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By K. Awuah-Offei

Energy efficiency has become significant due to cost and environmental considerations. Comminution and material handling have been identified as the two most energy intensive processes in mining. The objective of this work was to evaluate truck-shovel energy efficiency strategies using discrete event modeling. Energy audits and time and motion studies were conducted at a surface coal mine to acquire data. A discrete event simulation model of truck-shovel operations was built in Arena® and validated with the field data. The model was used to evaluate the effect of using a larger shovel, and optimizing truck-shovel matching on fuel efficiency. The results indicate that using a larger excavator increases the fuel efficiency of the operation while optimizing truck-shovel matching does not. However, using a larger shovel will lead to under-utilization of the shovel. This work shows the potential benefits of using discrete event simulation to model energy efficiency of mining operations.

Jan 1, 2012

By T. G. Legare

It is now well documented that trace amounts of silver, gold, and platinum group metals occur in certain geothermal brine deposits. A significant body of literature has been generated over the last twenty years which describes attempts to quantify the frequency and levels of these precious metals in the brines. This literature is often confusing and contradictory. For example Barnea 1 states that the Salton Sea geothermal field carries 2 ppm gold, yet more recent data by workers at Lawrence Livermore National Laboratory2 (LLNL) concludes that the gold level in Salton Sea brine is <0.07 ppb. They report a platinum level in one well of 55 ppb. This apparent contradiction may be explained by sampling source and technique, but is most probably explained by difference in analytical technique. Analytical techniques and problems will be discussed in the next section.

Jan 1, 1985

By James E. Lawver

The agriculture industry has made great strides during the past decade to increase agriculture yields through increased use of fertilizers. Increased use of fertilizers may prevent or at least delay mass starvation due to the alarming increase in world population. Phosphate was added to soil as a plant nutrient in the forms of calcined bones at least 2 000 years ago, (1) and man has used phosphate minerals as a source of fertilizers in one form or another for at least 100 years. During 1977 the world produced about 116 million metric tons of phosphate rock, with about 86% used for fertilizers and another 4% for animal feed supplements. More than three-fourths of the total production comes from the United States, Morocco, and the Soviet Union. From a mineral beneficiation point of view, the major sources of phosphate rock and the methods of beneficiation can be classified as follows. Marine deposits not containing appreciable carbonate minerals, marine deposits requiring a francolite carbonate mineral separation, igneous deposits not containing appreciable carbonate minerals, and igneous deposits, requiring an apatite carbonate mineral separation.

Jan 1, 1978

By M. Galetakis, C. Roumpos

A sustainable coal industry needs to achieve a number objectives concerning mainly with superior utilisation of deposits and improved environmental performance. Modern quality control systems, which are greatly based on the on-line analysers, play an important role in achieving sustainability targets. This paper discusses the testing and application of on-line ash analysers installed in the Ptolemais and Megalopolis lignite mines in Greece and examines the possibility of using this type of analyser to control blending and homogenisation operations. The effect of the accuracy of on-line analyser to control process, when used for the characterization of low rank coals with complex and variable composition, such as greek lignites, is examined.

Jan 1, 2005

By Jose A. Delgadillo

The hydrocyclone problem has been a challenging task for the last 30 years. In the 80’s and 90’s Computational Fluid Dynamics solution to this problem began to appear. These were unsuccessful due to over simplification. In the past 3 dimensional solution with ?-e model and Reynolds Stress Model have been published. In this paper RSM and ?-e models are compared with velocity profiles measured in 75 mm and 250 mm diameter hydrocyclones. It is shown that results are not satisfactory with RSM or ?-e and that a model called Large Eddy Simulation is needed to describe velocity profile evolution and size classification.

Jan 1, 2005

By Anna Eleria, Joseph Welna, Jim Herber, Nathan Campeau

Constructed by stonemasons over 120 years ago, a portion of the Trout Brook Storm Sewer Interceptor (TBI) owned and operated by the Capitol Region Watershed District in Saint Paul, Minnesota, needed rehabilitation. A routine inspection of the 10-foot limestone block tunnel revealed degraded and missing mortar between the blocks, allowing significant infiltration and soil migration through the tunnel joints. Conditions, including damaged and missing blocks, were considerably worse in a 250-foot-long segment beneath a busy mainline railroad corridor. Barr’s solution included tuck-pointing to repair the mortar joints, shotcrete overlay, and construction of a hybrid cast-in-place/shotcrete “tunnel within a tunnel” to support the mainline railroad loads.

Jun 13, 2021

By M. Ishaq, J. Rosami, J. Brune, E. Sidrow, C. Tsai, S. Slouka

Respirable rock dust poses serious long-term health effects to workers in mining and tunneling underground hard rock environments. When inhaled, respirable silica particles commonly found in quartz and other minerals will scar sensitive lung tissue and cause irreversible lung diseases. Characteristics such as concentration, type of mineral, particle size, and particle shape inhaled can harm workers to various extents. Therefore, this study characterizes rock dust particles less than 100µm in aerodynamic diameter that are released from cutting hard rock in the underground mining environment. In this study, laboratory full scale cutting tests on samples of potash rock were performed with radial picks to generate dust. Three stages of pick wear were tested: new, moderately worn, and severely worn. Comparisons between different stages of pick wear to dust concentration, size distribution, and particle shape characteristics are drawn from this study to start determining the scenarios when the released airborne dusts become potentially most hazardous for workers. Although further testing needs to be conducted to make viable conclusions, the moderately worn pick, or the pick with the most blunt tip, in these experiments are potentially the most dangerous. The blunt pick tip released the highest concentration of dust and generated particle shapes with the highest aspect ratio compared to the other two picks. The preliminary results of this study allow for the further development of optimum bit management and maintenance systems to control the exposure of respirable dust to mine workers.

Mar 2, 2022

By J. Tavares

It is no mystery why the mining industry has such lofty safety standards. In dealing with Mother Nature and gravity, the combination of the two can create significant hazards from high wall and tunnel collapses to huge landslides. The loss of production from a major disruption could be enormous. The price tag on the loss of human life is immeasurable. The evolution of geotechnical instruments and software has been ongoing for years. But the biggest innovations have occurred during the era of cell modems, internet, and wireless networks, allowing for real time data and alarms to be delivered globally anywhere and anytime to one?s computer, laptop and smartphone. Yet in some ways you can thank the urban construction projects for developing much of the technology in use by today?s mines. Due to the density of population and the billions in dollars of structures and infrastructure in cities throughout the US and the world, urban projects have faced intense scrutiny for years. Out of this scrutiny was born the necessity of real time automated monitoring of instrumentation and sensors, a defence against catastrophic failures, and real time early warning systems through alarms that can and do saves lives. It is also possible to identify areas of concern with subsequent remediation prior to failure.

Feb 23, 2014

By R. M. Bowen

To help solve problems associated with the optimization of complex coal preparation systems, a mathematical model has been assembled which can simplify calculations pertaining to the core of the plant, i.e. the coal cleaning section. It uses algebraic expressions, derived by fitting hyperbolic equations to Mayer curves, to calculate optimum settings for a specified array of coal cleaning units and feeds. This is done without search procedures, and with usually only minor iteration of a simple calculation to specify optima within 0.02% of specified product ash contents. The key to the calculation is a relationship derived via the analytical geometry of conic sections facilitating easy application of the incremental ash theory of separations. The model has been assembled in a generalised form to cater for N processes in parallel, each giving M separations to produce P final products. Examples are given involving assessment of some complex circuit options.

Jan 1, 1986

By B. W. Cavender

Capital investments are made for a variety of purposes, from providing incremental capacity at existing operations to developing and implementing new technologies intended to radically improve a company&apos;s capabilities. These projects generate very different business opportunities and create value in distinctive ways. For incremental improvements, the capital budgeting process assures at least a loose fit between short-term goals and readily available resources. However, the criteria used to evaluate capital projects often prevent a company from committing to more aggressive goals that lie beyond the firm&apos;s current abilities or resources. Such projects may not have clearly identifiable future cash flows, and the degree of interaction with other projects and the nature of the risk incurred may be difficult to estimate. Additionally, by focusing only on quantifiable benefits, the budgeting process often fails to recognize "soft" improvements such as increased operating flexibility or new knowledge generated by such projects. By rejecting these projects, the capital budgeting process may actually harm the company&apos;s future competitive position.

Jan 1, 1998

By J. P. Rider

The number of extended cut mining systems has increased significantly in coal mines over the last decade, and there is a constant push to extend the face ventilation systems to even greater setback distances. The need to maintain airflow at setback distances of 12.2 m (40 ft) and beyond requires that methods for delivering intake air to the face be improved, or alternative ventilation techniques be implemented. The emphasis of this research effort was to examine various techniques to improve the distribution of available air at the mining face in order to reduce face methane levels. A study was conducted comparing the performance of a jet fan, used in conjunction with a machine mounted scrubber, with blowing curtain ventilation in a 27.5 m (90 ft) heading. In addition, a second study was performed on blowing curtain systems examining how scrubber flow, intake air velocity, and curtain setback influence face methane concentrations. Results showed that when the heading advances to a depth of 27.5 m (90 ft) blowing curtain systems were more efficient at diluting face methane levels when compared to a jet fan. Also, increases in scrubber flows and curtain velocity resulted in lower face methane concentrations for blowing curtain systems at 9.2 and 15.2 m (30 and 50 ft) setbacks.

Feb 24, 1997

By Ryan P. Sullivan, Ben D. DiFiore, Robert J. Auber, Michael A. Piepenburg, Lisa M. Smiley

Pollution to Lake Erie will be significantly reduced by the Westerly Storage Tunnel (WST) system, which is mainly comprised of a 10,000-ft long tunnel and a dewatering pump station in the downstream tunnel shaft. Separate construction contracts for the tunnel and pump station required careful management of the interface risks. A key decision was to decouple the projects by relocating the mining shaft away from the pump station. The need to receive the tunnel boring machine (TBM) in the pump station shaft was eliminated by dismantling the 28-ft diameter TBM in the tunnel then carrying it back through the tunnel and up the mining shaft. This paper discusses how interface risks were successfully managed during design and construction to limit overall schedule impacts.

Dec 1, 2022

By Håkan Tyni, Jan Björkman, Per-Olaf Samskog, Irving Wigdén

Process automation can provide better utilization of capital investments. Furthermore, it is a necessity for securing the high demands of product quality. In this paper, process automation in underground mining as well as in the beneficiation plant will be discussed. The development of reliable broadband communication systems for real-time transfer of image, audio and data have enabled remotely controlled LHDs and drilling rigs. In the beneficiation plants, model-based expert control systems far on-line dynamic process optimization and control have been installed in unit operations such as grinding, flotation and induration.

Jan 1, 2000

By Brian J. Gorva

The key objective of forming a cartel is to increase profits to members of the cartel by taking the following action: a) control output; and b) control price. However, while attempting to obtain monopoly profits the cartel members have to contend with costs associated with cartelization and such costs include the following: political costs; the cost of coordinating output and price; organizational costs (such as cheating); and administrative costs (such as the cost of attending cartel meetings). The objective of commodity exchanges is to provide an open, free market where buyers and sellers may openly complete transactions and pricing information can be immediately disseminated. These transactions include the following: a) to provide facilities for "hedging", or transferring price risk from buyers and sellers of physical commodities to "speculators" through the medium of buying and selling futures contracts, and b) taking physical delivery of metal on due dates.

Jan 1, 1983

By VIVEK KASHYAP, PATRICK TAYLOR

The presence of iron in sphalerite induces the formation of zinc ferrite (ZF) during roasting. Zinc refinery residues (ZRR) and electric arc furnace dust (EAFD) contain a significant amount of zinc ferrite and are difficult to treat. According to the literature, up to 71% ZF has been found to be present in ZRR. The dissolution of zinc ferrite is inefficient even in aqua regia. The Waelz process is an existing process to recover zinc from electric arc furnace dust by reduction using carbon monoxide followed by the volatilization of zinc. In this study, zinc was selectively extracted from zinc ferrite by partial reduction of zinc ferrite at relatively low temperature followed by leaching in dilute sulfuric acid (20 g/L). Pure zinc ferrite samples were partially reduced to zinc oxide and magnetite by using H2 gas as a reductant. The presence of magnetite and zinc oxide was confirmed by X-ray diffraction (XRD) technique. A maximum of 95%zinc extraction was achieved after leaching with sulfuric acid on the reacted samples. The paper also discusses the effect of time, temperature, and concentration of H2 in the reducing gas on the extraction of zinc and iron from ZF.

Sep 16, 2020

By D. Arku

The increased use of sensors to facilitate automation has led to an explosion of data. As data sets grow in size, their use becomes more complex. Therefore, there is an incentive for reducing the size of the datasets, as long as this does not compromise information gleaning. With this in mind, this project explored basic aggregation as a viable alternative to amassing large amounts of data. The goal of the project was to determine if one would arrive at different conclusions had they analyzed aggregated data instead of raw data. In a mine, operational data is typically used for tracking process statistics, correlation between factors, autocorrelation and multivariate models (for a factor of choice). Therefore, this project compared results from such analyses when it was conducted with aggregated data (AD) with the results of analyses conducted with raw data (RD). The data consisted of one-minute-apart readings from a semiautogenous grinding (SAG) mill on the horsepower, feed rate (tons per hour), rotations per minute (rpm), noise, recycle (tons per hour), density (% solids) and bearing pressure (psig). This data was aggregated by averaging five and 10 continuous (one-minute) observations. Changes in statistical measures between the two approaches were typically within 5% of each other. Differences in correlation coefficients between RD and AD(s) were also within this range. Autocorrelations present within RD were preserved in AD, as long as the time lags were scaled for the amount of aggregation. Regression and neural network models were also developed for power consumption. The prediction performance of developed models was similar whether one used raw data or aggregated data. Overall, it appeared that aggregating the data based on 5- or 10-minute time spans would not have resulted in conclusions (from simple or complex analyses) being different from using raw data. In other words, whether one had used raw data or aggregated data, the conclusions would have been the same, suggesting that time domain aggregation, a common industry practice, is a good alternative to storing high-density data in this case.

By C. J. Roos

Ground engaging tools are used to prevent damage to the main components of earth-moving equipment. These tools consist of everything from shovel teeth to replaceable drill bits to dozer wear plates. The costs of these ?consumable? items are increasing with the costs of raw materials. This project developed a tool to be used by Newmont Mining Corporation to predict the consumption of excavator teeth. This paper presents the results of a Montana Tech research project in which an equation was developed to predict excavator teeth consumption based on production rates and rock properties.

Jan 1, 2009

By Osvaldo A. Bascur, J. Pat Kennedy

Large metallurgical complexes have more data than a small city and much of it is "real time," changing rapidly as internal and external conditions evolve. As corporations buy and sell assets and reengineer their staff, the structures and tools that were used to understand these data are lost. The lack of an integrated approach makes the profitability of metallurgical plants lag behind that of other industries despite technical advances that have occurred in recent years. This results in significant deterioration in the ability to maintain a "smart” operation. The solution is to use the sophisticated new tools built for the Internet so as to leverage information in a familiar browser format that people can use and understand. Combining real-time infrastructure with portal technology is becoming an accepted methodology. This paper introduces real-time portals and team sites to support decision making by work- groups which require both real-time and documentary information from manufacturing assets, vendors, head office and the Internet. Workers get insight from the overall process effectiveness index based on key variables such as losses due to plant availability, performance efficiency and rate of quality. Real-time portals and smart clients are part of any real-time performance management (RtPM) solution. Three case studies in large metallurgical complexes are presented. PLANTS ARE YOUR STRATEGIC HANDICAP Information technology is arguably one of the fastest moving technologies used by the mining/metallurgical industry. However, the business model for managing that

Jan 1, 2004

By Jr. Chesson

"Phosphate" is a misnomer as often used. The word is increasingly used to refer to any material containing phosphorus - an element essential to any form of life. Phosphate rock, a mineral - fluorapitate - is recovered from Florida&apos;s sedimentary deposits in particle sires ranging from 0.1 to 13.0 millimeter. This product of mining, washing, screening, and flotation is commonly called "phosphate". Its phosphorus content, measured and reported as P2O5, varies from 29% to 35%, and is essentially insoluble. "Phosphate" is also used to describe products containing soluble phosphorus obtained from acidulation of phosphate rock with mineral acids; primarily, sulfuric acid. Many miners have nearby chemical plants wherein phosphate rock is converted into upgraded products such as phosphoric acid, superphosohates, and ammonium phosphates with 45% to 70% P205, soluble and suitable for use as fertilizer. The rock and upgraded products are all commonly called "phosphate"; the plants, "phosphate plants&apos; and the producers collectively are known as the "phosphate industry". The public in Central Florida generally loses identification of the individual operators that include major corporations such as IMC. Williams Companies, W.R. Grace, Mobil, Embark, U.S. Steel, Borden, American Cyanamid and others. They all become just a "phosphate company".

Jan 1, 1978

By G. Velarde

This paper presents the metallurgical results of column and stockpile leach tests with forced aeration to determine the usefulness of this process in the operational leaching at Sociedad Minera Cerro Verde S.A.A. The evolution of the aeration system is presented and also an innovative solution developed to overcome forced aeration’s main problem, which is the early obstruction of the aeration pipes located at the base of the stockpile, causing a decrease in air and oxygen levels and therefore a reduction in the metallurgical benefits.

Jan 1, 2006