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Application of microprocessors, programmable logic devices, and other computer-oriented hardware and software on-board large surface mining equipment to optimize availability and productivity, stretch machine life, and protect against catastrophic breakdown has been a goal of heavy-equipment manufacturers for several years. Progress in this direction has not been as rapid as many manufacturers anticipated in the mid-1980s, and, on the other side of the coin, mining industry and machine operator acceptance of such products has not always been enthusiastic. However, the trend toward such development seems undeniable. Large surface mining equipment in the future will doubtless carry more, and not fewer, applications of computers and computer-related products. The intensity of development interest and degree of progress in commercializing such on-board computer and computer-related products on surface mining equipment varies considerably among the manufacturers. Summarized here are the on-board computer-oriented products of three heavy-equipment suppliers-P&H Harnishfeger, Marathon LeTourneau, and Haulpak not a comprehensive survey, but, perhaps indicative of the direction such development is taking.

Jan 1, 1990

By A. L. Anderson, J. T. Rybock

KEECO has developed the Silica Micro Encapsulation (SME) technology for the treatment of acidic, metal-laden waters. Utilizing a silica-based chemical formulation that entails chemisorption and micro-encapsulation of heavy metals in a permanent silica matrix, encapsulated particles settle quickly and are effectively isolated from the surrounding environment, producing a stable sludge that is characteristically non-hazardous. In a number of independently-verified pilot and full-scale applications (including the Bunker Hill Mine, Leviathan Mine, Wheal Jane Mine, and Meldon Quarry), SME has been proven highly effective. The technology has been featured in a number of mining publications and selected for innovative technology awards.

Jan 1, 2000

By R. Sellaro

It has long been understood that extended occupational exposures to respirable mine dusts can lead to chronic lung disease. In underground coal mines, coal workers pneumoconiosis (CWP) and silicosis are major concerns. While there have been many studies aimed at understanding total dust concentrations and silica content associated with different mining conditions (e.g., locations/occupations within a mine, cutting methods, geologic strata), little research has been completed to more comprehensively characterize respirable dust (i.e., by distributions of particle composition, size or shape). For such analysis, scanning electron microscopy with energy dispersive X-ray (SEM-EDX) may represent a powerful tool. This article is a preliminary investigation of SEM-EDX to characterize respirable dust from an underground coal mine in Central Appalachia. Samples were collected from various locations in the study mine, and individual dust particles were identified and classified by mineral type. A continuous personal dust monitor was also used to estimate respirable dust concentrations during sampling. This data was compared to particle densities observed under the SEM. Dust is generally defined as small, solid particles with an effective diameter between 1 and 100 µm. In underground coal mines, dust is produced by a variety of activities such as coal and rock cutting, materials handling, haulage and from a variety of materials. While the coal itself is primarily made up of organic carbon, it is estimated that as much as 60 percent of coal mine dust consists of mineral matter, including clays, metal oxides and sulfides, carbonates, quartz, phosphates and heavy minerals (WHO, 1997). Mineral matter may be ingrained in the coal seam or associated with adjacent or interlying strata, and may also be contributed by specific activities such as rock dusting. When dust is generated or made airborne, suspended particles tend to settle slowly with gravitational forces, but can remain airborne for extended periods of time depending on environmental conditions such as air velocity (Courtney et al., 1986) and particle properties such as size (ISO, 1995; WHO, 1999). Thus, miners working underground are routinely subject to occupational dust exposures ? with highly variable characteristics between and even within mines.

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 C. Chamberlain

The mining industry continues to underpin the regional economy. Australia, benefiting from a weak currency, receives 27% of the total goods export value from non-energy mining lead by aluminium, iron ore, gold and nickel. Consolidation has eliminated CRA, Comalco, North, Savage, Acacia, Ashton, Great Central, Aberfoyle, Placer Pacific, Plutonic, Normandy and RGC leaving Rio Tinto, BHP-Billiton, WMC, MIM and, increasingly, the South African companies Anglo, Gold Fields and Harmony as dominant players. Exploration stagnates with expenditure dropping 40% in Australia and 80% in PNG from peak levels. Major new regional developments include Rio’s West Angles iron ore project, Newcrest’s Ridgeway gold-copper mine and Inco’s Goro nickel-cobalt project in New Caledonia.

Jan 1, 2002

By R. M. G. Machunter

Computer models of metallurgical circuits are extensively utilised in design, and prediction of overall plant separation performance. As always, in the final optimised flowsheet design there is a compromise between the recovery of values and grade of the circuit output. This paper mathematically examines various circuit options for the generation of a heavy mineral concentrate from a generic mineral sands wet concentrator plant. Based on data derived from testwork, any particular mineral sand has a unique release curve describing the separation performance of the heavy mineral suite. Models are constructed that combine particular stage output streams as feed to other stages in various configurations. The ramifications of each option are discussed and reasons why one particular option is selected over the others examined.

Jan 1, 2005

By S. Hadley, M. Placha, M. Mishra, V. Choudhry

Under a DOE-funded project, four advanced flotation technologies (the Jameson cell, the Outokumpu HG Tank Cell, an open column and a packed column) were evaluated at the benchscale to identify the technology or combination of technologies that best improved fine coal recovery and reduced processing costs. The results indicated that two-stage application of the Jameson and packed column cells provided the optimal performance. Subsequently, proof-of-concept scale testing was conducted at the Cyprus Emerald Coal Preparation Plant. The results confirmed that levelized production costs were lower using two-stage cleaning with the Jameson cell followed by the packed column.

Jan 1, 1999

By D. E. Walsh

With the exception of the development of large scale mining equipment (haul trucks, draglines, shovels, etc.), there are likely few other candidates responsible for the ability to exploit large tonnage, low grade deposits, than the development of large capacity comminution equipment and circuits; crushers and grinding mills. Ball mills are often the final step in the comminution process and are responsible for providing what should be the optimum particle size distribution of ore to subsequent mineral concentration steps in the flowsheet. Because comminution processes are such high cost centers for milling operations, both capital and operating costs, an enormous amount of research has been conducted to study and model their performance, in order to improve efficiencies (Kelsall, et al., 1969; Austin et al., 1984; Napier-Munn, et al., 1999; Powell and Smit, 2001). With respect to modeling ball mills, estimates of the breakage rates for individual size classes of ore particles are fundamental, as are the particle size class breakage functions (the progeny of particle sizes produced from breaking a coarser particle size class), also termed appearance functions. Fundamental research into particle breakage in tumbling mills focuses on how much energy is input into single particles versus how they break and what size distribution of particles results. Several test methods, including JKMRC?s well known dual pendulum test and drop weight test, have been developed for the breakage of coarse particles down to 6 mm in size (Napier-Munn, et al., 1999). Work on the breakage of finer particles is still an area of intense research and single particle breakage is being investigated as are multiple particle, fixed bed methods (Hoffler and Herbst, 1990; Bourgeois et al., 1992; Whiten, 2007).

Jan 1, 2011

By D. J. Carpenter

Safe and successful mine closure represents a fundamental work element that needs to accommodate the geochemical conditions existing at the completion of the mining and ore processing effort. Given the interests in limiting costs and time associated with mine closure efforts enhanced prior understanding of the geochemical conditions likely to exist upon exhaustion of the economic reserves can provide important benefits. The purpose of this paper is to document the benefits associated with geochemical modeling and understanding how the ore formation process may impact mine closure efforts, using one ore deposit type as an example. Specifically, this paper will emphasize the geochemical processes leading to the formation of sandstone-hosted uranium roll-type deposits and how the resultant concentrations and distributions of ore and gangue phases need to be incorporated into understanding the geochemical conditions projected to exist at the end of mineral recovery efforts. The paper will describe the evolution of geochemical conditions leading to ore body formation and the geochemical effects induced by open pit mining and how these may be used to understand both the geochemical controls and constraints on residual mine water. In addition, a discussion will be provided on how these conditions may be simulated by solution equilibria and kinetic modeling to develop optimum approaches to achieve applicable closure standards. This paper will also discuss specific augmentations to existing industry standard solution equilibria and kinetic models and associated thermodynamic databases to maximize the predictive accuracy of the geochemical modeling results. The benefits of understanding the electrochemically reactive behavior of uranium and associated gangue phases and incorporating this behavior into mine closure efforts will be presented. The culmination of the benefits of the geochemical modeling will ultimately be the development of a sustainable approach to uranium mine closure that is based upon an engineered environment designed to return the ore body to stable geochemical conditions.

Feb 27, 2013

By G. Deschenes, W. Yen

Ammonium thiosulphate is a non-cyanide lixiviant for gold leaching. The major problem is the high reagent consumption. A combination of 0.3M (NH4)2S2O3, 0.03M CuSO4, 3M NH3 was used to leach a copper-bearing gold ore at pH 10.2 for 24 hours. 30 kg/t of thiosulphate was consumed. Oxygen and copper species were found to be responsible for thiosulphate decomposition. The thiosulphate consumption could be reduced to around 17 kg/t by adding chelating agent, reducing copper sulphate concentration to 0.001 M and replacing CuSO4 by NiSO4. The increase of pulp density might reduce the thiosulphate consumption to around 17 kg/t. By regulating the oxygen supply, the thiosulphate consumption could be reduced to 10 kg/t.

Jan 1, 2002

By D. B. Spears

The sillimanite group includes the aluminosilicate minerals sillimanite, kyanite and and alusite, all of which have the same chemical composition (Al2SiO5). This discussion also includes the closely related mineral, mullite(about Al6Si3O15), which, although rare in nature, is produced artificially for industrial use. All of the minerals in this group have a low coefficient of thermal expansion and high corrosion resistance. This makes them desirable for refractory applications, especially in the steel and foundry industries. Other uses include electrical insulators, abrasives and household ceramic products. The minerals in the sillimanite group decompose with an irreversible expansion at temperatures between 1,300° C and 1,600° C (2,372° F and 2,912° F). Sillimanite and and alusite have relatively small expansion on decomposition (4 percent to 6 percent) and, therefore, can be used as aggregates in refractory products. Kyanite’s expansion on decomposition is large (18 percent). So it is sometimes used to balance shrinkage of other materials such as clays in refractory mixtures. For applications requiring high-temperature volume stability, mullite is more desirable. As an additive, mullite improves resistance to creep and corrosion, and imparts thermal and electrical insulating properties.

Jan 1, 2005

By R. M. Corn

The Non-Time Critical Forest service CERCLA Action at Mansfield Canyon, Santa Cruz County, Arizona designated previous locators of unpatented mining claims as owners/operators of the Hazardous Waste Facility, retroactively liable for all reclamation costs including reclamation of mines acquired by the Forest Service. The CERCLA Action is based on non-existent tailings, a non-existent permanent resident, inaccurate and unreliable data and did not review or consider prior USGS and USBM data. The consequences of the Forest Service action include(1) reduced exploration, (2) loss of credibility, (3)public disillusionment and distrust.

Jan 1, 2000

By J. M. King

A crucial step in the acquisition by one company of the assets of another, the acquisition of the stock of another company, or the merger of two com-ponies, is the legal due diligence which needs to be performed in order for the acquirer to ascertain or confirm the obligations, liabilities and exposures to risk that are being assumed along with the assets or corporate stock being acquired. Where the obligations, liabilities, or exposures to risk arise from existing contracts, or from pending lawsuits, administrative proceedings, or threats of these actions, those matters are relatively straightforward to discover by careful review of the files of the party whose assets or stock is being acquired. However, where a company is engaged in ongoing mining or processing operations and has operated or owned mining proper-. ties, there are many sources of liability and exposure to risk which could have major adverse economic consequences to the acquiring party and which are not revealed, or at least are not clearly delineated, by the records of the company whose stock or assets are being acquired.

Jan 1, 1990

By Gino Vogt

In mechanized tunnelling operations, performance, consumption and safety are main factors for jobsites. One of the most important components effecting these factors, especially in slurry TBM operations, are Slurry Treatment Plants (STPs). Inadequately dimensioned and designed STPs create bottlenecks for tunnelling operation and jeopardize time schedules and performance. Inefficiently planned STPs could drastically increase consumption figures such as electrical power, bentonite, water polymers, etc. Inaccurately selected and treated suspension properties can cause a high-risk potential for the whole project. This paper debates the relevant key parameters for STPs from start to finish of a project and its results in influencing factors from the manufacturer’s point of view.

Dec 1, 2022

By Y. Wang

China is a big mining country with a long mining tradition and history. At present, there are nearly 200,000 different mines and 21 million workers. The total production value of mining makes up 6% of GNP. With the development of economy, the mining industry has played a more important role in our economic market, supplying more than 95% non-reusable energy, 85% of industrial and agricultural raw materials, over 75% of fertilizers and 30% industrial and agricultural water.

Jan 1, 2001

By R. L. Virta

Sixteen companies mined fuller’s earth in 11 states during 2004. Production during 2004, based on a preliminary survey of fuller’s earth producers, was 3.96 Mt (4.3million st) valued at $340 million. This compared with3.6 Mt (3.9 million st) during 2003, valued at $346 million. The 3.96 Mt (4.3 million st) probably includes some crude clay tonnage. And production of finished product probably was closer to 3.2 Mt (3.5 million st) in 2004. Georgia was the leading producer state of attapulgite-type fuller’s earth, followed by Florida. Georgia also was the leading producer state for montmorillonite-type fuller’s earth. It was followed, in descending order, by Mississippi, Missouri, Florida, Virginia, Illinois, California, Tennessee, Kansas and Texas.

Jan 1, 2005

By Greg J. Hasenfus, Allison M. Haines, Joshua M. Silvis

The floodable volume of longwall gob can be of great importance in developing accurate coal mine operation plans, particularly for mine water management and environmental control strategies. Given the inaccessibility and difficulty in direct measurement of gob characteristics following gob recompression, hydrologic, geomechanical, and spatial data and principles were used to solve for the porosity and height of the residual gob using a mathematical model framework and bulking-based techniques. Based on this approach, gob porosity of Appalachian longwalls appears to be tighter than previously reported, ranging between 4.99 and 14.31%. Residual gob height, as normalized with respect to mine extraction height, ranges between 1.90 and 2.45. A novel, bedding-based bulking approach is ampliative with respect to existing roof caving and bulking fundamentals, as it has greater explanatory value compared with the traditional, lithologic-based bulking application. The efficacy of using the residual gob characteristics determined by the mathematical model and bedding-based bulking is examined using a causal comparative method, whereby time series prediction of historical groundwater rebound is compared with observed mine pool elevation data. Prediction accuracy is significantly improved using a prototype model to calculate void volume of longwall gob, specifically, the dependence of porosity of the gob material upon the longwall width to overburden depth ratio for movement basins of subcritical and critical panel widths. The potential implication of these findings toward hydrologic, geomechanical, and ventilation studies of longwall gob could be significant.

Aug 13, 2021

By Adam Zanker

Smooth roll crushers are widely used as secondary crushers, operating most effectively when set for size reductions in a ratio between 3 or 4 to I. The feed supplied to these units varies from 13 to 102 mm in size and the product obtained ranges from 13 mm to about 20 mesh. Smooth roll crushers produce very few fines and absolutely no oversize. The diameter otfhe rolls varies with the clearance between them, feed size, and the coefficient of internal friction ofmaterial to be crushed, Detailed calculations of this relationship may be found in Unit operations of Chemical Engineering, (McCabe, W. L., and Smith, J. C., 1967, McGraw Hill, NY, Chapter 26, pg. 825). The geometrical arrangement of the roll crusher is shown on the accompanying sketch. A relatively simple relationship between the diameter of feed, the roll, and the gap between them is as follows:

Jan 6, 1980

By Reed Thorne

To many people, rescue from elevated, sometimes vertical, locations brings about thoughts of heroism mixed with brawn and self-sacrifice. Images are conjured of cliff rescues where the technical effort is hanging from a few seemingly small nylon ropes hundreds of feet above the ground. Such is the vertical realm of technical rope rescue. This is a technical field in which the author serves professionally as battalion chief of (rope) operations for a northern Arizona fire district, and as a private sector instructor to mines in the United States and Canada.

Jan 1, 1996

By Frank Agyemang, Zainab Nasrullah, Richard LaDouceur, Mehran Saddat

To sustain the circular economy, defence applications, and other renewable technologies, recycling rare earth elements (REEs) and other critical elements from their secondary resources is important. This cause has resulted in rigorous research and development for viable extraction and separation of REEs. Previously, Sm-Co recycling has been done with technologies, which fall under the categories of pyrometallurgy, physical separation, and hydrometallurgy. All these methods have limitations associated with energy, cost, and environment. Reportedly, the chemical leaching technology has successfully recovered and separated Sm-Co. Still, it has limitations associated with slow mass transfer and leaching kinetics, and there is a need to intensify the process to make it time efficient. This approach has also adversely impacted the environment by an extensive use of toxic, corrosive, non-selective, and expensive reagents. In this research study, chemical leaching of Sm-Co was performed using this new class of solvents, Deep Eutectic Solvents (DESs), which fall under the category of ion metallurgy. Four different DESs were used, proven to be green, non-toxic, biodegradable, cheap, and selective for cobalt over samarium by 82% leaching conversion. To improve the slow mass transfer and leaching time, this new technology of resonant vibratory mixing (RVM) was also tested. RVM intensifies mixing by establishing near instantaneous, low energy mixing conditions through resonance. It has been shown to improve the adsorption kinetics and was tested for the leaching kinetics. Four combinations of DESs were prepared, which are made up of two quaternary salts: Choline Chloride and Tetra Butyl Ammonium Chloride, and three organic compounds: Oxalic Acid, Urea, and Ethylene Glycol. These combinations were used for chemical leaching of Sm-Co with leaching factors of time, temperature, and type of DESs. After leaching, the samples were tested with and without resonant vibratory mixing with conditions of time, intensity (%), and type of DESs. Samples were analysed with Induced Coupled Plasma - Optical Spectroscopy (ICP - OES). Future work will involve a life-cycle assessment to assess the RVM technology with other conventional mixers, and an extensive study of DES properties to improve selective leaching.

Feb 1, 2025