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By Danqing Xu, A. W. Khair

This paper presents an analysis of mechanism of secondary fragmentation and respirable dust generation due to regrinding. In continuous miners, the recovered coal and uncleaned coal from the previous cutting cycle have to be transported through the circumference of the cutting drum, subjecting the coal to regrinding. Such regrinding comminutes the coal material utilizing kinetic energy, thus creating a great amount of respirable dust. The mechanism of a single particle subjected to regrinding is analyzed. A mathematical model is developed to describe regrinding in field conditions. The important factors influencing the comminution process are discussed in detail. Utilizing three types of coal seams, laboratory experiments are being carried out with an Automated Rotary Coal Cutting Simulator (ARCCS) to quantitatively evaluate the effects of some particular parameters, such as cutting velocity, depth of sump and properties of coal material, on breakage and on the amount of respirable dust generated. An orthogonal fractional factorial experimental arrangement is used to optimize experimental design. Preliminary experimental results are presented.

Jan 1, 1991

By I. G. Ediz, D. W. Dixon, W. M. Fidler

In this paper a new method for the arresting of tunnel explosions is presented. In the proposed technique, the on coming explosion is detected by a pressure sensitive device by a pre-determined rise in static pressure. The sensor then triggers a mechanism which causes the explosion door to be closed in a specially constructed concrete barrier zone. The doors are of a special construction and consist of perforated steel plates that allow part of the blast wave to be transmitted but do not allow the passage of the flame. A number of design parameters have been identified, including: the likely amplitudes of the transmitted/reflected pressure waves that would govern the explosion door pressure loading; thickness of the perforated steel packages; perforation dimensions; heat transfer across the door and other factors.

Jan 1, 1995

By P. D. Rao, D. E. Walsh, W. W. McClintock

A column flotation system was designed to conduct release analyses on a very finely disseminated, stratiform copper ore from the Denali Copper Prospect in Alaska. Chalcopyrite is finely disseminated in a carbonate matrix, and pyrite is disseminated in both the chalcopyrite and the gangue. Grinding to -20 µm is required for adequate liberation. A 25-mm x 2.4-m glass flotation column was designed. The ore and its flotation tailings were repeatedly floated to obtain a rougher concentrate. The rougher concentrate was then repeatedly floated to produce release fractions. These fractions were analyzed for copper, iron, calcium and magnesium, and release curves were plotted. The procedure was replicated at each of two grinds, i.e., 99% and 88% passing 37 µm (400 mesh). The procedure should find application for flotation characterization and process selection. Bond grindability testing was also conducted.

Jan 1, 1996

By O. A. Bascur

In recent years, metal-producing companies have increased their investment in automation and technological innovation, embracing new opportunities to enable transformational change. Transformation to a digital plant can fundamentally revolutionize how industrial complexes operate. The abundant and growing quantity of real-time data and events collected in the grinding and flotation circuits in a mineral processing plant can be used to solve operational issues and optimize plant performance. A grade recovery model is used to identify the best operating conditions in real time. A strategy for increasing the value of instrumentation in current plants is reviewed. An optimal Gaudin size distribution model provides augmented information from traditional sensors to find the optimal grind cut size to reduce metal losses in the flotation circuits. Sensors in flotation circuits enable an estimate of the recovery and determination of the optimal froth depth and aeration using an air hold up flotation model. A strategy of classifying data for online generation of insights to using operational intelligence tools is described. The implementation of a recovery/grind strategy with industrial examples in nonferrous mineral processing is presented.

By Ronald D. Mariani, Gregory E. Mahoski

BACKGROUND The steel and iron ore industry has had a long history of an adversarial relationship with its union and workforce. The Empire Mine during its first 40 years of existence was no exception. The "we-they" mentality went hand-in-hand with the normal by-product of an adversarial relationship, grievances and arbitration. This relationship was considered the norm and it was not until the late 1970s that consideration was given to changing this relationship. At this time the industry was involved in a fight for existence and the economic pressure demanded increasing productivity to lower cost. The challenge to survive highlighted the fact that an adversarial relationship was not conducive to attaining the needed gains in productivity. The first formal attempt to change the way we worked came in the 1980 Labor Agreement which provided for the opportunity to utilize Labor Management Participation Teams (LMPTs). LMPTs were established at the Empire Mine and they functioned for a couple of years. The teams spent most of their time working on creature-comfort issues and steered clear of dealing with productivity issues. Mine shutdowns had occurred in Michigan resulting in large layoffs, and the union was trying to add jobs and was not supporting teams that could increase productivity and eliminate jobs. When the 1986 labor negotiations began, the local union pulled their support of the LMPT process. Other initiatives were negotiated over the years to foster a change in the culture but, as with the LMPT program, they did not produce the desired culture change. It became abundantly clear: you cannot negotiate a culture change.

Jan 1, 2004

By M. W. Rutland, E. Manev, R. J. Pugh

Data collected from several different fundamental surface chemical techniques were compared to study the interfacial interactions in the dodecylaminelmica flotation system. In the present study, the method used was the microinterferometric free foam film technique of Scheludko (1967) in which the stability, thickness and interfacial potentials at the air/dodecylamine solution interface were determined. These results were compared to previously published data, obtained from surface force measurements (Rutland et al. 1992), in which the interaction and hydrophobic adhesion (pull-off force) between molecularly smooth mica sheets in the amine solution had been reported. Also equilibrium contact angle measurements were used for comparison. The data was collected over a range of pH values and related to the batch flotation response of mica in dodecylamine solution. It was found that maximum flotation occurred at pH 8, but this did not correlate with the minimum in double layer interaction potential. However, it appeared to correspond with a tightly packed collector monolayer giving maximum hydrophobicity to the mica surface. Finally, from the extended DLVO theory, it was shown that heterocoagulation between the bubble and the mica could only occur, providing there was a very long range hydrophobic interaction force to counterbalance the repulsive van der Waals and electrostatic forces.

Jan 1, 1995

By J. K. Ahlness

The US Bureau of Mines investigated technologies for determining the integrity of in situ leach mining wells. A self-contained trailer-mounted well integrity testing system (WITS) was designed and built to enable rapid testing of well casings for leaks as required by environmental regulations. The WITS utilizes two inflatable packers to seal off the entire casing length or any portion thereof. Water pressure is built between the packers to the desired test pressure, and the presence or absence of casing leaks is determined by monitoring the pressure drop between the packers. A winch and steel cable are used to run the packers in and out of the well. The WITS underwent an industry field test at the Irigaray in situ uranium leaching mine near Buffalo, WY. A total of 37 wells with an average depth of 69 m (225 ft) were tested at an average rate of four wells per eight-hour shift with a two-person operating crew. This represents a 75% time savings and an 83% labor savings compared to the rigid-pipe method previously used at the mine, with which a three-person crew tested an average of one well per shift.

Jan 1, 1988

By Gary Buchan

During several months in 1996 and 1997, Cyprus Twentymile Coal Co. (TCC) set world production records at its Twentymile Mine in northwestern Colorado. These records were due to the company's implementation of a state-of-the-art longwall mining and conveyance system along with a -highly dedicated work force. This article is a case study of the design of long panels at the mine from conception to implementation. Obstacles that needed to be overcome included subsidence engineering, environmental regulations, conveyance, ventilation, equipment design and continuous miner (CM) development timing.

Jan 1, 1998

By H. Bernatowicz

The Nucoalyzer (On-Line Nuclear Analyzer) is a new method recently made comercially available for monitoring the elemental composition of a process stream. Applications for the Nucoalyzer include grading ore on a conveyor belt before or after it has gone through primary crushing, monitoring the slurry being transported in a pipe to the concentrator, and monitoring the stream of concentrate or the tailings from the concentrator. The Nucoalyzer may also be used at the smelter to monitor elements in the feed that include copper, sulfur, iron and silicon where a uniform feed is desired. The advantage of the Nucoalyzer over most other techniques are (a) it performs the measurement directly on the process with no sampling necessary, (b) the analysis can be performed on streams of particulate and slurries, and (c) the system does not have to make contact with the material it measures. These Nucoalyzers are operating at coal fired power plants and several more are about to be placed in service. This paper discusses the principles of operation of the Nucoalyzer, our experience in the field, application of minicomputers to data reduction, and potential applications in the ferrous and non-ferrous industries.

Jan 1, 1982

By Michael G. Nelson, Dot J. Helm, Edmond C. Jr. Packee

Under a Section 319 Water Quality grant from the U. S. Environmental Protection Agency, a working group of government agencies, mining industry representatives, and University of Alaska researchers undertook reclamation of an abandoned mine site on Birch Creek, near mile 101 of the Steese Highway. Stream hydrology, water quality, and the extent and nature of natural revegetation, were measured before the site was then recontoured to decrease the bedload deposition and bank erosion of the streams. Methods for stabilization of streams and rivers appear to have much in common with those for locations further south, but are subject to complications unique to the North, such as the formation of aufeiss, and to a lack of accurate climatological data. Natural revegetation appears to be possible for most northern placer mine sites. However, it may take place more slowly than required by public perception. Preliminary data indicate a surprising lack of nutrients in the floodplains of mined areas. Natural revegetation may be enhanced by selective planting of grasses and willows, which will contribute variously to soil quality, bank stabilization, and short-term appearance. Monitoring of hydrologic and water quality data, and of natural and artificially placed vegetation will continue at the .Birch Creek site through the summer of 1995,

Jan 1, 1995

By Gill G. Geesey, Michael R. Hankins, Paul L. Wichlacz, Anita Gianotto, John G. Jolley, Randy B. Wright

Thin films of copper [2.0 nm on germanium internal reflection elements (IREs) and 3.4 nm on germanium discs] were exposed to 10% gum arabic (aqueous solution) , 2% alginic acid (aqueous solution), 1% bacterial culture supernatant (BCS, simulated seawater solution) and 0.5% Pseudomonas atlantica exopolymer (simulated seawater solution). The IRES were monitored in situ, in real time using fourier transform infrared/cylindrical internal reflection/attenuated total reflection spectroscopy as a function of time at ambient conditions. The discs were characterized (pre- and post-exposure) by X-ray photoelectron and Auger electron spectroscopies. Ancillary graphite furnace atomic absorption spectroscopy was used to monitor the removal process of the copper thin film from the germanium substrates. Results indicate that Cu was oxidized by gum arabic, alginic acid and BCS. Furthermore, Cu was removed from the Cu/Ge interface by all four polymers. The Cu was found associated with the polymer solutions.

Jan 1, 1989

By K. L. Whitehead, R. A. Jankowski, N. I. Jayaraman

Most continuous miner sections utilizing flooded-bed scrubbers also use blowing face ventilation. Blowing ventilation, however, interferes with dust capture and minimizes scrubber effectiveness. To enhance the efficiency of the scrubber system and reduce dust concentrations, the Bureau of Mines tested various combinations of operating parameters. Experiments for system efficiency took place in a full- scale model mine at 3.05 m roof height. In general, higher values for scrubber and face airflows resulted in lower dust concentrations. In addition, optimum dust controls would include a face ventilation to scrubber airflow ratio of one. When the airflow ratio was either less than or greater than one, the dust levels in the return and at the operator locations increased. No single dust control technique was the most effective one at all locations due to mutual interaction among techniques.

Jan 1, 1992

By R. D. Miller, D. W. Steeples

Application of shallow, seismic reflection to problems associated with mineral exploration, mine planning, abandoned-mine detection and environmental evaluation has been successful in many geologic settings. The increased dynamic range of recording equipment and the decreased cost of processing hardware and software have made shallow, seismic reflection a cost-effective means of imaging geologic targets significant to mining operations. Seismic data possess sufficient resolution in many areas to detect faulting with displacement of less than 3 m (10 ft) in coal seams as thin as 2 m (6.5 ft) at depths of 200 m (655 ft). Subsurface voids associated with abandoned mines at depths of less than 20 m (65 ft) can he detected and mapped. Seismic reflection has been successful mapping disturbed subsurface associated with dissolution mining of salt. Complex geologic features associated with deposition of various hydrothermal minerals have been mapped with high-resolution seismic reflection at depths from 80 m (260 ft) to more than 300 m (985 ft). Faults in sulfur-hearing cap rock over salt domes have been accurately located, allowing improved efficiency of the dissolution mining process. Shallow, high-resolution seismic reflection has the potential to enhance the economics and safety of mine operations.

Jan 1, 1996

By D. K. Sengupta, T. K. Rout, A. R. Prasad, B. P. Singh

The filter cake from the vacuum drum filters of a uranium ore processing plant still contains some leach solution. If the filter cake is not efficiently washed the associated leach solution is lost. Therefore, it is necessary to produce a filter cake that is permeable enough to allow efficient washing. The dewatering characteristics of the solid-liquid system must be improved to obtain flocs with sufficient strength to withstand the suction pressure of the filtration system. To facilitate efficient filtration with minimum cake moisture, studies were undertaken to improve the dewatering characteristics of the cake using different types of flocculants and surfactants. In these studies, flocs were formed with anionic, cationic or nonionic flocculants. The best performance was obtained with a low cationic high molecular weight flocculant. The filtration parameters, namely, capillary suction time, cake resistance, cake permeability and final moisture content of the filter cake, are improved by using a combination of flocculant and nonionic surfactant.

Jan 1, 2002

By G. F. Friel, J. C. Edwards, C. C. Hwang

In the implementation of a mine fire alarm and location strategy, the Interpretation of the fire signature Is Important. Smoke and CO are the two dominant fire signatures, and many mine fire detection systems utilize sensors which respond to smoke or CO through a diffusion mode or a mechanical pump mode. The fire signature may be modified during its transport along airways and at crosscuts. The modification occurs through dilution of the contaminants. In this Investigation, computer codes were employed to compute the effects of contaminant dilution on the contaminant signature when a straight flow passage has one dead-end crosscut. The model predicted the airflow within always and the entrainment of contaminants into the crosscut from the airway. One application of the model is to determine the most suitable location for CO detectors for early mine fire detection.

Jan 1, 1995

By D. Veigel, J. D. McKay

Model enhanced Expert control has been implemented at the Newmont Lone Tree mill grinding plant as well as rule based Expert control for flotation and thickening circuits. The project has been successful in producing benefits but more importantly has contributed to an ongoing effort for continuous process improvement. This paper discusses how the control at Lone Tree has evolved and the part that Expert control has played in the overall improvements made. Specific examples of how the advanced control has integrated with instrumentation and stabilizing control are given and illustrations of how it has been effective in defining limitations and bottlenecks in the process or process control areas are provided.

Jan 1, 2002

By A. A. Peshkov, N. A. Matsko, K. N. Trubetskoy

It is possible to divide the general objectives of a company into two components: maximum expected profits and viability over time. These components are designed to maximize the companies value over time. The evaluation of a project includes both a discounted cash flow (DCF) analysis and a risk analysis. The DCF analysis determines whether the project should be accepted or rejected, and the risk analysis helps to forecast possible deviations from the original estimates. However, the results of both methods do not allow for a quantitative comparison between the main objectives of the venture, and they do not resolve the issue of whether it is advisable to sacrifice immediate profits for future profits. This paper attempts to resolve this issue. The present research was carried out on mining projects with different waste-extraction schedules. Calculations were made using the US Bureau of Mines' usage-of-costs model. Russian experience in open-pit mining is reflected in this paper.

Jan 1, 1996

By Charles Fisher

When considering the biodiversity of fauna endemic to hydrothermal vents or hydrocarbon seeps one must consider not only the numbers of unique species, but also the physiological diversity (and potential biochemical/physiological uniqueness) of the fauna. The deep ocean ridge system is home to some of most extreme animal habitats found on Earth. In addition to the high pressure, low temperature, and lack of light characterizing the deep-sea in general, hydrothermal-vent environments are characterized by toxic chemicals and temperatures that would be hostile to most other animal life. Perhaps even more challenging than the absolute levels of chemicals, dissolved gases, and temperature with which vent animals contend are the extreme gradients in time and space of all of these parameters. For example, temperatures around some vent animals can fluctuate from ice-water to hot-tub levels over seconds and can exceed 350°C only inches away. Specially adapted animals not only tolerate these conditions, they often thrive under them. As a result, the biomass of many deep ocean ridge ecosystems rivals that of coral reefs and tropical rain forests. In the Gulf of Mexico, hydrocarbon seepage through the sea floor driven by salt tectonics results in environments that are geologically very different from hydrothermal vents, but are geochemically similar enough that closely related animals are found in the two habitats. This includes seep mussels, clams, shrimp, worms, and other animals whose close relatives are found in hydrothermal vent environments. Although many aspects of the biology of the animals from the two environments are very similar, there are also significant differences in their life histories and physiologies that reflect the fundamental differences in the geology of their habitats.

Jan 1, 2008

By S. K. Kawatra, C. A. Hardison, J. Gurtler, T. C. Eisele, K. Lewandowski

Acid soak tests were used to measure the effectiveness of binders in highly acidic conditions to determine their suitability for use in copper heap leaching. Soak tests involved placing the agglomerates on a screen, soaking them in a solution that replicates the pH of the raffinate used in a heap leach, and measuring the quantity of fine particles that passed through the screen. A wide range of binders were evaluated which had potential for functioning in acidic solution. Only a few binders were effective, with the best-performing binders being nonionic polymers designed for dust suppression applications. The most effective binder prevented all but 1.86% of the fines from being released and passing through the screen, while binderless agglomerates allowed as much as 29% of the fines to pass through the screen. The soak test developed for this study provides a useful method for rapidly identifying promising binders at a low cost, and for examining effects such as curing conditions on agglomerate quality.

Jan 1, 2005

By G. Brofas

Mt Giona situated in the floristic hot-spot of southern-central Greece has an especially rich flora that counts more than 1000 native vascular plant taxa (species and subspecies) and an important plant endemism that is estimated to be about 10% of the native flora. The danger of population reduction of rare and endemic plant species and the opportunity to use rare native species in rehabilitation projects are two different aspects of rehabilitation planning in Mt Giona. In this study, an inventory of rare and endemic species of the area, their classification into IUCN threatened categories and an estimation of their habitats vulnerability are provided. The results emphasize the necessity to develop a monitoring program to analyze population viability of certain threatened plant species. The creation of artificial micro-reserves on calcareous spoils derived from bauxite mining for the conservation of water-stress tolerant rare and endemic plants is also proposed. An inventory of the species that have colonized the mining spoils was also undertaken. Twelve of them are endemics. Seven native species, because of their biological and ecological features, were selected for rehabilitation purposes of disturbed areas by mining activities. Seed germination, aspects of their reproductive biology and seedling emergence after sowing in pots under field conditions were studied. The seed germination study in the laboratory led to the identification of the optimum germination conditions and the creation of germination protocol for each species. Seedling emergence depends on the sowing season and the mulching. The use of the above species is recommended for rehabilitation purposes. The creation of artificial micro-reserves on calcareous spoils derived from bauxite mining for the conservation of water-stress tolerant rare and endemic plants is also proposed.

Jan 1, 2007