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By Robert F. Randolph

New technologies confront mining organizations with unprecedented human factors challenges. Likely problem areas range from the design of the human- machine interface to the design of work groups and mine organizational structures. However, these human design considerations are commonly ignored in most industries, resulting in a failure rate of 75% for advanced technology programs. The U.S. Bureau of Mines is addressing these concerns through a program of research on the human side of high technology mining systems. Interviews with mining industry participants and researchers have identified concern in several areas, including training and equipment design. Although new mining technologies promise to improve overall safety by relocating miners away from hazardous areas, data from MHSA accident reports and other sources suggest that certain types of new hazards may be created. Many of these new hazards can be reduced though a systems approach to ergonomic design of equipment, tasks, and work processes. This evidence, combined with reviews of high technology human-machine systems in other industries. can help in the design of safe and efficient future mining technologies.

Jan 1, 1992

By Paul D. Tomlingson

A new sense of urgency permeates the mining industry concerning maintenance. Mining's continuous process environment demands around-the-clock maintenance support. And profitability conscious mining operations require that production targets be met on time - and economically. These goals require nothing less than an effective maintenance program. In turn, the effectiveness of the maintenance program depends on quality information: easily procured, complete, timely, accurate, and properly used. Information picture is changing Some of the fully integrated, mainframe maintenance information pro¬grams of better days remain. Their upkeep and cost of operation, though, is becoming more difficult to justify. Some operations, faced with production cutbacks a few years ago, downscaled and found they liked it. Now, during an upswing, these operations question the need for the more elaborate, administrative-heavy programs they used to operate. Package programs are not taking their place. Too often, the packages are vague and generic. Some vendors claim that if their offerings work in a hospital complex, they must work in an underground mine. That is not so. Maintenance information in the mining industry is different. The situation has changed There are now smaller, self-contained maintenance groups whose information needs are different. These include an electrical crew in a smelter, an underground mobile equipment shop, or a remote service shop between several distant operating pits. These working environments have changed the character of the information needed as well as the methods for obtaining and using it. Operations-maintenance link In coming back from a downturn, operations people realize that their ability to meet production targets hinges on reliable equipment and avoidance of downtime. They have become familiar with the need to use maintenance services effectively. They also want quality maintenance information. When coupled with the sense of urgency about maintenance, a business-like working environment emerges that has significant new differences in both work control and information. Work control impact Work control has been streamlined to improve communications. Supporting information has been streamlined as well. • Verbal orders are the rule rather than the exception to quickly bring a multi-craft crew to the flotation section or a pit crew to a disabled haulage truck. • Written work requests and work order forms are seldom used, or even needed. Rather, electronic work control logs permit operations to request work, maintenance to acknowledge it, get ready, and do it - quickly, without delay. • Routine servicing is triggered by operating hour accumulation (mobile equipment) or tons of throughput (fixed equipment). Operations is now taking the initiative in delivering mobile equip¬ment to the "bad order line," or switching to a bypass conveyor. Operations wants immediate follow-up reports on equipment condition.

Jan 1, 1989

By Peter J. Conroy

Introduction Most subsidence monitoring to date has been surface monitoring to develop empirical relationships of the magnitude and extent of subsidence effects. Federal regulations are forcing a better understanding of subsidence. Empirical methods of subsidence prediction may not be adequate, since the empirical relationships may not be valid between or even within coal fields. A better understanding of the mechanics of subsidence is required in order to develop and verify analytical models. This paper presents some of the results of surface and underground monitoring in longwall faces of a coal mine. The seam thickness in these mines ranges from 5 feet to 6 feet at depths of 600 to 1100 feet.

Jan 1, 1982

By R. Todd Swinderman

Variations in designs between belt cleaner systems are so wide that it is impractical to establish a dimensional stan- dard. The number of variables that affect the efficiency of belt cleaners is too great to assume a required number or style of cleaners for broad classifications of bulk solids or typical applications. The amount of carryback remaining on the belt is more dependent upon the characteristics of the bulk solid and the physical parameters of the conveyor system than it is on tonnage of material conveyed. Therefore, a performance-based standard is proposed. Three levels of cleaning performance are proposed: • Level I cleaning is general specified when concerns about carryback are not critical. Cleaning systems normally associated with achieving a Level I performance are single or double cleaner systems with one-piece blades undergoing poor to average maintenance. Frequent cleaning of the carryback that falls from the return run will likely be required. • Level II cleaning is generally specified when carry- back is of concern but does not create a safety or environmental problem. Cleaning systems normally associated with Level I1 performance are multiple cleaner systems with segmented blades undergoing the manufacturer's specified maintenance. Regular but infrequent cleaning of the carryback that falls from the return run will likely be required. • Level III cleaning is generally specified when con- cerns about carryback are critical. Concerns range from safety to environmental to product contamination. Cleaning systems normally associated with achieving a Level 111 performance are multiple cleaner systems in conjunction with at least one low- volume water spray. Scheduled inspection and the manufacturer's specified maintenance would have to be performed to maintain a high level of cleaning performance. Difficult-to-clean bulk materials may require the use of a washbox system with multiple cleaners using a combination of low-volume eater sprays to lubricate the cleaners and high-volume sprays to keep the washbox and discharge piping freely flowing. Further addition of a water and sludge recycling system reduces the amount of water that ends up in the product to a negligible amount. Very infrequent cleaning of the carryback that falls from the return run will be required. PURPOSE The purpose of this proposal is to propose a standard method for specifying belt cleaner systems based on user expectations and equipment performance over time. DEFINITION In bulk solids handling by conveyor belt, carryback is the material that adheres to the belt after the belt discharges its cargo. PROPOSED STANDARD Required Basic Good Practices There are a number of basic design and operating principles that are good practice for the selection, installation, and maintenance of belt cleaning systems on conveyors in order to achieve "standard belt cleaning performance over time. 1. The Belt Cleaning System shall be designed to meet the performance requirements based on the worst operating conditions and worst bulk solids proper- ties that are expected. 2. Each conveyor discharge point shall be designed to readily accept the manufacturer's recommended minimum number of belt cleaners. In addition, the discharge chute shall be designed to accept, with minor modifications, at least one additional cleaner if it is required.

Jan 1, 2004

By C. A. Rowland

Introduction Comminution efficiency, as measured by relating circuit performance to the consumption of energy and the time and money required, can be determined by the following comparisons: Theoretical efficiency: The theoretical efficiency is the actual energy consumed in a comminution machine compared to the theoretical energy required to perform the size reduction. Operating efficiency: The operating efficiency compares the operating work index of a comminution machine to the Bond work index of the ore, as determined from bench-scale crushing and grindability tests or pilot-plant tests. Economic efficiency: The economic efficiency is comparing income from production to predicted income. Key words: Comminution, Bond work index, Grinding, Crushing, Ball mills, Rod Mills. Theoretical efficiency In their book Process Engineering of Size Reduction - Ball Milling, Austin, Klimpel and Luckie (1984) stated that, "We have tried throughout this book to avoid the use of the term grinding efficiency because the degree of conversion of energy to useful size reduction is an ill-defined concept. In addition, the only efficiency, which is of real interest, is the meeting of product specifications at the minimum cost." The National Materials Advisory Board, National Re¬search Council (1981), in the abstract of a report titled "Comminution and Energy Consumption" stated that, "Up to 99% of the energy consumed in grinding these ores may be expended in the movement of machinery, with noise and heat the undesirable byproducts, thus leaving only 1% of the energy available for size reduction. Coupled with this is evidence that many of today's crushing and grinding techniques not only are antiquated but have little or no scientific base of understanding." Throughout the past 50-plus years, grinding efficiency has been referred to as being from 1 % to 10%. The measurable basis for these observations is difficult to establish, but they appear to be based on production performance compared to theoretical energy requirements for the work done. The theoretical energy requirements were determined from the energy required to break a single particle or a thin layer of monosized particles by compression or by a single impact from an impact-testing device. King, Tavaras and Middlemiss (1997), in a paper titled "Establishing the energy efficiency of a ball mill" described such a test. These batch single-breakage tests generally do not duplicate the continuous-breakage process in the comminution machinery used in ore concentrators. Operating efficiency The currently available crushers and grinding mills are fed at a controlled continuous flow rate, and they impart the breakage pattern needed to produce the desired size reduc¬tion. While theoretically inefficient, they are the most practical comminution machines available. The operation of this machinery is relatively simple and can be controlled with available control systems. The essential factors in determining the operating efficiency of comminution machines are energy, as consumed in the machinery, and the required energy, as determined from test work. Bond work indices, obtained from bench-scale or pilot-plant crushability and grindability tests are used in the following Bond equation (Bond, 1960) to determine the energy required to produce the required size reduction

Jan 1, 1999

By J. A. L. Campbell

Peabody's Camoy mining system is a truly continuous conceptual method of underground mining of coal. The system solves the three factors which limit coal from being mined continuously. Camoy's principal features are improved productivity and increased recovery. A conservative retreat production rate of 2 1/2 times normal continuous miner room-and-pillar mining rates are projected for a 6-7' seam. Overall mine productivity will be 2 times normal, with a potential for considerably higher rates. Major incremental production increases can be achieved by partial implementation of the system. Total mine recoveries of 75% are expected. The system includes both advance and retreat mining. The retreat half of the approach encompasses many of the features of short wall mining. A central panel is prepared for retreat mining by driving entries using room-and-pillar mining to the left and right of it. The room-and-pillar mining encompasses the advance features of Camoy. In the retreat phase, the roof of the face is supported by self advancing chocks or shields. All mining is done under the chocks by a continuous miner. As the miner advances the chocks continuously move forward behind it. Thus, as in a typical short wall system, continuous roof support is attained. Ventilation is unidirectional, another characteristic of short-wall type systems. Fresh air is brought in and passed over the working personnel. It moves to the face where the continuous miner is operating, picks up the generated dust and released methane, and is exhausted away from all personnel. Exposure to respirable dust and ignition hazards due to methane build-ups are almost totally eliminated. Thus, the second limiting factor is overcome and continuous ventilation is attained. Coal mined with the continuous miner is passed to a surge car and then to a Serpentix conveyor. The Serpentix, a Peabody invention, is a flexible conveyor capable of going around corners.

Jan 1, 1976

By JA Vallejos

High stress underground mining poses a significant challenge to rock mechanics and rock engineering. To overcome theses challenges significative improvements in solutions and best practices of the design and operation of mines under high stress have been developed and implemented. This paper presents certain topics related to the management of high stress for sustainable underground mining. The topics include; the effect of preconditioning techniques (destress blasting and hydraulic fracturing) in the seismic rock mass response to underground mining and the dynamic behaviour of rock support systems. The opportunities associated with research in rock mechanics and practical rock engineering are discussed.

Apr 26, 2022

By John H. Smith

Because of increased pressure from Federal & State Regulatory Agencies, most acid flows will require some sort of treatment prior to being discharged to receiving streams. In many industries, the volumes of liquors are large and their acid content varied. Pressure to minimize costs of waste treatment equipment and land usage makes development of a treatment process incorporating these desires mandatory. "Standard" methods of acid neutralization with lime have been known for years, however, the volume and characteristics of the resultant precipitated solids can create a disposal problem. Also, when standard lime treatment is used, the settling characteristic of the precipitated solids is normally slow. In some instances, the necessity of added dissolved solids removal, (such as iron, needing aeration) add to the problem of concentrating neutralized solids. In a paper published in the September 1970 issue of "Coal Age," *the results of extensive test work by personnel of the Homer Research Laboratories of Bethlehem Steel Corporation, Bethlehem Pa., were reported. This paper dealt specifically with development of a flow sheet to treat acid mine drainage (hereafter referred to as AMD) from coal mine operations. Regulations on discharged water required basic pH and low dissolved iron content after treatment. Liquid flows of over 9 MGD from

Jan 1, 1972

By C. L. McKenzie, R. A. Heig

The design and operation of metallurgical laboratories is discussed. Laboratory size, general laboratory equipment and metallurgical staffing are discussed from a standpoint of desired laboratory results.

Jan 1, 1986

By Dominic F. Howarth

Cuttability and borability assessment methods in rock and coal are reviewed. TBM, roadheader and coal cutting machine boring rates can be predicted from a knowledge of machine, intact rock property and rock mass parameters. Results that were obtained from a detailed analysis of two TBM borability prediction methods and comparison with data from twenty case histories, show that a simple, low-cost method that uses one machine parameter and one rock parameter compares very favourably with a sophisticated, high-cost method that also includes details of rock mass characteristics (discontinuity, type frequency and orientation).

Jan 1, 1987

By Roe-Hoan Yoon, lsmail Yildirim, Jinhong Zhang

Inorganic fillers and pigments such as kaolin, diatomaceous earth silica, and talc were treated with various surfactants, and the changes in their surface properties monitored. When they were treated with a cationic surfactant, they became hydrophobic and the overall surface free energies were decreased substantially. The decrease in surface free energy was mostly due to the decrease in the acid-base component (ysab) of the surface free energy, indicating that hydrophobizing an inorganic pigment entails a reduction in ysab. It was found that the surface characterization technique employed in the present work was useful for studying the effects of using various other surfactants for surface treatment.

Jan 1, 2003

By M. K. Pathak, A. K. Mukhopadhyay, D. C. Panigrahi

Changes in machinery operating and design parameters often result in unexpected vibrations or changes in the vibration patterns. Vibration in a system is an undesirable element that can cause machinery distress. Potential damage can be prevented by identifying the vibration level that is due to the changed operational parameters. This is necessary for the safe and reliable operation of plant equipment. This paper presents a documented study on vibration events that resulted from alterations in operating and design parameters in a mine ventilation fan and analyzes the causes by defining the sequence of events that led to its performance deficiency. This paper is based on experimental effort to study the vibration behavior of a ventilation fan under varying operating conditions.

Jan 1, 1999

By M. S. Celik, G. Onal, S. Atak

The beneficiation of boron minerals flotation with well defined systems has been only slightly, investigated in the literature. The difficulty arises from fact that boron minerals cover a spectrum of solubilities. Colemanite (a calcium-containing, relatively insoluble, boron mineral) and borax (a highly soluble boron mine, have been used to exemplify the flotation of boron minerals. Using sodium dodecylsulfonate (SDS) and dodecylamine hydrochloride (DAH), the floatability responses of these boron minerals are considerably different. This has been ascribed to variations in the solubilities of boron minerals and the presence of cations in the lattice structure. In study, flotation tests and zeta potential measurements used to determine the flotation mechanisms of boron minerals.

Jan 1, 1994

By K. Kim, T. M. Yegulalp

A numerical model is being developed to assess the enhancement of ore permeability by improving fracture connectivity with micro-hydrofracturing. As part of this project, a generic two-dimensional percolation model was developed to test the impact of various field conditions on permeability. Field data from Cyprus Minerals' Mineral Park mine was used to establish the statistical properties of the observed fracture systems. Results of statistical analyses of field data and examples of the use of the percolation model are presented

Jan 1, 1997

By J. A. Dille, J. P. Hand, J. D. Brown

The purpose of this paper is to inform members of the coal producing and consuming community about techniques used by The Carter Mining Co. to control product quality at a large surface coal mining operation. During the early years of mining operations, coal quality received adequate attention but the company's main emphasis was to build up its production rate and minimize mining costs. While these goals are still of prime importance, coal quality has received additional attention in recent years. An objective that no coal shipment should exceed any contract or company-imposed coal quality specification has been successfully met. To implement this guideline, geology and coal quality modeling procedures were improved, in-pit drilling and blending programs were refined, and detailed shipment procedures were developed.

Jan 1, 1987

By Donald W. Gentry

It appears that the competition for increasingly scarce international mining investment capital will continue among developing countries. Indeed, there is growing evidence this competition may be on the verge of becoming destructive and cutthroat in nature. While this may be viewed as good news by short-term, speculative investors, it could have dangerous repercussions for international minerals producers over the long-term. It seems there has been a continuous parade of traveling foreign delegations touting the virtues of mineral investment in one country or another. These pitches all contain the politically correct key words, such as macro-economic reform, political reform, privatization, liberalization of laws governing mining and related investment incentives, reconciliation of ownership and right-to mine issues, and tax reform specially tailored for the minerals sector. Unfortunately, some of the information being trumpeted is based on plans, concepts or hopes for change rather than actual reforms approved by all necessary governmental entities. In yet other situations, the information provided consists of half-truths at best. Too often, potential minerals investors, faced with metals and minerals prices hovering near their recession lows and the need to offset old, high-cost operations, desperately want to believe all they hear about investment alternatives cast in a near-utopian setting. However, the virtues being proffered for mining investment abroad do not eliminate the need for careful scrutiny of subtle variations of traditional risks associated with foreign investment that can drastically affect the economic viability of mining projects.

Jan 1, 1993

By J. A. Frew, R. M. Glen

Recovery of galena and sphalerite from fine grained lead-zinc ores by flotation normally requires re-grinding to achieve economic recoveries at acceptable concentrate grades. Re-grinding aims to reduce the coarse valuable mineral particles to a size where they float more readily and to liberate the composite valuable particles so that the gangue in these composites does not dilute the concentrate. Besides changing particle size and liberation, re-grinding changes the surfaces of the minerals and thus may alter the rate that mineral particles of a given size and liberation float. A method was developed to apportion the total change in recovery after re-grinding between changes in size and liberation and changes in flotation rates. The flotation behaviour of minerals, before and after re-grinding, was measured by floating samples of plant streams under controlled conditions in a laboratory cell. Results from several industrial lead-zinc circuits indicated that the change in behaviour observed fell into three different categories. It is concluded that the method will indicate whether the focus for optimization of existing plant should be on comminution or flotation, and it will help determine the path for laboratory testing in designing new regrind circuits.

Jan 1, 1995

By R. K. Young

Producing a sound plant design for a major project requires hundreds of engineers and many drawings. Economical accomplishment of this task is based upon careful and orderly organization of the design team so that at all times there is a complete and workable staff but at no time a surplus of costly talent. This paper will describe the various stages in the development of plant design which normally follow the laboratory and pilot plant investigations discussed in other papers today. An outline of the procedures used in the assembling of a project design group, within an established engineering organization will be presented. Actual procedures may vary according to the size and character of the plant, the special requirements of the owner, and the make-up of the engineering organization performing the design, but most of the points covered will be found to be basic to any plant design project.

Jan 1, 1960

By Steve Kral

The list of environmental issues facing industry in general, and the mining industry in particular, has placed greater emphasis on the concept of risk assessment and risk management. In informal terms, risk can be defined as the chance of injury, loss or damage. More formally, it is defined as the probability of an occurrence and its consequences. In simple terms, risk assessment involves three questions: What can go wrong? How probable is it to go wrong? If it goes wrong, what are the consequences? Experts on the subject of risk assess¬ment and management met in St. Louis, MO in October 1992 to discuss the extensive and innovative technology that has been developed in this arena. Each agreed that a consistent framework can be used to approach risk assessment/ management considerations in siting and design alternatives, as well as when considering financial aspects of mine development. And the environmental planning process for mines, as well as planning for operation through closures, will rely more heavily on risk assessment and management techniques. Risk assessment is a tool to assist engineers, scientists and managers make better, defensible operational decisions. A realistic and probabilistic risk analysis, coupled with a sound financial model, can combine a large set of alternatives and criteria to arrive at a defensible decision. Organizers of this regional SME conference believe that mining professionals should become fully conversant with risk assessment techniques and approaches because this arena provides opportunities to develop more rational decision-making techniques. Current health risk assessments rely heavily on Environmental Protection Agency (EPA) approaches. Several speakers and papers show how this approach has been applied to a variety of topics. Two major advantages come forward when applying risk assessment techniques to environmental clean-up options for contaminated sites. They are the selection of practical options and cost-effective alternatives. A probabilistic risk assessment provides results that can be directly related to clean-up costs. It has been shown that small reductions in risk are obtained for large increases in cost after a certain threshold value is reached. A preferred, practical clean-up alternative that provides permanent solutions can be selected based on a probabilistic assessment. Here are summaries of some of the papers presented at the meeting.

Jan 1, 1993

By C. J. Lewis

Commercial lime plants in the United States and Canada are depicted in Figure 1. The sources of lime available to Nevada and bordering states are rather few. Chemstar Lime has plants at Apex, Nevada and Nelsen, Arizona. Continental Lime, Inc. has plants at Tacoma, Washington, Townsend, Montana and Delta, Utah. However, Continental Lime has a new rotary kiln installation underway near Wendover, Nevada. This plant is scheduled to come on stream in the fall of 1989.

Jan 1, 1989