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By G. Bourque

One of the design criteria for the Mount Wright facilities was to incorporate the latest proven automation techniques and devices for the new crushing, grinding and concentrating plant. The heart of the centralized control system is a Fox 1 process computer, located in the central control room in the administration building. The entire operation, i.e. crushing, conveying, storing, grinding and concentrating, is monitored and controlled, through the process computer , by one operator via a CRT console. In case of computer failure, the control is automatically, and without process interruption, transferred to manual back-up panels. One of the newest management tools, the process computer is programmed to collect and automatically print out shift. daily and monthly reports on tonnage, metallurgy and equipment operating time, for better planning of operations and preventative maintenance.

Jan 1, 1977

By Geoffrey Purcell

Improvements which have been made in commericial flotation systems during the past fifty years have resulted more from trial and error methods in the mill than from research in the laboratory. Research has often provided explanations of why mill changes have improved the metallurgical process. Hopefully, in the next fifty years, changes in mill flowsheets will come about, primarily, as a result of research work. However, since minerals, in their infinite variety, cannot be reduced to a standard state, research on commercial ores will have only a local utility, and research on pure minerals will have little commercial application. What will emerge from research on pure systems are mechanisms of adsorption, and this in turn may throw some light on the very much more complex adsorption processes taking place in the pulps of commercial ores. Quartz, without a doubt, has been the subject of more research effort than any other mineral, but we are still a long way from completely understanding its behavior in flo¬tation. Hematite and calcite have received considerably less attention. Ores containing a mixture of all three minerals, however, are commercially important, and the iron deposits in Alabama have been extensively studied by the United States Bureau of Mines (1). The literature reveals no reports of research on synthetic mixtures of all three.

Jan 1, 1967

By E Nettleton, A Melkumyan

A probabilistic system for autonomous tracking of excavated ore in mining would be highly valuable. Currently, mine sites can have a vast array of sensors; examples include excavator load cells, bucket volume estimators and haul truck strut pressures which can be used to gather information about the excavated ore at different locations. These sensors can be utilised efficiently to increase the accuracy of mine estimates by introducing a real-time ore tracking system. This requires the introduction of a probabilistic ore tracking framework to consistently fuse information from any sensor input. Current modelling practices are manually intensive, deterministic (no recognition of the quality of data) and generally not a complete end-to-end system. This paper will provide a novel method for tracking extensive ore properties (mass, volume) and intensive ore properties such as chemical composition (eg Fe per cent, SiO2 per cent, Al2O3 per cent). This method is proved to ensure that correct correlations between states are conserved as material is transferred, combined and/or separated at different locations with any configuration of sensor inputs. This ensures that consistency of estimates is maintained and other benefits such as real-time probabilistic reconciliation can be implemented. A method for combining material of different mass and chemical compositions is also developed to enable accurate and efficient operation of the system. Representative experiments on a small-scale and a larger field trial which mimic the mining processes of excavation, haul and unload to ROM Stockpile will be used to verify the approach.

Sep 26, 2011

By Ryan C. Stephan, Zach Agioutantis, Christopher Mark

During the past 15 years, roof fall rates have fallen dramatically in US coal mines, particularly in regions where the roof is weakest. The remarkable reduction in the number of roof falls has been accomplished with more effective roof support systems. The purpose of this paper is to present a design methodology that builds on and quantifies the basic roof support concepts that have been successful in the USA. The methodology starts by defining three modes of roof support, based on the roof strength relative to the stress level: (1) suspension, where roof bolts mainly provide skin control for strong roof; (2) beam building, where moderate strength roof can be supported by roof bolts alone; and (3) supplemental support for weak roof. Next, a large database of roof fall histories at a number of mines is used to define the approximate boundaries of these three regimes based on the coal mine roof rating and the depth of cover. Finally, guidelines are presented for site-specific design of support systems within each regime. The new computer package, analysis of mine roof support (AMRS), implements the design methodology.

Sep 29, 2020

By Robert H. Peters

How can employees be stopped from engaging in unsafe work practices? It is often easier to prevent employees from performing unsafe acts through manipulations of the work environment than through various training or motivational programs. Therefore, it is important that accident prevention programs seek to identify the reasons for the unsafe behavior and to redesign tasks and the work environment (e.g., tools, equipment, physical surroundings) in order to remove employees from sources of harm and to prevent situations from arising that would prompt them to perform unsafe acts. Unfortunately, in the mining industry the work environment is often innately hazardous, rapidly changing, and difficult to predict, making it very difficult, perhaps impossible, to fully protect the employee by environmental manipulations. Therefore, it is important that effective methods be identified for influencing mine employees to work safely. Various strategies have been used to convince employees to avoid unsafe acts and/or adopt self protective behaviors. The intent of this article is to provide guidance to mine operators concerning the use of four techniques for influencing mine employees to work safely: (1) employee surveys, (2) incentives, (3) fear communications, and (4) disciplinary actions.

By S Jayakumari, E Ringdalen, V Canaguier

Silicomanganese (SiMn), containing approximately 16–30 per cent Si, is produced in submerged arc furnaces using various Mn sources and quartz as the primary raw materials, along with fluxes and reductants. In the high-temperature zone known as the coke bed, a silica-rich slag is formed. SiMn is produced through the reduction of SiO2 from the slag. Dissolution of quartz into slags with different compositions, the primary slag formed from the Mn sources and flux before any MnO reduction occurred, representing conditions at the top of the coke bed, and dissolution of quartz into a partially reduced slag to simulate conditions inside the coke bed has been investigated. Experimental investigations were carried out to study the dissolution of quartz particles of varying sizes, 5 mm and 25 mm in synthetic slags with different compositions at temperatures between 1400°C and 1600°C, with varying holding times. Observed results are compared with liquidus compositions and equilibrium phases for original and formed slags. Particle size has been shown to be of little importance for the dissolution. Quartz dissolved more easily in slag at top of the coke bed than slag in the coke bed. Complete dissolution was observed after 30 mins at 1600°C in all cases, but not after 0 mins.

Jun 19, 2024

By Milan Yekich, Emanuele Cauda, Justin Patts, Cody Wolfe

A worker’s personal exposure to respirable dust in occupational environments has traditionally been monitored using established methodologies which entail the collection of an 8-hour representative sample that is sent away for laboratory analysis. While these methods are very accurate, they only provide information on the average exposure during a specific time period, generally a worker’s shift. The availability of relatively inexpensive aerosol sensors can allow researchers and practitioners to generate real-time data with unprecedented spatial and temporal granularity. Low-cost dust monitors (LCDM) were developed and marketed for air pollution monitoring and are mostly being used to help communities understand their local and even hyper-local air quality. Most of these integrated sensing packages cost less than $300 per unit, in contrast to wearable or area dust monitors specifically built for mining applications which have been around for decades but still average around $5,000 each. At the National Institute for Occupational Safety and Health (NIOSH), we are leveraging the power of high-volume data collection from networks of LCDM to establish baseline respirable hazard levels and to monitor for changes on a seasonal basis as well as following any application of control technologies. We have seen the effective use and advantages of monitoring live data before, during, and after events like shift changes, operational changes, ventilation upgrades, adverse weather events, and machine maintenance. However, many factors have prevented a systematic adoption of LCDMs for exposure monitoring: concern for their analytical performance, the complexity of use, and lack of understanding of their value are some factors. This contribution outlines a one-year case study at a mine in Wisconsin USA, covering the installation, maintenance, data visualizations, and collaboration between NIOSH researchers and the industrial hygiene professionals at the mine.

Feb 1, 2024

By BLAllEY STEVENS

(Canal Zone Meeting, November, 1910.) I. INTRODUCTION. TEH object of this paper is to show how igneous intrusion is governed by definite mechanical laws. A distinction is made between dikes and fissures, and the various characteristics of intrusions are explained on an exact scientific basis. The modification of rock-stresses by intrusion is then considered and extensive isostress regions are recognized. Finally, a complete classification of intrusions is constructed covering all pos-sible cases. The generalizations of observed data, taken from Geikie's Textbook of Geology, conform to the laws of intrusion herein stated, and the deductions based upon these laws. No authority, however, is quoted for the type which I have named a corrugated intrusion. Its existence is a necessary deduction from the laws of intrusion, and even the entire absence of examples in technical publications cannot disprove its reality. In all probability, corrugated fissures would have remained undiscovered, but for the working of mineral veins. As intrusions of tabular form are seldom worked for commercial purposes, it has been left for theory to anticipate the discovery of corrugated dikes. In the light of these laws of intrusion and the corresponding laws of fissures,1 there seems to be a remarkable uniformity of stress-distribution in rocks at moderate depths. This renders .possible the mathematical calculation which should help us to approximate exact science in this and kindred branches of applied geology.

Jan 1, 1911

By N. Coulson, P. F. Stewart

The Mine Health and Safety Act No. 29 of 1996, as amended, embeds an occupational health and safety management system that facilitates communication between representatives of the state, capital, and labour. In underground mines, two communication loops between these role players serve to separate the production chain of command from the political tripartite relations. Worker-elected health and safety representatives are involved in both communication loops, but are severely constrained in escalating their occupational health and safety concerns to the legalpolitical level. This has a direct bearing on the exercise of the Right to Refuse Dangerous Work (RRDW). As previously reported, health and safety representatives were found to primarily consult their production supervisors in preference to their trade-union representatives. This follow-up article presents production supervisor perspectives on the RRDW. The study demonstrates how, for mineworkers, the two distinct communication subsystems constrain, rather than facilitate, implementation of the RRDW.

Apr 14, 2024

By S. L. Windes

For a number of years, the Bureau of Mines conducted tests on various types of structures to determine the effect of seismic vibrations emanating from quarry blasting in an effort to determine an index of damage . Associated with these tests , occasional records were made of the characteristics of. the air blast or concussion from the explosions . Although the importance of the air - blast problem was recognized , the equipment was not designed for air -blast measurements , nor was the early research program concerned with the problem . After the ground - vibration tests had been completed , attention was turned to study of the air blast and its effect . The air - blast problem in reference to quarry and mine blasting may be divided conveniently into three phases : (1 ) Determination of the fundamental characteristics of the air blast , such as the pressure - time relationship , speed of propagation, attenuation , and the like ; ( 2) effect of blasting conditions on these air -blast characteristics ; and ( 3) determination of the conditions necessary for damage to structures . The initial step was the development of microphones suitable for recording the anticipated blast pressures. Such microphones were designed and built during 1940 , and described in technical detail for publication ( 2)3/. Briefly, the microphone adopted was a small, plate - diaphragm condenser type . The recording was through special transducer amplifiers with low -frequency response to zero cycles per second and a Duddell - type oscillograph of special design .

Feb 1, 1942

By Yinan Zhang, Yi Luo

The widely used R70 method is modified to measure the self-heating propensity of low-rank coals. This modified R70 method enables the introduction of controlled amount of moist oxygen into the reaction vessel. Three coal lumps were collected from three different locations in a surface mine in the Powder River Basin. The coal samples were tested in oxygen flow with controlled moisture content under adiabatic condition. By measuring the relative humidity at the exhaust exit point of the testing setup, the flux and cumulative wetting heat that is consumed by coal samples can be determined. Through a better way of determining the coal’s specific heat, the total heat, including heat of wetting and coal’s oxidation heat, required to raise coal to a given temperature can be determined. Then, the contribution of heat of wetting at the different stages of the testing is quantified. The effects of evaporative heat through a group of tests have also been quantified. From this research, a better understanding of the effect of wetting heat on inducing low-rank coal’s spontaneous combustion can be acquired.

Nov 30, 2022

By E. Scheepers

The process under investigation is the large-scale production of phosphorus. Gravity delivers the feed, consisting of pelletised apatite, coke and silica (in the form of gravel), to a submerged arc furnace through ten, evenly distributed feed chutes ensuring constant packed bed volume. Within this packed bed, solid-gas reactions are dominant in generating the gaseous product. These reactions, as well as the packed bed itself, were the main focus in the development of a fully three-dimensional CFD model in which fluid flow and energy distribution are represented as functions of chemical reactions, heating and melting of material and heat losses. The associated complex process interactions necessitated the creation of two process-specific, user-developed models that integrates accurate, thermodynamical data with computational fluid dynamics calculations, as well as reaction kinetics. The boundary conditions are provided by industrial measurements, and the key model parameters of reaction kinetics were obtained by laboratory experiments for different feed mixtures. Thirteen temperature probes installed inside the refractory lining of the furnace especially for this project allowed parameter fitting and validation to be guided within the constraints of real measurements. Simulation results reveal a thin, dome-shaped, reductive zone where conditions are optimum for maximum phosphorus recovery, as well as evidence of a thermal reserve zone similar to an ironmaking blast furnace located above this reduction zone. When compared to actual operating data, the CFD model can successfully predict the specific power consumption, the phosphorus in the slag and gaseous product flowrate under given operating conditions. This CFD model forms part of a larger project that aims to create a Dynamic-CFD hybrid control model.

Jan 1, 2014

When the Middle Ages were drawing to an end and Rotterdam, then still a small fishing port, began to extend its trade relations to continental ports handling general cargo, a development was initiated which was to give Rotterdam a predominant position in maritime traffic in Europe 300 years later. Despite many setbacks and the silting up of the mouths of the Rhine and Meuse rivers, the port experienced a new rise towards the end of the previous century after the dunes at Hook of Holland had been cut through as planned by Dutch engineer Caland. With its favourable location in the mouth area of the Rhine and a hinterland opened up by waterways it was merely a matter of the city council pursuing a far-sighted policy to make the best of these natural advantages. Thus new port installations were erected on the southern bank of the Meuse in the first quarter of this century, which were expanded in the course of the subsequent decades. The New Waterway became the main artery for industrial enterprises, in particular oil industries, which sprang up along its banks (picture 1). Whereas 30 years ago Rotterdam's Waalhaven, with its new jettees for general cargo and mainly bulk goods, was still one of the most modern terminals, the growing size of ships, which increased by leaps and bounds for tankers, in particular towards the end of the 'fifties, necessitated much larger harbour facilities built further and further towards deep water.

Jan 1, 1972

By W. W. Agey

As a part of the program of investigation of domestic sources of manganese in the western United States, engineers of the Bureau of Mines examined. and obtained samples of ore from two properties in the vicinity of Barstow, San Bernardino County, Calif. In addition to these, samples from two other properties in the same vicinity were submitted by the owners. As the ores were too low-grade to be acceptable for the direct production of ferromanganese, beneficiation studies were made to determine the amenability of the ores to concentration by ore dressing. The Big Reef manganese claims axe about 140 miles east of Barstow, Calif. The claims were leased by W., E. Thurber of San Gabriel, Calif., from the owner, C. S. VanDoren of Daggett., Calif. Manganese oxides occur as a replacement deposit in heavily brecciated andesite along a fault plane. Four samples were taken by an examining engineer of the Bureau of Mines from the ore zone, which, when composited, were representative of all the exposed ore. Preliminary tests were made on lot B, and final tests wore made on the composite sample. The Trans-Oceanic property is about 20 miles southeast of Barstow, near Newberry, in the. Pisgah mining district, Calif. The sample, submitted by the owners, was taken from a 1,000-ton reject clump from a hand-sorting operation. The ore occurs as a replacement of rhyolite.

Jan 1, 1952

By E. Morrice

The metallurgical laboratory data developed in this study indicate an improved electrowinning process for producing higher purity cerium ingot. A typical sample of the Reno electrocerium contains 99.9 weight-percent cerium and the following impurities: Total other rare-earth elements, less than 0.04 percent; iron not detected; silicon and aluminum, less than 0.02 percent each; calcium plus magnesium, less than 0.01 percent; carbon, 0.01 percent; oxygen, 0.002 percent; hydrogen, 0.0003 percent; and nitrogen, 0.0015 percent.

Jan 1, 1960

By D. Bienstock

Using a nitrided fused-iron catalyst, the Bureau of Mines investigated the Fischer-Tropsch reaction in the oil-circulation process. The nitrided iron was quite stable and permitted the longest run obtained thus far in the oil-circulation process without the need for reactivating the catalyst--3,700 hours of operation. The effects of several operating variables--temperature, pressure, gas-recycle ratio, space velocity, synthesis-gas composition, and synthesis with and without reflux of oil to the reactor--on the production of oxygenates were studied. The importance of removing reflux oil and of high gas recycle in increasing the oxygenate content was shown. A finished gasoline containing 28 percent by weight alcohols was produced. The research octane number (RON) was 92.9 clear, increasing to 98.5 with the addition of one milliliter of tetraethyl lead (TEL). INTRODUCTION The Federal Bureau of Mines has been engaged since 1944 in a research and development program on the synthesis of gasoline from coal. Gasification of coal with steam and oxygen to yield a "synthesis gas"--a mixture of carbon monoxide and hydrogen--is being investigated at Morgantown, W. Va., and the synthesis of gasoline by catalytically reacting carbon monoxide and hydrogen over iron by the Fischer-Tropsch reaction is being investigated at Bruceton, Pa.

Jan 1, 1960

By K. Muralidharan, P. R. Rao, M. Momayez, K. A. Runge

The evolution of trapped geothermal heat in hot underground mine along with emission of toxic gases and dust during mine activity makes the mine environment unfavorable is hazardous to worker’s health. This imposes significant demand on cooling and ventilation systems. As a result, substantial costs are incurred while implementing environmental regulation processes to dissipate the heat and provide comfortable working conditions. Thus, as an alternative, the development of cost effective materials to act as efficient thermal insulators is on the rise. Thermal conductivity is an important property that is a direct measure of a material’s ability to facilitate/deter heat flow. In addition to their superior chemical resistance, adequate mechanical strength, abrasion and fire retardant as well as environmental benefits in comparison to existing building materials such as ordinary Portland cement, aluminosilicate based geopolymers are now gaining widespread interest as promising thermally insulating and sustainable materials. This paper begins with an overview of geopolymers, transitioning into a discussion of recent developments in the field of geopolymer development as a thermally insulating material broadly classified into: filled geopolymers and porous geopolymers resulting in structures with enhanced ability to impede heat flow.

May 9, 2020

By John D. Wiebmer

First, a definition of a small scale miner is in order. The US Bureau of Mines classifies him as one who produces 360 t/d (400 stpd) of ore or less. In Canada, he would be refered to as a "junior company." Mexico identifies the small scale miner as one whose gross income from operations is less than $880,000 per year. A small surface mine in India employs less than 400 people, and a small underground mine employs less than 150. Peru considers a small scale miner one who produces less than 54 000 t/y (60,000 stpy) of ore. Obviously, the term is relative. What may be a small mine in one country is a medium or large mine in another. This lack of agreement is understandable since small scale mining does not often cross national boundaries. Rather, its effects are felt at the regional and local levels within each nation. Its importance doesn't lie with any huge contribution to the GNP or balance of trade. Instead, its value is as a local employer and as a frontrunner in geologic exploration.

Jan 2, 1979

By Eugene O. Binyon

"Belt and shaker conveyors, used singly or as combined units, have for many years been an integral part of many coal-mine haulage systems. The belt conveyor has also been used extensively as a main haulage unit in open-pit iron-ore mines of the Lake Superior district, particularly on the Mesabi Range. Few underground metal mines, however, either in the ferrous or non-ferrous branches of the mining industry, use the conveyors exclusively or even extensively for underground haulage. At present, only five iron-ore mines in the entire Lake Superior district have belt- or shaker-conveyor installations of any significant size. Of these mines, three are in the Crystal Falls-Iron River district of Michigan on the Menominee Range, one is on the Marquette Range near Ishpeming, Mich., and one is on the Mesabi Range near Keewatin, Minn.Results of the studies of tackless haulage in the Lake Superior district will not permit the establishment of any formula to prove or disprove the advantages of belt or shaker systems at all underground mines. The studies do show that trackless haulage can be used to advantage where the proper conditions exist. Advantages are particularly apparent when development can be planned sufficiently in advance of exploitation to permit installation of belts or shakers as part of the development program and where the systems are extended to include haulage in stopes as well as main entries.During the winter of 1947-48, the Bureau undertook a study of all of the underground ore conveying systems known to be in operation in the Lake Superior district for the purpose of making available to the entire mining industry the technologic data developed in the area. Because conditions that led to the installation of the belt and shaker conveying systems were often a function of the character of the deposit or the method of mining, a brief description of those conditions is included in this report.After a preliminary investigation into the extent to which trackless conveyors were employed in the district, it was found that a detailed study at five bites would result in fair appraisal of that method of haulage in the underground iron-ore mines.Each of the five significant installations is described separately in this report. In one instance, however, company policy does not permit identification of the mine wherein the conveying is done. In that instance the operation is designated as mine ""A"".Unless otherwise specified, all tonnage figures quoted herein are gross.The cooperation of officials of all of the companies operating underground mines in the Lake Superior district permitted successful completion of preliminary studies of mining practices and conveying systems.Special acknowledgment is made to R. D. Satterley, general superintendent, and to operating staffs of the Sherwood and Morris mines of the Inland Steel Co. The assistance given by W. D. Whitman, assistant superintendent, and Douglas Tippett, mine captain at the Morris mine, and P. D. Pearson, superintendent, R. O. Marsten, engineer, and W. Johnson, mine captain, at the Sherwood mine, is acknowledged."

Oct 1, 1949

By Oliver C. Fursman

This work was conducted to determine the feasibility of producing aluminum-silicon alloys in a pit-type, three-phase electric-arc furnace. Two carbon-lined furnaces were used in the tests. The power input ranged from 120 to 240 kw. in the small furnace and from 420 to 460 kw. in the large furnace. Energy consumption ranged from 5.3 to 11.5 kw.-hr. per pound of alloy produced and electrode consumption, from 240 to 510 pounds per ton of alloy produced. A wide range of crude aluminum-silicon alloys was produced by direct smelting of clays or similar aluminum silicate raw materials, using hogged fuel or wood chips as the major source of carbon in the furnace charge, and silicon of high grade was produced by smelting quartz. The aluminum content of the aluminum-silicon alloys ranged from 15 to 55 percent. Alloys produced from a white opaline-silicate clay were relatively free of iron, titanium, and other impurities. Those produced from western fire clays and kyanite, although richer in aluminum, contained considerable amounts of impurities. The purity of the alloys depended largely on the composition of the raw materials.

Jan 1, 1960