,·es thnt a description of the current practice at ,·arious plants, including those ob,'iously more efficient features that each plant hns <le\"eloped and uses at one or another stage of treatment, will intere;; t and possibly help all persons operating or designing absorption plants.

Jan 1, 1919

By S O’Connell, M Scholz, A Robertson, M L. Bloss

The value created in any mining operation is a function of the mine plan. The quality of this plan is dependent on the strategies employed during definition drilling, resource estimation and mine planning. This paper presents opportunities to improve the value of an operation through better strategic management of these core activities. Case studies undertaken recently at Olympic Dam are presented to support the conclusions presented in the paper.CITATION:Bloss, M L, O’Connell, S, Robertson, A and Scholz, M, 2016. Do we maximise the value of our operations through our definition drilling, resource estimation and mine planning strategies? In Proceedings International Mine Management Conference, pp 9-20 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By Cameron Soltys, Hamid Ghorbani, Maher Al-Dojayli

Cooling staves in blast furnaces are used to minimize the process heat loads on steel shell and refractory system. Copper staves are exposed to significant fluctuating thermal loads which may lead to premature stave failures due to cracks, water leakage, bending, abrasion and resultant wear. In this paper, an assessment methodology is presented to evaluate the effect of thermal cycling on copper staves including bending, fatigue and thermal ratcheting. This approach incorporates temperature-dependent copper properties including creep and plasticity to more accurately capture inelastic deformations, damage and fatigue in staves under transient and cyclic thermal loading conditions. Root cause failure assessment and improvements to copper stave design can be assessed using the presented methodology.

Oct 1, 2019

By H. T. McAdams

The logic of regression analysis as an operations research tool is critically examined, and a formal basis for its application to mining problems is developed. The traditional view of regression analysis as a statistical discipline does not provide an adequate basis for evaluating a regression model in a specific area such as ore reserve calculation or process control. In particular, the validity of the residual-sum-of-squares criterion is questioned, and the need for a criterion based on interpolative features of the model is emphasized. Strictly speaking, a regression model is statistically supported only at points at which observations are available, yet inferences are drawn with regard to a continuum. When considered as a mathematical function, therefore, the model is observationally defined only on a domain consisting of a finite number of points. Extension of this domain to an interval of the real line must be based on physical rather than statistical argument. Vector space and function theory concepts useful as a logical framework for a physically oriented problem analysis are discussed and their usefulness demonstrated in a practical problem.

Jan 1, 1966

By Morris M. Fine, Norwood B. Melcher

It is out of the question, at this time, to select any one prereduction process as superior to the others. It is apparent that several share a basic similarity and that within the groups listed in Part 1, the reduction vessel is sometimes the only significant variable. Claims as to the virtues of one machine over another are difficult to substantiate: one may be rapid, another thermally frugal. Based on published data, however, all seem to be performing adequately. It would appear that processes based on carbonized pellets are most applicable to foundry iron at low production rates. Adaptation to large scale manufacture of blast furnace hot metal or to agglomeration of fine concentrates at the mine site is much less likely.

Jan 8, 1966

By Louis A. Panek

An improved centrifugal-testing apparatus has been designed and built in the Bureau of Mines laboratory at College Park, Md., which is unique in that it incorporates the use of resistance gages to measure directly the strains in a rotating model without testing it to failure. Owing to this feature, a more rapid testing method can be used; furthermore, model materials need not be restricted to those of the prototype. The behavior of any structure in which strains of significant magnitude are produced by its own weight may be studied in a small model subjected to simulated gravity loading. The model is rotated in a centrifuge to induce in it centrifugal forces, which, like the gravitational forces in the full-size structure, act on the volume elements and are proportional to the masses thereof. Centrifugal testing is, therefore, applicable to the design of mine openings and to the study of similar ground-control problems. It constitutes an experimental method for determining the state of strain in a structure for which analytical methods are excessively laborious or even impossible. In previous applications of centrifugal testing by other investigators, the models usually were tested to failure, and the analysis was made from-the type of break produced. The models were made of the same materials as the proto-type, and the test results were applied only to the particular prototype represented by the model. Beam deflections were measured from photographs of the rotating model, but no means was employed either to determine the actual distribution of stress in the model or to determine quantitatively the degree of restraint imposed on the ends of the loaded model beam, that is, to determine whether the loaded model behaved as a beam with rigidly fixed ends or as some other type of beam. With the apparatus described, it is possible to determine the state of strain, and thus the boundary conditions, in a rotating test model weighing up to 90 lb., which can be subjected to centrifugal forces up to about 2,600 times the force of gravity. The load-strain relationship, applicable directly to the prototype, can be determined from a Single model test. The test results can be presented as quantitative relations between the loads, strains, and dimensions and mechanical proper-ties of the structural members and can be applied to any prototype, whatever its component materials, that satisfies the similarity requirements.

Jan 1, 1952

By Carlie E. Banks

Tasks during Phase I of this contract effort were performed in four principal functional areas. These were geology, hydrology, reclamation and mining. Data were gathered from literature reviews, mine visits, survey of manufacturers, consultation with government agencies, and unpublished or private communications with contractors and consultants. The data collected were analyzed for omissions or inaccuracies, then organized into tables, graphs and flow charts to provide a concise body of technical and cost data suitable for the engineering analyses required in Phase II of this contract. Maps illustrating estimated grade and thickness of the oil shale were prepared, some of which are included as exhibits to this report. A preliminary mine layout was performed to test the completeness of the collected data.

Jan 1, 1975

By J. C. Yannopoulos

The quest for a continuous copper smelting and converting process, which has been going on for a long time, has not as yet reached its objective. The most recent efforts for the development of a continuous copper?making process started about two decades ago. Among the contending proposed processes, four have been piloted and three of them are currently in operation: the WORCRA process., the NORANDA process, the MITSUBISHI process, the OUTOKUMPU process. The WORCRA process, after some long pilot plant tests, failed to develop as an industrial process: The NORANDA process, as currently operating, is a smelting process and not a continuous copper?making reactor as initially conceived. The MITSUBISHI, although the only continuous process, has not been widely accepted. The OUTOKUMPU process can be applied only to a low iron concentrate feed and co?produces blister and high in copper slag. The thermodynamics of these "continuous" systems and the practical problems of their industrial application are reviewed and discussed. The achievement of efficient and inexpensive environmental control should&apos; be the primary objective of any new process development. A review of the environmental problems of the copper industry indicates that the quest for a continuous smelting and converting furnace should be intensified.

Jan 1, 1983

By T. Crivits

"Freeze lining technologies are used industrially to protect the integrity of furnace walls in pyrometallurgical reactors. This is achieved by solidifying a protective layer of slag on the inner furnace wall. In the current study, laboratory experiments have been undertaken to produce freeze linings in ‘Cu2232 O’-‘FeO’-MgO-SiO slags under controlled conditions using an air-cooled probe technique. Whilst most thermal models of freeze linings have assumed the freeze lining-bath interface to be at the liquidus temperature of the bulk bath and to be planar in geometry, the current research has demonstrated that this is not the case. Experiments undertaken using this high-temperature slag system have shown the interface at steady state conditions to be at subliquidus temperatures. The solid phases present at the interface do not include the primary phase and the interface is non-planar. The study indicates the need for improved understanding of the fundamentals of freeze lining formation, and of the influence of system properties and process parameters"

Jan 1, 2015

By F F. Pitard

The optimisation of a metallurgical plant requires two kinds of sampling systems. The first provides samples to follow process changes, so in due time actions to maintain key parameters within pre-established specifications can be applied. The second provides composite samples at the end of a working shift to demonstrate that valuable constituents sent to the plant went to either a final concentrate or to the tailings in a logical, expected proportion. Contrary to what many experts may claim, these two kinds of sampling requirements are incompatible and cannot be fulfilled using the same sampling systems; this is because the required samples have completely different objectives. A process control sample is an instantaneous sample with increments taken at short intervals, and the objective is to know where the process is at any given time. Excellent accuracy is not a must, however good precision is recommended since a possible process correction may need to be made. Online analysers fed with in-stream stationary cutters or other kinds of in-stream or by-stream probes can do well for such a mission. A composite sample for metallurgical accounting with increments collected over a long period of time, for which excellent accuracy and good precision are both required, must be generated by sophisticated and extremely well-maintained cross-stream sampling stations. The use of process control sampling systems to achieve good metallurgical accounting has been promoted by several manufacturers of sampling equipment around the world; it is a grave mistake that is misleading top management and a practice that should be scrutinised and preferably eliminated. Furthermore, bias tests used to prove otherwise are often based on insufficient data to draw valid conclusions; a guideline is provided.CITATION:Pitard, F F, 2014. Sampling systems for process control and metallurgical accounting, in Proceedings Sampling 2014 , pp 25–32 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 29, 2014

By Hakan Akcin, Pinar Eksert

The aim of this study was the safety risk assessment of accidents that occur because of production dynamics in deep coal mining, one of the highly dangerous business class, with spatiotemporal GIS. In this study, accidents that occur at certain times during production in underground mining workplaces are discussed based on evaluations of spatial and temporal dimensions. Accordingly, various analyses have been handled using criminology science tactics and strategies such as 80–20, kernel density, space–time cube, and hot spot, which have been adapted to GIS tools. Implementations have been realized on 3D underground cartographic models covering accident data from deep coal mine workplaces in the Zonguldak-Kozlu basin in Turkey between 2019 and 2021, at an average elevation of – 400 m. Space–time cube, kernel density, and time series analyses suggest that the Annual Bonus Incentives, which are repeated every year and given before the new year, increase the psychosocial risks for employees. It has been determined that this situation can lead to problems such as poor concentration among miners and loss of focus in some shifts. Additionally, significant relationships were found between the number of accidents and monthly production progress rates as a temporal parameter. The results demonstrate that applying a reactive approach with spatiotemporal GIS to accidents in deep coal mines is becoming increasingly important.

Apr 24, 2024

By D Reid

Run-out analyses of tailings storage facilities are typically undertaken using methods based on rheological theory. These are reasonable techniques to model the behaviour of tailings that, through significant run-out and possibly mixing with supernatant water, are generally acting in a fluidised manner. Such modelling often follows on from two-dimensional continuum analysis models where, if failure is predicted, grid failure often occurs when deformations begin to increase. This results in a disconnect between the prediction of failure and the modelling of the potential extent of the failure.Recently, rezoning methods have been incorporated into commercially available two-dimensional soil mechanics deformation codes. Rezoning techniques enable large deformations to be modelled within a two-dimensional continuum analysis framework; however, while promising, the use of such tools is not yet widespread, and a consensus is yet to develop on how they should be applied to tailings dam run-out modelling.This paper uses FLAC rezoning techniques to model the flow behaviour of two historic tailings dam failures. The purpose of these analyses is to critically assess the performance of rezoning against some available historic failures. The required data to undertake such an analysis is outlined, along with the inherent limitations and assumptions required. Parametric analyses are outlined to address some of these issues. In general, the analyses undertaken underestimated the flow distance observed in the historic failures by varying degrees; however, in some instances, the analysis reasonably reproduced the qualitative shape of the initial failure zone. A variety of potential reasons for the discrepancy between historical observations and the models undertaken are provided.CITATION:Reid, D, 2015. The use of rezoning techniques to model historic tailings failures, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 201–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015