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By John Relser

The production processes that are developed in the mining and minerals industry are manufactured to be exposed to very aggressive environments. Chemical, abrasion, and impact expose structures and equipment, steel or concrete, to a significant deterioration. This causes damage and adds high costs to operations that can be reflected in the destruction of equipment and structures in the arrest of the production process, which becomes very costly. Also, there is the potential for personnel accidents, which would require large sums of compensation for an employee, thus directly harming the image of the mining operation and company. Manufacturers of paints and coatings that have major centers for research and development (R&D Labs) distributed globally have developed high-tech products for durable protection from the elements for structures and equipment used in the mining industry. The difference between these paintings and coatings and what is normally known as conventional paints (e.g., those called domestic or decorative), is its chemical composition, structured around polymeric components that have highly resistant, chemical and physical properties to cope with extreme conditions to which they are exposed. With this, and only this, longer life of components can be achieved for equipment and structures used in the production processes of the mining industry. Today, in addition to the important features mentioned, some manufacturers of the paints and coatings dedicated to this highly modernized process have invested large sums of money in developing new products that add operational elements to the painting process. These coatings provide added value and significant performance to companies mining operations and that we can describe in three fundamental concepts:

Feb 1, 2014

"The National Mining Hall of Fame and Museum (NMHF&M) announced the 2015 National Mining Hall of Fame inductees and the 2015 Prazen Award winner. This year’s inductees, selected by the National Mining Hall of Fame’s Board of Governors, represent the technology, management, mineral policy, education and health and safety aspects of the mining industry. They envelope a diverse cross section of the mining industry and were selected for being visionaries, leaders, educators and ambassadors.In 2015, Frank F. Aplan, T S Ary, Ralph E. Bailey, John Campbell Greenway and Edward Steidle will join 227 other mining industry honorees when formally inducted into the National Mining Hall of Fame. The Prazen Living Legend of Mining Award will go to the Powell River Project Research and Education Center, a partnership of Virginia Polytechnic Institute and State University (Virginia Tech) and the Appalachian coal mining industry.The 2015 annual induction banquet and ceremony will be the 28th such event and will be held this year in Pittsburgh, PA, on Oct. 23, 2015, in the Omni William Penn Hotel ballroom.2015 National Mining Hall of Fame inductees:Frank F. Aplan is among the most influential mineral processing leaders in both industry and academia. His studies of the processes involved in the preparation of coal and mineral ores are acknowledged worldwide for their broad applicability. An authority on flotation, Aplan is especially known for his studies of the wetting of solids and their control through the adsorption of surfactant films, and for his work on atomic defects on properties and behavior of solid-liquid interfaces."

Jan 1, 2015

By William Gleason

With its 2011 acquisition of rival equipment company Bucyrus International, Caterpillar added underground mining and large shovels to its line of products and further solidified its standing as the leading mining equipment manufacturer in the world with solutions for every aspect of mining. When Caterpillar spent $8.8 billion to acquire Bucyrus, the global mining business was flourishing, as mining companies around the world worked to keep up with demands for nearly every commodity. Flash forward to 2013, and the global mining landscape looks very different. Lower demand for raw material from China and India and falling commodity prices have forced most mining companies to pull back on their production. The reductions from the mining industry have hit equipment makers like Caterpillar and Komatsu hard. In October, Caterpillar reported that its quarterly earnings had fallen 44 percent. The changing conditions have also changed the narrative from Caterpillar and other equipment makers to customers from offering solutions to move the most tons per hour, to now offering solutions for the lowest cost per ton. In September, Caterpillar hosted some of its mining customers and the trade press at its Tinaja Hills Demonstration and Learning Center near Tucson, AZ to talk about its range of products, from its MineStar System designed to help increase efficiency through better equipment management and planning, all the way up to the massive Cat 7495 and 7495HF electric rope shovel lines acquired through the Bucyrus takeover

Dec 1, 2013

"It’s been 80 years since Charles Warman invented the iconic Warman slurry pump, a pump that revolutionized the mining industry and continues to push the boundaries of pump performance to this day.In honor of this legendary brand, Weir Minerals hosted an event at the end of May in Kalgoorlie, Western Australia. Throughout the evening, attendees relived Warman pumps’ history and gained an insight into some of the future innovations planned.“It was a privilege to share this special night with some of our key customers, past and present employees, and members of the Western Australian School of Mines,” said Ricardo Garib, divisional president of Weir Minerals. “Warman is one of our leading brands. It has truly shaped the mining industry over the past 80 years and is a product we are all very proud of. The Warman pump, invented to solve high wear issues in slurry pumping, created a thriving industrial business that is now the cornerstone of Weir Minerals with more than 8,000 people, and more than 150 manufacturing and service centers across the globe.”Always inventingCharles Warman invented the Warman slurry pump in Kalgoorlie in 1938. It was a hardwearing slurry pump that used replaceable liners and a replaceable impeller, something that had never been done before.“Charles Warman was a visionary and an innovator. The use of rubber lining in the pump was groundbreaking as it reduced total ownership costs, was safer to handle and offered extended wear life in many abrasive slurry applications. It is a great example of solving customer problems with material science, and is still taught in universities today,” said Marcus Lane, global product manager for centrifugal pumps at Weir Minerals.It was quickly adopted throughout the goldfields in Western Australia and by the 1950s, as customer demand rose, Warman expanded his business by opening offices in Sydney and Perth.During the 1960s the rapid growth of the business continued with manufacturing and sales outlets established around the world. The Warman Series ‘A’ pump was accepted and became a world leader in its field. Further work on the Warman AH pump resulted in the development of interchangeable metal and rubber wearing components."

Jan 9, 2018

Evver since it first displayed an autonomous mining truck at the 1996 MinExpo show in Las Vegas, NV, Caterpillar has been building the blocks to a fully autonomous mine. In May, the company unveiled another block in that progression, the new Cat MineStar System that it says is ?the industry?s broadest, most comprehensively integrated miner operations and mobile equipment management system.? The full system is comprised of five capability sets ? Fleet, Terrain, Detect, Health and Command ? to help operators define the size and scope of their management system based on the needs of their mining operations. Michael Murphy, technology and autonomy manager for Cat Global Mining, explained that the customers were not ready for an autonomous mining truck in 1996, but that many customers wanted the building blocks to eventually get to autonomous mining. After 15 years of work, Murphy said the building blocks have come together in the form of the Cat MineStar System.

Jan 1, 2011

By W. Kennedy Gauger, Tim Oolman, Debra L. Bisson

Radian Corporation (Radian) has developed a process for treating Cr(V1)-contaminated soils that involves: 1) soil washing using an alkaline extractant, 2) biological reduction of Cr(V1) to Cr(II1) in the soil wash effluent, and 3) separation of Cr(II1) from the biologically treated effluent. Biological treatment has been demonstrated for immobilized cells in fluidized bed bioreactors and suspended cells in slurry bioreactors for Cr(V1) levels ranging from 30 to 600 mg/L which have been reduced to non-detectable levels (< 0.05 mg/L; method detection limit [MDL]) during hydraulic residence times as short as 12 hours. The resulting Cr(II1)-containing effluent stream was chemically treated to precipitate chromium hydroxide for removal by physical separation.

Jan 1, 1995

By William Gleason

"What will the mine of the future look like? Will it resemble the current operations that supply the world with the products it needs to function, or will it be something totally different? How will the demands from the communities that are most affected by mining operations shape the mine of the future? How will technology and innovation be used to help miners reach deposits that are getting harder to access, and what are the dangers of this new world? Who will work at the mine of the future, and what will that work look like?These are questions that do not yet have definitive answers, but they are questions that need to be asked for the mining industry to move into a future that is as filled with uncertainty and challenge as it is with promise and opportunity.On Feb. 16, the 2015 SME Annual Conference and Expo and the 117th CMA National Western Mining Association conference began with a keynote address, "The mine of the future: Forecasting opportunities and challenges for the global mining industry." Panelists from five sectors of the mining industry participated in the session, which was followed by the conference and expo, that in large part, were also trying to answer the question of what the mine of the future will look like.In coming months, Mining Engineering will continue the discussions and answer some of the questions submitted by members of the 2,000-person audience during the keynote address in a monthly feature called, "Predicting the Mine of the Future," and in Thought Leaders Podcasts with the panelists and other industry experts."

Jan 1, 2014

By William Gleason

"Ed Rapp is among those who believe in the saying that necessity is the mother of all invention. Rapp is the president of Caterpillar’s mining group. As such, he is tasked with leading the world’s largest mining equipment maker, and its customers, through this time of lower commodity prices, while also positioning his company to be prepared for better days that lie ahead.The decade-long mining boom fueled by growth in emerging markets and demand for commodities that led to record prices for some metals paused in 2008 with the global financial crisis. However, according to Rapp, thanks to stimulus packages around the world, and in particular the stimulus from China that was focused on infrastructure, the mining sector recovered fairly quickly, and from 2010 to 2012, mining was strong.And then the stimulus stopped. Credit dried up and global growth began to slow down and, in the three years since, commodity prices have declined by an average of 60 percent. Caterpillar expanded during the boom, acquiring Bucyrus, and investing billions into the mining sector. It has felt the pinch of the slowdown as much as any mining company in the world. These pages, and those of other mining publications as well as mainstream media, have been filled with stories of doom and gloom about the industry. But Rapp, while acknowledging that the difficult times have been painful, also said Caterpillar sees opportunity in the slow down and reaffirmed his company’s commitment to the mining industry as absolute."

Jan 1, 2014

By William Gleason

"During the past nine years the number of cellular phones connected to a network has increased from 34 percent of the world’s population in 2005 to 93 percent in 2014. These phones are powered by a combination of materials including elements such as gold, silver, copper and rare earths. And, as more parts of the world become connected to networks, the number of phones being produced, and the elements they will need, will continue to increase. The demand comes as prices for these commodities are slumping and access to the commodities is getting more difficult, technically and socially.These mobile devices have connected people around the world in ways that could not have been imagined two decades before, and, ironically, this communication has strengthened opposition to the development of the mines that produce the very materials they need to operate.In his keynote address to the 2014 SME Arizona Conference at the JW Starr Pass Resort in Tucson, AZ, on Dec. 8, 2014, John O. Marsden, SME President and president of Metallurgium, spoke to more than 500 attendees about the challenge to produce the materials that society needs while at the same time challenging the general public’s perception of mining that is often inaccurate and less than favorable.Marsden highlighted the amount of raw materials that will be needed not just for phones, but also for things such as automobiles, including electric cars, as a way to illustrate the importance of mining. Even so-called green products such as Tesla cars, which require about 317 kg (700 lbs) of aluminum, 13 kg (30 lbs) of copper and 36 kg (80 lbs) of cobalt for their eco-friendly batteries, will need materials mining provides.These are some of the numbers that the general public is often unaware of. They are part of the necessary things that mining provides for society but are rarely reported on. Instead, it is the accidents like the tailings spill at the Mount Polley Mine in British Columbia and at the Buena Vista Mine (Sonora, Mexico) that grab headlines and stick in the minds of the public, adding more challenges to an industry that already has its own complex technical challenges to deal with."

Jan 1, 2014

By R. H. Olson

Pigments are used in two segments of papermaking, as the major component in paper coating formulations and, in small percentages, as fillers in the paper web. Historically, the dominant use has been in coating, however, recent developments have fostered a multifaceted effort to substantially increase the pigment component in the paper furnish. Factors responsible for these developments together with their relationship to recent and forecast changes in papermaking technology are reviewed. Finally, some thoughts are presented on the probable timing and extent of these changes as well as their expected impact on the future demand for the common paper pigments.

Jan 1, 1985

By Vytas Svalbonas

Sophisticated computer analysis methods such as finite elements, finite differences, and numerical integration have become tools in the mineral processing industry for design of large mill shells. While use of such methods allows the analyst-designer to take new freedoms with his designed structure, there are also pitfalls and dangers which must be recognized for the proper use of such sophisticated tools. One of the worst of these is treating any computer answers as "gospel truth". The present paper discusses the knowledge required by the analyst-designer for proper use of computer analysis, as well as explaining to the layman how to identify questionable areas in such structural analyses.

Jan 1, 1979

By Y. C. Kim, M. Preston, F. Martino

Because of the high cost of obtaining coal washability samples, it has been difficult in the past to obtain washability variograms. As a result, it could not be determined if the geostatistical prediction tool known as kriging can be applied to predict in situ coal washability characteristics. This paper presents the obtained variogram models for the Upper Freeport coal seam in western Pennsylvania. Variogram model parameters are presented for a total of 27 models. They are for four different variables: float- weight, ash, sulfur, and Btu, at seven different specific gravities: 1.275, 1.300, 1.325, 1.400, 1.600, 1.800, and 1.80,Sink. Based on the obtained variogram results, it can be con¬cluded that all attributes of coal washability show definite spatial correlation structures, and, consequently, geostatistics can be used to predict the in situ coal washability characteristics.

Jan 1, 1990

By Zachary D. Jones

"Construction projects involve a great many risks. The risk that material prices will increase during construction or that the work under construction will be destroyed by fire, storm or some other act of God are just a few examples. In tunneling or other underground projects, one of the most significant risks is that the subsurface conditions encountered during construction will differ from what is expected. Each of these risks must be accounted for, managed and, ultimately, the duty of one party or the other to bear. The primary tool used to allocate the risks among the parties is the construction contract.How construction contracts allocate the risk that subsurface conditions will differ have changed substantially over the past century. Today, construction contracts typically allocate the risk through a series of provisions. The first is the differing site condition or changed condition clause. That clause, when included, typically provides that the owner bears the risk that the subsurface conditions will differ from what is indicated in the contract documents or what is reasonably expected. The second clause is one that provides that the contractor must conduct a reasonable site investigation and bear the risk of any conditions that such an investigation would reveal. The third provision includes disclaimers that are often included in geotechnical data provided by the owner (or the owner’s engineer) to the contractor which attempts to limit the information on which the contractor can rely. Because these risk-allocating devices seem to be somewhat conflicting, a brief discussion of each provides critical insight in understanding how the modern construction contract allocates the risk of differing site conditions.At the start of the 20th century, construction contracts looked substantially different than they do today. For example, one contract for the construction of a public water tunnel in Chicago, IL, drafted around 1895 contained the following clause:The contractor must take the work entirely at his own risk. No extra allowance will be made for quicksand, hardpan or boulders."

Jan 1, 2014

By D. Gu, B. Lin

Discussion of concept Breakage of rock by machine is one of the major methods of excavation. With the development of modern engineering techniques, the advantages of using this method have become even greater. Improving efficiency and reducing the cost of rock breakage is the main goal of mechanizing the rock-breaking operation. For a given stratum, the efficiency of a machine excavation depends, to a large extent, on the design and method of application of the tools used. In a planetary cutter head, the subcutter heads move like planets around the main drive shaft. The general structure of the cutter head is shown in Fig. 1. As shown in this illustration, the main drive shaft (1-1) is connected to the tie bar (1) and, thereby, to a gear (5) that meshes with a fixed-gear ring (2). The subcutter head (4) is rigidly connected to the gear (5) by the subcutter-head axis (2-2). When the main drive shaft (1-1) rotates, the subcutter head (4) rotates around the axis (2-2), under the action of the tie bar and with the help of sleeve pipe (3). At the same time, axis (2-2) also rotates around the main shaft (1-1). As shown in Fig 1, [a] is the angle between the main shaft and the subcutter-head axis. This angle determines the shape of the drilling face. If [a] equals zero, the drilling face will be a flat surface (Fig.1 (a) ), and if [a] is greater than zero, the drilling face will be a spherical surface (Fig. I (b)). For a planetary cutter head, the most important design parameter is the transmission ratio (i), which is defined as [i = (0210)1(1)] Where [(a] is the angular speed of rotation of the subcutter heads around their individual axes, and [o] is the angular speed of rotation of the subcutter-head axes around the main shaft. In Eq. (1), i is positive if the direction of rotation of a subcutter head around its axes is the same as the direction of rotation of the subcutter-head axes around the main shaft (see Fig. 1(b)). Conversely, i is negative when the two directions are opposite (see Fig. 1(a)). When i is positive, the cutters on the subcutter heads form epicycloid paths on the drilling face, as shown in Fig. 2(a). Conversely, if i is negative, the paths will be hypocycloid, as shown in Fig. 2(b). It should be noted

Jan 1, 1996

By L. H. E. Weyher

In a previous paper presented at the 1966 Annual Meeting of AIME we reported our work, conducted at the Pennsylvania State University, on the hydrocyclone washing of fine coal.&apos; The initial evaluation based on that work demonstrated the feasibility of hydrocyclones as fine-coal cleaning devices, and in that previous paper we presented selected test data that showed in principle how product yield and assay respond to variations of the major cyclone operating variables. The present paper reports in greater detail on the findings and presents a comprehensive evaluation of our data as follows: ? Hydrocyclone throughput rates were related to feed pressure and other variables by regression equations. These equations are compared with other capacity- versus-pressure drop expressions taken from the literature on classification cyclones.

Jan 1, 1968

By D. Gu

Breakage of rock by machine is one of the major methods of excavation. With the development of modern engineering techniques, the advantages of using this method have become even greater. Improving efficiency and reducing the cost of rock breakage is the main goal of mechanizing the rock-breaking operation. For a given stratum, the efficiency of a machine excavation depends, to a large extent, on the design and method of application of the tools used. In a planetary cutter head, the subcutter heads move like planets around the main drive shaft. The general structure of the cutter head is shown in Fig. 1. As shown in this illustration, the main drive shaft (1-1) is connected to the tie bar (1) and, thereby, to a gear(5) that meshes with a fixed-gear ring(2). The subcutter head (4) is rigidly connected to the gear (5) by the subcutter-head axis (2-2). When the main drive shaft (1-1) rotates, the subcutter head (4) rotates around the axis (2-2), under the action of the tie bar and with the help of sleeve pipe (3).At the same time, axis (2-2) also rotates around the main shaft (1-1). As shown in Fig 1, is the angle between the main shaft and the subcutter-head axis.

Jan 1, 1995

By B. Mather

Discussion by B. Mather I was very glad to see an article on alkali-silica reactivity of concrete aggregate in Mining Engineering. It is a topic that should be reexamined every 45 or 50 years. The last paper (that I am aware of) that examined this topic in Mining Engineering was Rexford (1950), who, at the time, was chief of the Petrography Section, South Pacific Division Laboratory, Corps of Engineers, Los Angeles, CA. The paper was presented at the AIME meeting in Los Angeles in October 1948. Professor Leming&apos;s discussion generally reflects the current state-of-the-art; but it provides no references for more detailed information. I wrote a paper titled "How to avoid excessive expansion of concrete due to alkali-aggregate reaction," which was included in the Proceedings of the Second International Conference on Alkali-Aggregate Reactions in Hydroelectric Plants and Dams (Mather, 1995). In it, I emphasized that it was the hydroxide ion (not the alkali ion) that caused the pore fluid in the concrete to dissolve reactive silica, producing alkali-silica gel capable of taking up water, thereby, causing swelling and rupturing of the concrete. Excessive expansion will not occur unless there is a sufficient amount of potentially expansive alkali-silica reaction product and water. However, this will not occur unless there is a sufficient quantity of reactive aggregate and unless there is a mechanism by which the pH of the pore fluid can get well above the normal value of about 12.6. In many cases it is sufficient that the cementitious medium not only contains portland cement but also contains ground granulated blast-furnace slag (GGBFS) or a pozzolan such as fly ash, silica fume, metakaolin, volcanic glass or calcined shale - any of which may have been included for economic reasons. If, however, the person selecting the ingredients for concrete knows that the aggregate is reactive (with no alternate nonreactive aggregate available) and if the person knows that the only available portland cement has a high alkali content (i.e., more than 0.6% Na2Oe; Na2Oe = % Na2O + 0.658 x % K20), then it becomes irresponsible not to establish what reasonable precaution one should take. Professor Leming suggests using one of the following: 30% Class F fly ash, 50% GGBFS or 7% to 10% silica fume. My view is that one should prepare test specimens with the cement and aggregate to be used and then expose these both with and without at least two dosages of each of the various alternative materials (slag, pozzolan and lithium salts), so that the required dosage to control the expansion is established. Then, economic considerations can dictate the final selection. I would point out to the author that GGBFS is not a pozzolan and is not an admixture, but, rather, it is a latent hydraulic cement. An admixture is, by definition, a material other than hydraulic cement. I commend him for suggesting that aggregate producers should become more active in knowing about the reactivity of their products and the precautions needed to permit those products to be safely used in concrete. ? References Mather, B., 1995. "How to avoid excessive expansion of concrete due to alkali-aggregate reaction," Proceedings, Second International Conference on Alkali-Aggregate Reactions in Hydroelectric Plants and Dams, US Committee on Large Dams, Denver, CO, pp. 421-439. Rexford, E.P, 1950, "Some factors in the selection and testing of concrete aggregates for large structures," Mining Engineering, Trans. AIME, Vol. 187, pp. 395-402. Reply by M.L. Lerning Mr. Mather has once again provided a cogent and useful discussion. I am grateful to him for bringing these issues to my attention, as well as to the readers, and I am grateful for his discussion of several important factors in alkali-silica reactivity. Mr. Mather&apos;s discussion of the mechanism of alkali-silica reactivity (ASR) notes the critical role of the hydroxide ion. While the alkali hydroxides are highly soluble (reducing the solubility of the other primary hydroxide in pore solution, i.e., calcium hydroxide, and providing hydroxide ions that initiate alkali-silica reactivity), it is, as Mr. Mather quite correctly notes, the hydroxide ion that attacks the silica structure. This point was not clearly stated in my original article. As noted in the text, the requirements for mineral admixtures to mitigate or control ASR vary widely depending on the specific characteristics of the materials

Jan 1, 1998

By Wallace N. Thomas

The present interest in large diameter grinding mills and the rapidly rising cost of the drive in proportion to the cost of the mill establishes a need to explore the drive system in detail. The drive for a seven to eight thousand horsepower mill will cost from 1350 thousand to $600 thousand which represents nearly half the total cost of the mill package, and requires as much building space as the mill proper. Some of the drive components require a longer time to manufacture and the installation time and costs are equal to those for the mill. It is apparent that the drive has become a dominant factor in the overall mill design consideration. A new plant requires a tremendous investment in both time and money. With the high degree of competition in the mining industry, low capital cost is an exceedingly important factor in the development of a project. It is just as important, however, to insure that the equipment is going to perform satisfactorily for the anticipated life of the project without adding unplanned operating, maintenance and replacement costs. This is the position in which the engineer or designer usually finds himself and is really one of his primary functions -- establishing a realistic compromise between cost and performance.

Jan 1, 1969

Joy Mining Machinery has developed a new generation of ultra-heavy shields for Anglo Coal Australia?s Moranbah North Mine in the Bowen Basin region of Queensland. These are the largest two-leg longwall shields yet produced by Joy. The longwall at Moranbah North posed a number of challenges, among them a thick, inclined, sometimes undulating seam with increasing depths. The result of this was the need for larger, heavier, more powerful roof supports. Knowing that future longwalls would be going deeper, mine management determined that shield yield ratings of at least 1,750 t (1,930 st) was what would be required.

Jan 1, 2011

By JIAQI JIN, Chen-Luh Lin, Amanda N. Erskine, Jan D. Miller, Shijie Wang

The liberation and exposure of valuable mineral grains in ore particles are of significant importance in understanding the efficiency of flotation separations. A flotation feed sample from the Kensington concentrator was scanned by micro Xray computed tomography (micro-XCT), to determine the liberation and exposure of auriferous pyrite grains. The analysis results suggest a satisfying extent of liberation for particle sizes smaller than 212 μm. Theoretical flotation recovery of pyrite for selected particle size fractions was predicted from the three-dimensional liberation and exposure analysis. The plant flotation tail was also characterized by micro-XCT to identify liberated and partially liberated pyrite particles that might not be collected into the concentrate. However, liberation analysis of the tail sample revealed that the majority of liberated pyrite was recovered in the plant flotation circuit. Trainable Weka, a machine learning segmentation approach, was compared with the Watershed thresholding segmentation for the 106 × 45 μm particle size fraction scanned at a voxel size of 1.85 μm. Improved segmentation of small particles was found using the machine learning method.

Mar 1, 2024