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By K. Kim

A site characterization strategy formulated for the probabilistic design of underground structures is presented, which takes into account the variability of rock properties and the stochastic nature of the rock failure process. It entails determining probability distributions of rock properties by utilizing the theory of extremes and Monte Carlo simulation. Laboratory and field test data are analyzed and presented to illustrate the methodology. The results indicate that the distributive characteristics of rock mass properties can be estimated using empirical relationships currently available. This results of analyses can be incorporated into the design of underground structures, and then, the relative uncertainties of the failure probability of the structures can be assessed.

Jan 1, 1995

By Joachim H. Schubert, David G. Hulbert, Ian K. Craig, Roger G. D. Henning

This paper presents a stabilizing controller for flotation plants which uses a quasi-multivariable technique. The controller monitors all the levels in the plant, and by anticipating interactions between various parts of the plant, is able to stabilize the plant far more successfully than the normal plant control. Once stabilizing control has been achieved, optimization of the process becomes easier and more sustainable. An estimate of the improvement in metallurgical performance is made and a singular value analysis was conducted to verify that the multivariable algorithm will theoretically control better than a collection of individual PID loops. Metallurgical results are presented to show that the improvements are attainable in practice. Control by the Mintek algorithm was alternated with normal plant control, to show that the improvements are statistically significant.

Jan 1, 1995

By Mahesh C. Jha, Frank J. Smit

Column flotation and selective agglomeration are promising advanced physical cleaning processes that can be developed for preparing premium quality coal-water slurry fuel from coal fines. Such a fuel could either replace oil or natural gas in certain industrial and utility boilers or else could be burned in advanced combustors currently under development. These applications require coal cleaned to sulfur and ash contents below 258 g/GJ and 430 - 860 g/GJ (0.6 lb/million Btu and 1 - 2 lb/million Btu), respectively, to meet clean air emission requirements. A highly loaded slurry must be produced in order to avoid derating the boilers, and the total cost of the fuel must be below $2.37/GJ ($2.50/million Btu) in order to penetrate the market by the turn of the century. Achieving these technical and economic goals depend critically on the selection of suitable feed coals. This paper describes the identification and evaluation of 18 coals and final selection of six coals from different regions of the United States as potential feedstock for preparation of premium fuel. The work is being performed under a cost-shared DOE project.

Jan 1, 1995

By R. Wensel

A composite material consists of two or more dissimilar components. These dissimilar components retain their identities when mixed together and contribute to the properties of the composite. A composite usually consists of two parts, the matrix and the reinforcing material, or extender that is added to the matrix. Typical materials used as the matrix in composites are metals, polymers, and ceramics. The reinforcing material can be added for any number of reasons. For instance, if the matrix is expensive, an inexpensive filler may be added to the matrix to lower the cost of the product without sacrificing properties. An example of this is calcite (CaC03) which is added to systems such as polyvinyl chloride (PVC), to lower the cost. Reinforcements may also serve as a means to enhance the properties of the matrix material. For example, carbon fibers are frequently added to plastics to increase their strength, and glass spheres may be added to plastics to improve flexural strength. Mg(OH)z is added to polymers to give the property of fire retardancy. The latter is the focus of this paper.

Jan 1, 1995

By W. P. Diamond, A. C. Smith, J. A. Organiscak, T. P. Mucho

The U.S. Bureau of Mines examined bleederless ventilation practices to evaluate their use as a spontaneous combustion control measure in U. S. coal mines. Results indicate that restricting airflow into mined-out areas (bleederless ventilation) is recognized worldwide as a spontaneous combustion control measure. However, ventilation practices commonly used to limit airflow to mined-out areas are not easily applicable to United States mining conditions, systems, experience and regulations. The types of bleederless ventilation systems used throughout the world and the spontaneous combustion risks associated with these systems are discussed. Primary design considerations for bleederless ventilation consist of the interaction of ventilation practices, methane drainage, ground control, seal construction and mine monitoring. Technological improvements needed for U.S. application of bleededess ventilation are also discussed.

Jan 1, 1995

By Edward R. Torak

The Ohio Coal Testing and Development Research Facility (OCTAD) was commissioned in 1992 by the Ohio Coal Development Office and the Ohio Power Company to support evolving process technologies that will lead to increased environ- mentally sound use of coal. OCTAD is equipped with advanced physical concentration devices and processes capable of beneficiating coal to levels beyond conventional practice. The first task of OCTAD operators was to test the cleanability of the Meigs Creek Seam Coal in advanced circuitry and compare the results to conventional cleaning levels. In testing the seams, OCTAD circuitry was configured to produce middlings on the coarse and intermediate size fractions. These middlings were subsequently crushed to a finer size (28M x 0) and subjected to cleaning in fine heavy-media cyclones and advanced froth flotation circuitry. Nearly thirty-six full-scale production runs at various operating conditions were completed during the campaign. The results of the test program are examined in this paper.

Jan 1, 1995

By A. Marabini, G. Belardi, N. Sheau, F. Veglio

The present paper deals with the modelling of a Multi-gravity separator in the treatment of chromite fines. A first screening study was carried out by 2" full-factorial experiments in order to check the main effects and interactions among the investigated factors: shake frequency, shake amplitude, tilt angle and washwater flowrate were taken in consideration in the study. Two size fractions were employed in the experimental tests. Successively, considering the factor with larger influence on the Cr203 and SiO2 grade and Cr203 recovery in the concentrate, a further improvement of the experimental design was performed to determine empirical models to describe the behaviour of the MGS in the mineral treatment. The results show how intrinsic interaction among the factors take place, highlighting that an optimization study must be carried out considering all the MGS setting parameters.

Jan 1, 1995

By Satya Harpalani

The four most important parameters controlling the flow of gas in coal are the gas content, permeability, diffusion coefficient and cleat characteristics. Estimates of these and, more importantly, a knowledge about the variation in their values over time are required for simulation of long-term gas production. This paper describes experimental techniques to determine each of these, along with their time dependency, under simulated in situ conditions. It is shown that the permeability, diffusion coefficient and the cleat aperture values are not constant as usually assumed to be. There is a significant variation in their values as a result of changes in the microstructure of coal associated with release and flow of gas.

Jan 1, 1995

By D. A. Poulter

The stability of a liner system is influenced by many factors which can be compiled into four basic groups. They are: 1. the liner system components and physical characteristics; 2. the geometry and slope of the liner system; 3. the loading conditions on the liner system; and 4. the foundation conditions under the liner system. Failures in the liner system that are due to one or more factors from the first three groups usually result in movement relative to the plans of the liner system. Failures associated with factors in the fourth group result in deformation(s) across the liner system section beyond its design limits. For purposes of these discussions a failure in the liner system refers to displacements or movements resulting in physical damage to the liner system such that it can no longer function.

Jan 1, 1995

By C. Woofter

Quarry operators must continue to change and adapt environmental compliance methods to meet the increasingly demanding regulations. To fulfill industry needs, a computer-based decision support system is being developed to facilitate decision making that mine operators are required to make regarding environmental responsibilities. This system can help to determine permitting and compliance measures needed for air, surface water, groundwater, noise, aesthetics, vegetation, wetlands, hazardous wastes, storage tanks and wildlife habitats during the development, operation, and closure phases of mining. Operators will utilize the system's user-friendly interface consisting of mouse driven responses and limited keyboard entries on a desktop computer. The system is easy to upgrade according to the user's needs and changes in current laws and regulations. Data input models, user interfaces, and support of decision making are explained. The program permits inclusion of the decision maker's own insights through "what-if' analysis, in which the user can change ad hoc entries and check the related consequences. Using this approach, the user has complete control over all steps of the decision making process. A storm water example is selected to demonstrate the potential benefits of the support system to environmental decision makers.

Jan 1, 1995

By Irwin R. Higgins, Richard S. Dennis

Acid recovery employs ion exchange resin as an adsorption media for the separation of inorganic acids from mixtures of acids and their metallic salts. This technology has been used to treat spent pickling and plating liquors to recover acid for reuse in the bath and to reduce waste acid neutralization costs. Acid recovery can also be used for electrolyte treatment to facilitate valuable metal recovery and to improve product quality. Conventional fixed bed ion exchange (I-X) systems are impractical for acid recovery because of complex control design and large resin inventories needed to process strong acid concentrations. TETRA'S CCIX™ continuous I-X contactor has been used successfully in a simple, continuous operating mode to separate acid from its salt. Efficient separation is enhanced by refluxing which allows acid to be produced as a salt-free product at nearly its original strength. Continuous treatment also recovers heat to the bath and improves metal quality due to consistent acid quality.

Jan 1, 1995

By R. A. Ynchausti

In January 1993, Pyramid Resources began implementation of a supervisory expert control system at a U.S Cu concentrator. The objective of this control system was to improve plant profitability through unit operation optimization and integration. This paper documents the key aspects of the project, including: economic and associated benefits, system architecture, concepts of implementation, process control strategies, practical aspects of implementation and conclusions. The implementation of expert control at this concentrator has resulted in an estimated benefit of $50,500 per day. This is a net result of improved tonnage, reduced reagent consumption, improved concentrate grade and reduced energy per ton produced.

Jan 1, 1995

By V. Karra, G. Beerkircher

Application of the innovative WaterFlush® crushing technology to the processing of gold, copper, and iron ores is presented for retrofit circuits and productivity gain in each case is stated. New operations containing WaterFlush are described in brief.

Jan 1, 1995

By M. R. Yalamanchili

The in-situ FTIR/IRS technique has been used to spectroscopically characterize interfacial water near a hydrophilic surface. Interfacial water was examined spectroscopically over known distances from the surface of a silicon single crystal by appropriate design of the geometry and optics of the internal reflection system. The in-situ FTIR/IRS spectra of interfacial water were examined by consideration of the 0 -H stretching region (3000 -3800 cm-1) associated with the vibrational spectra of water. The broad peak: in this region which describes the interfacial water structure was deconvoluted in order to isolate the overlapping spectral features of the interfacial water. Preliminary spectral results indicate the prevalence of an ice-like water structure (-3200 cm-!) at the silicon surface. Importantly, it appears that the interfacial water structure may extend a considerable distance (several tens of molecular layers) from the surface as established from the spectroscopic depth profile measurements which show that the free OH stretch at 3600 cm-1 becomes very significant at distances from the surface exceeding 400 nm.

Jan 1, 1995

By D. A. Meyer

The long and arduous process of bringing aggregate produced in Mexico to the Gulf Coast of the United States really began in the 1970s when the first exploratory trips were taken by Vulcan's geologists. It was not until the middle of the 1980s that all of the elements of the project seemed favorable and the largest capital investment in Vulcan's history was given the green light. The history of the project will be covered along with a discussion of the role that market forecasting played in the process. Is this the first of many or a once in a lifetime project? In July 1987, Vulcan and its joint venture partner broke ground in Mexico for a world-class limestone quarry and crushed stone production facility. This project is the largest ever undertaken by Vulcan's Construction Materials Group, with a total cost of over 200 million dollars -a cost shared equally by Vulcan and its joint venture partner, Ingenieros Civiles Associados, or ICA, a diversified Mexican company which is also the largest construction firm in Latin America.

Jan 1, 1995

By G. T. Adel, J. D. Miller, C. L. Lin

In view of the success of recent laboratory studies using X-ray computed tomography (CT) to determine coal washability and with the availability of high-speed CT systems, it now seems possible to design an on-stream washability system for the control of coarse coal-cleaning circuits. Design features for such a system are examined and possible control strategies are discussed for different applications.

Jan 1, 1995

By Cheng Zhengbing, Sun Baoqi

This paper summarizes several chemical purification methods used for producing high-pure industrial minerals These methods, mainly including alkali melting, acid leaching, oxidation-reduction bleaching, are respectively used to eliminate the impurities such as silicates in graphite and diamond, ferric oxides in quartz sand or other valuable silicate minerals, colouring impurities in kaoline, barite and other minerals which are required to have a high-whiteness. The fundamentals of the chemical purification methods and some practical examples in China are introduced in the paper.

Jan 1, 1995

By Palmer C. Sweet

Mining-related wastes, which are increasing, are being utilized more and more as valuable resources in Virginia. The Environmental Protection Agency (EPA) divides mining-related wastes into two categories: those generated from mineral extraction and beneficiation and those generated from mineral processing. Materials from both categories are produced in Virginia, where waste (by-product) materials are present at a variety of mining sites and processing plants; some of which have been exploited for various uses in the past and/or present. These materials include: used concrete recycled for roadbase material; pyrite coated with magnetite for use in portland cement; minor amounts of fly ash for use in concrete block, lightweight aggregate, and flowable structural fills; granite and diabase quarry fines for use as agricultural and asphalt filler; lime kiln dust for use in neutralizing and stabilizing coal refuse; soapstone aggregate for use in terrazzo heat retention panels; kaolin for use as a filler product and as an ingredient in white cement; slate quarry fines used as landcover and combined with aggregate for crusher run and as a filler in asphalt; and coal refuse for use as fuel in a lightweight aggregate plant. There are some materials available that have never been utilized, although several ideas were investigated to turn them into usable commodities. One such material is a high-alumina scrap produced as a by-product at a ferrovanadium processing plant. However, large quantities of waste materials from metal mining, industrial mineral, and fossil fuel operations remain to be disposed of in an environmentally safe and economic manner. In 1989, almost one million tons of fly ash were produced from burning of coal at eight coal-fired power plants in Virginia. Present uses for this waste such as an ingredient in concrete block, concrete aggregate, and in structural fills cannot dispose of all the available material; however, increased use of fly ash as a soil/rock substitute for structural fills and embankments may solve the problem of its disposal. Another waste material is calcium carbonate precipitate paste produced at a lithium carbonate processing plant and presently being used for back filling an on-site inactive underground limestone mine. Flue gas desulfurization (FGD) wastes in the form of CaS04 will probably increase threefold. If this material contains a minimum of 95 percent gypsum and negligible chloride, it may have a value to a wallboard manufacturer as we move toward the year 2000. Thought must be given how this increasing waste can be disposed of in an environmentally safe manner.

Jan 1, 1995

By Waldo Valderrama, Luis Magne, Paola Grandela

The effect of liner shape on power consumption was studied in a small laboratory mill under various operating conditions. It was found that the angle subtended between the lifter front face and the face in contact with the mill case has the most significant influence. The increasing height of lifter reduced power consumption, whereas the lifter spacing did not show any influence. The effect of height is less relevant at lower front angles. Highest power consumption is achieved with a 45" front angle. A comparison of cylinders and balls under identical conditions gives higher power consumption for ball charges. The data does suggest that, for maximum power draw, slip in the outer layers of the charge and the early recirculation of energy to the mill case should be avoided. Both factors prevent an efficient energy transfer to the mill charge.

Jan 1, 1995

By S. M. Robinson

Wollastonite is recognized as one of the most unique, non-metallic minerals in the world. Its history for use in industrial applications is recent compared to other minerals, however, its distinctive physical properties, such as acicular particle shape, and alkaline pH creates incorporation possibilities ranging from bowling balls to automotive fascia, from ceramic tiles to automotive brakes, and from thermal insulation board to industrial and trade sale coatings. Its future use will be impacted by the exploitation of deposits which will ensure maintenance of the acicularity and purity of this naturally occurring mineral. Additionally, closely held surface treatment technology will open up additional niches requiring highly engineered performance.

Jan 1, 1995