Search Documents

By Ashis Bhattacherjee, Subrata Chatterjee, Michael T. Dewey, Christopher J. Bise

In order to continue the advancements made during the past two decades in the reduction of the severity of accidents and injuries in underground coal mining, closer attention will have to be paid to the increasing number of accidents resulting in disabling injuries and lost time. With the increased emphasis on safety training reflected in the Federal Mine Safety and Health Amendments Act of 1977 (Public Law 96-1641, and on MSHA's current focus on the application of Job Safety Analysis, it appears that the acquisition, evaluation, and application of accident and incident data will take on an even greater importance. To manage this large amount of information will require a significant commitment of time and attention on the part of mine training departments. A USBM-sponsored research project is currently being completed at Penn State which focuser on the development of a model training program for mining. The program is based on five distinct steps which represent the coupling of a needs assessment with the program implementation. The five steps are: 1) database analysis, 2) workplace observations, 3) identification of trainable problem areas, 4) a library of training resources, and 6) the implementation of the program. In each of these areas, the microcomputer has proven to be a valuable tool for collecting, analyzing, and presenting accident and incident information. This paper will detail the manner in which microcomputers have been fully integrated into the model training program. Examples of applications at existing mines will also be discussed.

Jan 1, 1992

By Jerry Motz, Gary Beerkircher

Through a joint development program between Bougainville Copper Ltd. and Nordberg, the MP1000 cone crusher was developed and tested during the period between 1982 and 1987. Following the successful prototype work, Bougainville Copper purchased an additional three units. A second prototype was installed at Codelco's El Teniente three-stage crushing installation in 1987. This unit has also completed its test period successfully. Three additional units have been sold, making a total of eight, to date. Two will be installed as secondary crushers in two separate large aggregate plants. The first unit installed in the United States was placed in operation at Vulcan Materials Company's plant in Manassas, Virginia in early May 1990. Another unit is being installed in Asarco's Ray Mines expansion. The Asarco installation will be a SAG MILL pebble crusher producing approximately 600 STPH of nominal 1/2" product. Application Objective The objective was to design a crusher that would fit on an existing 7' foundation with minimum modification and yet be capable of twice the production of a 7' cone crusher. In meeting this objective, the power rating was increased to 1000 HP, the maximum design crushing force was increased and the crusher was designed to operate at higher speeds than an equivalent size Symons cone crusher. The MP1000 was also designed to operate with a head throw that can be greater than the equivalent Symons design. Design The crusher design criteria involved the recognition of the crushing force increase required for the finer crushed products than

Jan 1, 1992

By Christian Jeger

After recalling the principles underlying fire-damp flow in coal and the essential part played by permeability (Darcy's law) in the intensity of flow, a few theoretical and experimental results showing the possible causes and range of variation of coal seam permeability are presented. The study of firedamp flow into gate roads and of residual gas concentrations in coals as a function of the gate road distance, shows that, in French mines, coal seams in a virgin zone have a very low permeability, but they become permeable when destressed by mine workings, in particular overlying workings. This is the case not only in the fractured zone round a mine excavation in which the gas is released, but also beyond the limit of the zone degassed by the excavation. In the floor of flat seams, upward boreholes can be used for predegassing seams that have been relaxed but not degassed, as the result of an overlying coal face. In this respect we shall describe the predrainage experiment carried out in the Marienau district of the Lorraine coalfield. Predrainage can contribute considerably to the reduction of methane emission in the ventilation of newly opened longwall faces. But to be efficient and useful predrainage should meet certain conditions.

Jan 1, 1980

By R. C. Shodde, R. D. La Nauze

Major societal and industry changes over the last four decades have influenced the management of technology in the minerals industry. From the authors' experiences in both private and public sector R&D, the paper analyzes the range of strategic and structural changes and provides examples of some key technology delivery responses. For those charged with managing technology, the two key challenges facing them over the next decade are (I) moving technology development from a cost focus to a value focus (that is, from "how much long-term research can we afford?" to "identifying and capturing the value created from R&D”) and (2) the recruitment and retention of key talent. THE NEED TO ADAPT "Change is slow and gradual. It requires hard work, a bit of luck, a fair amount of self- sacrifice, and a lot of patience (Greene 1998)." Since the 1960s the world has changed and the minerals industry has had to adapt to the changing circumstances. In the '60s, minerals were there to be discovered and fortunes to be made; in Australia, the World War I1 embargo on exporting iron ore was lifted and the Western Australian iron-ore boom commenced, to be followed by the exploitation of the Darling Range bauxites; copper, lead, zinc and nickel were discovered and mines developed. The Australian dollar was worth US$1.11 whereas today it is around US$0.65. The oil crisis of 1976 sharpened focus on the sensitivity of the minerals industry on energy costs. By the late 1970s The Club of Rome was predicting the imminent demise of certain key metals-a prediction that has not been fulfilled-though the signs of the shift

Jan 1, 2004

By Frank E. McCall, John K. Marshal, Fred Garcia

Since the advent of longwall mining systems in the United States, mine operators are increasingly relying on methane drainage techniques to supplement the ventilation system. The most commonly used technique is the vertical gob borehole. The number and spacing of vertical gob boreholes per panel is generally based on experience and underground conditions. To design a more efficient methane drainage systems, mine operators must accurately determine methane gas produced. Thus, mine operators must monitor gas flow and methane gas concentration on every vertical gob borehole on active panels at least once or twice during each 8-hr shift. As the mine grows, it is possible to have more than one operating longwall and many vertical gob boreholes. Thus, daily visits to each vertical gob borehole site can become very time consuming. During weekends when methane gas concentrations typically drop because there is no mining activity, borehole sites may not be visited. To obtain accurate gas flow data, a gob borehole monitoring system was designed and constructed by the U.S. Bureau of Mines (USBM). Gas flow, methane gas concentration, gas temperature, barometric pressure, and vacuum pressure of the exhaust fan are the parameters collected by the system. The system also includes circuitry for automatic shutdown of the exhaust fan and an alarm system before an unsafe condition is created. Telemetry components were also integrated into the system to allow for transmission of borehole data to the mine office. As a test, the system was installed and operated on a vertical gob borehole for six months. Test results indicated that intermittent measurements with hand-held instruments from vertical gob boreholes were always higher than gas flows measurements made by the gob gas analyzer system. This paper describes the system components, operational characteristics, and the results of the test program.

Jan 1, 1995

By J. den Drijver, M. Opahle, R. Inderst

Safety reasons render necessary the advanced calculation of the amount of methane degassing from a longwall in the scope of the ventilation planning of mines. Today empirical methods, which are based on observations of operational procedures, are used for the calculation of the amount of methane. Despite of constant improvement those calculations are not always sufficient. In particular calculations which are based on operational facts but not proved by experience are not reliable. Most of all these calculation procedures lack physical-analytical descriptions of the procedure itself, presenting only the effects on important parameters such as the distance between seams in the roof or floor or gas pressure. Tschersich [Tschersich 961 developed an analytical model for an advanced calculation by analysing the degassing of seams in the roof and floor and the physical parameters of gasflow. This model might correct the lacks of existing procedures and improve the precision and reliability of additional calculations. The model simulates the emission record in seams of the roof and the floor. It takes into account not only a multitude of parameters such as the distance to adjacent seams and gas pressure but also the depth of seams, gas content, rank of carbonification, rock temperature, face advance rate, initial and succeeding mining and the face length. In order to comprehend and to verify those correlations we extended the model of Tschersich and programmed this enlarged model using the computer language C++. Aim of this research is to guarantee a much higher accuracy in calculating methane emission caused by mining. The improved planning is expected to result in more safety and better prevention of high methane con- tent in ventilation as well as in a better use of the capacity of the mining equipment. The application [Drijver, lnderst 961 of the ex- tended model will also be very useful in the course of research projects as it allows computer simulation, i.e. in-situ research can be extensively limited or even replaced.

Jan 1, 1997

By G. Lodewijks

Today most belt conveyors used for the transportation of bulk solid materials are driven in a centralized way with all drives in one location. The dynamics of these systems has been studied since the early seventies of the previous century and are well understood. Compared to the more conventional belt conveyor system with a centralized drive station positioned at the head and/or tail of the system, a decentralized driven layout with drive stations distributed along the whole length of the belt offers a number of advantages. However, to make a decentralized driven configuration a good alternative to a centralized driven, the system designer will have to balance these benefits with the increased complexity. The full potential of a decentralized driven system can only be realized if the right balance is found between the locally applied drive force and the motion resistances occurring along the system. From previous research it was found that in a multiple driven belt conveyor system the most dominant belt behavior occurs in the belt section between the tensioning device and the first drive station. In this paper different possibilities are analyzed to improve this dominant belt response and optimize the starting behavior. This can be accomplished by changing the predescribed start up profile, starting the drive stations in sequence rather then all at the same time and altering the locations of the drive stations.

Jan 1, 2008

By Michael H. Leon, John A. Organiscak

Controlling worker dust exposure on longwall mining systems is difficult because the working face area serves as an immediate return during the mining cycle and the amount of airborne dust generated is directly related to production. Since improvements in longwall mining technology have significantly boosted production levels, additional technology is needed to control the airborne respirable dust generated at present and future production levels. One concept to reduce longwall worker's dust exposure is to maintain two splits of air at the face -- a clean intake split in the workers walkway, and a return (dusty) split over the face conveyor. The U. S. Bureau of Mines has recently investigated a concept to overcome the visibility handicap of face partitions by utilizing a permeable polyester mesh. The mesh material was anticipated to provide adequate air-splitting capabilities as long as the pressure differential between the face and worker walkway was minimal. Initial testing of this concept at the Bureau's Lake Lynn Laboratory showed that notable reductions could be achieved with a 1/8 in (3.18 mm) and 1/16 in (1.59 mm) mesh opening size. Dust reductions at 100 ft (30.5 m) and 200 ft (61.0 m) downstream of source were 58 and 36 pct, respectively, for the 1/8 in mesh and 79 and 55 pct, respectively for the 1/16 in mesh. Longwall application of the 1/8 in mesh showed similar results to the Lake Lynn Laboratory tests. A flame retardant mesh was used underground with portable lighting mounted on the shearing machine for face side lighting.

Jan 1, 1993

By A. B. Samaddar

A prototype automated mapping and spatial information management system has been developed, and illustrates how a powerful map manipulation capability and a comprehensive display system can be combined using both raster and vector mapping: The concept of a mapbase and information retrieval mechanism, query language as well as text and graphical menus, is introduced. The Geographic Information System (GIS), which has been built around a system for storage and retrieval of spatial and textual data, allows interaction with geographic space represented on a displayed map. The prototype is demonstrated using maps and information of an open pit mine.

Jan 1, 1989

By Morgan M. Sears

In recent years, one large mine collapse and numerous smaller bump events have resulted in a renewed interest in coal bump research. With numerical modeling, the Energy Release Rate (ERR) calculation quantifies the ?release? of the gravitational potential energy of the rock mass into the environment as mining progresses. This release of energy can occur passively in the form of heat and sound or dynamically in the form of pillar bumps or rock bursts. From the initial application of a calculated energy release rate in the deep hard-rock mines of South Africa, the ERR was found to have a significant correlation with the risk or potential of damaging coal bumps or rock bursts. In this research, an ERR calculation is incorporated into the modern LaModel program to facilitate the analysis for potential coal bumps. Initially the ERR calculations in LaModel are verified using a case study of cut sequences originally modeled using the MULSIM/NL program. Then, the ERR calculations are applied to a bump-prone mine in Southern Appalachia were a number of different pillar recovery cut sequences were used in order to minimize the risk of bumps.

Jan 1, 2009

By Archie W. Fletcher, R. J. Wesely, Nathaniel Arbiter, A. D. Zunkel

In contrast to pyrometallurgy's six thousand year history in the production of metals, that of hydrometallurgy is of relatively recent origin. The earliest reference to it at all was in the 16th century, with the first applications to copper in the 17th and 18th. In the 19th century, increased demands for pure metal resulted in development of electrolytic refining, and early in this century electrowinning. The rapid growth in wpper production in the present century, paricularly in the United States and Chile, stimulated the development of new technology for leaching, and for the recovery of copper from leach solutions. Solvent extraction has become a major factor during the past quarter century by permitting novel leaching technology which produces dilute or complex solutions. In addition, solvents other than sulphuric acid, and chemical methods for precipitating copper metal are now of increasing interest. These are trends which should grow in importance in the future with the need to process lower grade and more complex materials. The evolution of copper hydrometallurgy is reviewed briefly and key factors in recent major developments are presented with details of specific operations and with trends for the future indicated. The relative importance of copper hydrometallurgy is compared to that of pyrometallurgy in the light of probable changes in ore supplies and character.

Jan 1, 1993

By K. S. E. Forssberg, M. I. Hallin

In many cases, the reuse of process water in flotation plants is desirable both for plant operating reasons and for environmental protection. The main advantages are better housekeeping of fresh water and process chemicals together with the reduction of polluting species to the environment. There are however a number of problems involved in the use of recycled process water. The main problem is that recycling sometimes has a deterious effect on the process and can occur months after the start of water recycling. The Division of Mineral Processing of Luleå University of Technology has been conducting experiments on recycling of process water at various sulphide plants in Sweden for over ten years. The experiments have been carried out in pilot- and full industial scale, in collaboration with the mining companies operating the plants. Until 1988 investigations were carried out in four different sulphide plants. The objectives of the experiments were: first to document differences in the composition of the process water during recycling; secondly to investigate any changes in the pulp chemistry of the flotation circuits wich may be due to the influence of recycled water; and lastly to establish critical levels, if any. of the parameters measured. While conducting experiments of this kind several things have to be kept in mind. Normally, recycling is done by using tailings pond water as process water. This means that time effects are important, because of the time lag between water input in the tailings pond and the reclaim of that water back to the plant. As will be shown, the

Jan 1, 1989

By D. M. Kjos

Large-diameter autogenous and semiautogenous grinding mills represent the primary thrust of the expanding grinding technology. In spite of initial difficulties, large autogenous and semiautogenous mills have reached an acceptable level of technology that provides the mineral engineer with a reliable, low cost means of ore comminution. A successful milling installation begins during the design stage of the grinding mill and the plant in which it is to be installed. This is particularly true in autogenous and semiautogenous mills. Critical mill and plant design factors should be considered while the mill and installation are still only "paper." Various current liner designs will be discussed ranging from lifter bar/plate to integral types. Modes of operation such as "high-low" will be considered. Liner maintenance procedures ranging from laydown area in plant design, proper mill shutdown methods, to installation and bolt tightening complete the equation to yield optimum performance possible for any particular grinding application. The objective of this paper is to discuss trends in wear materials, designs, and operating practices, and to provide some guidelines for good practice as we move through the 1980s. We will put together concepts that relate to the designs, materials, and applications so that higher performance can be obtained by the operator for his specific application. The concepts are shown as being in series became they are dependent on each other to achieve the desired performance: designs times materials times application results in higher performance (Arnson, Parks, and Kjos, 1983).

Jan 1, 1987

By Victor S. Sazhin, Alexander Kostenko

The hydrochemical method, which is based on the separation of aluminium oxide and silicon oxide by the hydrothermal decomposition of aluminosilicates by alkaline solutions in the presence of calcium oxide, can be effectively used for the complex processing of high-silicon aluminium ores. In this case, the silica is bound to a slightly soluble compound: Na20.2Ca0.2Si02•H20 (under the conditions: [&k]= 9, CaO/SiO2 = 1.05, alkali concentration in the solution: over 300 g/l Na20, T = 240...300 °C). If alkaline solutions of 100...150 g/l Na20 concentration are used, Ca0•SiO2•H20 or 2Ca0•Si02.0.5H20 compounds, depending on calcium oxide dosage, are formed at 280...320 °C. New methods for the crystallization of Na20.Al203.2.5H2O from concentrated alkaline solutions rand low-concentration solutions are proposed to isolate aluminium from solutions. The hydrochemical method, which involves no sintering process allows one to decrease the expenditure of heat by a factor of two, to reduce the investment and to exclude the pollution of the ambient air by dust-laden gases. The expansion of the raw-material resources base of

Jan 1, 1984

By L. R. Nelson

Cyprus Pima is a medium-sized open-pit copper mine located 35 km (22 miles) south of Tucson, AZ. The ore body was discovered using geophysical prospecting methods in 1953 and was originally worked as a small underground mine followed by small open-pit operations. As mining equipment grew larger and the economic ore grade dropped, the operation grew in size, through four expansions, to the present 50 500 tpd (56 500 stpd) milling rate. The remaining stripping ratio is about 2.5 to 1. Mining equipment includes 11 electric shovels ranging in size from 6 to 15 m3 (8 to 20 cu yd) and 42 diesel-electric haulage trucks ranging in size from 89 to 223 t (100 to 250 st). Mine planning is performed at Cyprus Pima to serve several functions. The most important is to plan ahead, one year at a time, to predict the ore grade and stripping requirements on a month-by-month schedule. This yearly plan is necessary for budget preparation and is revised once each quarter to incorporate variations in actual production experienced during the preceding quarter.

Jan 1, 1979

By Andreas G. Mueller

Gold-silver and copper-gold deposits with high-temperature wallrock alteration of Ca-Mg-Fe-Al silicates occur in ca. 3.0 Ga old greenstone belts of the Yilgarn Block, Western Australia. The deposits are hosted by amphibolite-facies komatiites, basalts and BIF, controlled by ductile shear zones and located within the contact-metamorphic aureoles of composite granodiorite-granite batholiths. Disseminated sulfides and free gold form foliation-parallel ore zones in a gangue of anhydrous silicates (garnet, clinopyroxene, olivine), hydrous silicates (amphibole, biotite) and calcite. The deposits may be classified on the basis of their dominant economic metals as: 1(1) Gold skarns with substantial silver as by-product, represented by the Marvel Loch mine (production: 2,200,000 t at 3.5 g/t Au), and characterized by the mineral association pyrrhotite, loellingite, arsenopyrite, galena, gold and magnetite. (2) Gold skarns with low silver contents, represented by the Nevoria mine (production:1,850,000 t at 3.4 g/t Au), and characterized by the mineral association pyrrhotite, chalcopyrite, arsenopyrite, gold, Bi-tellurides and magnetite. (3) Copper-gold skarns, represented by the Elverdton mine (production: 850,000 t at .7 5 Cu, 0.81 g/t Au), and characterized by the mineral association magnetite, chalcopyrite, pyrrhotite, pyrite, gold and Ag-Bi tellurides.

Jan 1, 1990

By Bryce T. Tripp

Utah's abundant industrial rock-and-mineral resources support a relatively small but important sector of the State's economy. In 1983, six of the top 10 nonfuel mineral commodities (by value) were industrial commodities. Portland cement was ranked fourth, potash fifth, halite sixth, phosphate seventh, construction sand and gravel eighth, and lime tenth. Portland cement was produced by three operators, principally from the Jurassic Twin Creek Limestone. Potash was produced by three companies from Pennsylvanian beds in the Paradox Basin, surface brine of the Great Salt Lake, and subsurface brines of the Great Salt Lake Desert. Halite was produced by eight operators, primarily from surface brine of the Great Salt Lake. Additional production came from salt beds in the Jurassic Arapien Shale, solution mining of the Pennsylvanian Paradox Formation of the Hermosa Group, and subsurface brines of the Paradox Basin. Phosphate was mined by one company from the Permian Meade Peak Phosphatic Shale Member of the Park City Formation. Construction sand and gravel were produced by dozens of operators, primarily from Quaternary Lake Bonneville beach and nearshore deposits. Lime was produced by four operators from Paleozoic formations in the Basin and Range physiographic province of Utah. The future production of these and other industrial commodities, though individually uncertain, is expected to increase gradually as a group. Factors favorable for the future of the industrial commodities industry in Utah include large to almost unlimited resources for the major commodities, a healthy projected population growth, an abundant local supply of relatively inexpensive energy from coal and natural gas, and a favorable corporate tax structure and business climate.

Jan 1, 1987

By James D. Bennett, David L. Passmore

The Coal Mining Section of the National Safety Council has selected hand and finger injuries of coal miners as a major topic for safety policy analysis [Tinney, 19851. So that facts about hand and finger injuries can be used to guide the Committee's work and the work of policy-makers, we present in this paper detailed analyses of the following factors related to hand and finger injuries received by coal miners between 1975 and 1983: occupations of the injured miners; activities of the miners when injured; machines involved; objects, substances, exposures, or bodily motions that produced or inflicted the injuries; principal physical characteristics of injuries; and events directly resulting in the injuries. We analyze hand injuries for underground and surface mines separately because of the remarkably different production methods and hazards evident in these two operating environments. We do not, however, provide information about hand and finger injuries that occurred in surface operations at underground sites (such as yards, shops, or tipples), auger mining operations, culm banks, dredging operations, mill or preparation plants, offices, or laboratories. The most comprehensive information about the safety of coal mining in the United States is assembled by the Health and Safety Analysis Center (HSAC) of the Mine Safety and Health Administration of the United States Department of Labor. Mine operators in the United States report to HSAC all injuries as required under Part 50, Title 30, of the Code of Federal Regulations (mandated by Section 103 the Federal Mine Safety and Health Amendments Act of 1977, Public Law 95-164). These regulations stipulate that injuries must be reported within ten days of their occurrence on a United States government data collection form, Mine Accident, Illness and Injury Report (MSHA Form 7000-1). HSAC maintains these data primarily to produce federally-mandated reports. HSAC resolves injury reports that are incomplete, checks for errors in data coding and handling, and corrects inconsistencies in data submitted by

Jan 1, 1986

By S. D. Morrison, J. L. Watson

It is well known that the density and viscosity of a mill pulp have optimum levels for grinding efficiency, and sophisticated control loops are employed to control pulp density in industry. However, these control loops rely on a number of plant measurements, and often the input data will not permit effective determination and control of the mill pulp density. The use of a single remote pulp density measurement has obvious advantages, and it is suggested and demonstrated for laboratory batch grinding that mill noise measurements can indicate the effective density of the mill pulp. In addition, the mill noise is shown to indicate the actual effective pulp viscosity in the mill and hence permit the identification of the dynamic rheological regime existing in the mill. It is demonstrated that mill noise increases with grind time and, at any given grind time, with increasing pulp density in the pseudoplastic range. This increase in mill noise level with pulp density is interpreted as indicating a decreasing pulp viscosity. The results show that the transition from dilatant to pseudoplastic conditions within the mill, with increasing pulp density, can be identified by this increase in mill noise. When the pseudoplastic pulp started to exhibit yield characteris- tics, the mill noise fell dramatically. The technique of mill noise analysis is then used to investigate the effect of a grinding additive on the batch grinding of two ores. With a magnetite ore, the additive was shown to increase the mill noise, and hence decrease the pulp viscosity, in the pseudoplastic region and to increase the effective grinding. The molybdenite ore, however, did not show significant noise level changes and did not show improved grinding efficiency.

Jan 1, 1987

By Lawrence W. Teufel

Knowledge of in situ stress and natural fracture distribution at depth improves our ability to stimulate and produce low permeability reservoirs. The focus of this study is three closely spaced, 2.5 km deep vertical wells in the Piceance Basin of Colorado. The wells were completed through the tight lenticular and blanket gas sands of the Mesaverde Group. In situ stress directions and magnitudes were determined from hydraulic fracture tests and anelastic strain recovery measurements of oriented core. The distribution, orientation, and characteristics of natural fractures in the subsurface were determined from detailed observations of over 1300 m of core, of which 400 m was oriented. Stress measurements clearly show that horizontal stresses are strongly influenced by lithology. In a sandstone/shale sequence at a depth of about 2.0 km in situ stresses in sandstone formations are anisotropic, with the average ratios of the minimum and maximum horizontal stresses to the overburden stress being 0.82 and 0.96, respectively. In sharp contrast bounding shale formations are lithostatic. This stress contrast between sandstones and bounding shale formations could act as a barrier to hydraulic fracture propagation during stimulation and impede vertical fracture growth. Natural calcite-filled fractures are present in over 7 percent of the core, with several horizons having a much higher frequency of fractures. Fractures are found primarily in sandstone. The fractures have a strong preferred orientation of N 1060E[+]110, which is aligned with the maximum horizontal stress and direction of hydraulic fracture propagation. The interaction between a well developed fracture fabric and anisotropic stresses in sandstone formations produces a permeability anisotropy, with the maximum permeability aligned with the fracture fabric and maximum horizontal stress.

Jan 1, 1986