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By Leroy O. Gieseke, John B. Begley

If the particles produced and transported in your plant are as chunky as rough crushed coal or as fine as cement, there are probably several conveying and elevating systems suitable for your operation. The problem is deciding which is most suitable in terms of space, energy cost, allowable product degradation, productivity, and angle of movement. Each conveying and elevating method should be fit to the products it can handle successfully, to desirable economics, and to suitability for the overall operating scheme. Matching along these lines will result in selection guides that should be useful for many years, although design evolution is expected for the materials handling equipment involved. There are several common bulk material handling devices for moving solids: belt conveyors, screw conveyors, bucket elevators, chain conveyors, and en-masse conveyors/ elevators. En-masse conveyor/elevator equipment is commonly compared and contrasted with the other devices. These comparisons often involve en-masse versus all others. En-masse has developed into a versatile technique because the machines can move materials horizontally, vertically, or in closed circuit. Such machines unload, elevate, store, reclaim, and distribute materials-all without ancillary equipment except for chutes and gates. Bulk material can be carried, as with a belt conveyor or bucket elevator; pushed, as with a flight or screw conveyor; bumped, as with a vibrating conveyor; blown, as with a pneumatic conveyor; fluidized, as with a dense phase pneumatic conveyor; or by applying internal forces to it to induce "en-masse" flow. Conveying en-masse is analogous to the flow of a fluid in an open channel, and elevating en-masse is analogous to the flow of fluid in a pipe. In the case of a fluid, flow is caused by a differential in pressure. With en-masse movement, flow results from resistance to shear induced by the movement of chain and flights.

Jan 12, 1980

By Dan Nilsson

Open pit mining is the strong sector of the American mining industry. In the middle of the 60's. 17-18% of the ore in metal mines was mined with underground methods. From the middle of the 60's to 1980 the production in open pit metallic mines increased from about 400 to close to 600 million short tons while at the same time the underground mine production decreased a little, from about 90 to about 80 million tons. Less than 15% of the ore prodction now come from underground mines. Large amounts of waste rock were also handled in the open pits. In the middle of the 60's about 600 milion tons were handled, in 1980 1,200 million tons were moved. This means that the average stripping ratio increased from about 1.5 to over 2.0 tons of waste rock per ton of ore, figure 1.

Jan 1, 1983

1. BOYD, JAMES. Statement on the Investigation of Natural Resources. Hearings before National Re-sources Economic Subcommittee, Committee on Public Lands, U.S. Senate, 80th Cong., 1st sess., on Investigation of the Factors Affecting Minerals, Fuels, Forestry, and Reclamation Projects, May 15, 16, and 20, 1947, pp. 125-131. 2. BUCH, J. W., HENDRICKS, T. A., AND TOENGES, A. L. Statement on the Investigation of Natural Resources. Hearings before National Resources Economic Sub-committee, Committee on Public Lands, U.S. Senate, 80th Cong., 1st sess., on Investigation of the Factors Affecting Minerals, Fuels, Forestry, and Reclamation Projects, May 15, 16, and 20, 1947, pp. 231-235. 3. CONGRESS, U.S. An Act to Provide for the Establishment and Operation of a Research Laboratory in the Pennsylvania Anthracite Region for Investigation of the Mining, Preparation, and Utilization of Anthracite, for the Development of New Uses and Markets, for Improvement of Health and Safety in Mining, and for a Comprehensive Study of the Region to Aid in the Solution of Its Economic Problems and to Make Its Natural and Human Resources of Maxi-mum Usefulness in the War Effort. Public, No. 812, 77th Cong., 2d sess. (S-357), ch. 764, approved Dec. IS, 1942, 2 pp.

Jan 1, 1962

By M. Saghaeian, R. Hejazi, L. Hosseini, M. V. Sheikhzadeh

HPGR equipment has been well proven to be energy-efficient in the first stage of grinding in iron ore beneficiation plants. Numerous advantages of utilising HPGR grinding prior to ball mill grinding, such as reducing the power consumption in a ball mill through generation of micro-cracks, has been thoroughly studied. Less attention has been paid to efficiency of the HPGR circuit rather than the downstream ball mill circuit. In this study the HPGR circuit has been optimised through feed size reduction by crushing, and feed iron content upgrading by dry cobbing. This optimisation leads to better operation of the HPGR, and a smaller product size which is expected to result in a lower wear rate of ball mill liners and balls. It is also expected that the top size of the ball mill balls be reduced. Additionally, by reducing the feed size of HPGR from 30 mm to 15 mm, it is possible to achieve similar K80 of HPGR product in lowered pressure, i.e. 2.5 N.mm-2 instead of 3.5 N.mm-2 which translates to ease of operation. Similarly in a given roll pressure, smaller feed sizes result in higher specific throughput of ~10% which means higher production capacities. The results also reveal that this optimisation increases the concentrate weight recovery by about 10%. It also results in slight increases in the Fe grade of the product iron concentrate. Keywords: HPGR, HPGR circuit optimisation, crushing prior to HPGR, dry cobbing prior to HPGR, ease of operation, concentrate grade optimisation, weight recovery optimisation

Jan 1, 2020

By V. F. Parry

The object of this report is to present certain pertinent data on the physical and chemical properties of South Arcot lignite and to present the results of several special tests to show how the raw lignite can be upgraded to superior fuels for certain special uses. The Bureau of Mines Branch of Coal Technology laboratories at Denver have advocated the drying and carbonization of all low-rank fuels for special uses and have introduced and developed new techniques for upgrading and refining noncoking coals. Application of these techniques to the South Arcot lignites was the object of the investigation, and this report presents significant data necessary for planning a fuel program based on utilization of dried and carbonized dusts. In general, the South Arcot lignite is similar in chemical properties to the high-moisture lignites found in the United States and has some physical properties similar to Australian brown coals. The samples submitted for test had lost moisture before delivery to the laboratory, and it has been necessary to estimate the analysis of the lignite in place in the mine. Various observations made in India by qualified technicians indicate that the bed moisture content of the entire seam is in the range of 54 to 56 percent. For estimating purposes in this report, the bed moisture content has been taken as 56 percent and the ash content of the fresh coal as 2.5 percent. The average analysis estimated for the as-mined lignite is: [Moisture percent 56.0 Volatile matter do.22.0 Fixed carbon do.19.5 Ash do.2.5 Heating value B.t.u. per lb. 4,890]

Jan 1, 1957

By W B. Edgar, I M. Platten, C A. J Towsey, B W. Cuffley

The evaluation of historical goldfields has been common over the past 15 years, reflecting changing economic conditions, improvements in knowledge and technology and lack of greenfield sites. Many goldfields comprise narrow gold-quartz veins, which are structurally complex with an irregular distribution of gold, have variable geometry and architecture and display late deformational effects. The study of historical mine records can be an important tool during early and advanced project evaluation, since it contributes to understanding the orebody, exploration target size and setting expectations. Mine records include documents such as plans, sections, reports, news cuttings, production tabulations, etc. A major advantage for the modern explorer is the capability of computer modelling to display this data in 3D. Historical records can give the explorer substantial information on various deposit characteristics, not least grade and geological continuity, geometry and architecture, mineralogy, metallurgical properties, bulk density and ground conditions. From an evaluation perspective, historical records can be used to support a Mineral Resource estimate, though its application will depend upon the quality and quantity of the data and judgement of the Competent Person. Effectively used, historical records can reduce geological uncertainty and focus evaluation efforts û thus reducing project risk.

Jan 1, 2009

By V. Jiricny

There is a growing need to process galvanized steel scrap from automobiles, etc., in order to remove the zinc coating that otherwise causes problems in remelting of the scrap in electric arc furnaces. One approach that has moved to the pilot plant stage is that of Metal Recovery Technologies, Inc., of East Chicago (MRI). That company leaches the zinc fiom the scrap with a sodium hydroxide solution. The leached and washed scrap can then be returned to the steel industry. What is left is a sodium hydroxidelzincate solution which must be processed to recover the zinc and the NaOH. Presently, this is done by MRI using electrodeposition on planar electrodes at moderate current density and the resulting zinc is in the form of fine powder which is hard to process into, say, zinc for galvanizing. MRI has supported an investigation of a novel electrode, the spouted bed electrode (SBE), for zinc electrodeposition. In laboratory cells, zinc particles with low porosity have been grown up to 3mm in size. Microanalysis of the deposited zinc showed low level of impurities. DC energy consumption values were usually in the range of 2-2.5 kWg which is well below the energy consumption of the existing cells (and of present-day cells for electrowinning from acid sulfate electrolytes). These results were achieved at current densities (few thousand A/m2) that are much higher than possible with conventional electrodes. Discussion is provided of the scale-up of the cell to a commercial scale.

Jan 1, 1998

By Bern Klein, Tichang Sun, Daozhen Gong, University of Science and Technology Beijing, Chunbao Sun, Stefan Nadolski

"This paper is focused on the effect of modifying the SAG mill/ball mill transfer size on the energy efficiency of SABC circuits. The transfer size is considered to be a parameter which provides operators with the opportunity to improve comminution circuit performance. In this study, the Moly-Cop tools package was employed to predict the energy consumption of SAG mill and ball mill circuits under different operating conditions. An Energy Benchmarking model was adopted to calculate grinding energy efficiency. The SABC circuit at the Huckleberry mine was selected for this case study. It was observed that after increasing circuit transfer size (T80) from the existing 3.3 mm to 4.8 mm, the Benchmark Energy Factor (BEF) of the SABC circuit decreased from 4.30 to 4.05. In terms of energy consumption of the SABC circuit, 1.17 kWh/t of specific energy saving was achieved through the transfer size optimization.It was also observed that when a transfer size was selected such that both SAG mill and ball mill circuits operated at their highest energy efficient states, the entire SABC circuit was the most energy efficient. The maximum energy efficiencies of these three circuits were all approximately 25% when compared to the minimum practical energy required to carry out an equivalent comminution duty. Single-particle compression breakage testing was used to determine the minimum practical energy associated with the Huckleberry mill feed. In combination with geo-metallurgical data, this study also provides an opportunity to perform dynamic optimization of SABC circuits."

Jan 1, 2016

By Makoto Ohlsuka

The ternary Ni2MnGa intermetallic compound is an intelligent material which has both a ferromagnetic property and a shape memory effect (SME). The use of the shape memory alloy films for an actuator of micro-machines is very attractive because of its large recovery force. The purpose of the present study is to investigate the effects of fabrication conditions and to clarify the relationships between these properties and fabrication conditions of the Ni-Mn-Ga films. The Ni-Mn-Ga films with a thickness of nearly 5 um were deposited with a radio-frequency magnetron sputtering apparatus using a Ni50Mn25Ga25 or Ni52Mn24Ga24 target. They were heat-treated at various temperatures between 873 and 1273 K for homogenization and ordering and then cooled in a furnace. The composition of the films depended on the sputtering power. The as-deposited films were crystalline and had columnar grains. After the heat treatment the grains widened and the grain boundary became indistinct with the increasing heat treatment temperature. The martensitic transformation temperature of the heat-treated films increased with increasing nickel content. Furthermore the effect of plastic deformation and constraint aging on SME is also investigated. After plastic deformation, the two-way SME was shown through the martensitie transformation and its reversion, The intensity of X-ray diffraction peaks from stress-induced martensitie phase was found. The constraint-aged films also showed the two-way 3ME by thermal cycling.

Jan 1, 2003

By Makoto Ohtsuka

The ternary Ni2MnGa intermetallic compound is an intelligent material which has both a ferromagnetic property and a shape memory effect (SMB), The use of the shape memory alloy films for an actuator of micro-machines is very attractive because of its large recovery force, The purpose of the present study is to investigate the effects of fabrication conditions and to clarify the relationships between these properties and fabrication conditions of the Ni-Mn-Ga films, The Ni-Mn-Ga films with a thickness of nearly 5 um were deposited with a radio-frequency magnetron sputtering apparatus using a NisoMn2sGa25 or Nis2Mn24Ga24 target. They were heat-treated at various temperatures between 873 and 1273 K for homogenization and ordering and then cooled in a furnace, The composition of the films depended on the sputtering power. The as-deposited films were crystalline and had columnar grains, After the heat treatment the grains widened and the grain boundary became indistinct with the increasing heat treatment temperature, The martcnsitie transformation temperature of the heat-treated films increased with increasing nickel content. Furthermore the effect of plastic deformation and constraint aging on SME is also investigated, After plastic deformation, the two-way SME was shown through the martensitie transformation and its reversion, The intensity of X-ray diffraction peaks from stress-induced martensitie phase was found, The constraint-aged films also showed the two-way 5MB by thermal cycling,

Jan 1, 2003

"Hematite pellets were electro-deoxidized to iron in molten sodium hydroxide to produce iron containing about 10-wt % oxygen. The anodic reaction was the evolution of oxygen on an inert nickel anode. Before the electrochemical reaction, there is a reaction between sodium hydroxide and ferric oxide to form sodium ferrite and, in order to compensate for the reduction in sodium oxide content, 1 wt % sodium oxide is added to the melt. In a laboratory cell, the cell voltage was 1.7 V with a current density of 5000 A m-2, a current efficiency of 90% and an energy consumption of 2.8 kWh kg-1.Introduction The iron and steel industry contributes about 2.3 bn tonnes/annum of the carbon dioxide to the atmosphere, which is about 10% of the total, and some believe that, in order to prevent a catastrophic rise in the earth’s temperature, carbon dioxide emissions must be reduced by 50% come 2050. However, by 2050, it is likely that the iron and steel industry would have grown significantly so that the production may have risen to 2 or 3 bn tonnes/year so in order to meet the 50 % reduction on today’s figure, the carbon dioxide may have to be reduced to 25% or less, which is a very demanding requirement. There are probably three ways of reducing the carbon dioxide output:1. By capture and sequestration, but this may be technically very demanding.2. Reduction using hydrogen in place of carbon."

Jan 1, 2009

The Waste Isolation Pilot Plant (WIPP) is adding a third fan to operate in parallel with, and supplement, its two existing main fans. An engineering analysis conducted in 1995 identified the need for improved system availability and efficiency. The WIPP, located near Carlsbad, New Mexico, is a U.S. Department of Energy (DOE) Carlsbad Area Office facility designed to permanently dispose of U.S. defense-generated transuranic waste in a deep bedded salt deposit. Engineers at the WIPP performed a feasibility analysis for either modifying, supplementing, or replacing its two main mine fans. Since the centrifugal fans were installed in 1988, multiple operational and performance concerns have been identified. A comprehensive engineering study was conducted (K. McDaniel, et al., 1997) to: identify and quantify operational concerns, evaluate possible alternatives, and recommend an optimum solution. The study indicated that adding a third single-duty centrifugal fan similar to the two existing fans, and equipping that fan with Inlet Van Controls (IVCs) was the best choice. This alternative provided the most desirable combination of operational readiness, and improving system performance. The fan installation project accommodates several operational and scheduling constraints. WIPP is scheduled to receive waste in May 1998. This milestone is proceeded by an operational readiness review. Fan installation could not be allowed to compromise the WIPP's ability to declare facility readiness and had to minimize operational disruptions during the system tie-in. All engineering for the project is completed and physical modifications started in July 1997. The project will be completed in early 1998.

Jan 1, 1998

By Lon Santis

In 1923, Ralph Assheton compiled a report for the Institute of Makers of Explosives (IME) on accidental explosions in manufacturing plants. The report chronicles the type and amount of explosive involved in the event and the effects and distances to nearby buildings and workers for over 100 events from 1880 to 1916. Apparently, this report was never published but served as the origin of the IME’s first intra-plant distance table published in Pamphlet No. 3 in 1926. The effort was a parallel effort to the IME’s development of the American Table of Distances. The intra-plant distance table has never been changed by the IME and follows the US Department of Defense (DoD) standard very closely. This paper freshly compiles the data from the 1923 report and analyzes it with modern methods not generally available in 1923. Interestingly, the analysis indicates that the original intra-plant distance tables were established primarily to protect workers from serious injury and that preventing propagation was a side benefit. The data shows that a strong relationship exists between the probability of injury and the traditional K-factor. The data indicate that people in the open are better protected than those inside structures and that barricades reduce risk close to an event. Individuals at the intra-plant distance had a 95 percent chance of receiving no worse than a minor injury. A comparison of the data to explosive event consequence models indicate the models are overly conservative in regards to risk inside inhabited building distances.

Jan 1, 2010

By James H. Williams

More than 100,000 residents of Springfield and surrounding communities live on karst (sinkhole) terrain on the Springfield Plateau in southwestern Missouri. The city occupier much of the headwaters area of Wilson Creek basin, which is underlain by the Burlington Limestone (Mississippian), a cavernous, massively bedded formation averaging 150 feet in thickness. Sinkholes, some as deep as 75 feet, pock-mark the uplands. Stony red residual clay mantles the pinnacled limestone bedrock. Surface water lost to sinkholes and losing reaches of upstream areas resurges in springs and estevellas (reversible sinkholes) in the lower reaches of Wilson Creek. The Springfield Southwest Treatment Plant, an activated sludge process sewage treatment facility, situated about mid-basin at the confluence of Wilson Creek and a tributary, South Creek, serves the entire city. Effluent from the treatment plant together with industrial, street-wash and other waste from the-headwaters of the basin have degraded both surface and ground water quality in much of the Wilson Creek watershed. The area affected includes Wilson's Creek Battlefield National Park and recreational reaches of James River below the mouth of Wilson Creek.

Jan 1, 1970

By A. W. Henderson

This investigation was performed to develop chlorination methods for extracting tungsten from scheelite and from an ore concentrate containing a mixture of scheelite and wolframite. On a laboratory scale with proper temperature control using elemental chlorine, over 90 percent extraction of tungsten is achieved. Carbon and sulfur dioxide were studied as reducing agents. The effects of salts such as calcium fluoride and sodium chloride were studied as additives to increase extraction and to reduce impurities in the volatile tungsten chloride product. Sodium chloride reacts with ferric chloride to form a nonvolatile double salt; whereas the chlorides and oxychlorides of tungsten are volatile and consequently condense free of iron. Separation of tungsten from molybdenum from an equal molar mixture was successful by fractionally distilling the oxygen-free chlorides and by selectively condensing the oxychlorides. Yields of 60 and 80 percent, respectively, were achieved for separating the less volatile tungsten chlorides containing less than 0.5 percent molybdenum.

Jan 1, 1965

By A. Boehm

Mineral selective flash roasting (Steiner process) in oxidizing atmosphere was tested successfully for the efficient low intensity magnetic separation of siderite from ankerite and other gangue minerals within the ore of the Steirische Erzberg, Austria. The calcium, magnesium and manganese containing siderite turns selectively into a ferromagnetic oxide phase while ankerite remains paramagnetic. The expulsion of CO2 increases the volume specific surface depending on the selected temperature. Unlike pure iron oxides absorbing SO2 below 530°C, the calcined siderite (enriched in the magnetic product of the Steiner process) acts as a sorbent for SO2 between 500 and 820°C. The effect was studied by thermogravimetric analysis and particle bed tests complemented with neutron thermo diffractometry (D20/ ILL). The energy input was simulated with the help of a tube furnace. The composition of the artificial combustion gas permeating the bed was close to that measured in pilot scale tests (6 % CO2, 12 % O2, 700 vpm SO2). The evaluation of data relating the SO2 variation in the off gas monitored by electrochemical cells to the actual phase composition revealed an intermediate ferrite phase as absorber. During the rapid decomposition in oxidizing atmosphere starting at 500°C the occurring siderite alters to a (CaO, MgO, MnO)Fe2O3 ferrite as an intermediate phase accompanied with sudden SO2 absorption. SO2 disintegrates the ferrite structure forming MgSO4 and MnSO4, taking Fe2O3 as a catalyst. Ankerite (enriched in the non magnetics of the Steiner process) starts to absorb at temperatures above 1000°C forming gypsum. The findings support the SO2 controlled operation of the Steiner process by ?autodesulfurisation?. It explains aspects of the SO2 implementation reactions within off gas recycling in Austrian sinterstrands. Keywords: magnetising flash roasting, neutron thermo diffractometry, SO2 absorption, siderite, ankerite

Sep 1, 2012

By J. R. Koehler

Effective barrier pillar design is essential for safe and productive underground coal mining. This U.S. Bureau of Mines report presents an overview of available barrier pillar design methodologies that incorporate sound engineering principles while remaining practical for everyday usage. Nomographs and examples are presented to assist in the determination of proper barrier pillar sizing. Additionally, performance evaluation techniques and criteria are included to assist in determining the effectiveness of selected barrier pillar configurations.

Jan 1, 1995

By Alan J. Fejes

As part of its mine subsidence research program, the Bureau of Mines and the American Electric Power Co. cooperated on a study, conducted at the Price River Coal Co. No. 3 Mine, directed toward developing the capability to estimate the surface subsidence resulting from longwall mining in a geologic, topographic, and mining environment common to coalfields in the Western United States. Subsidence was monitored at the No. 3 Mine over two adjacent longwall panels. The subsidence study area was reduced when the two planned panels were reduced in length because of equipment failure and a mine fire. Subsidence was measured for 21 months. Subsidence continued for 6 months after mining had been completed. A maximum of 2.2 ft of subsidence occurred over the two longwall panels mined at an overburden depth ranging from 300 to 1,500 ft.

Jan 1, 1986

By Joseph B. Cummings

The Twin Buttes camp embraces eight mines in the Pima mining district. The first mining claims in the camp are said to have been located in 1876, but little mining was done until 1905. Intermittent operation of five of the mi.nes to 1928 yielded 388,231 tons of ore averaging 6.19 percent copper and 8 small tonnage of high-grade oxidized zinc ore. While the Bureau was investigating the area, one mine was active, and it started to produce in 1944. The mines of the Twin Buttes camp are at or near contacts of intrusive granite with Paleozoic limestones and quartzite. The ore shoots lie in metamorphosed sediments adjacent to a zone of garnet rock that separates the ore from the footwall granite. Small fissures that originate at the contact and cut the sedimentaries appear to have been controlling factors in ore deposition. No important ore bodies are exposed at the surface, and those developed wore discovered by sinking on the fissure veins to the contact zone. Most of the area overlying the favorable ore zone is covered by alluvium ranging in thickness from 5 to more than 20 feet.

Jan 1, 1950

By R. Burns, A. I. A. Salama, M. W. Mikhail

"Large amounts of oil sand tailings are produced in the Fort McMurray area, including sand, clays, and misplaced bitumen. The objective of the present study (as part of the overall engineered tailings program) is to select and evaluate the role of hydrocyclones in removing most of the solids from the tailings slurry and producing an underflow product containing about 75% solids.Multistage cyclones were evaluated in pilot plant tests. Slurry feeds with different percents solids and increasing ratios of superfines (–44 µm) were used in testing multistage cyclone circuits. A two-stage Linatex separator circuit gave high recovery to the underflow of 98.8% to 99.6% by mass with the desired high solids content in the underflow of 73% to 75% by mass. Changes in feed solids content (20% to 50%) had little or no influence on cyclone underflow recovery and solids content. The keys to achieving such results were the apex control mechanism and operation at relatively low feed pressure (<60 kPa for 23 cm F cyclone) when the feed solids content was high. Increasing superfines above 7% by mass in the feed resulted in a significant reduction in the recovery to the underflow, probably due to the heavy medium generated by excessive amounts of clays in the cyclone. Pilot plant results were better than those predicted by available cyclone simulation models in terms of recovery and solids concentration in the underflow.Increasing cyclone diameter from 23 cm for the Linatex separator to 51 cm for the Krebs cyclone appears to have little or no effect on size cutpoint."

Jan 1, 1997