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By J. Feldman

This report contains a description of the distillation laboratory at Bruceton, Pa., which was established to aid in the separation and identification of the products produced in the synthetic liquid fuel processes under study there. Compounds present in synthetic liquid fuels may include aliphatic from C1 to C60 or greater. Alcohols, ketones, esters, aliphatic carboxylic acids, saturated hydrocarbons, olefins, and diolefins are all found in Fischer-Tropsch products. Coal-hydrogenation products contain, in addition to aliphatic compounds, a large proportion of naphthenic material and aromatic compounds ranging from benzene to coronene; in addition, appreciable quantities of tar bases and tar acids are present. In designing the laboratory, therefore, provision had to be wade for the greatest amount of flexibility and versatility. A great deal of standardization of basic equipment had also to be designed to permit interchange of parts and services.

Jan 1, 1951

By R. L. Grant

The Bureau of Mines developed two new gap-sensitivity methods for explosives, and especially permissible explosives, to overcome certain disadvantages of the present routine half-cartridge method. The revised methods are based on the statistical up-and-down method and give more useful measurements of the 50-percent' gap values than the nonstatistical routine method. The new methods use full cartridges and incorporate certain physical improvements such as the use of cardboard tubes for containing the explosives and coal dust gaps to simulate actual mining conditions. A total of 60 samples of permissible explosives were evaluated simultaneously with the 2 improved methods and with the half-cartridge method

Jan 1, 1967

By D. R. Nagaraj

The traditional (popular) approach to reagent development and optimization, which has become entrenched in both research and practice for many decades, is highly reductionistic, incremental and costly, does not produce robust chemical solutions, and is not sustainable. There are also several other key drivers and changes in the mineral industry that clearly warrant a new approach. In response to these, an intense effort was made at Cytec over the past fifteen years to develop a meaningful, efficient, and sustainable approach to develop new reagents and robust chemical solutions in mineral separations. This effort culminated in three important outcomes: a) development of the holistic approach, called FLOTATION MATRIX 100? process, b) novel reagents, and c) enhanced application knowledge for reagents. In this paper, the efficiency, utility and power of the holistic approach will be demonstrated with examples using both existing and new reagents in the processing of Cu-Au, Au and Cu-Mo ores.

Jan 1, 2014

By Ewan Alexander

"As human beings, we have managed risk since the dawn of the ages and have been adept at doing so. In order to survive, we hunted or gathered. If we did not take enough risk, we died. If we took much risk, we died (Fig. 1). As individuals and tribes, risk had to be optimized to maximize our chances to thrive, as individuals and as tribes.In today’s world, the risks are vastly different, but in order to thrive, these must be managed. And no industry knows this as much as mining. In fact, the International Council of Mining & Metals (ICMM) has proposed the Critical Risk Model (Fig. 2) as a means of identifying critical risk, critical controls and associated performance standards. The ICMM focuses on sustainable development performance in the mining and metals industry. It has 23 members, representing some of the largest mining companies in the world.This approach is going to help the mining industry. But it must be applied effectively, with the acknowledgment that the system alone cannot be effective. We can say this confidently, as even companies known for the strength of their risk and safety management systems continue to experience significant incidents, and, in some cases, catastrophes. Why does that happen when all safety metrics, including injury rate, are pointing in the right direction? In the view of the author, it is only when leadership, culture and systems work in complete harmony that the resilience of an organization to manage its significant risk is at an optimal level. It remains an ongoing leadership challenge to maintain that balance and the optimal mindset in the organization. So how do you maintain that special balance?Let’s start with a basic premise. Leadership, supported by simple effective systems, creates culture which creates outcomes. Everyone going home safely is an outcome, as is cost effective operations, and to achieve those outcomes efficiently, the organization must focus on the inputs. And those inputs include effective leadership, effective systems (for the purposes of this article, risk and health, safety and environment (HSE) systems), good planning, stable operations and competent workers. This article will focus on gaining maximum performance from your risk management system."

Oct 1, 2016

By Charles E. Locke

DEPRESSION in all lines of the mineral industry except gold, which began in 1930 and continued, even worse, through 1931, had its effect on ore concentration. Construction was limited to the completion of plants already begun. Every possible economy was adopted. Changes and improvements involving expense were postponed. Research was largely abandoned. Operations became highly efficient and costs were cut down, although this did not necessarily mean a lower cost per ton because of the greatly reduced capacity at which mills were run. Lower metal prices caused the operators to seek the optimum ratio of concentration and grade of concentrates looking toward maximum economic recovery; that is, net profit. In the crushing field no marked changes occurred. The Symons cone crusher for intermediate work is in use almost everywhere. Its manufacturers claim that 900 machines have been installed in 21 countries, replacing two previous steps of crushing and yielding a product sufficiently fine to form a satisfactory feed for rod mills and ball mills. A new Telsmith crusher has appeared which has curved jaws something like the Symons cone and consequently the same advantage as the latter.

Jan 1, 1932

By G. W. Luxbacher

This volume describes the use of the Penn State Mine Ventilation Simulator (PSU/MVS) to model existing mine ventilation systems and, in addition, to evaluate the effect of system modifications. Ventilation survey methods designed to insure computer input data of sufficient accuracy for simulation purposes are covered in comprehensive detail, including quantity and pressure measurement and fan performance testing. The development of input data from ventilation survey results is discussed and illustrated by the use of an actual field survey. Two programs, written in FORTRAN IV with WATFIV, are presented to calculate airway head losses from altimeter pressure measurements. An existing coal mine ventilation system is analyzed and modifications to the system are simulated and evaluated. In addition the application of the PSU/MVS to non-coal mines is briefly discussed. An extensive bibliography on ventilation surveying and simulation is included.

Jan 1, 1977

By Laurent Airaud

For around ten years, electronic detonators are available for those who want to use advanced methods and to apply theories promoted by engineers and professors to reduce blast concerns or improve fragmentation and dilution. Furthermore, decision makers can verify the use of electronic detonators to drive down mining costs. Engineers and more specifically blasters are the actual users and have to be convinced of the easiness of electronic detonators. This paper deals with electronic detonators and the notion of easiness. Common feelings about the notion of easiness are discussed. Then, examples of new technologies like, automobile, photography or Information Technology are discussed to observe how they progressed throughout time with new features and sales volume. For the specific explosive initiation industry, each step of the life of an electronic detonator is dealt with concerning the easiness and a table is used to quantify this notion.

Jan 1, 2004

By Daniel C. Boteler

Five lignites from the northern Great Plains province were carbonized at temperatures from 500° to 1,000° C in a bench-scale unit. A replicated Greco-Latin square experimental design was employed to allow testing of four independent variables at five levels. Independent variables investigated were temperature, source of lignite (mine), weight of charge, and moisture content of charge. Dependent variables were char yield, tar yield, light-oil yield, tar plus light-oil yield, carbonization gas yield, and carbonization gas heat yield. An analysis of variance indicated that, at the 99-percent confidence level, the independent variables of carbonization temperature, source of lignite, and weight of charge were significant for yields of char, tar plus light oil, and carbonization gas, whereas moisture content was only significant for carbonization gas yields. At the 95-percent confidence level, moisture content significantly influenced the carbonization gas heat yield per pound of lignite charge and the yields of dry tar plus light oil. All dependent variables were determined on a moisture- and ash-free basis. Multiple regression equations for predicting seven different factors of carbonization yields as functions of carbonization temperature and initial composition were developed using computer techniques. Equations for yields of char, tar plus light oil, and carbonization gas were compared with equations previously developed by others at the 500° C level.

Jan 1, 1970

By N L. Turner, D J. Robinson, A J. McFarlane, N M. Chapman, L L. Kuhar, R L. Meakin, R Martin

A number of geometallurgical tests have been developed within the AMIRA P843A Geometallurgical Mapping and Mine Modelling (GeMIII) project, an interdisciplinary collaborative research project involving four research groups and over 20 global mineral companies. Researchers at the Commonwealth Scientific and Industrial Research Organisation (CSIRO) have been focusing on the development of predictive hydrometallurgical indices for the GeMIII project via rapid, small-scale, cost-effective tests and protocols for comparative ranking of attributes relevant to leach performance. One of the focus areas has been the development of a leaching scheme for determination of the mineralogical deportment of copper in a large number of samples for geometallurgical applications.Various leaching schemes have been used over the last 20 years to identify the mineralogical deportment of copper. Typically, weak sulfuric acid and cyanide are used to target copper oxides and æsecondaryÆ copper sulfide minerals, covellite, chalcocite and bornite, respectively. Residual copper is assigned to chalcopyrite and/or bornite. Adaptations of this scheme have included the use of a weak organic acid to target oxides or ferric sulfate to target secondary copper sulfides. Testing of the weak acid/cyanide scheme in the GeMIII project using head and residue QEMSCAN mineralogical data analysed with a statistically reliable comparison method indicated that the inferred mineralogical deportment from various leaches could differ markedly from the theoretical or assumed value. Based on this initial work, test development and leach tests on samples from multiple sites has resulted in the development of a scheme to target copper oxides, chalcocite, covellite, bornite and chalcopyrite. This paper presents results from leach tests conducted on a large sample suite from two pits in a Cu-Au ore deposit with results calibrated using mineral liberation analyser (MLA) mineralogical analysis. This study has assisted in the development of a protocol for determining the mineralogical deportment of copper in a large number of samples for geometallurgical applications.CITATION:Kuhar, L L, McFarlane, A J, Chapman, N M, Meakin, R L, Martin, R, Turner, N L and Robinson, D J, 2013. Calibration and testing of a geometallurgical leaching protocol for determining copper mineralogical deportment, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 177-186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By Ralphie Adams, Tiana Rasmussen, Ashley E. Shirer

Transmission line foundation designers must rely on limited subsurface information, from easily accessible locations, resulting in subsurface uncertainty, increased design risk and increased construction costs. This paper presents a different approach for foundation analysis conducted in mountainous and alluvial floodplains located northwest of Phoenix, AZ. The region is dominated by fault-bounded, northeast dipping mountain ranges, where rock types and drillability can vary from granite to intact basalt. The valleys between are comprised of “basin-fill” deposits ranging from conglomerates and cemented soils to lose alluvium. Recently deposited alluvial fills can vary in depth significantly from location to location due to erosion and deposition from active and historic hydraulic features. To limit the subsurface uncertainty for foundation design, a phased approach using geophysical surveys along with detailed geologic reconnaissance was employed. Both compression wave and shear wave velocities were measured in order to identify the depth and properties of loose erodible materials from more scourresistant cemented, conglomerate, and rock deposits. These analyses were used in combination with limited subsurface drilling and sampling to evaluate direct embedment steel pole foundations for over fifty structures. Post analysis results from limited construction drilling reports were used to assess this approach.

Sep 8, 2021

By A. D. Kalogeropoulos, T. N. Michalakopoulos

This paper deals with the numerical simulation of rock cutting laboratory tests using the discrete element method. The main objective is to provide a method for calibrating numerical DEM models of rock cutting in a systematic way so that realistic results are yielded. The numerical models are developed with the discrete element code Yade, which models rocks as a collection of bonded spheres. The models are calibrated in a four-step process based on the design of experiments method and optimization. The calibrated models are evaluated both quantitatively and qualitatively against actual laboratory cutting tests, in terms of the ratio of the simulated mean cutting force to the actual one and the cutting force time series, respectively. The fully calibrated models showed that the simulated cutting process matched qualitatively the actual cutting force recordings and underestimated the mean cutting force by approximately 3%. It is concluded that well-calibrated numerical simulations of the rock cutting process can provide not only a better understanding of the process itself but also quantitative data regarding the cutting force and energy requirements.

Dec 28, 2022

By Anderson Pereira

SORM 3plus (SORM = Superfast Optical Roughness Measurement) is a system enabling online measurement of roughness parameters during continuous strip processing. Increased requirements for new materials and more complex components call for ever increasing process safety. The roughness parameters are important quality features of uncoated and surface refined strips. The traditional method of measurement involves using a mechanical stylus based instrument. For this purpose the operator must stop the production line or samples are taken from the end of the coil and measurements are made offline in the lab. SORM 3plus, however, is a non-contact, online surface roughness measurement system that can be used for metallic and many non-metallic surfaces at strip speeds of up to 2400 m/min. The surface roughness data are stored in the system computer, displayed to the operator and if needed are fed into a higher-level network. The operator is alerted, if the limited values preset by him are exceeded or if any changes within the line will put at risk the production process. SORM 3plus calculates the roughness parameters as defined in the standards, such as the arithmetic average roughness (Ra) and the peak count (RPc).

Oct 8, 2019

By R. R. Swanson

Liquid ion exchange is becoming more and more important in hydro-metallurgical processing and recovery of metals. The key to success for this process are reagents which have suitable operating characteristics. One of these important characteristics is a relatively fast phase separation rate in the extraction and stripping circuits, as this greatly affects the size of plant required. A test for measuring phase separation rate is needed to help evaluate liquid ion exchange reagents. Such "a test also would be useful for evaluating carrier solvents that are used for diluting the re-agents. In fact, one standard test method would be very desirable as it would provide a common basis for comparing reagents and sol-vents. The phase separation test described in this paper has been used successfully for several years with the copper reagent, LIX®64N. The test is set up for feed liquors containing low copper concentrations. For other types of systems, modifications in procedure probably would be necessary. However, this test and the associated apparatus could be the basis for a standard phase separation test.

Jan 1, 1972

"The content of production reports has its origins in raw measurements taken in harsh production environments. The ensuing measurement/estimation errors always affect reproducibility such that, regardless of the fact that they are balanced through statistical data reconciliation, reported numbers are simply the most probable values of inferred probability distributions. This has important implications for how metal recoveries should be monitored and reported. Indeed, in a context where many process optimisation activities are based on small improvements in recovery, there should be no doubt that inadequate handling of measurement/estimation errors can easily exaggerate or mask actual changes in process performance. However, estimates of the reproducibility of reported metal recoveries are rarely reported to plant management. This situation persists despite the fact that a code compliant metal accounting system must inform management about business risks related to metal accounting. To this extent, this paper focuses on the continuous management of reproducibility level of metal recoveries in compliance with the best practices. Sensitivity analysis of primary and secondary metal accounting models is performed to show the resulting probability distributions for metal recoveries. Some guidelines are given for designing and managing metal accounting systems capable of achieving and sustaining predefined levels for the reproducibility of metal recoveries.INTRODUCTIONEach and every mineral processing plant produces daily, weekly and monthly production reports in which metal balances for payable and penalty elements are presented. While such production reports are usually consulted in offices, underlying raw measurements are taken in harsh production environments where mechanical vibrations, humidity, corrosion and dust, to name a few, disturb measurement procedures. It is thus no surprise that several authors (Francois-Bongarcon & Gy, 2002; Gaylard, Randolph, & Wortley, 2014; Holmes, 2010; Spangenberg & Minnitt, 2014) have reported pervasive issues related to mass/sampling measurements in the context of mineral processing."

Jan 1, 2016

By A. Navarra

Peirce-Smith converting (PSC) is applied for roughly 50% of primary nickel and 70% of primary copper production. PSC cycles produce batches of ironfree sulfide matte (or blister copper, in the case of copper smelters), that are subject to further processing. However, the number of cycles that can be performed simultaneously is limited by the offgas handling system. Moreover, PSC suffers from variation in the yield and duration of the cycles. This variation is managed by conventional smelter designs, in which the upstream smelting capacity exceeds the nominal converting capacity; PSC is thus a major bottleneck in conventional nickel and copper smelters. Stabilization and standardization of PSC operations can therefore increase smelter throughput. The current paper presents a discrete event simulation (DES) framework to assist in smelter debottlenecking. It features random number generation to represent cycle variability, and time-adaptive finite differences to represent thermochemical complexity. Preliminary computations are presented.

"Caterpillar has developed the Cat GH800B longwall plow system, designed for mining very low coal seams at high rates. Building on the attributes of the proven GH1600 plow system, the Caterpillar longwall team in Lünen, Germany, worked with the German Ibbenbüren Mine to design and construct a system for mining an anthracite seam averaging only 0.85 m (33.5 in.) thick. The result is the GH800B plow and associated longwall system, which is now operating in the Ibbenbüren Mine - where the seam does not exceed 1 m (39 in.) in height.The Cat GH800 plow, with an installed power of 2 x 400 kW, has been the plow of choice for seam heights from 0.9 to 2 m (35 to 78 in.), regardless of seam inclination or coal hardness. But the lower the coal seam, the more difficult the extraction process. Flexibility, reliability, efficiency and serviceability of the whole system had to be refined for maximum productivity in such a minimal height, but several key modifications led to success.The armored face conveyor (AFC) modifications for the GH800B plow system include PF4 plow line pans with a replaceable top trough and a new plow guide made of a one-piece casting to provide extra strength and durability while being lower in height than the previous welded version. External dogbone connectors between the line pans and a strong and flexible relay bar between the AFC and the roof supports (shields) further adapt the conveyor for very low seam operation. To increase coal throughput, the engineering team widened the conveyor crosssection with extended side plates."

Jan 1, 2014

By Miles B. Royert

Crude Minnesota taconite was charged in the Bureau of Mines experimental blast furnace so that smelting characteristics of such highly siliceous raw materials could be studied and smelting costs compared with those of a standard Mesabi ore. The Bureau recognized that the highly siliceous nature of the crude ore and its relatively low metallic content would be serious economic deterrents to commercial use of the raw taconite, but compensating factors would be low capital investment in production facilities, large tonnage available on short notice, high recoveries of iron, and low delivered cost. Crude taconite smelted readily in the experimental blast furnace. Coke consumption per ton of metallic product was very high, compared with the average established requirements for smelting normal grades of metalliferous raw materials. Slag rates were also inordinately high. Metal quality was erratic as to silicon, and sulfur contents were objectionably high.

Jan 1, 1961

By H. F. Yancey

Although a general relationship exists between the two criteria used to measure sharpness of separation -error area and probable error -they sometimes give quite different appraisals of a particular washing operation. Error area takes into account how the entire raw coal was treated, whereas probable error reflects only how the material of intermediate density was separated, ignoring completely the recovery of clean coal and the rejection of heavy impurity. Error area is thus more reliable for general use. In heavy-medium cleaning, sharpness of separation decreases with increase in separating density, but ordinarily the change is not great enough to affect the yield and ash content of washed coal measurably. Therefore, distribution curves for heavy-medium units can be transposed from one separating density to another, at least in the range of separating densities ordinarily used in the United States.

Jan 1, 1955

By R. E. Ray

"As real estate for new development in urban settings becomes scarce, commercial high rises are being constructed above open passenger rail tracks and vehicular roadways. Rail and roadway overbuilds are treated as tunnels requiring emergency ventilation systems for train or automobile and truck fires. The value of floor space in residential and office towers poses challenges to engineers responsible for designing fan rooms and shafts for tunnel ventilation systems within the towers. This paper describes a case study of the unique incorporation of tunnel ventilation fan plants in the overbuild structure of a passenger railyard and an adjacent roadway.INTRODUCTIONTunnel ventilation systems are required for passenger rail and transit (subway) tunnels by the NFPA 130 Standard for Fixed Guideway Transit and Passenger Rail Systems, and the NFPA 502 Standard for Road Tunnels, Bridges, and Other Limited Access Highways requires tunnel ventilation systems for vehicular (road) tunnels. Passenger rail and transit (subway) tunnels are typically ventilated with a series of shafts placed longitudinally along the tunnels to provide piston relief for normal train operations and emergency ventilation of train fires utilizing reversible axial flow fans. The shafts are incorporated in dedicated ventilation buildings that house the tunnel ventilation fans and starters, switchgear to power the fans and other equipment and systems in the building, Programmable Logic Controllers (PLCs) to control fan operation with Supervisory Control and Data Acquisition (SCADA) software, and HVAC fans and ductwork to ventilate the spaces in the building. These ventilation buildings may also provide access to the tunnels below with ingress/egress stairs for use by first responders and firefighters entering the tunnels and train or transit system passengers exiting the tunnels in an emergency. A photograph of a passenger rail ventilation building that encompasses four tunnels is shown in Figure 1."

Jan 1, 2019

By Raja V. Rarnani, Robert L. Frantz

"Mining is one of the oldest of human occupations. The awareness of occupational illnesses associated with mining, even in ancient times, is evident from the writings of Hippocrates (460-370 BC), Pliny and Elder (AD 23-79), and Galen (AD 131-210). Georgius Agricola (1494-1535), in his De Re Metallica, refers to the diseases of miners and the need for their control through good planning and operating practices and responsible management (Schwerha, 1989). Coal workers' pneumoconiosis (CWP), often called Black Lung disease, is an occupational disease which results from inhalation of coal mine dust which usually contains relatively small amounts of free crystalline silica.A pneumoconiosis is best defined as the accumulation of dust in the lungs and the tissue's reaction to its presence [Lapp and Castranova, 1993]. Silicosis is the name given to the fibrotic disease of the lungs caused by the inhalation of dust containing silicon dioxide, primarily in the free crystalline form. Silicosis is the older and more well known of these mineral pneumoconioses. In contrast, CWP was not recognized as different from silicosis until the pivotal work of Collis and Gilchrist [1928].The U.S. Bureau of Mines (USBM) still regards worker exposure to respirable aerosols in mines as the most serious health problem in mining [USBM, 1994]. The National Institute of Occupational Safety and Health (NIOSH) is considering recommending a reduction in the standard for occupational exposure to respirable coal mine dust from 2 mg/m3 to 1 mg/m3 [NIOSH, 1993]. The Mine Safety and Health Administration (MSHA) may require new criterion for sampling procedures in the mine that would evaluate the ambient dust concentration in the mine atmosphere based on a single sample, instead of the current practice of averaging five samples (MSHA, 1992; Ramat* 1993). Several high-production longwall mining faces currently have extreme difficulty meeting the existing dust standards, and some already operate at reduced production levels to achieve mandated levels [USBM, 1993]. The importance of adequately protecting the miners from high concentrations of coal mine dust, as well as of reducing the incidence and severity of the Black Lung disease, cannot be overemphasized. The importance stems, first and foremost, from the humanitarian viewpoint and, second, from the perspective of the overall welfare of the coal industry.The histopathologic hallmark of CWP is the coal macule (Balaan, Weber and Banks, 1993). Autopsy or open lung biopsy reveals the coal macule to be an amorphous mass of coal particles, dust-laden pulmonary macrophages, reticulin, and collagen. No pathognomonic signs or symptoms identify workers with CWP. A CWP diagnosis requires that the worker experienced the appropriate dust-exposure setting (e.g., underground coal mining) and duration (usually 10 years or more) and, has the characteristic chest radiograph. Based upon the International Labour Organization (ILO, 1980) international classification, pathologists and radiologists have established case definitions for characterizing the pathology and the appearance of CWP on chest radiography (Weeks, 1993). CWP appears in two principal forms: simple, with small opacities, and complicated, with opacities larger than 10 mm in diameter. For all practical purposes, diagnosis of CWP in the living miner is wholly dependent upon the chest radiograph interpretation."

Jan 1, 1995