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In its largest product launch in company history, Cummins Engines welcomed more than 200 customers, vendors and media to witness the unveiling of its new QSK95 engine at its Seymour Engine Plant in Seymour, IN on Nov. 1. It took the efforts of 150 engineers to design the QSK95 and more than $100 million in investments to establish a new production line and test facility at Cummins? Seymour Engine plant. The result of these efforts is a new platform of engines that Cummins says will provide as much as 2,983 kW (4,000 hp) and will be the most powerful, high-speed diesel engine ever built.

Jan 1, 2012

By J. F. T. Agapito, R. R. Goodrich

Yield pillars have been used for many years to help reduce stresses near mine openings and improve roof and floor stability. A yield pillar is often defined as a pillar that fails but retains residual strength. Stress transfer occurs through the roof and floor after the peak strength of the pillar is reached. High stresses are transferred from around the openings onto abutments that can be barrier pillars or unmined ground. This mechanism, often referred to as pressure arching, is possible as long as the width of yield pillars is less than the critical width above which stresses cannot be carried by the overburden. Significant stress transfer also can occur due to small amounts of pillar and/or floor yielding before the peak strength is reached. This is accomplished in a quasi-elastic manner with little or no visible roof and pillar fracturing or floor heave. Long-term stability may be achieved when stresses and mechanical properties are favorable to pre-failure yielding. This paper gives practical examples where improvements in stability and resource recovery were achieved with this mechanism. Yielding was assessed by comparing measured and calculated vertical pillar stresses. Results indicated that calculated stresses in the pillars were 25 to 40 percent higher than the measured stresses, demonstrating significant arching load transfer to the abutments. Pre-failure yielding is probably often present but unintentional in both development and production areas. Better recognition and use of this mechanism should lead to improved designs as mines become deeper.

Jan 1, 2001

By M. Martins

This work presents and discusses the influence of the surface tension (gLV) of methanol/water mixtures on the flotation response of apatite versus gangue minerals conditioned with flotation reagents (75 g/t cornstarch and 100 g/t Berol 867) at pH 10.6. Berol 867 is a collector composed of sodium alkyl sarcosinate plus nonionic surfactant. The highest Schulz efficiency of separation (recovery of apatite minus recovery of gangue) was achieved at ?51.0 mN/m. The critical surface tension of wettability (gC) of apatite was found to occur at 34.7 mN/m when determined by means of gamma flotation experiments, and it was 33.9 mN/m when determined by Zisman?s approach.

Jan 1, 2009

By R. L. Virta

Four companies mined ball clay in four states during 2005. They included H.C. Spinks Clay (owned by Franklin Minerals), Kentucky-Tennessee Clay (owned by Imerys), Old Hickory Clay and Unimin. Production was estimated to be 1.32 Mt (1.45 million st) valued at $53.3 million, based on the results of a preliminary survey of the ball clay industry. Production in 2004 was 1.22 Mt (1.34 million st) valued at $54.1 million. Tennessee was the leading ball clay producer state with 61 percent of domestic production, followed by Texas, Mississippi and Kentucky.

Jan 1, 2006

By P. A. Hagerty

Biological treatment of metals-impacted water using sulfate reduction is a viable means of treatment that has been applied in pilot and full scale at numerous projects. One of the fundamental challenges with this type of treatment is the selection of an appropriate substrate to support the sulfate reduction process long-term. The substrate degradation products provide a carbon source and an electron donor for metabolism by sulfate-reducing bacteria and consequently organic characteristics are critical; however, the physical attributes of the substrate are equally critical to an efficient and optimized substrate mix. This paper explores the affect of particle size (a.k.a. grain size) of several substrate mixes on the treatment efficiency of sulfate reducing treatment systems. Substrate selection can be separated into two phases of evaluation, the primary selection phase and the secondary optimization phase. The primary selection phase considers such fundamental attributes as source availability, economics, bioavailability and longevity. These fundamental activities are conducted in order to identify potential candidate ingredients of the substrate mix which are regionally available, economically viable and consistent with the biogeochemical aspects of the project. Recent work has been conducted in the development of testing protocol for organic substrates to quantify bioavailability (Martinez Hernandez et al. 2010, Place et al. 2006) as part of the primary selection phase. Once the substrate ingredients have been selected based on the primary criteria, the mixture of these ingredients is then developed based on an optimization process, including consideration of the substrate ingredient?s particle size distribution.

Jan 1, 2011

By M. Wickham

Design of an open pit backfill requires an understanding of highly varied processes including slope stability, hydrogeology, pit lake chemistry, climate, runoff, and mine waste behavior. Dynamic systems modeling (DSM) provides flexibility to the designers of open pit backfill, allowing them to directly integrate many different physical processes and varying levels of complexity. DSM also provides for the efficient application of uncertainty analysis to define a range of possible results, the sensitivity of the results to uncertainties in model inputs, and the value of additional data. This paper presents the results of an analysis using DSM to evaluate a pit backfill design at an Arizona mine. The objective of the partial backfill was to stabilize an active slope that threatened facilities adjacent to the pit. DSM was used, in part, to develop a pit lake water balance model for evaluating the influence of the backfill on the ability of the pit to maintain passive hydraulic containment of groundwater and surface water inflows and for evaluating costs for various backfill scenarios.

Jan 1, 2001

By Louis A. Panek

Using an approach based on the theory of similitude, the author develops a general equation and related concepts that provide new insights to an old problem. The load-bearing capacity (strength) of a square, rectangular, or cylindrical prism of a brittle material such as rock, coal, or concrete is expressed as the mathematical product of a size effect, a shape effect, and a function of the mechanical properties (deformability, cleat/joint spacing, and friction) of the pillar, roof and floor materials. Through an application of multivariate statistical analysis, the results of assorted tests and observations of failed pillars can be combined into a fundamental scaling equation, which provides a unified, consistent approach to the estimation of mine pillar strength. The form of the equation is sufficiently general to be able to incorporate refinements in the characterization of the basis factors, as they become available through future experimentation and analysis.

Jan 1, 1979

By S. Al-Thyabat

In this work, the floatability of Jordanian phosphate slime (-38 µm) was evaluated in a batch column flotation cell, 100 cm high and 5 cm inner diameter. Flotation was conducted using sodium oleate as a collector and methyl isobutyl carbinol (MIBC) as frother. Rougher flotation yielded concentrate assaying 29.19% P2O5 with 90.29% recovery at the following flotation parameters: 2.6 cm/s superficial gas velocity, 20 ppm frother dosage, 0.205 mM collector concentration and 40% weight solids. It was also found that conditioning with the same collector dosage but with a different solids weight percent gave different flotation results. However, pulp collector concentration was the key operating parameter; increasing collector dosage at the same solids weight percent decreased flotation recovery by 3%, while increasing solids weight percent at the same collector dosage increased phosphate recovery by 18%.

Jan 1, 2011

By H. Verakis, M. J. Sapko

The Pittsburgh Research Laboratory (PRL)1 of the National Institute for Occupational Safety and Health (NIOSH) in collaboration with the Mine Safety and Health Administration (MSHA) Technical Support Center has devised a prototype hand-held instrument which can provide a direct assessment of the potential explosibility of a coal and rock dust mixture. Current Federal regulations require that rock dust be applied in all underground areas of a coal mine to mitigate the propagation of a coal dust explosion. To determine compliance with the Federal regulation, mine inspectors collect dust samples from sections of underground coal mines for an MSHA laboratory analysis of incombustible content. However, the laboratory analysis may not be completed for more than a week or two, during which time the mine area from which samples are taken may be inadequately protected. The operation of the Coal Dust Explosibility Meter (CDEM) is based on the difference in optical reflectance between light rock dust and dark coal dust. For a given coal volatility, the optical reflectance of such mixtures is relatively constant at the limit of explosibility, independent of the coal dust particle size. The CDEM is not intended to replace the current MSHA laboratory analysis of coal mine dust samples for incombustible content, but to serve as a supplemental device for enhancing mine safety through improved rock dusting practices.

Jan 1, 2006

By Bradshaw, Y. S. Cho

The size of bubbles plays an important role in flotation. Equations used to calculate the size of bubbles all show the effect of liquid/gas surface tension. However, the surface tension does not change much with frother concentration and experiments conducted using single capillaries (or single-hole spargers) do not reveal any clear effect of the frother concentration on bubble size. The size of bubbles does, however, strongly depend on frother concentration when multi-hole spargers are utilized (or when measured in a flotation cell); at low frother concentrations the bubble size is much larger indicating coalescence as a main mechanism determining the size. Coalescence can be prevented at frother concentrations exceeding the critical coalescence concentration (CCC), which in turn was found to be interrelated with the dynamic foamibility index (DFI).

Jan 1, 2001

By E. F. Schnitzer, D. R. Haight, G. T. Krogman

The 1997 New Year’s Day Rogue River flood near Medford, Oregon, USA, entered historic channels, eroded a 150-foot-wide buffer, and captured an inactive gravel pond located within the channel migration zone. Channel redirection caused by pit captures threatened adjacent inactive gravel ponds. In response to this capture, a stakeholders group of concerned individuals and organizations was formed. This group ultimately developed a rehabilitation plan, which conformed to the Rogue River’s geomorphic trends. A two-dimensional model, FLO-2D, was used to evaluate channel splits, flood storage, backwater, and future conditions. Modeling results coupled with trend analysis were used to create a stable design where stream barbs, gravel redistribution, a channel outfall spillway, bendway weirs, bank reshaping, and revegetation were integrated into a single plan for a three-mile reach. The quick action by the stakeholders group averted further damage to the Rogue River system and surrounding environment. The project has preserved three miles of mainstem habitat, one mile of side channel habitat, and protected ten gravel ponds from pit capture.

Jan 1, 2006

By M. Javier

This concept paper is presented in the hope of raising the awareness of mankind on the necessity for its peaceful coexistence with nature. It is a food for thought. It takes compromise and sacrifice of people, who will have to learn to curb their greed and move toward a more organic form of prosperity. A nature-friendly sustainability is first step toward the protection of nature that is critical to the mutual survival of mankind and nature. People need the resources from the finite earth to survive and nature needs the prevention of human destruction in order to continue to regenerate and provide. The contemporary notion of sustainability is self-serving. It serves the interest of industry by camouflaging itself to look like nature?s protector. The ?sustainability? concept presented in this paper aims to extend the longevity of the utilization of the limited natural resources for many generations to come. It is an important, responsible first step in creating a healthy sustainability concept that, when implemented, extends the longevity of mankind by the most efficient use of the finite resources on this limited Planet Earth, all the while taking into consideration the increase in anthropogenic activities due to exponential human population growth. This new definition of ?sustainability? has completely different characteristics than its contemporary versions. Nature has its own destiny, rules and principles. Being a part of nature, human society depends on it for survival and must play by its rules and never the other way round as in its initial pretensions. Society should not try to humanize nature, but rather to respect the rule of the nature in a peaceful way of co-existence. When implemented, this new concept of sustainability aims to affect the designs of engineered structures and revolutionize the recovery methods and processing of natural resources, such as mineral resources in the most efficient manner. Finally, this paper intends to stimulate critical thinking and initiate serious discussions aiming at producing a general consensus for the best definition for human society to not only enrich, but to extend its existence. Thus, the spirit of this new definition is pro future generations and environment. KEYWORDS: Sustainability Definition, Nature, Geomímic, Deproduction.

Feb 27, 2013

By A. B. Cecala

Two recent Bureau studies evaluated workers' dust exposures in automated pallet loading processes. The first study involved a Bureau designed dust control system using a push-pull ventilation technique. The unit was shown to reduce workers' dust exposures by 76% during pallet loading at a ground silica operation. A hydraulic lift table was used to automate the bag stacking process; this kept the loading height constant throughout the entire pallet loading cycle. The second study evaluated different commercial automated pallet loading systems. These systems automatically stack the bags onto pallets, shrink wrap the pallets, and deliver the pallets to a fork lift pickup location. Results from a ground silica evaluation site indicated respirable dust samples taken were below the Threshold Limit Value (TLV) as established by the Mine Safety and Health Administration (MSHA).

Jan 1, 1990

By R. P. Killmeyer, W. W. Wen, B. K. Parekh

A continuous pilot-scale test of the GranuFlow Process was conducted using a screen-bowl centrifuge for the dewatering and reconstitution of column -flotation concentrate at a coal preparation plant in Virginia. In this test, a slipstream of the fine clean-coal slurry from the column flotation con¬centrate was treated with a bitumen emulsion before dewatering. The treated products from the screen-bowl centrifuge appeared to be dry and in a free flowing granularform, while the untreated products were wet, sticky and difficult to handle. Test results indicated that the average moisture contents of the dewatered coal products were 35.7%, 35.5%, 32.6%, 29.9% and 26.5% (by weight) with Orimulsion additions of 0.0%, 0.7%, 3.2%, 4.8% and 6.4% (by weight), respectively. The handleability and dust reduction of the dewatered coal products were also vastly improved.

Jan 1, 2000

By Hyung Jeek Kim, Jongmin Joo, Jonguk Kim, Jai-Woon Moon, Kyeong-Yong Lee

"Co-rich ferromanganese crusts (Fe-Mn crusts) distributed on seamounts in the western Pacific are potential economic resources for cobalt, nickel, platinum, and other rare metals in the future. Evaluation and selection of a mining site can be established based on abundance and grade of Fe-Mn crusts in the site as well as topography that should be smooth enough for mining operations. Therefore, acquisition of shipboard echo-sounding and acoustic backscatter data are prerequisite to the selection of potential mine sites in addition to visual and sampling operations. Acoustic backscatter data can be used to locate crust-covered areas on a regional scale with the understanding of acoustic properties of crust through its correlation with visual and sampling data.During an expedition that took place from January to March 2014, KIOST collected geophysical and geologic data to assess the resource potential for Fe-Mn crusts on three seamounts (guyots) in the Western Pacific. In OSM11, one of the three surveyed seamounts, three camera tows were performed to observe the distribution of Fe-Mn crusts on the summit and slopes of the seamount. Although sediments of various thicknesses generally cover most of summit region of OSM11, several regions with high backscatter signals occur on the periphery of the summit. The occurrence of Fe-Mn crusts, observed during the camera tows, on those high backscattered regions suggests that the backscatter signals of shipboard multi-beam sonar can reflect changes in the geology of the seafloor from sediment layer to Fe-Mn crust deposits. The Fe-Mn crust deposited around the summit region is worthy of notice because of its topographic characteristics, including shallow depth, flat or gentle inclined surface, and smooth relief, which are more suitable for mining operation compared to the flanks of seamount."

Sep 1, 2014

By Michael L. Ogilvie

The proportion of underground coal production as a percentage of overall Australian production has fallen in the last 10 years, with underground production remaining more or less static at about 53 Mt (58 million st). However, underground coal mining remains a viable industry in Australia, due to use of modern longwall mining systems. In 1993-1994, 26 longwalls were in operation, with total production exceeding 39 Mt/a (43 million stpy). Some of these longwalls achieve productivity levels approaching efficient opencut operations, and in some cases, they exceed them. These high-production longwall mines are not without problems when depth and distances from outcrop increase and the gas content of the seams approaches or exceeds critical limits. When gas content of a coal seam exceeds 6 m3/t (233 cu ft/st), gas flows into the mine may be sufficient to interrupt production from time to time.

Jan 1, 1995

By Y. FUJII, E. CHANDA, J. KODAMA, D. FUKUDA, M. NISHIHARA, Y. NAKAYAMA, P. SINKALA

For over 40 years, Mufulira underground copper mine has been recording incidents of rockburst. Laboratory tests and numerical analyses were carried out to understand the rockburst mechanism at the Mufulira mine. Rockburst did not occur in the chain pillars or at the mining face, but mainly in the mining drives along diminishing pillars or ahead of the mining face. RQD suggested that the rock mass in the rockburst areas was relatively intact. Laboratory tests confirmed that the rock at Mufulira mine is very strong and brittle. Elastic stress analyses for the rockburst sites by 3D displacement discontinuity method (DDM) indicated very high stress in the chain pillars and low-stress concentration at the sites of rockburst during the initial mining stages. However, there was no apparent positive correlation between the elastically calculated normal stress values and the occurrences of rockbursts. The 2D elastic FEM analysis was conducted under the concentrated stress by DDM and indicated that some stress increase with face advance for the rockburst in the vicinity of the mining face. However, stress severity indicated almost no increase, and the rockbursts cannot be explained as an instantaneous rock mass failure due to stress increase by mining. Therefore, a creep damage model was proposed to clarify the mechanism of the rockbursts. Cumulative rock damage was evaluated for the edge elements of each sidewall of the mining drives, based on the normal stresses by 3D DDM. The rockburst occurrences were well hindcasted. A method to estimate the volume of the rockburst source was proposed, and a likely result was obtained.

Aug 12, 2022

By A. El-Midany

Dolomite impurities are increasing in the currently mined phosphate deposits in Florida. Several research efforts have been conducted in various laboratories around the globe to find methods to economically removing the dolomite. However, a universal and cost-effective process is not now in commercial use. In this paper, a new process for dolomite/apatite separation is presented. The differential solubility of dolomite in slightly acidic solution is utilized to generate micro CO2 bubbles at the dolomite/water interface. Particle (dolomite)/bubble aggregates float to the surface leaving phosphate concentrate with low MgO content. Interestingly, up to 6.0 mm particles can be floated by such micro-bubble/particle aggregates. Different surface-active agents were tested to stabilize the bubbles. Results of these tests are presented, and the mechanisms involved are discussed.

Jan 1, 2009

By Charles L. Allie

Since Reserve Mining Co. began commercial operations at Silver Bay, MN, some 25 years ago, major improvements in taconite processing technology have become available. In addition, significant new government standards have been imposed on industrial operations. By implementing a $370-million modernization program, Reserve was able to accomplish two major company objectives: the quality of concentrates produced from the Peter Mitchell mine has improved, and the operation meets both present and foreseeable environmental standards. Process modifications at Reserve were designed to: •Reduce the pellet silica content from 9% to 5%; •Increase the pellet iron content from 62.5% to 65.8%; •Implement a tailings disposal system utilizing "best available technology" water quality controls; and •Reduce air emissions by installing "best available technology" air emission controls. By adding dry cobbing, fine screening, and flotation to the concentrating process, pellet silica content has been reduced; the process reclaims and reuses all process waters; all tailings are stored in a zero discharge tailings basin; and all air emission standards are being met. Initial Beneficiation at Silver Bay Reserve's Peter Mitchell mine at Babbitt, MN, is on the eastern end of the Biwabik iron formation. The open-pit mine is approximately 16 km long, 0.8 km wide, and presently has a maximum depth of about 50 m. Principal constituents of the ore body are magnetite, quartz, and iron-magnesium silicates. The company's large commercial plant began operating at Silver Bay, 75 rail km from the mine, in 1955. Facilities have historically had the capacity to process 31.5 Mt/a of taconite, containing an average 24% magnetic iron, into 11 Mt/a of iron ore pellets. Reserve's initial beneficiation process-which existed up to early 1979-consisted of two crushing stages at the Babbitt mine site, two additional crushing and screening stages at Silver Bay, grinding in a conventional rod-ball¬regrind mill circuit, size classification with cyclones, and concentration with magnetic and hydraulic separators. Concentrate produced by that circuit assayed 65% iron and 8.5% silica, with a screen analysis of 94% -44 µm, and a surface area of 9300 cm2/cm3. Pellets produced from this concentrate assayed 62.5% iron and 9% silica (dry basis). Construction began in 1977 to modify Reserve's operation. Process modifications were designed from pilot scale operations that had been operated and researched by Reserve for more than 10 years. There were two design restraints imposed on the process: economic constraints that Reserve continue to use much of the existing processes and structures in the new operation; and a substantial number of government-imposed permit constraints. In effect, the tailings process was designed first and then a concentrating process was developed that would "fit" the tailings disposal system. Operation of the modified process began in June 1980. Crushing Remains Unchanged No changes in process flow were made at either the Babbitt mine and crushing plant or at the Silver Bay fine crusher. Gyratory crushers reduce run-of-mine taconite to -90 mm-diam at the mine. Taconite is then transported to Silver Bay by intra-plant railroad. There are 10 fine crushing lines. Each consists of a double deck screen, followed by a heavy duty short head crusher, a second double deck screen, and second short head crusher. All screen undersize material bypasses the crushing lines, resulting in an open circuit crushing process. Fine crusher product is approximately 98% - 20 mm, 80% -12 mm, and 50% -10 mm in diameter. Each fine crusher line processes about 400 t/h of crude taconite. Cobbing Provides Aggregate for Tailings Dams The first major process change was the addition of dry cobbing, a dry magnetic separation step between the fine crusher and concentrator. Dry cobbing serves two major purposes in the new process. Its principal function is to provide large volumes of dry coarse aggregate for use in construction of tailings dams. This process rejects about 20% of the fine crusher product as tailings with a size analysis of 98% -20 mm and 50% - 10 mm. These tailings are free draining and have high frictional shear strengths-two key requirements for dam building aggregates. Fine crusher product is conveyed to a new dry cobbing building. Here crushed ore is discharged into one of two 30-minute capacity surge bins. Crushed ore is withdrawn by 12 constant speed conveyor belts; each discharges 500 t of crushed taconite into a dry cobbing machine. Each machine consists of a 3-m-long riffle splitter and two vari-

Jan 12, 1980

By E. D. Attanasi, M. W. Bultman

Most statistical measures of mineral exploration continued downward in 1986. Prospects in 1987, however, appear to have brightened for exploration as the overall economic health of the mineral industry improved. The Society of Economic Geologists (SEG) survey of US and Canadian firms documents the marked decline in US mineral exploration since the early 1980's. From 1981 through 1986, the total exploration expenditure by US firms declined by more than 73% (Fig. 1). Exploration expenditures by US firms declined by 66%%. US based professional exploration staffs were slashed by 70% (Fig. 2). Also, many firms have written off some reserves because of weak markets or have not delineated new reserves to replace production. The Canadian government reported that between 1981 and 1986 Canadian molybdenum re¬serves had declined by 30%, lead and zinc reserves by 20%, and nickel and copper reserves by 15%. The SEG survey also shows the immediate impact of the decline in the dollar on US exploration expenditures abroad. Between 1981 and 1986 the share of the exploration dollar spent by US firms outside of the country declined by nearly one-half and exploration acreage abroad declined by 69%. The downward trend of the last six years may finally be near the end as a leaner and more efficient minerals industry starts to gear up for a period of increased activity. An industry survey reported to Mine Development Bimonthly (Metals Economics Group) indicates that mining firms were expected to increase exploration expenditures in 1987 by at least 10% above 1986 levels. Worldwide expenditures for 1987 by companies covered by the report were expected to top $800 million. It is the first time since 1984 that an increase in exploration expenditures was expected. Also, the US Bureau of Land Management reported a 30% increase in new mining claims for fiscal year 1987 over fiscal year 1986. The bulk of the increase in claims was in states having intense gold exploration, particularly Washington and Oregon. Much of the optimism is undoubtedly due to the increases in metal prices that occurred in 1987. Some of these increases include gold, average price up about 20%; copper, average price up 24%; aluminum, average price up 26%; and nickel, average spot price up 20%. The SEG survey shows precious and base metals accounting for 89% of the exploration expenditures in the US in 1986, up 52% from 1981. The US Bureau of Mines estimates that 80% of US exploration activity in 1986 was directed entirely at gold (1986 Minerals Yearbook). Worldwide exploration plans indicate the continued dominance of gold exploration. New programs were announced for Ghana, Malaysia, and Indonesia. Major new exploration programs were also launched for lead-zinc sulfides in Morocco, platinum and palladium in northwest Brazil, rare earth minerals in Greenland, diamonds in Indonesia, and heavy minerals off-shore Australia. Significant gold discoveries were made at Angels Camp in Oregon; South Africa, near Potchestroom; India, in the Chitradgra district; Northern Ireland near Mt. Speerin; Chile, San Cris-

Jan 5, 1988