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By Paul K. Edwards

The forces of nature have concentrated sand at various geographical locations that are being mined and processed for a large variety of industrial uses. While most operations serve a number of industries, this paper deals only with the foundry requirements. The forces that have decomposed a source rock, transported this material and redeposited it, have created two general types of sand. These types are classified as the (1) Lake and Bank Sands and (2) Silica Sands. The Lake and Bank sands will contain 92 to 94% Sio2 while silica sands are in excess of 98.5% Si02 and most of the producers wash these sands to up grade their products to 99.5% or better. Included in the Lake and Bank sand would be the river sands that are used primarily for construction purposes. The Foundry Industry is broken down into three types of castings : 1. Grey Iron Foundries The grey iron castings largest market is the automotive industry in Ohio, Northern Kentucky, Indiana, Illinois and Michigan. These castings are poured at temperatures ranging from 2400° to 2700°F. The Silica Sands or the Lake and Bank Sands will satisfy the requirements of the grey iron castings. There are 2 ½ to three million tons per year shipped from the state of Michigan far grey iron castings by the Lake and Bank Sand Producers.

Jan 1, 1974

By Gerald H. Luttrell, Joe Shoniker, Jaisen N. Kohmuench, Christopher J. Barbee, Michael J. Mankosa

The HydroFloat technology was specifically developed to upgrade phosphate sands that are too coarse (>0.6 mm) to be efficiently recovered by conventional flotation methods. In this novel process, classified feed is suspended in a fluidized bed that has been aerated using an external sparging system. The air bubbles selectively attach to particles that have been made hydrophobic through the addition of a fatty acid collector. The teetering effect of the fluidized bed forces the low-density bubble-particle aggregates into the overflow, while hydrophilic particles are rejected as a high solids content underflow Since the HydroFloat is actually a density separator, the process can treat much coarser feeds than would be possible using traditional flotation processes. In addition, the high solids content of the teeter bed promotes bubble-particle attachment and reduces the cell volume required to achieve a given capacity. This paper presents test data from ongoing pilot-scale trials of the HydroFloat cell in the phosphate industry.

Jan 1, 2002

By Ian S. Lowndes, Adrian T. J. Moll

With the current trends towards the concentration of extraction to fewer but higher production units in deeper seams, often of higher coal rank, the role of methane drainage ranges has become critical. As mines exploit seams at greater depth and more remote locations there has been a need to extend the lengths of methane drainage ranges and to increase the capacity of the surface pumps. This trend has highlighted the need to effectively simulate the operation of a methane drainage range in order to produce the optimum design and operation of a safe and economic system. This paper describes the development of such an analytical tool. The application of this computer model is illustrated by the analysis of the operation of the drainage system of an extensive mine. The paper concludes by considering the development of a [Knowlege Based or Decision Support System] which will assist the ventilation engineer in assessing the current performance of an existing drainage range and will suggest possible remedial modifications or design strategies which may improve the system performance. INTRODUCTION In order to maintain the general body methane levels to below predetermined statutory threshold limit values (TLV's) on major longwall production units there are, for a given production rate, two major complementary control devices which may be employed by the ventilation engineer. These are the combined design and application of a competent mine ventilation and methane drainage system. The methane drainage system should be designed so as to maximise the capture of the methane (firedamp) from the seam being mined and the strata gas liberated in the vicinity of the extraction zone from gas bearing seams or other reservoirs of gas situated at above or below the mining horizon. The design fresh air quantity entering the face should ensure that under normal operating conditions the methane entering in the vicinity of the face is rapidly dispersed and dilute to well below statutory TLV's. The drainage system must therefore be designed to maximise the capture of the methane gas liberated to minimise the amount of gas which enters the ventilation airstream. GAS DRAINAGE The inherent dangers of methane emissions in mine workings have been a problem of concern to mining engineers for many years. To alleviate the risk, methane drainage has been employed for some years to capture the gas before it becomes a hazard to the operation of the mine. The method of drainage employed will be dependent on a number of factors which include the longwall mining method and production cycle employed, the characteristics of the coal seam being extracted and those of the adjacent gas bearing strata. The location of the gas bearing potential of the over and underlying coal measures must be determined. The gas bearing

Jan 1, 1993

The most common method used for cleaning the fine fraction in today's coal preparation plants is froth flotation. Past research and practice has found that froth flotation achieves excellent separation efficiencies for fine coals having only a small fraction of middling particles. However, its efficiency decreases sharply as the concentration of middling particles increases due to the flotation of high-ash particles having a small amount of hydrophobic coal present at the coal surface. Since gravity-based processes are much more efficient at treating middlings, the application of centrifugal washing for fine coal cleaning has been studied with an emphasis on the primary cleaning of fine circuit feed. Results will be shown from a parametric study using a Falcon centrifugal concentrator which reveals that the separation performance is a function of particle size, bowl geometry, feed solids content, and feed rate.

Jan 1, 1994

By Vincente M. Jr. Lim, Brain W. Lawrence

Underground mining operating costs consist pri¬marily of direct costs such as labor, supervision, ma¬terials, and supplies, plus indirect costs. The material and supply costs vary substantially between mines but commonly range from 35 to 60% of the total direct costs. As part of the preparation of accurate operating cost estimates for a project, information must be as¬sembled to select the material and supply items and to determine the quantities of these items that will be required. Cost data then can be incorporated with the estimated material and supply requirements to determine the total material and supply costs for the project. Estimated quantities will vary considerably between mining projects depending upon factors such as the type of material being mined, the mining method, the equip¬ment selected, drilling and blasting techniques, mucking and haulage methods, ground support requirements, number of men employed, etc. Valuable information often can be obtained from suppliers and manufacturers, including data on current operating practices for similar projects, recommenda¬tions for the specific project, and preliminary cost quota¬tions. However, quotations obtained for estimates are generally higher than the prices paid at the time of purchase. Mines operating in the area, or those mining under similar conditions, also can provide essential design information, but it often is difficult to obtain cost information from the operators. Estimated costs for the most common major items of underground materials and supplies are presented in the accompanying tables. They represent current costs or cost ranges and are intended to be used only as a guide when preparing budgetary estimates for materials and supplies. Cost data were obtained mainly from suppliers and manufacturers, with up to three quotations being ob¬tained for each item whenever possible. In most cases, as noted in the table footnotes, prices were based on quantities representing normal requirements for me¬dium-size mine operations. Every attempt was made to assure accuracy. However, the cost for most items, especially those with multiple sources, can deviate sig¬nificantly for various reasons such as geographical loca¬tion, current market conditions, quantities ordered, size of the customer (which could influence the ultimate quantities purchased), and the ability of the purchasing department. It is also for these reasons that the actual amount individual mines are now paying for specific items may vary from the estimated cost in the tables. The cost for specific sizes of items that do not appear in the tables often can be factored from the data pre¬sented. Costs for many items can be converted easily to a unit that sometimes is more basic, but not as com¬monly used, such as from a length to a weight unit. Other items not listed, such as repair parts for equip¬ment, will involve contact with suppliers to determine specific recommended requirements and to obtain costs for these items as related to each individual project. Costs are expressed in terms of US dollars as of 1978 unless otherwise specified. All measurements, sizes, and weights are expressed in conventional units (i.e. feet, inches, pounds) ; applicable metric conversion fac¬tors follow each table. Costs are represented for drill steel and bits; mining explosives; blasting caps; blasting supplies; ground sup¬port items; ventilation equipment; utility pipe, utility hose, and accessories; mine track and accessories; tires for underground equipment; lubricants and fuels; and miscellaneous supplies.

Jan 1, 1982

By Jon C. Jenkins

In order to plan the most efficient mine installation, a company should take advantage of all available information and tools. One of the first factors of a coal reserve that needs to be determined as accurately as possible is the quality of coal the mine will have access to during the life of the installation. With the aid of many types of well logs and computor analysis, we are investigating several methods of log correlation to determine such data as moisture, ash, sulphur, and BTU on an in place basis. It may be possible to determine this data more accurately in this manner than by using diamond drill cores for analysis and thus allow for a more profitable mine installation. The production of an underground mine is based on many factors, two of these being roof control and line water, where present either in the roof or coal seam. Using many of the same logs obtained from reserve and active mine areas, we have attempted to determine roof and floor characteristics such as strength, lithology, and moisture properties. Using data obtained from this program, we will make comments on possible length of bolt to be used, possible mining width, and pillar size as they would pertain to these reserves and active mine areas.

Jan 1, 1969

By Howard L. Hartman

The federal government's declining role in funding research has created a critical dollar gap for university departments of mining engineering. Industry is not unaffected by the drought: not only is research lagging, but hard- pressed universities are going to the private sector for funding. This paper's thesis is not that mining companies should shower universities with philanthropy, but that a quid pro quo ought to be exacted: a research partnership should be contracted on a pay-as-you-go basis. A model exists at The University of Alabama (albeit not in mining) that may lend itself to adoption by our industry.

Jan 1, 1984

By Stephen Krickovic

"Bleeding", as used in mine ventilation language, has a number of meanings among mining men and is regarded with different degrees of importance. This lack of uniformity stems from a number of specific situations. A method that is adequate in a mildly gaseous mine may fall short in a very gaseous mine. Projected bleeders could be dependable under a certain type of roof, and totally unsatisfactory under a different type. Similarly a plan of bleeders can be rendered useless due to undulations of seam and water in one mine and function well in another. Finally, what is effective in a mining system with partial recovery will not suffice with full recovery. You may wonder, then, if there is a common denominator for the essential function of "bleeding". In my opinion, there is, and it can be defined as controlled movement of air across an active pillar line toward the back and outby ends of the adjacent gob area into the headings provided for the purpose. The objective is to maintain as methane-free as practicable a belt adjacent to the working places, so that, if face ventilation is interrupted temporarily, the gas will not accumulate in dangerous volumes at the working faces before ventilation is restored. It's possible for these temporary interruptions to be unnoticed in time or at all. In such cases, ineffective bleeding could cause a disaster. This has happened. To control, there must be power. That is to say, there must be adequate air, pressure differential between the front and back ends of a pillar line to facilitate proper regulation for diverting of air to the various portions of the gob and as far away from the active section as is practicable. As an indication of the importance of pressure, it is noteworthy that one may provide and maintain in a reasonably open condition a heading or two for a bleeder system and fail to obtain effective bleeding .because air pressure differential is inadequate. On the other hand, you are all familiar with the fact that pillar lines in some seams can be ventilated adequately by air flow straight across the gob when the section is near a main return shaft and thus obtains a heavy pressure differential.

Jan 1, 1962

By R. L. Grayson, R. C. Althouse, M. J. Klishis

The health and safety of employees, efficiency of the operating system, and production are paramount goals in underground coal mining. The section foreman assumes responsibility for making his part of the total system function to meet these goals. However, section foremen often have not been prepared to assume the full range of their responsibilities upon becoming a supervisor. This paper addresses the full range of section foreman responsibilities and concomitant authority. Management principles that must be mastered by him are presented, and performance expectations as well as criteria for their evaluation are examined. The benefits realized from effective foreman training are discussed.

Jan 1, 1987

By Frank F. Aplan, Robert S. Thomson

A placer ore jig, typically used to recover fine gold, tin and diamonds from alluvial ores, has been modified to remove fine pyrite from minus 6.4 mm (-114 inch) coal. In parallel tests, it proved to be far superior to two conventional coal jigs, the Baum and the Baum-feldspar, in removing fine pyrite from coal. The Pan-Am placer jig was found to remove essentially all of the +28 mesh pyrite and from 99% to 90%, decreasingly, in the 28 to 200 mesh range. This jig also showed a superior performance to the Baum-Type jigs in removing fine coal from its associated refuse. The superiority of the Pan-Am placer jig is related to the strong emphasis given on the suction stroke and, hence, on consolidation trickling, whereas the Baum jigs principally emphasize the pulsion stroke during jigging.

Jan 1, 1995

By P. A. Lindberg

Early Proterozoic ore deposits in the Verde district at Jerome, Arizona have produced 33.7 million metric tons of ore (1893-1975). The United Verde and United Verde Extension deposits produced most of the ore that yielded 1,644,323,100 kg Cu plus large amounts of Au, Ag, and Zn. These deposits are situated on the fractured and hydrothermally altered apex of a large submarine rhyolitic extrusive (Cleopatra formation). Precambrian lithologies are penetratively deformed and at Jerome the Fl folds plunge steep to the NNW. For the past two decades the volcanogenic model has superseded the replacement theory of ore formation.

Jan 1, 1992

By George D. Tikkanen

The world supply of zinc and lead is reviewed. The nature of zinc and lead deposits, production constraints, current production and reserves, new developments, possible future developments, and closures are considered. Lead sup- plies for the future are adequate. Zinc supplies are expected to tighten in the longer term due to growth in zinc consumption and orebody depletion.

Jan 1, 1986

By J. R. B. Lima

The present work emphasizes the selection in the separation of the apatite/calcite by the direct anionic flotation versus the double flotation, with a reverse second stage of the Jacupiranga phosphate ore. The double flotation would allow the obtaining of two concentrated solutions: one of them mainly constituted by a calcium carbonate material (CaCO3) and the other one, phosphatic (apatite). The calcium carbonate concentrated solution is used for the production of cement. The presence of phosphatic material in the calcium solution is not desirable, phosphor being a harmful element to cement. On the other hand, smaller quantities of calcite in the phosphate concentrate would represent a substantial economy in the processes of production of phosphated fertilizers. These processes make use of sulfuric acid to the solubilization of the apatite and the presence of calcium material consumes acid. Also that, when carbonates are solubilized, unwanted products are formed resulting in losses in the process and diminishing the quality of the fertilizer produced. These characteristics are discussed in the paper and are compared to another Brazilian phosphate ore, the reverse route of which can be considered more adequate. The results are discussed according to recent discoveries, and special emphasis is given to the use of corn starch and its crucial role in promoting the selection in the direct flotation process.

Jan 1, 1993

By J. E. Miller

The development of a new means of measuring the relative abrasivity of a slurry came about by necessity in 1967 during a full scale loop test of a 560 H.P. reciprocating pump handling magnetite slurry. In order to evaluate the life of expendable fluid end parts, the question of the amount of attrition in a re-circulated slurry had to be considered. An expected reduction in abrasivity as a result of this attrition would certainly give erroneous data on a parts life test. There- fore, some means of measuring such change in abrasivity became imperative. Several test methods were investigated1 but it was felt that these did not fully represent the wear due to back and forth rubbing action associated with a reciprocating pump. A "rubbing block" device used some years ago to determine the quality of hard facing materials was recalled, along with its shortcomings, in that an attempt was made to suspend a small percentage of abrasive particles in a colloidal viscous "mud". Erratic results were attributed to the fact that it was difficult to maintain a consistent slurry concentration under the metal wear block and the reciprocating speed was not great enough to maintain good agitation.

Jan 1, 1973

By C. Bemelmans, L. Chia, T. O’Keefe

Lead alloys function effectively as oxygen-evolving anodes in copper SX-EW operations, and they are highly resistant to corrosion. However, the presence of an organic (from solvent extraction circuits) in the electrolyte seems to enhance solution line attack. Laboratory tests showed that lead is soluble in D2EHPA, Acorga and LIX 984 to a limited, yet measurable, degree. Lead alloys and various lead phases formed on the anode were tested to evaluate their effect on the corrosion process in organic media. Possible causes for anode corrosion and mechanisms responsible for their initiation are discussed.

Jan 1, 1998

The concept of classification in wet, closed circuit ball milling is expanded beyond the performance of the classifying equipment to include all aspects of the fines removal system of the grinding circuit. Design and operating parameters that effect fines removal are identified and discussed, and a quantitative index for circuit classification effectiveness is presented.

Jan 1, 1987

By Sangwhui Cho

In comminution processes including crushing, grinding and pulverizing, the efficiency of the comminution system is very low. Since the early 1980s, research has been conducted to increase the efficiency of pulverizing mills. Additionally, the application of microprocessors and Personal Computers to process control have come into general use. Given appropriate models of the process and control algorithms, these systems can economically control comminution processes. The ring-roller type mineral pulverizer is known as an energy saving mill. In this study, a control strategy to increase the efficiency of this type mill is explained.

Jan 1, 1992

By J. Felipe Costa, Andrew H. White, Marcot T. M. B. Vilhena

Ordinary kriiing (OK) is an interpolation algorithm mostly used in earth sciences applications where it provides satisfactory results. Robust kriging (RK) is an alternative algorithm which at- tempts to minimise the problems caused by the existence of outlier values within a given data set. Robust kriging essentially consists of an editing step prior to running the traditional OK method. This study compares the interpolation results obtained by OK and RK. Two data sets were used. The first data set consists of 140 samples mimicking a drilling survey named cluster.dat. An additional feature of this sample data is that its parent population, the reference data set, is available, thus permitting direct quantitative assessment of the effectiveness of a given estimation technique. The second data set consists of a grid sampled at 1x1 m. The estimates obtained by OK and RK using cluster.dat were compared to the reference data set. RK provided better results in terms of quality of the estimates than OK

Jan 1, 1996

By J. C. Norman

The boron review arrived too late for the June issue. The United States was the world's largest producer and consumer of boron compounds during 1993. Boron mineral concentrate and chemical production in the United States totaled an estimated 958 kt (1.05 million st), yielding 526 kt (580,000 st) of B203, according to the US Bureau of Mines. Estimated value was $322 million. This level of production was about 5% less than 1992 revised production figures. The United States continued to provide essentially all its own boron while maintaining a strong position as a source of sodium borate products and boric acid to foreign markets. Domestic employment in the mining and beneficiation of boron products in 1993 was 900 people, about the same as in 1992. That was down from 1988 levels of 1250 people. Total world production of boron in 1993 was about 2.5 Mt (2.75 million st), yielding about 1.2 Mt (1.3 million st) of B203. World production in 1993 was about equal to revised 1992 levels. Production United States In 1993, mines and processing operations in southern California were the only domestic sources of boron mineral concentrates and chemicals. Domestic producers, in order of quantity of production, were: • US Borax and Chemical Corp., which operates an open pit kernite and tincal mine at Boron, CA, producing boric acid and borax products, • North American Chemical Co., which produces boric acid and borax products as coproducts from chemical operations at Searles Lake, CA and • American Borate Co., which produced small amounts of colemanite and shipped from inventories from its operation in Death Valley, CA.

Jan 1, 1994

By Richard R. Klimpel

INTRODUCTION The purpose of this paper is to summarize the current status of reagents used in the mineral industry plus present some current challenges and possible new technologies of the future. Table 1 lists the important families of reagents which, when taken together, constitute at least 95% of the current commercial reagent market. A very approximate estimate of the free world reagent market size in mineral applications is about 1.5 to 2.0 billion dollars (U.S.) using 1985 data. Obviously, to serve such a large market requires the effort of many different types of commercial supply sources. It is estimated that there are over 300 industrial firms in the free world that have a dedicated business/technical structure for supplying reagents related to the mining industry. There are a number of characteristics which are associated with the product families listed in Table 1. Understanding these characteristics helps to provide a realistic economic/technical basis for outlining future challenges in mining chemicals. 1.Essentially all of the products listed are old chemistry in the sense that the molecules have been known and manufactured for at least 25 years. This has not been a highly dynamic field of endeavor from the viewpoint of new product introduction. 2. The greater majority of the products listed can be viewed in commercial terms as "commodity" chemicals, that is, they are available from many sources and the pricing of a some- what generic product generally dominates differences in product quality or uniqueness. With commodity pricing, reagent suppliers significantly reduce research expenditures, loosen product quality somewhat if the applications of the reagents allow, etc. in order to be cost competitive.

Jan 1, 1989