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By A. L. Hauff

As US Coal producers are looking more and more to the international markets, they face the complex job of planning and managing transportation logistics which make effective use of production capabilities, considers the various contract requirements to be fulfilled, Train, Truck and Vessel capacities, port restraints, etc. Pulling all the necessary pieces of information together to allow proper planning throughout the supply chain is often a time consuming, manual but necessary task. This paper will discuss the various constraints, requirements and considerations to supplying coal to a global market.

Jan 1, 2012

By Leonard Sugin

Recent changes in the field of ore and bulk commodity handling has forced a reevaluation of previously conceived notions. When vessels were small, and sources of raw material were reasonably close to areas of need, the role of the shipping terminal was of secondary importance. Now terminals must be built to take advantage of the economic benefits of the supercarriers. The shipping rates of the 80's will not be determined by the 60,000 DWT or even 150,000 ton capacity bulk carrier, but rather by the supercarriers in the 250,000 DWT class or larger. When the Suez Canal was closed, the shipping industry took a hard look at the economics of the large bulk carrier. Naval architects overcame the problems and successfully designed large supertankers, which today are plying the seas in excess of 350,000 DWT. Orders have been placed for tankers of 480,000 DWT. The shippers of dry bulk materials are now coming to similar conclusions about the economics of supercarriers. As of today, over 40 orders have been placed for vessels in the 250,000 DWT class, representing an investment of over 11/2 billion dollars, and many more are being considered. These vessels are being designed as combination ore/oil (0/0) or ore/bulk/oil (OBO's) carriers. The oil industry has seen the need for terminals which can accommodate these supertankers. The dry bulk shippers, and particularly ore shippers, must now act.

Jan 1, 1972

By K. J. Reid

With the current trends of increasing costs and decreasing head grades the mineral industry is no longer operating in very high profit areas and has been forced to pay greater attention to the application of modern technology. Although here are many technological advances to the credit of the industry in recent years there are still many processes being operated in the traditional manner and still many areas awaiting the application of methods which have been proven in other industries. Compared with the chemical industry the mineral industry is seriously ageing in the general areas of process analysis and process control, more so than can be justified by the complications arising from having to deal with particulate systems with properties far different from ideal, or even non-ideal, liquid systems. One area in which there has been a remarkable lack of application in the Mineral industry is that of analog computation and the authors feel that there is considerable scope for the use of the analog computer in studying mineral industry processes. The paper outlines the basic principles and features of the analog computer and describes its role as a simulation tool in some engineering and mineral processing systems.

Jan 1, 1972

By M. J. Raffaldi, K. W. Harris, K. A. Perry

"Highwall miners have been widely used to extract additional coal reserves from existing surface operations, particularly on contour operations in the Appalachian coalfields. Using a continuous miner cutting head, coal may be extracted from significant depths (such as 150 m), leaving behind an array of web and barrier pillars with the purpose of maintaining highwall stability. This method inherently involves elevated risks to both equipment and personnel due to proximity to and increased exposure time near highwalls. As a result, modern operations should actively design web and barrier pillars to maximize extraction while providing adequate stability. The ARMPS-HWM software, an empirical-based program created for the design of web and barrier pillars at highwall mining operations, is one such approach. The calculated stability factor is compared with empirically established guidelines produced from examining case histories.The ARMPS-HWM program is a handy tool for initial design, but understanding the site’s structurally significant geologic features and geomechanical behavior is important and may potentially increase extraction. We created a two-dimensional numerical model using FLAC3D and calibrated it to ensure pillar strength, closely following the Mark- Bieniawski formula for a typical range of pillar geometries and overburden properties. The development of pillar stresses along a highwall panel was then numerically investigated as mining progressed, and the stress distribution between barrier pillars was found to be asymmetric, which can result in an over-design of the closeout web pillars if tributary area loading is assumed. Finally, the importance of adequate barrier pillar stability is highlighted."

Jan 1, 2014

By B. Valentim

Policies for reducing NOx emissions have led power plants to restrict O2, resulting in high-carbon fly ash production. Therefore, some potentially useful fly ash, such as the economizer fly ash, is discarded without a thorough knowledge of its composition. In order to characterize this type of fly ash, samples were collected from the economizer of a Portuguese power plant burning two low-sulfur bituminous coals. Characterization was also performed on economizer fly ash subsamples after wet sieving, density and magnetic separation. Analysis included atomic absorption spectroscopy, loss-on-ignition, scanning electron microscopy/energy-dispersive X-ray spectroscopy, optical microscopy, and micro-Raman spectroscopy. Key words: Fly ash; Petrology; Petrography; Economizer fly ash

Jan 1, 2009

By Arcy R., D&apos George

Removal of S02 from smelter gases is being investigated, using an innovative technique that results in the almost simultaneous recovery and production of elemental sulfur. S02 is removed from the gas stream by scrubbing with suitable aqueous salt solutions or high-boiling organic fluids. The S02-laden liquor is then reacted with H2S Crystalline, high-purity sulfur is instantly precipitated and, after filtration, the regenerated liquor is recycled. The H2S required for the process is produced by reacting a portion of the recovered sulfur with hydrogen or with methane and steam. The chemistry and results of preliminary laboratory research are discussed.

Jan 1, 1969

By C. F. Giermak

Over a considerable period of time great interest has been shown in selective dry concentration of fine ferromagnetic particles, although it is only recently that new permanent magnetic materials have been made available to permit building of such permanent magnetic separators. It is well known that the conventional drum separator does' not efficiently separate fine materials. The centrifugal force on any drum acts in accordance with the particle size and gravity, which may beat varying magnitude-.opposite to the magnetic force, especially when the material is not closely sized. The Magnetic-Mechanical Separator (MMS) is designed for the concentration of fine, unsized magnetic materials where the percentage composition of magnetics to nonmagnetics, or the nature and texture of the materials, is such that its unique agitation and shake-out action with no centrifugal force provides greater efficiency than is obtainable by conventional magnetic separation equipment. This machine consists of a complete double belt conveyor unit with a premagnetizing Axial Pole Agitating Pulley at the feeding end of the lower conveyor belt and a special agitating concentrator magnet above the lower belt of the upper conveyor.

Jan 1, 1965

By K. L. Boyd

"Can the ever-increasing tonnages of ore and waste being mined today be accommodated simply by using bigger and better crushers? This paper reviews the latest primary crushing and large cone crusher designs. It highlights how—in addition to using the larger crushers now available—maximizing the utilization percentages in each of the four stages of the rock size reduction circuit will assist in meeting the larger production requirements of existing and new mining operations. Its goal is to help consultants and operators select the optimal equipment and custom-designed items in the material handling flowsheet from the mine to the mill, maximizing operating hours per year. INTRODUCTION Are larger crushers the answer to meeting the demands of existing or new mining projects for increased tonnage? Boyd (2002) predicted that larger crushers for primary and fine crushing would be beneficial and contribute to the further development of mineral processing. Larger crushers for primary and fine crushing applications are now available. The rock size reduction process from the mine to the selected milling process facility has not changed since man first broke a rock to get at the interesting mineralization within. The rock size reduction process circuit from the mine to the mill can be summarized in four stages: • Stage 1: Mining (rock breakage and fragmentation) • Stage 2: Pre-screening (scalping) • Stage 3: Primary crushing • Stage 4: Fine crushing (secondary, tertiary and quaternary) Plant throughput and ore delivery schedule will form the basis for flowsheet design and equipment selection. Once the project design criteria and the mine plan have been established, the circuit’s utilization percentage (percentage of hours when the circuit is being utilized) can be optimized for each of the four stages. The mining and process departments are the key stakeholders in the selection of the final comminution circuit, and both departments should be familiar with and contribute to the design of the circuit. This paper focuses on the four stages of a rock size reduction circuit from the mine to the mill, equipment selection, various ore and waste handling flowsheets, and improvements in crusher station design, all with the purpose of maximizing availability and plant utilization percentages. What is a large tonnage? From 1907 to 1914, the American Panama Canal excavated 300 million tonnes of material in 7 years (History of the Panama Canal, Wikipedia). Today’s large mining operations can move the same material in 10 months, using large crushers or multiple crushers for ore processing and large crushers and a mixture of truck haulage and conveyors for handling the large waste tonnages. Some examples include:"

Jan 1, 2017

By J. Sanko

When faced with the task of designing a process control system the control engineer must consider the following: 1. The type of process to be controlled and the manner in which the process must be controlled (the algorithm). 2. The type of equipment to be used to implement the control system. 3. A means of describing the control system for use in the following areas: a. Project engineering. b. Procurement of the control system equipment. c. Plant startup. d. Operator training and reference.

Jan 1, 1981

By Thomas J. Lien

Granitic Pegmatite deposits are the chief source of commercial feldspar, micas, lithium minerals, tantalum-columbium, beryl, and certain types of kaolin. The output from pegmatite mines in the United States is small compared to other mineral products in terms of bulk or value, and much of it comprises only minor metals and nonmetals. Nevertheless, pegmatite minerals play a vital part in our domestic industrial economy, particularly in the ceramic and electrical industries. Numerous special purpose uses also are important, even though they require small quantities of raw materials. In recent years, realizing the potential importance of the pegmatite minerals, the U.S. Geological Survey, the United States Bureau of Mines, several state Bureaus of Mines, and a few private companies have carried on extensive programs of pegmatite studies in the New England and southeastern states, in the Black Hills area of South Dakota, in the Rocky Mountain region of Wyoming, Colorado, and New Mexico, and in various parts of Washington, Idaho, Utah, Nevada, Arizona, and California. Currently, some of the pegmatite minerals such as micas and spodumene are selectively separated by the flotation process. To a lesser extent a few plants are selectively floating feldspar and quartz. Much of the credit for the above progress goes to the fine work done by U.S. Bureau of Mines (1), and companies such as Foote Minerals (2). Additional research efforts by the New Mexico Bureau of Mines (3) has successfully demonstrated selective separation of micas, beryl, spodumene, lepidolite, microlite, quartz and feldspar from a complex Pegmatite containing all these minerals. Since the nature of the mineralization of various valuable components of a pegmatite deposit is such that selective separation of some of these can be carried out at a coarse size using the Heavy Media Separation technique, it was felt that such a system should be investigated for selective preconcentration of their minerals. It was also felt that of all the :MS systems available, the DYNA WHIRLPOOL (DWP) device which allows a close control and adjustment of specific gravity should provide a means of achieving the above goal. Once the desired preconcentration of one or more of the pegmatite mineral assemblage is achieved, the available selective flotation techniques should provide effective recovery of various minerals into marketable products. This paper presents technical and economic aspects of selective preconcentration of some of the pegmatite minerals followed by selective flotation to produce marketable products.

Jan 1, 1978

By Yehia M. Youssef, Nourhan Moukhtar, M. H. Abdel-Aziz, Ibrahim Hassan

Copper was recovered from copper sulfate solution in a batch-recycled galvanic reactor operated under forced convection with the generation of electrical energy during the cementation process. The divided galvanic cell consisted of parallel copper and zinc plates. The mass transfer rate and the amount of electrical energy generated were found to be directly proportional to the solution flow rate and the initial concentration of metallic ions and inversely proportional to the distance between electrodes. The experimental results were expressed in terms of a dimensionless correlation including all parameters. The wastewater treatment presented herein cell can be utilized to recover many soluble heavy metal ions from solution with high efficiency.

Oct 2, 2020

By Veerendra Singh, NILAMADHABA SAHU, ARIJIT BISWAS

Manganese alloys are important raw materials for steelmaking. However, selective mining of high-grade manganese ore resources has resulted in a scarcity of these high-grade Mn ores (Mn: >42; Mn/Fe: >5). The present research work is carried out to explore a new smelting reduction process to produce high-Mn/Fe syntheticMn ore from low-grade ferruginous manganese ores. Representative samples of low-grade ores (Mn: 25–30%; Mn/Fe: ~1) were collected and smelting reduction studies were carried out using variable smelting power (20–30 kWh), carbon rate (10–20% of ore) and slag basicity (0.1–0.3) to produce high-MnO slag and manganese pig iron. Studies have shown that different-grade high-MnO slags (MnO: 38.57–58.24%; Mn/Fe: >15) and manganese pigs (Mn: 5.16–24%) can be produced at optimum process conditions. The high-MnO slag can be used as synthetic ore for the ferroalloy production process. The developed process is capable to effectively segregate the iron and manganese in the metal and slag, respectively. The optimum Mn and Fe separation (>95%) was achieved by smelting of 10 kg Mn ore batch in a 50-kVA electric arc furnace using 30 kWh smelting power and 0.16 kg of coke. The slag basicity was maintained at 0.3 and the optimum slag SiO2 was ~30%. The studies indicated that the upgrading of low-grade ferruginous manganese ores is a promising solution for achieving high-Mn/Fe-ratio synthetic ores for ferroalloy production. It can help the manganese alloy industry to overcome challenges associated with the scarcity of high-Mn/Fe-ratio Mn ores and efficient utilization of low-grade resources.

Aug 3, 2020

By J. C. Zelanko

The U. S. Bureau of Mines conducted a multi-faceted geomechanics research project at a bump-prone longwall coal mine in eastern Kentucky. This mine presented a unique opportunity to study coal mine bumps in that the problem appeared to be confined to areas beneath a sandstone channel of limited areal extent. The Bureau's research plan sought to exploit the uniqueness of the site by monitoring strata behavior and longwall support reactions as the longwall face approached and passed beneath a sandstone channel. The study incorporated static pillar stress and strata deformation measurements, shield support leg pressure measurements, and microseismic monitoring as well as geologic mapping and the collection of observational data. Data collection was underway when a major coal bump occurred on the longwall face at the mine. Pillar behavior (load and deformation), shield loading, and microseismic activity were monitored prior to, during, and after the bump. Observations in the tailgate indicated that these pillars were failing prior to and after the face bump. Shield load data which were evaluated in an effort to identify trends which could be used to forecast coal bumps appear to provide a measure of the effectiveness of destressing operations conducted on the face (e.g. shot firing). Analyses of microseismic data revealed anomalous values associated with microseismic "energy" prior to the face bump. In addition, microseismic source location data and underground observations provided some insight as to the sequence of pillar and face bumps.

Jan 1, 1991

By Galymzhan Karamyrzayev, Rashid Nadirov

Zinc ferrite ( ZnFe2O4) is a by-product of non-ferrous metal production and is considered a promising source of raw zinc. The most efficient way to extract zinc from its ferrite is via acidic extraction, specifically leaching by hydrochloric acid. A comparative study of synthetic zinc ferrite hydrochloric acid leaching in isopropanol, aqueous, and the mixed solvent was performed. Zinc ferrite was obtained by sintering a zinc and iron (III) oxide mixture. Crushed samples were subjected to leaching in 1 M HCl at 323, 333, and 353 K and pulp density of 1 g/100 mL. The dissolution of zinc and iron into solution in organic media reached 77% at 353 K, while in an aqueous environment this value was 65%. The activation energy of 70.0 kJ/ mol was found for the leaching process in an isopropanol environment, which is lower than that in an aqueous solution by 15%. The more efficient leaching effect of isopropanol is attributed to the lower dielectric constant of the alcohol which increases the affinity of chloride anions for zinc and iron cations at leaching.

Jun 5, 2022

By Arif Emre Dursun, Ali Aras, Hakan Özşen

Specific energy (SE) is defined as the amount of work required to cut a unit volume of rock and is used to estimate the performance of excavation machines. Generally, the SE value is produced from full-scale or small-scale rock cutting tests. However, these tests require expensive equipment and experienced personnel, and the testing procedure is time consuming and impractical. Therefore, for estimation of SE, this study aimed to find a solution to estimate SE using rock mechanics test results and Bond work index values (BWi), which can be produced in a more practical, less time-consuming manner and with inexpensive test equipment. Small-scale rock cutting, rock mechanics and Bond work index tests were carried out on seven rock samples, which can be grouped into two different type of rocks: marble and travertine. In addition, the instantaneous cutting rates (ICR) of a selected roadheader were calculated using SE values. Rock mechanics tests performed in this study were uniaxial compressive strength (UCS), Brazilian tensile strength (BTS), ultrasonic velocity (Vp), Schmidt rebound hardness (RL), corrected point load index (Is(50)) and density (ρ). The simple regression method was used to estimate SE from rock properties and BWi. As a result of this simple regression, a significant and highest correlation was found between SE vs. UCS and Is(50). A good correlation was found between SE vs. BTS, RL and BWi values. A moderate correlation was found between SE vs. Vp and ρ.

Jul 28, 2021

By J. L. Hoover, P. W. Conrad, J. Downey, S. Parrow, S. Rosenthal

The goal of the drill bit consumption study was to develop an equation(s) based on various components that affect drill bit wear and use that equation(s) to estimate the consumption of bits during production drilling. Drill bit data from various geographic locations were compiled and used to develop linear regression equations using the Microsoft Excel software package. Multiple drill bit consumption equations were developed and statistical analysis was used to verify the accuracy of those equations. The equations will allow mining companies to more accurately forecast drill bit consumption when evaluating new mine properties. This capability becomes increasingly beneficial to forecasting as the cost of consumables increases.

Jan 1, 2012

By Y. J. Wang

The selection of a shaft size for ventilation purposes is a classic problem of concern to mining engineers. This presentation is concerned with the sizing of conventionally-sunk circular shafts with concrete or shotcrete linings. Costs of sinking shafts of three different depths (from 500 feet to 1000 feet) and six different diameters (from 14 feet to 24 feet) were obtained through questionnaires to shaft contractors. The primary objective of the economic model presented is the balancing of detailed annual capital and operating costs to achieve the minimum overall cost of the shaft installation over its life. The economic model is similar to previous analyses but treats several of the individual cost categories in an updated fashion. Included in the paper is a detailed analysis of the effects of varying power costs on optimal shaft size. Also included are a statistical analysis of current shaft costs and comments on the choice between shotcrete and concrete linings.

Jan 1, 1977

By C. A. Oestreicher

For sulfide minerals, the presence of dissolved oxygen in the water phase is an influencing factor for separation by flotation. Klassen and Mokrousov(I:217l distinguish three stages of oxygen adsorption; namely, reversible adsorption, activated adsorption and, finally, surface oxidation. While contraversial, limited adsorption of oxygen is believed to improve the interfacial reactivity between collector and mineral. Intensive surface oxidation of sulfide minerals usually results in unsatisfactory flotation with collectors of the xanthate type. The influence of dissolved oxygen in the water phase has received consideration for sphalerite, galena, chalcopyrite, arsenopyrite, chalcocite, and covellite(2,3,4,5,6). However, the nature of surface oxidation products of sulfide minerals has received very limited investigation(6,7). Lightly oxidized galena promotes the adsorptive reaction of surfactant (xanthate or dixanthogen). Tolun and Kitchener(8) state that limited interaction occurs between galena and xanthate under relatively reducing conditions. And, that exposure to oxygen raises the electrochemical potential of the galena to that required for reaction with xanthate or dixanthogen. In the latter condition, the galena has an "effective flotation surface". On the other hand, intensive oxidation of galena reduces the chemical reaction with xanthate collectors (9) . Complete flotation with xanthate-type surfactants with increasing oxygen content in the water phase has been determined to have the following sulfide mineral sequence(3): galena, pyrite, sphalerite, chalcopyrite, pyrrhotite and arseno-pyrite. The work of Cusack(4) suggests that some threshold amount of oxygen is necessary for flotation to occur, but heavy oxidation hinders flotation with xanthates. According to Tolun and Kitchener(8) catalytic oxidation of xanthate to dixanthogen occurs. From infrared studies, Poling and Leja(IO,II) found that in the absence of oxygen in solution, xanthate ions do not adsorb either on

Jan 1, 1972

By G. A. Munoz

Gold leaching of an auriferous pyrite ore from the Portovelo deposit in Ecuador indicates that noncyanide leaching systems, such as thiocyanate and thiourea, are not as effective as the traditional cyanide system. For example, whereas approximately 95% of the gold can be leached from the ore with cyanide, only about 50% gold dissolution can be achieved with a thiocyanate leaching system. Electrochemical measurements indicate that gold is not cathodically protected by pyrite in these systems. Based on the results of preliminary diagnostic experiments, it appears that gold dissolution in thiocyanate and thiourea systems is limited by passivation due to the formation of either elemental sulfur or sulfur compounds on the gold surface.

Jan 1, 1999

By H. Walqui, S. K. Kawatra, C. H. N. Jeltema, T. C. Eisele

"The literature contains many cases where the shape of hydrocyclone efficiency curves vary from the ideal “S” shape. These often appear as changes in slope, or inflections. These inflections can be divided into two categories: “coarse” inflections, which are caused by differences in the density of the minerals being separated, and “fine” inflections, for which there are a number of competing hypotheses concerning their cause. The existing literature addresses either the fine inflection or the coarse inflection, but no studies have reported both types of inflection occurring at once in a single hydrocyclone test. This paper presents hydrocyclone results from both in-plant studies and laboratory experiments that show both coarse and fine inflections. The industrial significance of both types of inflections is discussed. Hydrocyclone efficiency curves show the probability of any given particle reporting to the hydrocyclone underflow as a function of its size. Selectivity functions, S(d), are used to represent the fraction of the feed material in size fraction “d” that reports to the hydrocyclone underflow. Plotting this selectivity function against particle size leads to the standard S-shaped efficiency curve shown in Fig. 1. In the “uncorrected” curve, the tail of the curve does not go through 0%, because a portion of the solids are bypassing classification. This happens as a result of their being carried along by the water, and is most important for the finest particles. The curve can be “corrected” based on the fraction of the feed water that reports to the underflow, represented by the bypass fraction, Rf. The corrected curve then normally passes through 0%, as shown in Fig. 1.The act of correcting the curve shifts the value of the d50 size, which is the size that has an equal probability of reporting to either the overflow or to the underflow. Correcting the curve to account for the bypass fraction makes it easier to compare cyclone performance under conditions that cause the quantity of water in the underflow to change, but that do not alter the actual corrected cut size (d50c).The corrected efficiency curve can be expressed closely by equations such as Plitt (1976):"

Jan 1, 2015