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By J. E. Gebhardt, J. A. Herbst, K. Y. Lee

Benefits of proper control of reagent usage in flotation circuits are typically improved metallurgy and savings in reagent costs. Improved metallurgy can mean more consistent product quality, i.e., final concentrate grade, better recovery of product values from the feed, or higher plant throughput at existing target recovery, and grade values. Flotation performance is sensitive to a variety of process disturbances which occur in operating plants, such as changes in flow rate, percent solids, size distribution. flotability of mineral species, etc. A way to handle these variations is to fully understand the dynamic flotation responses to disturbances and to implement a suitable control strategy to compensate for these disturbances. Depending on the objectives of the control system, various types of control strategies are available which employ different levels of refinement to achieve the desired performance. Typically, variables such as collector and frother dosages and reagent addition points can be manipulated to affect the performance of the circuit. In the case of sulflde mineral flotation, manipulation of the process electrochemical potential, in flotation and in grinding, offers another degree of process control. Because of the complex and interactive nature of flotation process variables, optimized reagent control requires consideration of all, or at least the most important, interactive variables of the flotation circuit. Model- based optimizing control provides a framework to handle the complex and dynamic nature of flotation reagent process control.

Jan 1, 1994

A new separator, known as the HydroFloat cell, was developed to overcome the limitations of traditional flotation cells in recovering coarse particles. The HydroFloat cell separates particles based on differences in mass after the selective attachment of air bubbles to the hydrophobic component of the feed stream. Proof-of-concept testing, utilizing phosphate matrix, heavy mineral sands and anthracite slag, indicated that significant improvements in separation efficiency can be achieved using this air-assisted teeter-bed system. Based on the encouraging laboratory results, a pilot-scale HydroFloat cell was fabricated and installed at a central Florida phosphate plant. Test data collected using the pilot-scale unit suggest that the BPL recovery of the +35-mesh plant feed can be increased by snore than 40% through the application of this new technology. This improvement is particularly beneficial due to the very high grade (-73% BPL) of the +16-mesh particles in the HydroFloat concentrate. This article describes the theoretical basis for the development of the HydroFloat cell and provides an overview of recent laboratory and pilot-scale test results.

Jan 1, 2002

By Pierre Mousset-Jones, Felipe Calizaya

This paper summarizes the current research trends in the ventilation design for the construction of very long tunnels, and presents the results of leakage flow measurements in three auxiliary ventilation systems. The study includes an estimation of an important design parameter, namely, the leakage path resistance, and a discussion of its effects on the overall efficiency of a ventilation system. A sample problem is used to illustrate the calculations.

Jan 1, 1997

By Alex Harrison, Steve Kasper

Various countries around the world have testing and manufacturing standards in place for steel cord belting. These standards are very comprehensive in what they allow the end user to specify, however, their practical significance in terms of belt life is more difficult to quantify. Such testing standards will be briefly reviewed in this paper in relation to the implication for end user expectancy. Since there is no US standard of manufacture, the end user is left with writing their own specifications. In addition, such standards do not address the effect on belt life of manufacturing faults, such as cord plane buckles, or lateral cord movement. Some new technology used to test steel cord belting will be described as an aid to both manufacturer and end user. Specific end user related issues addressed on this paper are: Tracking and belt quality Cord plane irregularities and performance Cord size and belt life Cord fatigue and testing

Jan 1, 1993

By Paul C. Miclea

With the growing urban population and the concern for traffic congestion and pollution (emissions control), public transportation is becoming more and more attractive to both city dwellers and managers. To gain access to the central area of the city, the sub- way remains the most viable alternative, despite its higher cost when compared to above ground or elevated transportation systems. There are relatively few regulations and criteria for subway ventilation, particularly when compared with mine ventilation. The main document that provides guidance and general recommendations for subway ventilation and environmental control is the Sub- way Environmental Design Handbook, published in 1976 (2nd edition) by the U.S. Department of Transportation, Office of Re- search and Development. Many of the subway systems in existence today have been designed and built with ventilation features adequate for normal train operation, but their design does not consider stringent criteria for such emergency conditions as a train fire in a tunnel. The National Fire Protection Association's Standard for Fixed Guideway Transit Systems known as NFPA 130 as well as the ASHRAE Handbook - HVAC Applications (1995) provide specific design and operation requirements for subway ventilation systems. Some of the existing, old subways are upgrading their ventilation systems to comply with the new regulations. The ability of a particular ventilation system design to provide adequate ventilation during normal and emergency conditions can be evaluated using computer modeling and simulation techniques. A train fire will cause a sudden change in the tunnel ventilation pattern by adding an unsteady and fast-growing source of heat. The hot air and gasses created by a fire will tend to flow uphill, possibly against the normal flow, producing a 'backlayering effect." To prevent this effect from happening, enough ventilation must be provided and the governing criterion to establish the required airflow is called 'Critical Velocity." Several software packages are available for special applications on tunnel and station ventilation as well as to model the spread of smoke and heat in case of a major tunnel fire, using Computational Fluid Dynamics. This paper presents the current issues in subway ventilation, as shared by the public transit community around the world, together with modern alternative design concepts vis-à-vis the more stringent emerging Fire-Life Safety criteria. Examples of recent studies and ventilation systems design are provided.

Jan 1, 1997

By F. Mauviel, J. Bernard, G. Herrouin, J. P. Lenoble, C. Charles, B. Taine

Manganese nodule projects were quite fashionable during the 1970s. At the beginning of the 1980s, low metal prices led to an almost complete reduction of such activities; however, the Law of the Sea incited the countries that signed it to build a strategy for this ocean resource. Gemonod was created in France in 1984 with a four-year mission. This paper presents the results of its program devoted to the technical and economic studies of nodule exploitation. A commercial mining system is presented. The nodules would be collected by a self-propelled miner and lifted hydraulically through a rigid pipestring. A complete optimized scenario has been built taking into account offshore mining, ore transfer at sea, transportation and processing to analyze the profitability of the project. Considering an average conservative basis for metal prices, after a deep analysis of the market, the return rate of investment of the project appears fairly interesting. These results are new and are explained in comparison with previous foreign studies. These results must not hide the innovative nature of the project nor the associated risks. This is why a mining pilot is required and has been specified by Gemonod.

Jan 1, 1991

By R. M. Balderrama

Bench-scale laboratory flotation and gravity separation tests were conducted on tailings samples to remove the sulfidic material, mainly pyrite, the source of acid generation. A combination of xanthate collectors, promoters, and frothers were used during flotation. Pyrite recoveries were in the range of 42 to 97%, depending on the tailings being treated. Sulfide sulfur contents of 12.8 to 0.37% in the feeds were reduced to 8.68 to 0.01% in the treated tails. Flotation tests were conducted to evaluate the ARD potential as a function of percent pyrite remaining in the tails. Standard ARD predictive tests were used to evaluate the success of the treatment. In some cases, removal of only 50 to 55% of the pyritic fraction was required, thereby demonstrating the conversion of the waste material from acidic to non-acidic. A laboratory vanning table was used to evaluate the amenability of sulfide-bearing tailings samples to gravity separation. The pyrite recoveries varied from 38 to 86%. The sulfide sulfur content of 12.8 to 0.37% in the feeds was reduced to 6.0 to 0.14% in the treated tails. Predictive ARD tests performed on tailings before and after the gravity removal of pyrite showed that most samples changed from "probably" acid producing to the "uncertain" range. Data reported and analyzed in this paper demonstrate source control for ARD prevention through the removal of metal sulfides from sulfide-bearing wastes using conventional flotation and gravity separation techniques.

Jan 1, 1995

By Hongjie Yu, Mike Mooney

Transitions between geological/geotechnical soil units have a critical impact on the operation and performance of a tunnel boring machine (TBM). Geostatistics-based probabilistic modeling is used to quantify the uncertainty in soil transition locations. This paper presents two unique soft-ground tunneling case studies where the results from the geostatistics-based probabilistic modeling are compared to the TBM data and as-encountered ground conditions derived from the actual TBM data. The assessment enhances the confidence in using geostatistics to improve ground awareness for efficient tunnel construction, minimizing different site condition (DSC) claims, and improving decision-making on tunnel projects.

Dec 1, 2022

By K. T. Cunningham

The Oakfield, New York Hine of the United States Gypsum Company is a shallow, room and pillar mine developed in the Camillus Formation of Silurian Age on the up-dip edge of the northern Appalachian Basin. The gypsum comes to subcrop beneath a variety of glacial materials and is subject to solution activity by groundwater. A geologic environment unfavorable to mining activity is thus created. Since 1978 seismic studies have been used to supplement core drilling to determine a conservative boundary between normal and questionable mining environments. A single channel seismograph, originally in use, is now replaced by a twelve-channel unit and is used to determine bulk material velocity which is the basis for defining the mining limit.

Jan 1, 1987

By Robert B. Hopler

Explosives research and development has historically been motivated by coal mining. Whether to solve safety problems or to improve productivity and cost, the result has been the same: better explosives products and initiation systems. Today, this process continues at an accelerated pace due to the tools presently available to the explosives and mining industries. Background Explosives have been used in coal mining since the industry's earliest days. Black powder, introduced into metal mining in 1627, undoubtedly was introduced into coal as soon as a need to replace pick work was apparent. Until the invention of the safety fuse by William Bickford in 1832, the only initiation methods available were the straw, quill and miner's squib. Disastrous explosions underground in England brought about studies on their possible causes (Atkinson, 1886). The studies showed that, while explosives contributed to the accidents, the real villain was coal dust, since that was the agent that transmitted the disaster throughout the mine workings. To improve underground safety, research was applied in an attempt to make explosives that could be safely fired in a methane air atmosphere. The Prussian government was apparently the first to establish a testing station for coal mine explosives. This occurred in 1885 (Guttmann, 1909).

Jan 1, 1993

By J. D. Miller, Jon J. Kellar

Researchers in flotation chemistry have long sought to describe collector adsorption phenomena in greater detail including kinetics, orientation and interactions between adsorbed species. Now a quantitative description can be made in-situ using FTIR internal reflection spectroscopy. Details of the adsorption process at the surface of mineral crystals, machined into internal reflection elements, can be described from first principles, provided the refractive indices, incident angle, and wavelength of light are known. Collector orientation can be established based on spectral characteristics of plane polarized and perpendicular polarized light. Examples of the use of in-situ FTIR internal reflection spectroscopy are given for the sapphire-sodium dodecyl sulfate system and for the fluorite-sodium oleate system. It is expected that quantitative in-situ analysis of collector adsorption reactions by FTIR internal reflection spectro-scopy will continue to grow in importance and will provide an important new dimension in our understanding of flotation chemistry.

Jan 1, 1989

By R. L. Miller

The potential for recovery of enriched uranium from spent nuclear fuel which has been consolidated into a nuclear waste form was explored in the studies reported here. The waste form of interest is iron-enriched basalt (IEB)--a silicate-based, fused-cast ceramic. IEB samples were prepared containing fuel assembly materials that simulate the core debris of Three Mile Island Unit II;1,2 the nominal composition of the consolidated waste form is given in Table 1. Ore Types The IEB samples, or man-made uranium ores (MMUO), are in two different mineralogical forms. Each MU0 was made by melting the constituent materials and holding at about 1500°C for 1 h. The MMUOs were then heat treated to control crystallization and crystal growth and then cooled to room temperature.

Jan 1, 1983

By Prasannarao Dontula, Kal V. S. Sastry

Advances are made in the field of mineral processing on a continuing basis both in the industry and the academia. These advances do not always get used fully because of the inherent difficulties in the transfer of knowledge and reduction to practice. In recent years, knowledge engineering is being increasingly employed in other fields to overcome some of these difficulties. This paper presents a vision of how knowledge engineering can be applied to the benefit of the mineral processing industry and includes a discussion of associated principles, techniques, and advantages.

Jan 1, 1993

By J. C. May, G. M. Elliott, J. J. Brady

Increased clearance was required in two railroad tunnels that were built about the time of the Civil War. Clearance infringements, whether they be excavation tights or caused by ice accumulation, reduce tunnel serviceability. Achieving increased clearance often means disturbing the ground and old ground support structures. Access and transportation needs dictate how and when the work can be carried out, and strongly influence the design approach and the methods used by the contractor to execute the work. This paper explores the pertinent considerations of the owner, the designer, the field inspection team, and the contractor in bringing this project to a successful conclusion.

Jan 1, 1997

By J. W. Carson

Introduction Many bulk solids such as coal, limestone, and fine moist ores often flow unpredictably out of bins, hoppers, and boreholes. Vast amounts of time and money are spent-with or without success-on flow promoting devices. In addition, many solids segregate in storage, feed erratically, flood, arch, rathole, and stick to bin walls reducing the live capacity. This article discusses bulk solids flow properties and provides guidelines for designing storage bins, hoppers, and feeders to provide reliable flow. Bulk Solids A bulk solid is a granular material consisting of discrete solid particles-submicron to several inches in size-that is handled in bulk form (for example, in a bin or silo). The gas filling the voids is generally insufficient to fluidize the material and the liquid (usually water) content is assumed to be less than saturation. Types of Flow Problems To design an efficient storage system, an engineer must be aware of problems that can arise during storage and flow of bulk solids: • No flow. A stable arch or pipe (rathole) develops within the solid, stopping flow. • Erratic flow. Momentary arches form within the solid, (ratholes), partly or completely empty out, and then collapse. • Flushing. Powders become fluidized, aerate, and flush uncontrollably through the bin outlet. • Lack of design capacity. A large part of the stored material remains stable around a rathole. Manual prodding, severe vibration, and even explosives may be used to restore flow. • Segregation. Smaller particles tend to sift through the voids between larger particles causing accumulations of fines and coarse in various areas of the bin. • Product degradation. Some materials spoil, cake, or oxidize if they remain in a bin too long. This is usually caused by a first-in-last-out flow sequence. • Level control. Measuring the volume of material left in a bin is difficult if a rathole develops. In one portion of the bin the level control device may indicate the bin is full; in another portion it may indicate it is empty. Eliminating Flow Problems All flow problems can be minimized or prevented by suitable design of the bin/feeder unit. This involves knowing the flow properties of the solid, then choosing the appropriate type of bin and feeder to establish the desired flow pattern. There are three types of flow patterns that may occur in a bin: funnel flow, mass flow, and expanded flow. Funnel flow occurs when some of the material in the bin is stationary while the rest is in motion. Funnel flow bins, shown in Fig. 1, are characterized by: • Low head room. A flat bottom or shallow hopper bin has large storage capacity with minimum height. Unfortunately, all this storage capacity may not be usable ("live"). • First-in-last-out flow sequence. The first material put into a funnel flow bin is the last material withdrawn because the flowing material is concentrated in the region directly above the outlet. • Ratholes. Because of the flow channel that forms, a stable rathole develops if the material has sufficient cohesive strength. • Erratic flow. Once a rathole becomes partially or completely empty, it may collapse creating a stable arch and erratic flow. • Flushing. Collapsing ratholes cause flushing and flooding of fine material. • Segregation. If a bulk solid has a tendency to segregate, this tendency will be accentuated as the material is discharged from a funnel flow bin. Funnel flow bins are suitable for coarse, free flowing, nondegrading solids, when segregation is not important. Mass flow occurs when all the material in a bin is in motion whenever any is withdrawn. Char-

Jan 3, 1983

By Alan P. Cook

Methane levels have been measured around continuous miners and compared with computer simulations of methane flow. A multi-channel data logger, reading continuously from six methanometers, has shown methane levels to vary at different positions around a continuous miner, with the cutting drum and the immediate face area not necessarily recording the highest concentrations. Methane levels in the driver's cabin are generally low compared with the return side. Computer simulations, using computational fluid dynamics, have been supported by the measured data, and have shown that methane behaviour within the first few metres of the face varies considerably for different bord and pillar development stages. Methane is diluted rapidly to acceptable levels, but the distance required for this is extended when ventilation flow to the face is restricted.

Jan 1, 1995

By M. Polat, S. Chander

Many models have been suggested in the past to obtain a satisfactory fit to flotation data. Of these, first-order kinetics models with a distribution of flotation rate constants are most common. A serious limitation of these models is that type of the distribution must be pre-supposed. Methods to overcome this limitation are discussed and a procedure is suggested for estimating the 'actual' distribution of flotation rate constants. It is demonstrated that the classical first-order model fits the data well when applied to coal flotation in narrow size-specific gravity intervals. When applied to material which is fractionated on the basis of size alone, the use of three parameter models, which were modified from their two parameter analogs such as rectangular, sinusoidal, and triangular, gave most reliable results.

Jan 1, 1995

By Hans G. Kok

At this time in the history of engineering and construction, cost indexes give weekly evidence of the sharply rising costs of labor and materials. Paralleling the rise in construction costs are the costs of plant maintenance. Automation of the modern industrial plant has permitted a substantial reduction in the total number of employees required for plant operation. Of this reduced total, however, up to one-half of the employees may be engaged in plant maintenance. Management's decision to risk investment capital for a pro- posed plant or improvement is increasingly dependent upon the engineer's ingenuity in designing plant systems and structures which will require a minimum of materials and labor for manufacture, installation, and operation and which will be maintenance-free to a maximum degree. This paper concerns itself with the structural elements of bulk material handling systems in which the foregoing factors influenced the design to a considerable extent.

Jan 1, 1969

By Zhang You-di

A comprehensive model has been set up for surface mine long range planning. It is a system simulation model based on the oriented graph theory. Via this model, a series of mining results such as mineral and waste volume, mineral quality, mining intensity, material haulage distances, dumping area parameters and mining coat for different mining alternatives, can be derived and optimized. This model has been applied to 37 mining alternatives in several surface coal mines and proved mathematically correct and results reliable.

Jan 1, 1986

By Alden B. Carpenter

Brines (a solution containing more than 100,000 mg/l dissolved solids) in sedimentary basins are genetically related to evaporites in one of three ways: (1) dissolution of evaporite minerals, generally halite; (2) interstitial fluids in evaporites which are expelled from their source rock during compaction; (3) incongruent alteration of hydrous evaporite minerals (carnallite). Most brines of commercial interest originate as interstitial fluids in halite-rich rocks. These fluids are initially rich in magnesium, sulfate, and potassium but evolve in composition to an Na-Ca-Cl brine during their migration to their present host rock. A particularly important reaction in this process is: 2CaCO3 + Mgt+ = CaMg(CO3)2 + Cat (1a) This reaction reduces the magnesium content of the brine and ultimately converts it to a calcium-rich brine. The loss of sulfate occurs by two mechanisms. One of these is by direct precipitation as calcium sulfate (either as gypsum or anhydrite): Ca 2+ + SO4 2- = CaSO4 (2a) Additional sulfate may be lost from the brine by sulfate reduction: S042 + 1.33CH2 + 214- = H2S + 1.33CO2 + 1.33H20 (3a) The loss of carbonate species occurs by precipitation as carbonates: H2O + C02 + Cat = CaCO3 + 2H+ (4a) The net result of reactions 3 and 4 is: Ca 2+ + SO4 2- + 1.33CH2 = H2S + CaCO3 + 0.33H2O + 0.33CO2 (5a) The loss of potassium from brines is caused by the formation of potassium aluminosilicates: 2K+ + Al2Si2O5 (OH)4 + 4SiO2 = 2H + 2KAlSi2O8 + H2O (6a) The hydrogen ions produced by this reaction dissolve carbonates: 2H+ + CaCO3 = Ca 2+ + CO2 + H2O (7a) The net result of reactions 6 and 7 is: 2K+ + CaCO3 + Al2Si205 OH)4 + 4SiO2 = Ca2 + 2KA1Si3O8 + H2O + C02 (8a) A study of brines from central Mississippi has shown that the composition of these brines is related to the interaction of pore fluids from evaporites with minerals in the enclosing sedimentary rocks.

Jan 1, 1978