Search Documents

By J. O. Stephens

During the late 1940's and early 1950?s, the Westinghouse Combustion Turbine Division built and demonstrated a residual oil-burning locomotive on six eastern railroads. Plans were made to convert to burning pulverized coal, and a single combustor was operated at a full-pressure condition in the laboratory for about two years. During the mid-1960's to mid-1970's, there was considerable interest in coal-burning MHD and a combustor was developed which would also be applicable to combustion turbines. In the early 19801s, the BCR National Laboratory (BCRNL) became affiliated with the University of Pittsburgh, and a program was begun, supported by the Stare of Pennsylvania, to develop an all-purpose combustor for use with industrial and utility boilers and eventually with combustion turbines. In this paper, we review the work of almost 40 years, indicate our present position, and propose steps to be taken leading to efficient and environmentally acceptable power generation from coal, and specifically to coal-burning locomotives.

Jan 1, 1986

By Robert Hochscheid

When the original water-only cyclone patents were established in the 1950?s, the supplies of low cost oil and natural gas were abundant and low selling prices for metallurgical and steam coal provided little incentive for developing more sophisticated coal cleaning systems. Bituminous coal sold for less than $5.00 per ton, and in this period many domestic coal producers discarded to the slurry pond the coal finer than 0.5-mm. For many producers, the selling price would not permit the recovery of the capital and operating costs required for dewatering and drying the fine coal. Water-only Cyclones Clean Fine Metallurgical Coal The first broad interest in the water-only cyclone became evident in the mid- 19601s, and though some work was done on coarser coals, investigators were particularly interested in cleaning coal finer than 0.5-mm. Flotation was the only fine coal cleaning method that was broadly accepted, but short-comings were recognized and investigators were looking for an effective fine coal cleaning device or system. Because of the greater market value and the need for reducing pyritic sulfur in metallurgical coals, much of the development work of the 1960's was done on coking coals.

Jan 1, 1981

By Aixiang Wu, Minjie Zhang, Zhuen Ruan, Yiming Wang

This paper combines theoretical and experimental analysis to conduct relevant research to improve the accuracy of predicting paste yield stress by slump flow. The analytical model of slump flow for yield stress is derived based on a mini-cylindrical mold with a height-to-diameter ratio of 1. It shows that the dimensionless slump flow is a monotonic decreasing function of the dimensionless yield stress and is independent of the material type (specific gravity), which provides a theoretical basis for quantifying the rheological properties of paste with slump flow. Three different tailing-prepared pastes were tested for their slump flow and implemented rheological tests simultaneously. The yield stress is obtained based on the Bingham model fit, as the measured value of the yield stress is substituted into the derived theoretical model. The studied pastes yield stresses range from 34.78 to 524.08 Pa, with corresponding dimensionless slump flow of 3.43 to 1.09. The results showed that the calculated slump flows were generally greater than the measured values. The analysis showed that this was mainly due to the thixotropy of the paste, with minor deviations ranging from − 1.5 to 5.8% for the less thixotropic pasted prepared from tailing C. An approximate analytical solution for yield stress as a function of slump flow is obtained using Taylor’s formula. However, it is unsuitable for predicting the yield stress because the yield stress calculated by this function is much higher than the measured value. The empirical yield stress model was constructed and experimentally verified. The results show that the empirical formula has high accuracy and good generality. The deviation of the studied pastes is between − 15 and 5%, which provides a practical method for rapid and accurate prediction of paste yield stress in mine sites.

Jun 1, 2023

By C. Feng, W. Song, B. Moudgil, P. Zhang, W. Xiao

Separation of dolomite from phosphate is the most challenging problem in phosphate mineral processing. Over 50% of the future phosphate reserves in Florida contains too much dolomite to process using the current industry practice. The FIPR Institute has collaborated with worldwide experts in the field to address this issue. As a result, the industry is now offered with three feasible options. Optional 1 involves crushing and grinding of high-dolomite phosphate pebbles followed by dolomite flotation at slightly acidic pH using a new collector that does not require phosphoric acid as a phosphate depressant, achieving a final concentrate analyzing less than 0.9% MgO at about 87% P2O5 recovery. Option 2 offers three methods for reducing MgO content in the concentrate from the Crago process, including adding a dolomite depressant in the rougher flotation step, dolomite flotation of the cleaner concentrate, and scrubbing the cleaner concentrate in quartz sand. These methods could reduce MgO content in the final concentrate by 20-40%. Option 3 is a gravity separation technique using an innovative separation jig, and may well be the ultimate solution to the problem. INTRODUCTION Magnitude of the Dolomite Problem With the depletion of the higher grade, easy-to-process Bone Valley deposits, the central Florida phosphate industry has moved into the lower grade, more contaminated ore bodies from the Southern Extension. The phosphate deposits in the Southern Extension may be divided into two zones: an upper zone and a lower zone. The upper zone is readily processable using the current technology, but the lower zone is highly contaminated by dolomite. Geological and mineralogical statistics (Hassan and Bogan, 1994) show (Table 1) that more than 50% of the phosphate resource would be wasted if the lower zone is bypassed in mining, and about 13% of the resource would be wasted if the dolomitic pebbles in the lower zone were discarded.

Jan 1, 2019

By M. C. Rockwell

There are approximately 1,800,000 t of discarded dolomitic-limestone tailings from the Gays River lead/zinc mining operation in Nova Scotia. Neutralization effectiveness similar to an agricultural grade limestone and low contents of residual metals make the tailings a suitable source' of soil conditioner material for the local market. However, the fine particle size, 98% passing 147µm, and a high moisture content make their handling and application difficult. Agglomeration of the tailings into relatively small hard pellets was investigated and difficul¬ties were overcome. Pellets with a range of pH values and various amounts of soil nutrients and moisture content less than 10% were obtained, from tailings containing 20% initial moisture, through the addition of less than 15% selected materials.

Jan 1, 1985

By Robert A. Jankowski, Charles A. Babbitt, Natesa I. Jayaraman

Today, approximately 31% of underground coal mining operations have designated occupations or areas with more stringent (below 2.0 mg/m3) respirable dust standards in place. Many U.S. coal mines have been able to maintain compliance with very low dust levels, and the Bureau of Mines, in an effort to identify those factors contributing to low dust levels, completed a survey of twelve continuous miner sections which were able to maintain their dust levels at or below 0.5 mg/m3. The quantity and quality of face ventilation appeared to be the most important factor in controlling dust exposure. The results directed Bureau research towards identifying improved face ventilation techniques for reducing quartz dust levels on continuous mining operations. This research has involved the evaluation of a half-curtain face ventilation technique which reduces the cross-sectional area of the entry, thus increasing the air velocity over the operator. The Bureau has also conducted extensive laboratory studies to compare tubing versus brattice, including an evaluation of both systems in a crosscut turn. In an effort to improve ventilation and reduce dust exposures of roof bolter operators working downwind of the continuous mining machine, the Bureau has evaluated two novel face ventilation systems. The first system consists of a fan discharge tubing technique which routes dusty air away from the return entry being bolted. In a technique similar to the fan/tubing concept, exhaust air from the upwind continuous miner face can be scrubbed using a dust collector to capture a portion of the dusty air, clean it, and supply it to the bolter operators as a split of clean intake air. A better understanding of face ventilation techniques should lead to solutions to the problem of more stringent dust standards due to quartz.

Jan 1, 1989

By Nawal Kishore, Nilesh Pratap Singh, Amit Kumar Verma, Vikram Seervi

In India, demand for coal exceeds its countrywide supply, despite its natural abundance, due to failure to achieve high production targets, especially in opencast mines, which are responsible for 94.98% of total raw coal production within the country. Employment of technological solutions, such as surface miners, is key to achieving higher coal production and productivity in an eco-friendly manner, especially in the populated areas adjacent to the mining zone and, hence, require restricted blasting operations. It eliminates blast hole drilling, blasting, and primary crushing units, thus reducing related environmental hazards like ground vibration and fly rocks. This paper encompasses the applicability, advantages, constructional features, and performance assessment models for each working mode of a surface miner. The current paper discusses the correlation between coal production and key productivity indicators, namely, machine shift-time, pick, and diesel consumption of surface miner in three different geo-mining conditions. Furthermore, relationships between machine shift-time, pick, and diesel consumption of surface miner and coal production were evaluated through bivariate regression analyses along with their coefficient of determination. These key productivity indicators of surface miner follow polynomial relationships with coal production on a daily and monthly basis, having Pearson correlation values from 0.774 to 0.907 and coefficient of determination, from 0.664 to 0.909 in opencast coal mines.

Jan 20, 2023

By Missy Isaman

"Mixed ground tunnels come in all kinds. In rock tunnels with possible faults and high pressure water, the challenges are many. With the advent of Crossover TBMs, contractors can minimize machine wear in such conditions while maximizing efficiency. The newest generation of Crossover is exemplified by two projects in Albania and Turkey. A 5.56 m Crossover TBM destined for Turkey’s Gerede Water Transmission will be assembled using Onsite First Time Assembly (OFTA) from within an existing tunnel. The unique machine will bore through 30 fault zones requiring the TBM to be sealable to up to 20 bar so pre-consolidation grouting can be done. If boring under pressure is required, the TBM will bore sequentially using the screw conveyor fore and aft gates. Skewing further towards hard rock, a unique 6.2 m diameter Double Shield TBM with Crossover features was designed for Albania’s Moglicë Headrace Tunnel. The machine features closure doors and a sealing system to contain inrushes of water until they can be grouted off. This paper will discuss the unique aspects of the Crossover designs, including their inception as based on past projects in difficult ground, and their utilization at the two current projects. INTRODUCTION Specialized tunnel boring machines have been made for years to tackle specific types of ground conditions. Traditional types of TBMs bore within a specific set of ground conditions. If a project is located in a competent granite face, then a Main Beam machine is a good solution. In soft ground, Earth Pressure Balance (EPB) machines are the method of choice. Years of experience and engineering advancements have made both types of machines fast and economical solutions for tunneling. Unfortunately not all ground conditions are a perfect swath of one material, and the need for a more diverse machine is apparent."

Jan 1, 2016

By P. K. Kaiser, M. Cai

When designing an efficient and effective support system for burst-prone ground, it necessary to select the most appropriate, i.e., the ‘right’ support components, including areal and reinforcement components. For this paper, it is assumed that the areal support is not the weakest link and the support performance is controlled by the rock reinforcement and holding components (bolts). We discuss the loading modes of rockbolts under static and dynamic loadings and analyze published data from laboratory and field tests. The mechanisms of energy absorption of dynamic rockbolts are presented and rockbolts are categorized based on factors such as energy absorption capacity, energy absorption rate, direct and indirect energy absorption capacities, rock mass bulking or displacement control, and shearing resistance capacity. Guidelines for selecting the ‘right’ rockbolts to build an effective rock support system for burst-prone ground are provided.

Apr 26, 2022

By B. H. Johnston, B. N. Doyle

Introduction In 1983-84 Kidd Creek Mines Ltd. in Timmins, Ontario, started up the second commercial zinc pressure leaching plant based on the Sherritt Gordon Mines Ltd. direct pressure leach process. The first plant using this process was that of Cominco Ltd. at Trail, B.C. (Parker, 1981; Martin and Jankola, 1985). The Kidd Creek plant was constructed to take advantage of the extra capacity that the existing purification, cell house, and casting sections had in comparison to the roasters and acid plant. In addition, pressure leaching offered flexibility in other areas such as treatment of low grade concentrates. The process design package and the detailed design of the autoclave system was carried out by Sherritt. The detailed design for the rest of the plant was done by Cambrian Engineering Ltd. under the direction of Kidd Creek. The construction and commissioning of the plant has been described earlier (Johnston, 1983). This paper describes, briefly, the application of the direct pressure leaching process for zinc concentrates and the integration of the pressure leaching plant into the main zinc plant at Timmins. It discusses some of the startup problems and changes made to the plant. The damage following a fire inside the autoclave is also described. The subsequent repair and recommissioning of the autoclave has enabled Kidd Creek to demonstrate the originally sought advantages of pressure leaching and to take advantage of their extra cell house and casting capacity to produce more zinc. Process principles The development of the direct pressure sulphuric acid leach of zinc sulphide concentrate at temperatures above the melting point of sulphur and at elevated oxygen pressure has been described in detail in a number of papers (Martin and Jankola, 1985; Johnston, 1983; Veltman and Bolton, 1980; Kawulka et al., 1975; Veltman et al., 1977). The most significant aspect of the process is that sulphidic sulphur is converted to elemental sulphur in reactions that can be simply described as follows. ZnS + H2SO4 + 1/2 O2 ZnSO4 + S° + H2O (1) FeS + H2SO4 + 1/2 O2 FeSO4 + S° + H2O (2) The rates of these reactions increase with temperature. However, at temperatures above the melting point of sulphur, 12°C, the presence of a surface active agent is necessary to prevent the occlusion of the sulphide particles by elemental sulphur and the consequent termination of the leach. The zinc that is dissolved according to reaction (1), after purification of the zinc sulphate solution, is recovered by electrowinning. The iron that is put into solution according to reaction (2) is further oxidized to the ferric state and subsequently, as the acidity decreases, precipitates as hematite or as complex basic sulphates. MINERALS AND METALLURGICAL PROCESSING Examples of this are shown below. 2FeSO4 + H2SO4 +1/2O2 - Fe2(SO4)3 + H2O (3) Fe2(SO4)3 + 6H2O - Fe2O3.3H2O + 3H2SO4 (4) 3Fe2(SO4)3 + 14H2O - 2(H3O)Fe3(SO4)2(OH)6 + 5H2SO4 (5) (hydronium jarosite) The conventional zinc process involves concentrate roasting to produce zinc oxide and sulphur dioxide. The zinc oxide is leached in spent electrolyte and the sulphur dioxide is converted to sulphuric acid. The pressure leaching process can, therefore, be used to replace conventional concentrate roasting, sulphuric acid manufacture, and atmospheric leaching with one unit operation. Integration of pressure leaching into the Kidd Creek flowsheet A block flowsheet of the Kidd Creek zinc plant, with the new pressure leach plant integrated, is shown in Fig. 1. The original plant, which was constructed in 1972, is based on standard electrolytic zinc plant technology. Concentrates are dead roasted to remove sulphur. Sulphur dioxide is treated to produce sulphuric acid. Calcine is leached in two stages using cell-house electrolyte. Iron is precipitated as jarosite and solutions are purified to remove copper, cobalt, nickel, and cadmium to provide feed for a partially mechanized cell house. Zinc is plated from solution, and the resulting cathode is melted, cast, and sold (Johnston, 1983). The integration of the pressure leaching plant into the main zinc plant is relatively simple. As shown in Fig. 1, a fraction of the zinc concentrate and spent electrolyte are fed to the pressure leach autoclave, while part of the calcine from the roaster is used as a neutralizing agent in the oxidation step along with. the jarosite leach solution. The main exit stream from the pressure leaching plant is the slurry discharged from the oxidation step, consisting of neutral zinc sulphate solution, unreacted calcine, and precipitated iron oxides. This slurry is transferred to the neutral leach step in the main zinc plant. The leach residue from the pressure leaching step, consisting of basic iron sulphate and elemental sulphur, is washed and impounded along with the jarosite residue produced in the main plant.

Jan 1, 1987

By F. B. Kuhnow

When performing blasting operations in open pit settings, energy is released and transmitted through the geology. Some negative effects can have significant impacts on mining operations and adversely affect mine production. This technical paper presents recommendations for blast design to prevent damage due to ground motion from blasting on adjacent concrete structures of underground operations. The paper includes a case study describing a problem regarding an open pit mine expansion and asks whether production blasting will damage concrete shaft structures due to blast stress waves and blastinduced ground motion. Based on the results, a set of criteria is provided to implement in current and future mining operations that involve blasting near underground concrete structures. A set of techniques on how to improve vibration levels for safe operations is also presented. Knowledge of particle velocity and wave propagation for site-specific circumstances to determine a safe level of vibration is recommended. Emphasis is placed on making use of electronic detonators and early delay detonators to achieve successful levels of vibration. A dynamic analysis is necessary to determine if vibration from blasting can damage the concrete shaft structure. When reinforced concrete structures are subject to blast loading, both concrete and steel are subject to very high strain rates. As opposed to static loads, when subject to high strain rate loads these materials increase their strength significantly. In fact, they increase by more than 50% for reinforcing steel, by more than 100% for concrete in compression, and by more than 600% for concrete in tension. This finding is of significant importance in mining operations because it allows an increase in flexural capacity of individual members as a result of high strain rates. Therefore, an elevated ground vibration (PPV) or particle velocity is permissible when blasting takes place near concrete structures.

Jan 1, 2014

The properties of interfacial water at hydrophilic surfaces are of great importance in many technological areas including flotation, solid-liquid separation, dispersion and emulsions, flocculation, adsorption, corrosion, and soil contamination. This paper examines the use of FTIR/internal reflection spectroscopy (FTIR/IRS) to study the spectral characteristics of interfacial water at silica surfaces. FTIR spectra were characterized by consideration of the OH stretching region (3000-3800 cm-1) associated with the vibrational spectra of interfacial water. The broad peak in this region was deconvoluted in order to isolate overlapping spectral features that describe the nature of hydrogen bonding in interfacial water. Three distinct bands were found; -3600 cm-1 (free OH), -3400 cm-1 (incomplete tetrahedral coordination), and -3240 cm-1 (complete tetrahedral coordination) and the variation of their intensities with pH was found to be significant. This spectral information helps to explain orientation and bond ordering of interfacial water molecules at hydrophilic surfaces.

Jan 1, 1998

By A. A. Jonke

The combustion of fossil fuels in a fluidized bed of calcined limestone particles is a potentially efficient and economically attractive process for the generation of steam for electric power production and other uses. The process results in greatly reduced emissions of both sulfur oxide and nitrogen oxide pollutants. Development work, evaluations and design studies are being carried out by various organizations under contract with the U. S. Environmental Protection Agency and the Dept. of Interior (Office of Coal Research). The AEC's Argonne National Laboratory is one of the principal participants in the development program under interagency agreements with EPA and OCR. This paper covers the principal reasons for developing fluidized-bed combustion, its advantages and disadvantages over conventional combustion methods, and some of the potential applications of the process. The participants in the multi-organizational program, the sponsoring agencies, the general status of development of the overall project, and the chief program areas that still require resolution are discussed. The main features of the program of work at Argonne National Laboratory and the results achieved so far are also included.

Jan 1, 1974

By David E. Nicholas

Design of underground openings is becoming more critical as the mine deposits become lower in grade, initial investments increase, ore depth increases, additional safety regulations come into law, and increased ore recovery is required for conservation of minerals. Stability of these openings is dependent on the strength of the rock mass and the pre-mine stress field. The rock mass is composed of solid blocks of rock (rock sub- stance) and structural features (faults, joints, bedding, etc.). Methods of testing the rock mass strength are improving and be- coming more common, however it is difficult to justify the high cost of large scale testing for an initial mine design. An alternative to testing the rock mass is to measure the rock substance and the structural features separately, and then combine them to estimate the rock mass strength. The rock mass strength will vary depending on the orientation of the opening with respect to the structural features. The other factor affecting the stability of underground open- ings is the pre-mine stress field. Methods are available to measure "directly" the pre-mine stress in competent and relatively massive rock. These methods are costly to employ, therefore, they may not be justified in an initial study. The pre-mine stress field can be estimated based on the structural relationships formed from past tectonic events.

Jan 1, 1976

By Gordon B. French

In order to better understand the relation- ship of underground and surface oil shale processing systems, a block flow chart is presented in Fig. I. From this figure only modified in-situ and Room and Pillar underground mining are currently committed and into the Detailed Design and Construction phases. Figure II illustrates the times required (Federal land site) to bring oil shale operation into production. As this example shows, only those companies having progressed beyond the exploration stage have a chance to obtain oil shale production within the next 10 years. A more detailed breakdown of the oil shale development for those on private lands or having already obtained Federal lease lands is shown in Fig. III for shale oil development (without major regulatory changes).

Jan 1, 1981

By Amar Prakash, V. M. S. R. Murthy, Ajoy Kumar Singh, Avinash Paul, John Loui Porathur

Weak, layered, and fragile rock mass formation, if not supported properly, is subject to roof failure thereby affecting safety and productivity in underground coal mines. Though Central Mining Research Institute – Indian School of Mines Rock Mass Rating (CMRI-ISM RMR) based well-defined support design guidelines are established, still occurrence of roof failures in underground coal mines is a real matter of concern for mining engineers and researchers. Numerical modeling techniques are successfully used by several researchers by simulating rock mass condition for stability assessment of mine openings. The analysis becomes crucial in case of weak and fragile rock formation. The present research envelops the determination of 31 cases of rock load by CMRI-ISM RMR under different geo-mining conditions followed by the development of modified Rock Mass Rating (RMR), i.e., rock mass rating dynamic ( RMRdyn) by incorporating P-wave velocity as a new parameter. The rock load determined using RMRdyn and numerical models was correlated and found in close agreement. In addition, the deviation in rock load determined by all the three approaches, i.e., CMRI-ISM RMR, numerical modeling, and RMRdyn, was compared with the actual field data. The percentage deviation obtained in RMRdyn and numerical modeling is less compared to CMRI-ISM RMR.

Sep 1, 2023

Experimentation was performed on the flotation of apatite and dolomite separately using anionic collectors in the presence of Mycobacterium phlei. Also, the flotation of mixtures of dolomite and apatite in the presence of anionic collectors and in the absence and presence of the bacterium were studied. It was found that M.phlei functions as a depressant for both minerals. However, it functions as a better depressant for dolomite than for apatite. Experimentation was extended to two different Florida dolomitic phosphate rocks. In this investigation a concentrate grade of less than 1.0% MgO was achieved.

Jan 1, 1997

By D. M. Larsen

Since start-up in 1985, the Cannon Mine has produced and shipped a 170-g/ton (5 oz/ton) gold flotation concentrate to various smelters for gold and silver recovery. Several processes have been investigated to economically produce done' at the mine site from the refractory concentrate. This paper describes laboratory and pilot scale test work used in the process design and engineering. feasibility study of a 73-t/d (80 stpd) pressure oxidation and carbon-in-leach (CIL) facility. The designed pressure oxidation circuit utilizes a series of verti¬cal autoclave units operating at 170°C (338F) and 1.4 MPa (200 psig). Projected operating costs are discussed.

Jan 1, 1993

By M. Kane, O&apos

BHP Iron Ore initiated research programs in January of 1995 to develop long term plans for decommissioning of the waste rock material at their Mt. Whaleback operation. More than 2 billion tonnes of waste rock were deposited during the past 30 years. Ultimately, the operators will deposit a total of approximately 5 billion tonnes in waste rock dumps constructed near the open pit. The Mt. Whaleback operation is located in a semi-arid climate adjacent to Newman, Western Australia, approximately 1200km north-northeast of Perth, Western Australia. The primary research program includes the development of technology for the long term performance of the waste rock dumps with respect to vegetation, slope stability, surface runoff, erosion, and water infiltration. This paper focuses on the design and implementation of a cover system to prevent water infiltration to the underlying waste rock. A laboratory program and the soil-atmosphere modelling completed to design the horizontal field test plots are described. The construction of the horizontal surface field test plots are discussed together with the field instruments installed to monitor performance. The key components of the instrumentation program are the design and installation of large scale field lysimeters to measure the unsaturated flow of moisture into the waste rock from the base of the cover layer. The cover system is designed to maximize infiltration during wet periods for subsequent evapo-transpiration while minimizing surface runoff. The result is a near zero net infiltration to the underlying waste material. A key feature of the design is the use of pit run waste material as the cover material. Monitoring is in progress and will continue for at least two annual wet/dry cycles. The optimum cover system should minimize the net infiltration of water to the underlying waste rock while maintaining physical and ecological integrity for long term performance.

Jan 1, 1998

By M. Adnan Goksel

The hydrothermal agglomerating process described (U.S. Pat. 3,235,371, (1966)) is different from the conventional high temperature processes. Green pellets or briquettes made with mixtures of moist iron ore concentrates and burned or hydrated lime fines are hardened in an autoclave at 198°C and under steam pressure for 1/2 to 5 hours, with or without previous drying. Under the neutral conditions, oxidation of magnetite does not occur as in the conventional processes. The resulting agglomerates are hard and resistant to abrasion and weathering, and they do not disintegrate in the Linder test. The equipment required for the process is not complicated, and favorable operating costs are projected because of the low temperature and efficient heat recuperation. A low capital investment makes the process attractive even when the annual pellet production is below a million tons.

Jan 1, 1968