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By J. Herbst, C. C. Harris, G. Poling

The modern flotation machine is the result of decades of adaptation to a changing environment. In response to falling ore grades, and rising demands, tonnages, and costs, attempts are now underway to expand machine capacity by about an order of magnitude, while at the same time maintaining metallurgical performance and if possible reducing power requirements per unit throughput. Empiricism and rule-of-thumb have guided flotation machine design and scale-up, and a current need is for the development of a fundamental understanding of the subject. Design features of current and some obsolete machines are discussed in an attempt to outline those principles of flotation machine design which are known, and to delineate topics needing investigation. Attempts are made to distinguish between essential machine features required by the physics of the process, those features resulting from speculative theories on the flotation mechanisms, and features which are essentially styling variations. Topics discussed include: flotation mechanisms; tank and impeller/ stator design and dimensions; impeller speed; aeration; power consumption; particle suspension and dispersion; capacity; correlation of design parameters and operating variables; scale-up and scale- down; materials flow; problems in machine design. Design details and operating data for several current machine families are provided in Appendices.

Jan 1, 1976

By Leonard W. III Joseph, William H. Buttermore

Noise control is an important consideration in the design and operation of coal preparation plants. It is essential to understand and control noise sources to provide a safe environment for operating personnel. The average noise exposure levels in a typical coal preparation plant generally range between 95 and 100 db. An operator should not be exposed to noise levels of this magnitude for more than 4 and 2 hr, respectively, according to MSHA (Mine Safety and Health Administration) regulations. The major noise sources in a coal preparation plant include noise from impacting the inside surfaces of steel chutes, vibrating screens, coal crushers, pumps, motors, fans, and blowers. The magnitude of noise varies considerably from one situation to another. NOISE EXPOSURE IN COAL PREPARATION PLANTS Noise regulations established by the Occupational Safety and Health and- ministration (OSHA) are accepted by MSHA relative to coal preparation plants. Fig. 14-43 shows a graph of the time of noise exposure in hours per day to which a worker can be exposed for each A-weighted sound level. According to this graph, a worker is permitted to spend 8 hr in a 90-db noise environment, but that time must be halved when the A-weighted sound level increases 5 db. The noise dosage a worker receives is determined by the ratio of the length of time the worker spends in a particular noise environment divided by the length of time he is permitted to spend in that environment. If the worker is exposed to several different sound levels, his total dosage would be the sum of each of the individual dosages. The equation for determining the dosage is: where C is the actual duration of exposure at a given steady state noise level and T is the noise exposure limit for the level present during the time C According to MSHA regulations, the dosage, D, should not exceed one (1) for any worker for a full day of work. As an example of typical plant noise levels, vibratory screens and crushers emanate noise levels in excess of 90 db at a distance of 3 ft (0.9 m) with no material flow. With material flow, noise level increases 1 to 10 db depending

Jan 1, 1991

By Andy Ingriselli, Andrew Famiglietti, John Westland, Greg Landry

Atlas Dewatering was contracted to install and maintain a groundwater control system for the new Bessarion Subway Station and the Tail Track Structure on the Toronto Transit Commission’s new Sheppard Subway Line. Atlas met the challenges presented by the project by closely reviewing the contract documentation provided by the Program Geotechnical Consultant, Golder Associates and by working with the general contractors, Bondfield Construction Company and PCL Constructors Eastern, inc., throughout the duration of both projects. In addition to concerns about soil loss, excessive settlement and seepage, the consultant was concerned about spreading hydrocarbon-contaminated groundwater between the two aquifers present at the Bessarion Station site. By installing a system of multi-level vacuum eductor wells around the perimeter of the excavation, Atlas was not only able to provide a dry excavation for construction, but, due to a unique well design was also able to prevent cross-contamination of the aquifers.

Jan 1, 2001

By Elisabeth Tønnesen, Lloyd Tunbridge

"SUMMARY Injection grouting in rock around tunnels is used to reduce or stop water inflow. Little is known about the distribution of pressure within the rock mass during and after grouting. Instrumentation was developed to record pressure at the back of the packers inside the rock mass during injection grouting in order to improve our understanding of the process. Using this equipment measurements inside multiple injection holes during injection pumping have been made during several rounds of injection grouting in a tunnel. The data has been compared to the data recorded on the grout pumping rig and analysed to gain an understanding of the behaviour of grout injection process in the rock mass. The initial results are reported in this paper. INTRODUCTION Construction of a tunnel in soil or rock below the ground water table frequently results in the flow of ground water into the tunnel if the ground is permeable or fractures conductive. The injection of cement or chemical based grouts is frequently used during tunnel construction to reduce flow of water into a tunnel. Significant water flow into a tunnel is undesirable for several reasons: • there is a high cost in pumping out water over the lifetime of a tunnel; • drips and flows of water have to be diverted from the roadway or track; • where freezing conditions occur there is the possibility of ice build up and; • ground water levels may be changed possibly affecting surface water such as causing drainage of lakes and ponds, and changes in vegetation. Grout injection is most effectively done ahead of excavation to ensure that the grout penetrates the ground. Where heavy flows of water already occur into a tunnel the grout may be washed out before it sets. Normal practice in ground where water flows are encountered is to inject grout in a number of long holes ahead of the face with outer holes forming a ring around the proposed tunnel excavation – eventually forming a shield of grouted rock around the final tunnel, Figure 1. The holes may be sealed off a couple of metres into the rock with an expandable rubber plug around a pipe through which the grout can be injected, Figure 2. A one-way valve in the plug stops the grout from flowing back out of the hole when pumping stops and avoids grout flowing out through neighbouring holes. The rubber packer with a one-way valve permanently installed in the injection hole precludes the measurement of pressure down the hole when pumping is stopped."

Jan 1, 2016

By Robert A. Jankowski, Ellsworth R. Spencer, Jay F. Colinet

Longwall mining is the most productive method of under- ground coal mining in the United States (US.), and record levels of production have been reached in recent years. These ever-improving production levels have the potential to generate significantly higher quantities of respirable dust. Consequently, the longwall industry continues to struggle with controlling dust liberation and maintaining compliance with the federally-mandated respirable dust standard. In response, longwall operators have in- creased the application of primary dust controls, airflow and water flow, in an effort to improve respirable dust control and reduce worker exposure. Pittsburgh Research Center (PRC) personnel conducted dust surveys at 13 longwalls operating throughout the U.S. and collected information to: identify current operating practices on these longwalls, identify the types of dust controls in use, document the levels at which these controls are being applied, and measure the respirable dust levels present. This data was analyzed to quantify the dust levels generated by the major sources on the longwall section and to evaluate the relative effectiveness of the control technologies in use.

Jan 1, 1997

By Nasri Munfah

Long Island Rail Road’s (LIRR) service to New York City is limited to Penn Station on the West Side of Manhattan, which is operating at its practical capacity for the commuter railroad. This situation imposes serious considerations for future growth and limits the destination of many Long Island commuters. The East Side Access Project will provide a connection of the LIRR to the landmark Grand Central Terminal (GCT)on the East Side of Manhattan. The construction of the connection will require significant tunneling and underground work utilizing a variety of construction techniques. In Queens, the connection will require five soft ground tunnels using pressurized face tunnel boring machine. In Manhattan, the connection will require a series of rock tunnels and caverns connecting to two deep large station caverns under GCT to accommodate eight tracks with four platforms in a stacked configuration. The caverns housing train rooms are connected to the lower level of GCT where a large concourse will be provided. With a budget of $4.3 Billion, The East Side Access Project is the largest transportation project ever undertaken in New York City. This paper provides an overview of the project, discusses its environmental and the engineering challenges, and provides an insight into the design development to date.

Jan 1, 2001

By M. A. Pipke, C. M. Brown

The semiautogemus grinding circuit at the Utah Mines Ltd., Island Copper operation, located on Vancouver Island, British Columbia, is described. Since startup of the operation in 1971, grinding circuit throughput has been progressively increased from the initial design rate of 90 000 (99,000) to the current average 45 000 t/d (49,600 stpd) of porphyry copper ore. Key developments ad modifications in operating and maintenance practice that have contributed to this increase are reviewed.

Jan 1, 1987

By J. J. Schwoebel, M. J. Mavor

Rapid coal extraction techniques in gassy mines may strain a ventilation system if a degasification approach is not utilized. Design of mine ventilation systems requires estimates of gas emission rates from unmined coal into the existing mine workings. A degasification system for a specific property can be properly engineered to improve mining economics if the proper geologic and reservoir information is collected. This paper describes methods to determine the degasification rates for horizontal boreholes and vertical (stimulated and unstimulated) wells and the rate of gas emissions into the mine workings. The methodology is demonstrated by a specific example. Horizontal boreholes drilled in advance of mining are demonstrated to be the most effective means of coal seam degasification and reduction of gas emissions into mine workings. The significance of the paper is that few published methods for these estimates are available

Jan 1, 1991

By S. K. Das Gupta

The rock laterite was first discovered and described in the State of Kerala, India in 1800 A.D. by Francis Buchanan. It had been used here, and elsewhere in India, for many centuries as a building stone, but in Buchanan's time it was not known that some of these laterites were highly aluminous and could be processed to produce alumina. After World War I India started searching for bauxite reserves with a minimum grade of at least 50% A12O3. By 1960, it was estimated that India had a potential reserve of 245 million tonnes of bauxite, about 10% of which was in the "Proved" category. Subsequent geological exploration now reveals that India has an overall resource of more than 2 billion tonnes of aluminium ore, not all of it bauxite, as defined by earlier geologists. In this paper, the geology, resources and distribution of bauxite and aluminium ore throughout India are described. The generalised stratigraphy, typical laterite and bauxite profiles and summary of the resource position are shown in the attached Tables 1 to 8. It is generally agreed that a tropical to sub-tropical climate, intermittent wet and dry season, good permeability of country rock and suitable drainage, as well as physiographic and ground water conditions are important in the development of bauxite.

Jan 1, 1984

By Patrick Ph. D. Kennedy, Osvaldo A. Ph. D. Bascur

With the revolutionary progress in information and computer technologies, applying the latest information technologies in metallurgical complexes has become a serious challenge to both a major opportunity and a serious challenge to both management and technical teams. The emerging component and object technologies are changing the way everyone can beneficially use their computer and networks to add to their corporate bottom lines. Most mining and metallurgical plants use predictive maintenance policies based on statistical analysis and special techniques, like vibration analysis and oil and lube analysis for critical equipment. Process control strategies are installed in several metallurgical sites. All process equipment and control strategies require maintenance from local personnel at the mine. Integrated use of existing and emerging technologies is making it possible to implement an overall process effectiveness control index. This index is based on key indices such as losses due to plant availability, performance efficiency and rate of quality. The availability of real time and process history to identify the most critical part of the processing system from mechanical integrity is highlighted. An emerging plant integration paradigm is described to simplify the implementation of business enterprise resources management and distributed plant management systems.

Jan 1, 1998

By S. C. Westerfeld

The original patent for the gyratory crusher was granted to Philetus W. Gates in 1881. This first crusher was used by the Buffalo Cement Co. At the time these early gyratory crushers were developed all mining and quarrying, either underground or open pit, was done by hand; tonnages generally were small and product specifications simple and liberal. Likewise plants were small and demands for small product sizes practically nonexistent. In addition to substantial amounts of hand labor, the available material handling equipment was small, simple, and not suited to handling large run of mine ore. Mine can, cable ways, or belt conveyon transporting crushed material to the mill had limited capacity per hour. At the turn of the century the largest Gates crusher, the No. 9, had a receiving opening of 21 x 48 in. with a three-arm spider and a 21 x 80-in. opening with a two-arm spider. The steam shovel began to change the entire picture of open pit quarrying. As a result of the use of steam shovels around 1910 crushers with 48-in. receiving openings were built; thus it can be seen that the basic gyratory crusher was developed prior to World War I. The improvement of the internal combustion engine and the use of pneumatic tires created a new set of operating conditions. Early mines were small, using shrinkage stoping and small mine can. The capacity of material handling was small, limiting the size of the largest piece and the feed rate. Improved material handling resulted in more and more large open pit mines with large shovels and a tremendous increase in the size of off road or mine haul trucks or rail can. Primary gyratory crushers also increased with receiving openings as large as 60 in. and connected hp of 1,000.

Jan 1, 1985

By S. S. Peng

This paper presents a computer program package for predicting surface movement and deformation caused by under-ground coal extractions. It is capable of: predicting final surface movement and deformation over underground openings; predicting dynamic surface movement and deformation process associated with underground lingual mining operations; processing and bookkeeping subsidence survey data; recommending subsidence parameters for those new coal mines where no subsidence data are available; and deducting subsidence parameters from collected subsidence data.

Jan 1, 1986

By I. Meliadis

This study presents the methodology and proposals for the restoration of an abandoned quarry in the Greek island of Milos. The local data (soil, vegetation etc.) of the island were collected, analysed and compiled into thematic maps using Geographical Information Systems. The restoration plan was based on the G.I.S. database and suggested the revegetation of the disturbed lands with herbaceous (grasses and legumes) or woody (shrubs and trees) plants. Plants should be indigenous or from other areas with the same vegetation type. Herbaceous plants establish and grow easily protecting the soil from surface erosion. The revegetation success depends on the seed quality, planting season and methods as well as local environmental conditions. Our proposals aim to restore the abandoned quarry with methods that follow the natural succession of vegetation, have minimal environmental impact, low cost and the expected result will be similar to the surrounding undisturbed land.

Jan 1, 2002

By E. L. Mann, Robert L. Virta

Asbestos is a generic name given to six fibrous minerals that have been used widely in commercial products. The six types of asbestos are chrysotile, crocidolite, amosite, anthophyllite asbestos, tremolite asbestos, and actinolite asbestos (Table 1). Chrysotile is the asbestiform variety of serpentine. Crocidolite, amosite, antho-phyllite asbestos, tremolite asbestos, and actinolite asbestos are the asbestiform analogues of riebeckite, cummingtonite-grunerite, anthophyllite, tremolite, and actinolite, respectively. Although amosite is an acronym for the Asbestos Mines of South Africa (AMOSITE) and does not specify a mineral type, it generally is composed of cummingtonite-grunerite asbestos so the terms are assumed to be synonymous.

Jan 1, 1994

By Jean-Luc Cornet

Downhill, or regenerative conveyors have always been a challenge to the design engineer due to their natural instability under load. The last decade has seen the appearance of high tonnage, high negative lift conveyors with several hundred meters of drop. These conveyors have made necessary the development of new braking systems and intelligent drive controls to address their starting and stopping requirements under various load conditions. This paper describes the critical design criteria of large regenerative conveyors and some of the advances in mechanical braking systems and drive control technology developed by Conveyor Dynamics, Inc. (CDI) to address their specific requirements.

Jan 1, 1993

By Song Xiaotian

Studies have been carried out to optimize the VCR's mining sys- tem on the basis of synthetic analysis at Fankou Pb-Zn mine in Southern China. The synthetic e- valuation method is proposed for selection of mining alternatives and stope dimension optimization techniques. Theoretic calculation and computer optimization of the fragmentation of rock blasted by multispherical explosive charges are discussed. The mathematical and optimal fragmentation models are built. The optimum model is built for the main mining operations such as drilling, blasting and haulage. Lt can be used to evaluate VCR?s mining projects, select mining parameters and provide design fundations. From the point of view of system research on the geomechanical process, stoping technological process and benefit, the complex method of optimization is proposed for VCR's mining. Using computer simulation, based on this model, the optimal parameters are established and analysed. An effective approach is provided for research on the mining method optimization and getting better economical benefits from the application and improvement of VCR's method.

Jan 1, 1986

By Andrzej Walentek

This paper presents the results of numerical modeling of the fractured zone around longwall gateroads. The numerical computations have been based on the results of underground measurements of the fractured zone around longwall gateroads, which were performed for various geological and mining conditions and measured with the use of the endoscopic method with a digital camera. Having results of the underground investigations, trials of duplicating them by the Finite Element Method using software PHASE and the Hoek-Brown failure criterion were performed. In order that the fractured zone predicted by the model-based computations closely simulate that measured underground, some selected parameters in the Hoek-Brown failure criterion were modified based on the earlier determined relations used for prediction of the roof-to-floor convergence in longwall gateroads. As a result, the model-based computations produce results very close to those obtained from the underground measurements. Determination of the fractured-rock zone around the mine roads is of great importance to mining practice, especially in planning and designing supports for longwall gateroads. The influence of the front abutment pressure causes the fractured rock zone around the roads to increase and results in an increase of support load. Moreover, proper determination of the fractured rock zone is one of basic elements in the process of planning roof bolting for mine workings.

Jan 1, 2009

By Jeffrey L. Zelms

There is no known, practical substitute for lead in the automobiles, communications systems, medical equipment and computers that Americans use every day. However, there are many who say lead should be stopped at its source -- banned. As America's largest lead producer, The Doe Run Company has ralized that it must do more than mine and reclaim lead efficiently and safely. It must also earn the public's consent to operate if it is to continue to be a viable business. LEAD - THE BRILLIANT PERFORMER: REFURBISHING AN IMAGE It's been an embarrassingly long time since I was a college student. However, I remember there was no course at the University of Missouri's School of Mines and Metallurgy that had anything to do with the public relations aspects of mining or, put another way, the politicization of mining. It's been an embarrassingly long time since I was a college student. However, I remember there was no course at the University of Missouri's School of Mines and Metallurgy that had anything to do with the public relations aspects of mining or, put another way, the politicization of mining. I haven’t perused the course catalog for Penn State’s College of Earth and Minerals Sciences. But I strongly suspect I wouldn’t find such a course there today, either. A statement by the chairman of one of the country’s largest chemical companies leads to the point I want to make. He described his business this way. He said, “We’re a public affairs company that just happens to produce and market chemicals.” Like chemicals, minerals and mining are politicized today. To the extent that we don’t understand that reality, we don’t understand that reality – and act on it – we’re less likely to survive in this business. Some of you may well be saying to yourselves, “This guy Zelms is an alarmist.” That’s fair enough. Because it is absolutely true that there’s n o known, practical substitute for lead today. And it’s also absolutely true that, knowingly or not, Americans use lead everyday. It’s in our automobile batteries. It’s an integral part of communications systems. High tech (and low tech) medical equipment contains lead. And lead is an essential component of computer and TV screens. But even with all these uses, lead has a negative image today. An image so negative that its very existence is threatened. If you doubt that, consider these two statements made in 1989. Statement one. “It is probably reasonable to argue that exposure is the single most important and critical environmental health problem in the U.S., and possibly also the world…” Statement number two. “Many of the uses of lead should be terminated. We need to go back to the ultimate source: that is, taking lead out of the ground and putting it into the product stream and we need to turn it off at the ultimate source. Not the approximate lead in gasoline, or lead in air, or lead in food. Go right back to the source and start cranking it down." (End quote.) Those are what I call strong statements. And they weren’t made by some celebrity spokesperson for the environment like Meryl Streep. Both these statements were made by Dr. Ellen Silbergeld, whose long list of professional and academic credentials includes: o Adjunct professor and research scientist at the University of Maryland Medical School and Johns Hopkins: o Chief toxic scientist and director of the Toxic Chemicals Program of the Environmental Defense fund; o and President of the Society for Occupational and Environmental Health. If Dr. Silbergeld were the only person making these kinds of statements, it would be one thing. But she’s not a voice in the wilderness, by any means. Also for those of you who say, well since there’s no known substitute for lead, how on earth could it be banned. I refer you to a number of bills before Congress that would permit the EPA to ban any product if it is determined that its

Jan 1, 1992

By F. A. Aplan, Richard R. Klimpel

This article discusses the role of mathematical optimization techniques as applied to the design and analysis of particulate processing plants. The emphasis will be placed on the macro engineering view of integrated multiple operation plants such as those that typically involve stages of size reduction, sol id-sol id separation, solids storage, chemical reactions involving sol ids, sol ids disposal, etc. The macro engineering view is chiefly concerned with balancing and optimizing the bigger picture of how various unit operations interact technical and economically with each other in an approximate sense rather than how a specific unit operation can be technically described and optimized in detail (micro engineering.)

Jan 1, 1991

By Michael J. Friedel

As part of a study aimed at understanding the hydrology of in situ leach mining (ISLM), the Bureau of Mines, in cooperation with the Cyprus Casa Grande Corporation and the University of Arizona, is investigating dynamic transmissivity conditions during ISLM of a copper oxide ore deposit. Spatial and temporal variations in ore zone transmissivity during two years of ISLM operations at the Cyprus Casa Grande mine are evaluated during sixteen intervals of steady-state injection and recovery well operation. Direct inversion of an analytical hydrologic model is used to obtain estimates of transmissivity at 58 well locations during these intervals. Univariate statistical and geostatistical methods are used to describe the temporal and/or spatial relationships that exist between transmissivity and other ISLM parameters, including average well injection pressure, average sulfuric acid concentration in leach solution, and the relative configuration of injection and recovery wells. Average transmissivity during the sixteen steady-state time intervals varies between 6.00 x 10-6 m2/min. (6.46 x 10-5 ft2/min.) and 3.61 x 10-8 m2/ min. (3.89 x 10-7 ft2/min.). A trend toward decreas¬ing transmissivity is evident during two year of ISLM operations. This decreasing trend is found to correlate with a decreasing sulfuric acid concentration in injected leach solution, and suggests increasing geochemical precipitation within the deposit. Geostatistical analyses reveal a dynamic and anisotropic transmissivity structure within the target ore zone, that is dependent upon spatial and temporal changes in injection pressure and well configuration.

Jan 1, 1992