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By D. M. Conner

An innovative patented process has been developed to convert high volume wastes--fly ash from coal-fired power plants, municipal solid waste (MSW) ash from incineration, solids from waste water treatment and paper mill sludge into a high value and environmentally benign product in the form of a lightweight aggregate. Lightweight Aggregate is widely used in the building construction industry in the United States, Europe and some Asian countries. This paper will present the development of the process, the process itself and details on the first commercial scale plant. The commercial plant is owned and operated by Wisconsin Electric Power (WEPCO).

Jan 1, 1997

By Tukkimies M

During the late-1980s crawler-mounted crusher units established their position in the aggregates industry. Between 1986 and 1994 about 700 units were delivered to customers all over the world for surface operations, mainly in Scandinavia and central Europe. The crawler-mounted units are popular among smaller crushing operators because they are versatile and easy to move between sites. In large quarries the greatest benefit is obtained by combining a primary crawler-mounted crusher unit with mobile belt conveyors which eliminates the need for costly haulage by dump truck. Savings of up to 40 per cent in production costs prior to secondary crushing have been achieved. Today the environmental aspect in quarrying is assuming ever greater importance. Besides being costly the dump trucks are also the major source of dust and exhaust fumes within a quarry. A complete face crushing system consisting of a crawler-mounted crusher unit and mobile belt conveyors can be electrically driven and can be equipped with dust encapsulation and dust collectors. A mobile crushing unit is not a new idea. From the mid-1950s onwards the mobile and self-propelled units have been built equipped with crawlers, tyres or walking mechanisms, with weights usually of 500-1000 t. Due to their massive size these unit are not mobile in the same way as the today's mobile units. It is not feasible to move them more than a few times a year unlike today's fully mobile units which are often relocated once an hour. This means that the massive units can not continuously follow the production face and their loading always requires a certain amount of haulage. Today the mining industry is facing new challenges. With low mineral prices and high labour costs, increasing productivity is essential for survival. New standards are also being set for the labour safety and the environment. Large research programs have been launched to meet these challenges. However, technology which can partly solve these problems already exist and is only waiting to be introduced into underground applications as well - the mobile crushing unit followed by belt conveying. As in surface operations the elimination of truck haulage also brings considerable savings in operating costs in underground mines and reduces the amount of dust and exhaust gases generated. An additional benefit especially in underground applications is improved safety. In an underground mine most accidents are caused by moving vehicles.

Jan 1, 1995

By M. R. Shahan, C. E. Seaman, S. E. Mischler, T. W. Beck

"Float dust deposits in coal mine return airways pose a risk in the event of a methane ignition. Controlling airborne dust prior to deposition in the return would make current rock dusting practices more effective and reduce risks of coal dust-fueled explosions. The goal of this NIOSH study is to determine the potential of open-air water sprays to reduce concentrations of airborne float coal dust (<75 µm diameter) in longwall face airstreams. This study evaluated unconfined water sprays in a featureless tunnel ventilated at a typical longwall face velocity. Experiments were conducted for two nozzle orientations and two water pressures for hollow cone, full cone, flat fan, air atomizing, and hydraulic atomizing spray nozzles. Gravimetric samples show that airborne float dust removal efficiencies averaged 19.6 percent for all sprays under all conditions. The results indicate that the preferred spray nozzle is operated at high fluid pressures to produce smaller droplets and move more air. These findings can be used to select sprays and design spray arrays to control airborne float dust over the entire longwall ventilated opening. INTRODUCTION Coal mining processes produce airborne dust that naturally deposits on the floor, roof, and ribs of mine airways. These fine dust particles, termed float coal dust when smaller than 75 microns in diameter, are deposited in return entries of coal mines and can be re-entrained by pressure waves induced by methane-air explosions (Rice et al., 1911; Nagy, 1981; NIOSH, 2006). These particles are also those most likely to participate in coal dust-fueled explosions, which can potentiate and propagate explosions resulting in extensive damage. In order to meet compliance requirements of at least 80 percent incombustible content in the composition of material deposited in mine entries (CFR, 2016), coal mines apply an inerting agent, specifically, rock dust (Harris et al., 2009). Should methane be present in the mine atmosphere, the required fraction of incombustible content is further increased by 0.4 percent for each 0.1 percent methane. The removal of airborne float coal dust (AFCD) prior to deposition is an approach intended to make current rock dusting practices more effective by increasing the proportion of inert material to combustible material, resulting in a lower risk of coal dust-fueled explosions. Water sprays are both effective and widely accepted as a method for controlling underground coal mine dust. In fact, water sprays are considered to be the most economical and technically feasible means of reducing dust concentrations in underground coal mines (Courtney and Cheng, 1977; Barker and Humphreys, 1996). Sprays are used in several ways to control dust in mining processes: inhibiting dust formation, immobilizing dust to prevent it from becoming airborne, and capturing airborne dust (Cheng, 1973). Reductions in airborne dust concentrations have frequently been attributed to inertial impaction between water droplets and dust particles, forming larger agglomerates which then quickly precipitate out of the airstream (McPherson, 1993). Inertial impaction activity is generally accepted as the major capture mechanism for airborne particles larger than 0.5 µm in diameter. It is this mechanism that is evaluated in this study."

Jan 1, 2017

By D. Noort, M. Dawborn, D. O. del Castillo

This paper was originally presented at the North American/9th US Ventilation Symposium, June 2002, Kingston, Ontario, Canada. Reprinted with permission of the publishers, A.A. Balkema Publishers, Rotterdam, Netherlands. This paper is a study of the ventilation, cooling and refrigeration system design of the Mindola copper mine in Zambia. The challenges that were addressed varied from the restrictions imposed by an ageing infrastructure to the requirement for increasing the annual production rate, coupled to the introduction of a higher level of mechanization while maintaining acceptable conditions and limiting total ownership costs. A description of how the ventilation, refrigeration and cooling systems were modelled in order to obtain the projected heat loads associated with two different mining methods over the life of the project. The methodology included a number of iterations to optimise the design and include aspects such as the expected inrush of hot fissure water, the operation of diesel machinery at depths in excess of 1500m below surface, developing a cost-efficient cooling strategy and selection of the refrigeration machinery to meet the requirements imposed by the cooling strategy. This paper demonstrates the successful implementation of an integrated design approach.

Jan 1, 2005

By O. K. Brown

U.S. Borax has two tailings disposal requirements which are uniquely different in many respects, but with the common goal to minimize the impact on the environment, utilize dependable technology and minimize the economic impact. The existing borax mine in the grid Mojave desert of Southern California has gone through a series of changes in tailings disposal practices in the 56 years of operations, The other tailings disposal requirement is a new molybdenum mine, presently in the feasibility phase, in the high precipitation setting of Southeast Alaska. II. Introduction U.S. Borax is faced with two tailings disposals situations, at diverse locations:

Jan 1, 1984

By Jeffrey C. Schuh, Logan Bloemer, Daniel P. Dietzler

Over the past 30 years, the authors have encountered numerous projects where recognizing the geology, soil properties and groundwater conditions, and considering alternative construction techniques have promoted efficient and cost-saving construction. The construction documents for these projects, produced by various engineering firms, provided basic information on geotechnical conditions. The authors became involved in each project either because there was a problem during design or construction or, as a contractor, won the project because they saw a value engineering opportunity to take advantage of the geologic setting of the project to design and build alternatives to what the designer depicted. Understanding the geologic setting is critical before planning and designing begins. Being able to work with the geology and the materials on site is preferred before specifying more costly and complex solutions, which often require the importing of materials and adherence to unnecessary and/or inappropriate specifications. Failing to understand the geology or not knowing all the techniques available for construction can lead designers to develop solutions that could be inappropriate. This paper presents several examples of value engineering and project performance enhancements developed through knowledge of basic soil mechanics and implementing innovative solutions. History and Background Most people attend DFI meetings, present their experiences, listen to others, and read articles and papers with the hope they can learn from others. Geotechnical engineers and contractors often interface with others in the execution of projects who have, at best, a rudimentary knowledge of geology and soil mechanics. Of course, there is a need for architects, bankers, and regulators, etc., but they typically do not have much interest in the nuances of geotechnical engineering, which relies on both art and science. Thus, significant time is spent educating counterparts in the need for comprehensive subsurface investigation programs and the intricacies of construction in the “dirt,” as they typically refer to soil and rock.

Jan 1, 2019

By Claudio Toro, Alex Moyano, Jonkion Font, Carlos Caballero, Pedro Morales

"Codelco-Chile in the last decade has carried out industrially-oriented research as an alternative to the traditional batch-type converting process. In a first stage carried out preliminary evaluations in a rearranged Peirce Smith (PS) converter, and then an exploratory test in a “Convertidor Teniente” (Teniente converter, TC) for the Codelco-Chile Continuous Converting Process. However, the validation test for this process in the TC was delayed up to the second quarter of 2007 where the validation studies were done satisfactorily.Thus, the objective of this paper is to present the results of the campaign tests validating the Codelco-Chile Continuous Converting Process in the TC1 of the Codelco Norte smelter.The results of charging the solid or liquid matte or high grade matte (“white metal”) by Garrgun, or by mouth of the 22 m x 5 m TC1 are presented. Some features of the industrially validated process are discussed, and the pilot test results of the matte injection are also presented."

Jan 1, 2009

By H. E. Wilborg, G. V. Henderson

This chapter deals with those sands employed by foundries for the manufacture of cores and molds used in the casting of such common metals as steel, gray iron, ductile iron, aluminum-based alloys, and copper-based alloys. Most metal is cast in "green sand" molds in which the sand mixture, consisting primarily of silica, clay, and water, forms a plastic material. This plastic material is rammed around a pattern in a split box called a flask, then the box is separated, the pattern is withdrawn, and the metal is poured. These green sand molds are broken apart when the metal has solidified. The sand is then remixed and a new mold made for the next casting. To a lesser extent silica sand is mixed with resins or oils and, after forming, the mixture is hardened by either heat or chemical reaction. In any case, the foundry mold or core is used just once before being broken up and remixed for manufacturing another core or mold. By far the greatest consumption in the foundry is of those types of sand high in silica, low in clay (under 0.5%), and occurring in numerous locations thoughout the United States. Consumption End Uses Foundry sands fall into four distinct categories: silica sand, lake sand, bank sand, and natural molding sand. Silica sand is a general term used to describe washed, graded, dried, and cooled clay-free sands which are found in many parts of the United States. They generally contain 90 to 100% silica but vary greatly in chemical analysis and grain structure. Lake sand is the sand dredged from Lake Michigan or dug from the dunes bordering that lake. Bank sand is composed primarily of silica grain but containing up to 5% clay. It is shipped in both the damp and dry state but the normal processing of bank sand consists only of drying and scalping. Occasionally two different grades of bank sand are blended prior to or during loading. Natural molding sand is a term used to describe a sand containing sufficient clay as mined to be suitable for molding purposes. Clay content may vary from 10 to 24% with the balance of the material consisting primarily of silica sand. These sands range in fineness from one peaked on the 20 mesh to one which contains more than 50% of the particles passing the 270 mesh. Lake sands are relatively coarse and are used in great quantities for the production of automotive castings. Bank sands and natural molding sands are gradually phasing out as the production of castings becomes more a science and less an art. The vast majority of foundry sands used today are those known as the silica sands and lake sands. Foundry sands are used in two basic ways. The majority are used in the green or uncured state with the balance used in the cured or set state. Green sand is grain bonded with clay and contains varying amounts of water to plasticize the clay in order to bond the grains together. Green sand is either naturally bonded or "synthetic" sand. The naturally bonded molding sands are generally found in the Hudson River Valley of New York State, Cumberland County in New Jersey, and in Tennessee and Mississippi. Synthetic sand is molding sand compounded in the individual foundry. It is made up primarily of graded silica sand, western or southern bentonite, water, and carbonaceous and/or cellulosic materials. Green sand is used primarily in making molds. The use of naturally bonded green sand has been declining for many years, primarily because naturally bonded sands are more difficult for the foundryman to find and control. Synthetic green sand, on the other hand, can be

Jan 1, 1983

By Stefan Medel

As a pioneer Herrenknecht started in 2018 to automate the production of tunnel lining segments. Since then, many automation processes became state of the art. Robots cleaning and oiling the moulds, hydraulic units opening and closing them fully independently. Artificial Intelligence (AI) controls the works and ensures the quality requirements. Data management has become a massive tool from a simple data collector towards a control and optimization tool. Sensors controlling concrete maturity and supporting the precast team to optimize the concrete mix. These state of the art and new innovations will be presented in this paper.

Jun 23, 2024

By WILLIAM J. LINNEY

MAGNETITE ore from Lyon Mountain, so- called "Low Phos Chateaugay," has long been known to the iron and steel industry for its almost complete absence of impurities. These magnetites occur along the northern foothills of the Adirondacks in several parallel and folded stringers which are continuous for several miles, striking generally northeast-southwest and dipping usually over 45° to the northwest, or roughly toward the St. Lawrence River. Ore of minable thickness is found in shoots of various sizes as to length and breadth, but of undetermined and possible great depth.

Jan 1, 1943

By Joseph C. Buchen

IN principle, production of salt from sea water is a simple operation. Sea water is trapped in ponds, the sun and wind cause evaporation of the water, and what is left is principally salt. Commercial production of solar salt, however, requires a careful consideration of many factors. Obviously, sufficient evaporation must take place throughout the making season to produce an economically adequate crop. Other factors are density of soil, contour of ground, height of ground above sea level, minimum dilution from fresh-water streams, and distance from market. Unfortunately, in the United States the localities of greatest evaporation, allowing for the other factors, are not the most suitable for the manufacture of sea salt by solar evaporation. The south end of San Francisco Bay most

Jan 1, 1937

By Allan M. Hale

The central Florida phosphate industry is not a recent development. The first phosphate mining occurred in approximately 1888 (1). Many of the original mining companies were "wildcat" operations operated with rapid phosphate extraction as the sole purpose and no long-term commitment to development. Many of the early pioneers were ill-equipped to mine phosphate at either a practical or economical level; as a result many of these early companies "folded" after only a brief period of operation. However, as these early companies went out of business, several large companies developed, expanded their mining territories bought up the folding companies and by 1903 (little more than 10 years after the first mines were started), approximately 37 of the original 60 mines were control- led by three major companies (1). In the early period, mining reclamation was nonexistent. The mined out areas were left to revegetate and reclaim "naturally" over the period of many years. Reclamation practices were only started relatively recently and the various reclamation techniques developed and used in the past have continued to be employed with varying degrees of success through the present time. The reclamation techniques used in the past and currently include land and lakes restoration, sand tailing reclamation, slime ponds reclamation and overburden fill.

Jan 1, 1980

By Lawrence Devon Smith

"This paper examines the impact of the various assumptions that go into an economic evaluation, and shows how these can be combined to show an exciting result that may not really exist. An example of an embellished case (the kind that one frequently sees when projects are being promoted) is developed and the cumulative impact is analysed to show the actual project underneath. The paper also points out some areas to watch for overly optimistic assumptions such as prices, inflation, and debt. The concept of a ""bare bones"" base case is proposed (constant metal prices, constant dollars, no inflation, no debt, no interest, on a project basis, after tax) as a common reference point.As well, the discount rate is examined as a fundamental means of reflecting risk in discounted cash flow evaluations. Current industry practice is discussed, and a methodology for the analysis of risk levels is proposed that assesses the constituent components of the discount rate: real interest, mineral project risks, and country risk.INTRODUCTIONOften, the first time that all of the technical and economic data for a mineral project comes together in one place is when the economic evaluation is developed. This typically happens when work on the project has progressed to a sufficient level of detail that the effort to produce a year-by-year cash flow is justified, usually at the pre-feasibility or feasibility study stage. The data involved will include:• production; tonnes waste and ore mined, ore grade, mining recovery, metallurgical recovery, metal sold• revenue; metal price, smelting & refining charges, marketing costs• operating Costs; mining, milling, administration, fees, royalties• capital Costs; exploration, development, construction, indirect costs (engineering, management), contingencies, start-up, inventories, working capital, replacement and sustaining capital, closure costs• taxes and royalties• exclusions; depreciation (this is not a cash item), sunk costs (only costs going forward)."

Jan 1, 2003

By White L. R, Boger D. V

The paper describes the surface chemistry and particle physics that control the fundamental flow properties (Theology) of mineral particle slurries. We further address, through a series of case studies, the design data that emerges from experimental studies of the flow properties of complex, high volume fraction mineral slurries. The case studies are drawn from mineral oxide concentrate processes, tailings dewatering operations and from filter cake production and management. The paper emphasises the essential links between design of process slurry handling systems and the control of the flow of such slurries by control of the pulp chemistry.

Jan 1, 1992

By K. Thuro, H. Käsling, F. Menschik

"With increasing data volume, due to enhancing requirements for ground investigation programs for large construction projects, the demand for more efficient filing systems is more and more growing. Depending on the project we also have to use flexible systems to cope with varying data out of different lab and field tests.The chair for Engineering Geology at TUM is developing a web-based database solution to handle all project relevant data in a more appropriate way. We aim to optimize our data management to achieve a fast and easy way of collecting, documenting and analyzing our gained data. The second objective is to provide an easy access to our data for project partners across broadly distributed locations.This Database system consists of a PHP web interface and a MySQL database core. The current setup allows an online access via Internet (www). We are able to grant and constrain access to all data or only arrays of data with our user management system to guarantee the safety of project data and respect all rights and proprietorship. The database system is of modular design and consists of the following three base modules: module of general project data, module of laboratory data and user management module. At the current stage we are able to save and work with all usually generated specific values from unconfined compressive strength tests, brazilian tensile strength tests, point load tests, CERCHAR and LCPC abrasivity tests and ultrasonic tests. The user is able to perform a simple statistical analysis within our database (e.g. average calculation of one sample) and export data as csv or xls files for further analysis.For specific questions within projects we are able to deploy and integrate further modules in our database system. At this moment, we are developing an add on to use this database for different drill test analyses. One of the tools correlates drilling performance and drill head wear measured in the field with rock mechanical properties, and extrapolates the data to estimate the performance and wear in new projects. Today we are managing 90 projects with 550 samples and almost 1350 lab tests with the base module.In our contribution we aim to demonstrate an efficient way of data structuring using a relational database for laboratory and field testing data."

Jan 1, 2015

By Thomas W. Dawson

The H. C. Frick Coke Co. has used belt conveyers for handling coal for the last eighteen years but, until recently, only for small tonnages and over short distances. The first installations were outside the mines for distributing coal to various parts of plants. A belt conveyer was put in service at Colonial No. 4 Mine in November, 1906, to carry coal from the main hoisting shaft to a storage bin serving two blocks of beehive ovens on the other side of the valley; it was in constant service until the Colonial No. 4 ovens were abandoned less than a year ago. This conveyor was in an overhead gallery that spanned our sidings and yard tracks and the main line of the Pennsylvania Railroad. It was a crude installation, from the viewpoint of present conveyor engineering practice. It had no mechanical feeding device, the coal simply ran through a gate in the side of a bin on to the belt; but one belt on this conveyor lasted eleven years. This conveyor is about 300 ft. long center to center of pulleys. It operated at a speed of 250 ft. &apos;per min-and carried about 400 tons per day. On this basis, the belt life of eleven years means that not over a million and a quarter tons was carried by the belt. whi1e: this is not a large tonnage, the cost per ton was much less than by any previous method in use for supplying coal to ovens located at a distance from the main shaft. The next belt conveyor was installed at Bridgeport Mine in 1907. It carried about the same daily tonnage as the first, delivering from the hoisting shaft to a coke-oven bin. Very few data were kept on this conveyor. It also operated until the coke ovens at the plant were put out of blast and the coal taken to the Clairton byproduct plant by river. In 1916, work was started to equip the Bridgeport, Palmer, Gates, and Ronco mines to load their entire output on the river for transportation to the Clairton byproduct plant, which was then being built. These mines were all operating at that time and had a large area of coal available for river shipment. The Monongahela Railroad was located between the hoisting shaft and the river at each of these plants and, therefore, had to be crossed at each location to deliver coal to the river. After careful study, it was decided to transport this coal from the hoisting shaft to the river at each of these plants by belt conveyors.

Jan 1, 1925

By J W. Lee, E Baafi, N Aziz

Ground subsidence due to mining is a common dilemma confronting the underground coal mining industry. The effects of underground longwall mining on river valleys have come under scrutiny, especially when mining is located underneath catchment areas. As public awareness of mining impacts on the environment increases, there is the need to develop damage mitigation strategies. Results of numerical modelling show that river valley response to underground longwall mining can be simulated and evaluated.

Jan 1, 2005

By T. E. Durney

In the Fall of 1987 The Wellmore Coal division of The United Company installed a fines separation circuit in its #20 plant near Big Rock, Va. The addition of the fines circuit included a bank of classifying cyclones and two flotation units; one a conventional 4 cell, 34 m3 Wemco cell, the other an 2.4 meter diameter by 7.6 meter tall, 28.3 m3 column flotation cell. The new fine coal separation circuit is depicted in Figure 1. The column flotation cell is manufactured by the Deister Concentrator Company, Inc., under the trade name Flotaire. The Deister Flotaire column cell utilizes a counter current flow arrangement and a different means of generating air bubbles than that of conventional mechanical flotation cells found in coal processing plants. Other features include diffusers for additional air supply and a froth washer. This cell is one of the few commercial scale column cells processing coal.

Jan 1, 1990

By C. A. Heiland

THIS year&apos;s review of geophysical activities has a somewhat different complexion than usual. With the ending of the war, the time seems opportune to supplement the customary report on operations and discoveries in oil and mine exploration by a review out-lining the contributions of geophysicists to the. war effort. To give as much space as possible to the latter, presented as Part 2, some of the usual review features have been omitted from the statistical section, given as Part 1 immediately following.

Jan 1, 1946

By Robert E. Wood

The temperature dependency of the low-density viscosity coefficients, ?°T, of helium and of nitrogen, 100° to 1,000° K, is correlated with empirical equations, and the temperature and composition dependencies of the low-density viscosity coefficients, ?°T, of helium-nitrogen mixtures are correlated with the Chapman-Enskog expressions by using the Lennard-Jones (6:12) potential function. The residual viscosity, ?T,P - ?°T (the difference between the viscosity of a compressed gas and the dilute gas at a given temperature), was found to be a function of the thermal pressure coefficient, (?P/?T)V, and two parameters, a and 1, which are characteristic of gas composition. The equation ?T, P = ?°T + a [(?P/?T)V]ß represented 1,340 higher pressure experimental viscosity values with a mean absolute deviation of 0.86 percent, and this equation was used to compute viscosities of the gaseous helium-nitrogen system for a range of temperatures and pressures including those encountered in Bureau of Mines helium purification processes and in a crude-helium conservation gas reservoir. Tabular viscosities for helium, nitrogen, and 13 helium-nitrogen mixtures are presented for 110 temperatures, 133° to 740&apos; K, and 49 pressures in the range 1 to 240 atmospheres. The accuracy of the tabulated viscosities varies because correlation parameters were obtained from experimental data of unequal reliability. It is estimated that uncertainties in the computed viscosity values are ±5 percent for the region 325° to 740° K, ±2 percent for the region 183° to 325° K, and ±5 percent for temperatures below 183° K. The latter uncertainty may rise to y10 percent as critical conditions are approached.

Jan 1, 1970