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By Forrester P. I, Richardson W

Methane in coal mines is an ever present hazard resulting in loss of lives and serious economic consequences. For effective control of methane, ventilation alone may not be totally adequate in some situations. In order to deal with such cases, new methods for the control of methane are being researched. One such method based on biotechnology has been investigated in Canada in the past several years. This method involves bringing methane oxidizing micro- organisms into contact with coal to oxidize the methane released to non-flammable products.

Jan 1, 1988

By Michael Wortley

Metso?s Process Technology and Innovation group is a world leader in mineral processing consulting. A significant amount of this consulting work involves process integration and optimization (PIO) studies, which include investigating the effects of drill-and-blast design and implementation on downstream processing. Critical to these studies is the ability to track specific ore into, and through, the plant. To increase the accuracy of this ore tracking, Metso Process Technology and Innovation (PTI) developed a system to track ore using a radio frequency identification (RFID) transponders technology designed to allow tracking of ore from its source through blasting, run-of-mine (ROM) pads, crushers, intermediate stockpiles and, finally, into the concentrator. The system is called SmartTag. Since its commercialization in 2007, SmartTag has been used in the majority of PTI?s consulting projects, and several permanent systems have been installed worldwide.

Jan 1, 2012

By Rafael Abreu Fraga, Carlos Noberto Paula da Silva, Emanuelle Garcia Reis, Daniel Bojikian Matsubara

Since 2016 Gerdau Ouro Branco has been producing steel plates of various qualities and grades. However, it was not until 2018 that the first plates produced by accelerated cooling process were made available for external testing, in this case for large diameter UOE pipes manufacturing. Recent line pipe and OCTG specifications are showing that the oil and gas market still consumes regular API grades, such as X60, X65 and X70, however with increasing wall thicknesses, reaching values up to 1.5 inches. These specifications also demand longitudinal and transverse tensile guarantees and drop weight tear tests in temperatures as low as -40°C. Projects with these types of mechanical properties present process requirements as challenging as those necessary for higher API grades in lower thicknesses. This paper shows the steel design concepts and rolling routes for achieving the necessary properties for X70 steel plates in 28.15 mm. The microstructural features were also investigated and associated with the production process and the tensile and toughness results. Finally, challenges such as tensile anisotropy and DWTT abnormal fracture are presented.

Oct 1, 2019

By C. S. Kucukkargoz, A. Bhalla

"The solid-state reduction of ilmenite concentrate with graphite was studied under argon atmosphere at temperatures between 1050°C and 1350°C. The rate of reduction increased with increasing temperature and decreasing particle size, with the maximum extent of reduction found to be 80% at 1350oC with a particle size in the range of -106 +90 µm. The activation energy for the reduction reaction was calculated to be 257 kJ/mole. The trivalent iron oxide was reduced first to divalent iron oxide and then to metallic iron. An annular ring of a partially reduced oxide phase containing metallic nuclei was formed around the core of ilmenite, which grew in size as the original ilmenite core shrank with progressive reduction. The reduction of titanium dioxide also took place during this stage, which produced the Magneli oxides in the form of TinO2n-1. The metallic phase had very high Fe and low Ti contents throughout the reduction, whereas the partially reduced oxide phase adjacent to the metallic phase was high in Ti and depleted in Fe. The metallic phase globules formed during this stage were small and are considered suitable only for leaching and not for other concentration processes. The core of the particle generally retained the composition of the original ilmenite. The purpose of this work was to remove iron and increase the titanium oxide content of the ilmenite to produce a high-titanium containing charge for subsequent smelting.IntroductionThe titanium-bearing minerals ilmenite (FeTiO3) and rutile (TiO2) are the primary natural raw materials used in industry to produce titanium metal and titanium-based products. The common titanium-bearing minerals are ilmenite, rutile, anatase, brookite, leucoxene, arizonite, and perovskite. Although the formula of ilmenite is commonly expressed as FeTiO3, the mineral can accommodate Mn and Mg, which are chemically bound in the form of (Fe,Mn,Mg)TiO3. Ilmenite concentrate can also contain Fe2O3 and Al2O3 in addition to the physically separable oxides such as SiO2 and CaO. The crystal structure of ilmenite is an ordered derivative of the corundum structure with a trigonal-rhombohedral symmetry. Fe2+ and Ti4+ ions occupy the octahedral sites, leaving the tetrahedral sites unoccupied. In each FeTiO3 unit, there are three O2- ions creating three octahedral sites, two of which are occupied by Fe2+ and Ti4+ (Wilson et al., 2005)."

Jan 1, 2017

By Thomas M. Barczak

The U.S. Bureau of Mines has been conducting research to optimize the design and utilization of mine roof support systems. An objective of these efforts is to evaluate the mechanical and structural responses of various mine roof support systems under simulated load conditions in the Bureau's mine roof simulator. Underground studies are also made to evaluate the in situ behavior of support structures. The purpose of this report is to document practical applications for longwall face and gate road supports that have resulted from these studies. This report is not intended to be an all-inclusive manual on every aspect of support utilization, but it does provide a comprehensive assessment of practical considerations relating to the mechanical and structural behavior of these support systems. Forty-six recommendations are made to provide assistance to mine operators in the testing, selection, and utilization of longwall face and gate road supports. Many of these recommendations offer innovative solutions to everyday problems faced by mining personnel in the control of ground in longwall mining.

Jan 1, 1989

By R. M. Lamya

The kinetics of copper cementation during atmosphere leaching of a Ni-Cu matte in CuSO4-H2SO4 solution was studied as a function of initial copper ion concentration, initial acid concentration, temperature, stirring rate, particle size distribution and pulp density. It was found that all these process variables influenced the rate of cementation. A two-stage rate of reaction was observed inmost of the experiments, with the rate of cementation in the initial stage being slower than that of the subsequent second stage. The increased rate of cementation in the second stage was attributed to the enhancing effect of the surface deposit. The cementation process was found to take place by two different rate-controlling mechanisms. At a temperature range of 50?70°C, an activation energy of 74.6 kJ/mol was obtained, indicating a surface reaction controlled process. At higher temperatures (70?80°C) a lower value of activation energy was observed (18.2 kJ/mol), indicative of a process controlled by diffusion through surface layers. The structural characteristics of the cemented deposit could not be determined in the investigated system where the deposit was mixed with the leach solid residue.

Jan 1, 2005

By C. Pomeroy, J. Weyer, J. Brune

"Mining began in the Erzgebirge (“ore mountains”) region of Saxony, Germany more than 800 years ago, and extensive underground workings cut through the entire area. Some of these old workings are still used today: not for production, but for offering an underground venue for research, tourism and university teaching. One example is the Reiche Zeche mine at the Technische Universität Bergakadamie Freiberg which hosts one of the oldest mining engineering programs in the world. It is imperative to keep all active mine workings well ventilated to make the mine safe for students, visitors and researchers. Since the mine workings at Reiche Zeche are so vast, extensive and, to a large extent unexplored and unmapped, it has been difficult to provide a complete, functioning and adequate mine ventilation model for this mine that accounts for all known and unknown leakage air flows. Researchers at the Colorado School of Mines have cooperation with their colleagues at Freiberg to establish a mine ventilation network model based on a limited number of air readings in known and accessible drifts. In order to balance the measured air quantities, leakage flows were quantified and mapped by comparing input and output flows of mapped drifts, and modelled using Ventsim Visual, a powerful visualization software package. The resulting mine ventilation model is used to locate and quantify the leakage air flows and to examine how much air is lost in each area. With this model, ventilation changes and improvements underground can be documented reflected in the model. This enables the Bergakadamie Freiberg to project air changes required for scientific experiments and to set up mine ventilation in specific areas and for specific needs. The model also enables better ventilation control and monitoring than before. Finally, the model can be used to predict ventilation changes and escape way contamination in case of a fire, ground fall or inundation in the mine. The latter becomes important as the lower mine workings are often flooded during spring runoff, which has created uncertainty about mine ventilation in the past. HISTORICAL BACKGROUND The discovery of silver, lead, zinc, tin and other valuable metal ores in the Erzgebirge region of Saxony, Germany began in the12th century and started a mining boom than lasted for centuries. Surface mines quickly developed underground to access the higher grade veins. Explored by the early geologists and driven by the ingenuity of the miners, the underground works expanded vastly throughout Freiberg and the surrounding region. Development followed the highest grade veins, and engineers developed solutions to drain water and provide limited ventilation to the underground workings. Still, engineered and planned ventilation was usually not a priority in the development of a new drift, which today makes ventilation modeling a significant challenge."

Jan 1, 2015

By Jochen Petersen, David G. Dixon

"Although heap leaching may be perceived as a somewhat low-tech route for the extraction of low-grade minerals, the underlying physical, chemical and biological processes are in fact extremely complex. There has been increased interest in heap leaching of sulphide minerals in recent years with the advent of controlled bio-heap leaching, and the need to mine more marginal ore deposits.A detailed investigation into the dynamics of heap leach processes has provided much insight into the underlying complexities, and has led to the development of a sophisticated modelling tool. Some of the features include mineral kinetics, particle level effects, bacterial growth, oxidation and adsorption, gas adsorption, pore diffusion, bulk advection, gas balance and heat conservation.Two case studies are presented which illustrate specific features of the model for different applications and how these have helped to identify key areas of concern. In each case the model has proved as an invaluable tool either for the improvement of existing heap leach practice or for the development and assessment of novel applications."

Jan 1, 2003

By C. A. Vining, J. R. Nopola

"Evaporites, such as salt and potash, pose unique problems to ground-support designs not encountered in other rock types. Evaporites are subject to continual creep and no amount of ground support can successfully arrest this process. Common ground-support techniques that are useful for most rock types may reduce the effective life of bolts in evaporite mines and can create unseen hazards. A different approach to ground support must be applied to provide long-term support in areas where high creep rates are present. The goal of effective ground-support designs in these situations is not to contain the rock and prevent it from moving; rather, the ground-support design must be able to move along with the rock and contain any fully detached slabs until additional remediation measures can be undertaken. The most appropriate ground-support designs will consider both the expected movement of the rock and the duration that the area needs to remain accessible.INTRODUCTIONEvaporites, such as salt and potash, pose unique problems to ground-support designs not encountered in other rock types. The factors that must be considered in design stem from the deformation behavior of salt, which can fail in a brittle manner, akin to most rocks, but can also deform in a slow, ductile manner, resembling the stretching and elongation of steel. The deformation behavior of salt has been well established in technical circles where it has been studied for decades (Hardy and Langer, 1984). Much of the research in salt mechanics is related to repository science, specifically at the Waste Isolation Pilot Plant (WIPP) in southwest New Mexico. RESPEC has been continually involved in the WIPP from the initial design considerations (Gnirk, Grams, and Zeller, 1977) to the current day (Keffeler, 2016) and has been able to leverage cutting-edge research of salt mechanics into practical solutions for mining operators. While a detailed description of salt mechanics is not provided in this document, Fossum and Fredrich (2002) include a fine overview of salt mechanics. The following list paraphrases their chapter on basic facts about salt to provide some context for the reader unfamiliar with salt mechanics:"

Jan 1, 2018

By S J. Clarke, C S. Walker

The South West Rail Link (SWRL) project involved construction of a rail line to service new residential areas in south-west Sydney. The 11 km rail line is conveyed through a short tunnel at shallow depth where it crosses beneath the eight lanes of the Hume Highway. The underpass location is one of the most heavily trafficked within Sydney’s motorway network.The New South Wales Roads and Maritime Services (Roads and Maritime), as the owner of the highway asset, had the responsibility of managing the risks to the highway and traffic associated with the tunnelling project from the pretender stage through to completion. This paper considers the primary risks and mitigation measures employed, including geotechnical investigation, and development of appropriate construction constraints and concept design of an extensive real-time survey system to monitor pavement deformation during the tunnel works.The geology comprises fresh Minchinbury Sandstone in the tunnel invert and side walls, and variably weathered Bringelly Shale in the haunch and crown. Few tunnels have been excavated in these rock types in Sydney, and there is little information relating to the in situ stresses and stress-relief deformations in these materials.During tunnel construction the monitoring data indicated unexpected surface heave of up to about 24 mm. A multiparametric back-analysis of the deformation data is presented, which provides information on the deformation mechanisms and key geotechnical parameters, including rock mass modulus and in situ stresses.The approaches and methodologies developed for the SWRL underpass were effective in maintaining the safe operation and traffic capacity of the highway throughout the construction period, and the analysis of the monitoring data provides a useful reference for similar future projects, or projects constructed in similar ground conditions.CITATION:Clarke, S J and Walker, C S, 2014. Deformation mechanisms of the South West Rail Link underpass beneath the Hume Highway, in Proceedings 15th Australasian Tunnelling Conference 2014, pp 631–640 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By Charles H. Buclmam

"Environmental regulatory requirements for discharge of solutions and closure of operations for the gold mineral processing industry have been gradually lowered and in certain instances have been targeted to USEP A inorganic drinking water standards for dissolved ions in solution. The use of jar tests for water treatment process development is suitable for preliminary scoping work to be conducted in the research laboratory, as well as for optimization studies at the site of the treatment requirement. This paper will describe experimental methods which were performed using standard jar test equipment in efforts to produce solutions which meet USEP A inorganic drinking water standards after chemical treatment of cyanide solutions. The materials tested included gold bearing pregnant solutions from heap leaching operations, gold plant barren solutions from the Merrill-Crowe zinc cementation gold recovery process and gold heap leach wash solutions after carbon-in-column gold recovery. Experiments included cyanide destruction with sodium hypochlorite and arsenic and selenium co-precipitation coupled with mercury precipitation.IntroductionCyanide leaching solutions are used to selectively dissolve metallic gold from commercially viable mineral deposits. The heap leaching process involves stacking of gold bearing ores on specially designed solution containment pads and percolating alkaline cyanide solutions through the ore to dissolve the gold. Pregnant solutions containing the dissolved gold are collected and sent through a gold recovery process. After selective recovery of the gold, the barren solutions are recycled to the gold extraction process after adjustment of the solution alkalinity and available cyanide concentrations."

Jan 1, 1997

By Sanjeeva Latchireddi

"Deteriorating ore grade and high demand of metals has tremendously influenced the unit capacity of SAG mills. Pebble circuits have been added to the existing SAG circuits to increase their unit capacity. To make the pebble circuits justifiable, the grate openings are increased almost to 4.5 inches to draw large quantity of pebbles. The inherent transportation problems associated with SAG mills in closed circuit with pebble fraction are more complicated than the single stage SAG mill operation, because the coarse pebbles behave significantly different to that of slurry in pulp lifters. In addition, operation of mills at higher speed, to take advantage of precise design of high release angled shell lifters significantly reduces the discharge efficiency of the conventional pulp dischargers. The presence of a sizable quantity of pebbles in the pulp lifter limits the space available and reduces the flow gradient through the grate thus increases the load inside the mill and hence the mill power-draw. This paper analyses all the problems associated in discharge of slurry and pebbles in SAG mills with pebble circuits. The Outokumpu patented Turbo Pulp Lifter (TPLTM) aims at eliminating the inherent material transport problems to ensure good grinding conditions. Recent installation of TPLTM in a 26-ft SAG mill has proven these claims by reducing the specific power consumption while increasing the mill capacity.INTRODUCTIONThe conventional wisdom is to look at the semi-autogenous grinding (SAG) mill as just another grinding mill in which ball charge, mill filling, and mill speed are varied to attain maximum throughput. Liner design for the SAG was also approached more from a wear perspective rather than a metallurgical and hydraulic-flow perspective. The extensive research work carried out by Latchireddi and Morrell (1997,2003a and 2003b) has demonstrated to think of the SAG as more of a pump in which the grates and pulp discharger end (“impeller”) were designed to efficiently discharge the product sized particles smaller than the grate size with minimal recirculation out of the mill.The rock load in the mill is essentially depends on ore characteristics and the discharge rate of broken particles. The discharge rate of the product material depends on how efficiently the discharge pump (grate and pulp lifters) is operating. Similar to the impeller design affecting the pump capacity, the pulp lifter design affects the discharge capacity (or mill throughput) of the SAG/AG grinding mills. The general arrangement of AG/SAG mills discharge system is shown in Figure 1."

Jan 1, 2007

By D. Georgiou

Direct sulphuric acid leaching of nickeliferous limonites is the process of choice to recover nickel and cobalt from equatorially located lateritic ores. These ores are rich-in-iron (-45 wt%) existing in the form of goethite enriched with nickel. The merit of this process is due to its high nickel selectivity because of simultaneous iron separation and acid regeneration. Under acid leaching conditions (-250 to 270°C) iron follows an acid dissolution-hydrolytic precipitation path yielding a very low concentration level depending on temperature and acidity of the final leach liquor. The primary precipitation product of iron is hematite which also forms as a scale on reactor internals along with co-existing aluminum. In this paper, an overview of the behaviour of iron solid products under process conditions is made. The evolution of goethite to hematite transformation, as well as the role of iron in reactor scale production, are studied using SEM/EDX characterization techniques.

Jan 1, 1995

By C. Özgen Karacan

The methane emission rate into an underground mine environment from overburden strata during longwall mining is impacted by reservoir and geomechanical characteristics of the coal measure rocks in the overlying strata, as well as the presence of any coal seam. The reservoir characteristics and how they change during mining potentially affect the performance of gob gas ventholes, which consequently impacts the efficiency of methane control in the mining environment. This study presents reservoir and elastic properties of coal measure rocks in the Lower Monongahela Group in Greene County, southwestern Pennsylvania, of the Northern Appalachian Basin. Since the source of methane in this region from underground mining is located between the Sewickley coal and the Pittsburgh coal, a specific emphasis was given to this interval. Core analyses were performed in the laboratory to determine rock porosity and permeability. Geophysical logging data (gamma, density, sonic) obtained from two exploration boreholes were used for evaluating formation boundaries, shale contents, log porosities, and geomechanical properties of formations. Permeability was also calculated using density-log data and empirical equations and compared with laboratory measurements and slug tests performed in isolated intervals of boreholes. The results presented in this study can be used as data sources for reservoir studies related to the production and control of methane.

Jan 1, 2009

By Jack T. Work

Spiraling costs in every segment of the open-pit mining cycle is a fact of life that every operator must reckon with. The introduction of various shock absorbing devices for rotary drilling is one recent innovation that may significantly reduce overall drilling cost, increase drill availability, and lower maintenance requirements. In a recent all-inclusive test in taconite ores, shock absorbers on Bucyrus-Erie BE 60R and Gardner¬Denver GD 120 rotary drills were directly responsible for overall savings of up to $41.06 per hour. What is It? A shock absorber is simply a device installed between the rotary drive head and drill steel that cushions the two. It functions in the same manner as springs and shocks on an automobile. Some benefits associated with use of the tool are readily apparent on a daily basis; other benefits are realized over longer time intervals and through continued use. A properly designed shock absorber will: •protect the drill from severe vi¬brations, improve rock bit performance, allow application of the best weight-on-bit and rotating speed under all drilling conditions, •function effectively over a wide range of applied bit weights, • have a spring rate soft enough to perform its primary function of absorbing both rotary and vertical vibrational forces generated by rough drilling, •be reliable and subject to as little maintenance as possible, •be easy to install and remove, and • be of such an economic benefit so as to offset the added expense of its application. A shock absorbing tool developed by BJ-Hughes Inc. was used in a recent test. The "Smoothdrill" is just one of the products currently available. This unit absorbs both rotary and vertical shock loads and has no mechanical parts so lubrication is unnecessary. A rebuild of the unit consists of removing the worn rubber element and inserting a new element, an operation taking less than one hour. Minimizing Vibrations Severe vibrations on a blasthole drill operating in broken and discontinuous formations have visible effects. These vibrations often cause structural damage when allowed to' continue, resulting in fatigue cracks in the mast and related structural components in the drill. When rough running formations are encountered, drilling must be interrupted and possibly shut down. Usually, the drill operator resumes drilling using less down pressures and various rotational speeds until firmer drilling is encountered. An effective shock absorber can substantially reduce these vibrational forces so more down pressure can be applied in bad ground. It is generally accepted that longitudinal vibrations and cyclic forces are more effectively reduced if a tool is designed to incorporate a relatively "soft" shock absorber. The softness of any shock absorbing tool is best judged by its spring rate-the weight required to produce a given amount of deflection, commonly expressed in units of kg per mm or pounds per inch of deflection. All shock tools use a resilient member such as rubber springs, steel springs, fluid, or gas springs to absorb

Jan 4, 1980

By Albert L. Brautigam, Michael R. Yenchek, Jeffrey Shawn Peterson, James C. Cawley

The National Institute for Occupational Safety and Health investigated how the starting of induction motors may cause nuisance tripping of short-circuit protection on coal mine power systems. This research had a dual purpose: 1) to identify how motor-start waveforms differ from those for short circuits and 2) to devise a method to provide short-circuit protection without intentional time delays to account for motor starts. This technology will help ensure that surface temperatures of energized electrical apparatus will not exceed gas or dust ignition thresholds when short circuits occur.

Kinetics of Reclamation of E-Waste by a Bioleaching Route

Sep 13, 2010

By R. Barany

This report contains the results of experimental work conducted by the Bureau of Mines to obtain the heats of formation at 298.15° K. of analcite, dehydrated analcite, lawsonite, anorthite, hexagonal anorthite, and leonhardite. Thermodynamic data for these minerals have applications in ceramics, extractive metallurgy, and particularly in geochemistry. Except for data on anorthite, no previous similar data existed. The present results will be a substantial aid in deriving the temperature-pressure-equilibrium relationships among these minerals. The heats of formation were determined by solution calorimetry, with hydrofluoric acid as the reaction medium. The results were expressed both in terms of the constituent oxides and in terms of the constituent elements. The heat of formation data were combined with related entropy values to obtain the free energies of formation at 298.15° K.

Jan 1, 1962

By L. J. Habegger

This paper considers the potential water quality impacts of future energy scenarios which project an approximate doubling of coal utilization from 1975 to 1985. The major impacts estimated for coal extraction are related to effluents from unregulated activities (reclaimed areas prior to stable vegetation) and pollutants (e.g., metals and ammonia). Where applicable, the EPA effluent guidelines to be in effect by 1983 reduce the impact of individual sources to low levels. For example, total suspended solids and acidic discharges are to be regulated to levels generally below recommended water quality standards for receiving streams. However, implementation of these guidelines, particularly for coal extraction, has not been demonstrated on a wide scale. Water quality is not expected to be a major constraining factor for increasing capacity of coal fired utility and industrial boilers. Water quality control has not been demonstrated on a commercial scale for coal conversion to synfuels, but adequate control technologies appear to be feasible.

Jan 1, 1978

By Goran Mathisson

PLASMARED is a process in which one well established and one new advanced technology have been merged into a practical tool for production of high quality direct reduced iron at lowest energy consumption and costs. Before describing the process, we have to reiterate the simple fundamentals of making metallized iron from iron ores: The main components necessary are: - Iron oxide - Carbon and/or hydrogen - Heat

Jan 1, 1982