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By Rob Robertson

The problem of fine coal slimes has been addressed in a unique way at A. T. Massey Coal?Company. Several plants have employed two-stage classifying cyclones to separate the minus 1 mm raw coal into 3 sizes. Larger cyclones make the initial cut at approximately 150 µ (100?mesh) sending the underflow to a cleaning circuit (usually spirals) while the overflow is pumped to a secondary cyclone circuit using smaller cyclones. The small cyclones make a cut at near 70 µ (200 mesh) and produce an underflow that is a des limed flotation feed. The overflow is discarded to refuse due to its high ash and superfine size which would produce a high moisture product even if suitably recovered.

Jan 1, 1998

By M. Tanaji

Over the last many decades, a significant amount of research has gone into the domain of slurry transport. However, design engineers still face many challenges with respect to prediction of pressure drop, critical velocity and other design parameters as a function of Solids % and Particle Size Distribution (PSD). The industry requirement is to transfer the slurry at the maximum concentration as possible (above 30% (volume %)) to make slurry transport more economically viable and to reduce water consumption. To facilitate the design and scale-up of slurry transport in pipelines and in process plants, there is a need for a correlation that can predict slurry pressure drops over a wide range of operating conditions and physical properties of different slurries. The objective of this study is to overcome the limited range of applicability and validity of existing correlations and to develop a generalized but more rigorous correlation applicable to a wider range of slurry sys-tems. The existing Wasp et al. (1977) method is based on multi-phase flow modeling approach. This study attempts to modify this approach by considering material-specific values of Durand?s equation co-efficient and by defining flow regimes based on particle Reynolds number. When compared with experimental data, the modified Wasp method proposed in this study predicts the pressure drop for slurry flows more accurately than other available correlations. Also, the pro-posed method requires minimal test/experimental data for a particular slurry system and can be extended over different input conditions. An iterative computer algorithm is developed to calculate the criti-cal settling velocity and pressure drop in a pipe as a function of Solids % and PSD. The solution method can easily be implemented in de-signing slurry pipes, design validation, and studying the different slurry transport scenarios. The modified method can also be extended to accurately predict pressure drops in dynamic pressure flow networks used in commercial process simulators.

Feb 23, 2014

By H. Sevim

The utilization of high sulfur Illinois coal by utility plants has been decreasing since the enactment of 1990 Clean Coal Air Act Amendment. Illinois coal producers can make their coal saleable by offering the choice of taking the combustion by-products from the utility plants and placing them in the abandoned sections of their mines. To be competitive, however, coal producers need to select an environmentally acceptable transportation-handling-placement system through which the cost-per-ton of by-product disposed can be minimized. In this paper, a few such systems are presented. The favorable operating range of each system is determined in terms of distance and tonnage. A case study is given whereby cost analysis is conducted for an underground coal mine receiving by-products from two Illinois utility plants.

Jan 1, 1997

By Andrew B. Cecala, Emily J. Haas, Jay F. Colinet

Researchers from the U.S. National Institute for Occupational Health and Safety (NIOSH) studied the impact of an unregulated dust control technology (the Helmet-CAM) and a regulated dust control technology (the continuous personal dust monitor) within a sociotechnical system (STS) framework to mitigate respirable dust sources. The results address how to best incorporate the overarching principles of meta-design STS during the technology integration process. Specifically, quantitative and qualitative data show that a prominent focus on the social factors within an STS framework could help reduce organizational unpredictability and may improve communication within the system to help reduce technology adoption time.

By Raphael Victor

The construction and modification of tunnels brings a requirement for precise measurement of convergence and divergence to safeguard the structure, maintain safety and provide the assurance needed to maintain efficient progress. Established methods include manual measurement using tape extensometers and automated methods using photogrammetry and automated total stations. Drawbacks include the need for frequent access, power supply, cabling, and cost. The paper describes how the development of reliable optical displacement sensors (ODS) has changed the landscape. ODS sensors are connected to a long-range wireless mesh communications network via a solar-powered gateway outside the tunnel, with data instantly transmitted to the internet. A sensor and its reflector target can be installed in 20 minutes and is maintenance free for a decade. Tunnel movement is measured to sub-millimeter precision with repeatability of ±0.15 mm. Integration of a triaxial tilt sensor allows slope distance to be converted to horizontal and vertical changes and allows rotational movement to be determined. Applications include new-build and long-term structural health monitoring. Case studies will be given, including the refurbishment of rail tunnels in Spain where the ODS measured movement during track lowering in a situation where no other automated system was considered viable.

Jun 13, 2023

By Evan Brinkerhoff, Steve Chorley

The largest hard rock TBM ever to bore in the USA, an 11.6 m diameter Robbins Main Beam TBM, recently underwent a planned in-tunnel diameter change to a more compact 9.9 meters. The first-of-itskind conversion process for the Main Beam TBM was undertaken 2.8 km into the bore and was not done inside a shaft or pre-excavated portal. This paper will detail the unique dual-diameter machine designed for the Mill Creek Drainage Relief Tunnel in Dallas, Texas, USA, machine performance, and successful size conversion process that took place in early 2021—a process that utilized the four C’s of construction to enormous benefit: Communication, Cooperation, Collaboration and Coordination.

Dec 1, 2022

"The National Mining Hall of Fame and Museum (NMHFM) announced the 2017 National Mining Hall of Fame inductees. This year’s inductees, selected by the National Mining Hall of Fame’s Board of Governors, represent exploration and extraction of new frontiers, environmental stewardship, leadership in formulating U.S. mineral policy, education, and research and development, including the use of computers in planning, designing and managing mineral industry operations. The contributions of these individuals have undoubtedly had a significant and lasting impact on the mineral and mining industry. These individuals were selected for being visionary leaders, innovators, authors, pioneers in corporate social responsibility, and long-standing advocates for the U.S. mining industry.Dr. Thomas V. Falkie, Leonard Harris, Dr. Vincent E. McKelvey, and Gordon R. Parker will join 236 other mining industry luminaries when formally inducted into the National Mining Hall of Fame on Sept. 23, 2017. The 30th Annual Induction Banquet and Ceremony will be held at the Pinnacle Club, Grand Hyatt Hotel in Denver, CO.2017 National Mining Hall of Fame inductees:Dr. Thomas V. Falkie — In a career spanning six decades, Falkie’s accomplishments in industry, academia, government and professional societies demonstrate a pattern of integrity and sustained excellence. His gravitas and management style left highly favorable impressions in every position he held. He was the chairman and president of Berwind Natural Resources Corp.; President of SME; President of the American Institute of Mining, Metallurgy and Petroleum Engineers; Director of the U.S. Bureau of Mines and head of the Department of Mineral Engineering at the Pennsylvania State University. He played major leadership roles in the American Mining Congress, National Coal Association, Mining and Metallurgical Society of America, and the National Mining Association. He served on the board of directors of Foote Minerals and Cyprus-Amax and was very active in the National Academy of Engineering, the SME Foundation and the National Mining Hall of Fame and Museum.Leonard Harris — A highly regarded metallurgist and business executive, Leonard (Len) Harris may be most remembered for the heart he has for the people whose lives were touched by his career. For more than six decades, Harris has been a true pioneer in corporate social responsibility, leading companies to understand that doing the right thing for the local people is also the best path to business success. After an early career in Australia and Ghana, Harris moved to Peru in 1955 to join Cerro de Pasco Corp., owner of several mines with one of the most complex metallurgical operations in the world. Harris was quickly promoted through multiple positions and was ultimately named director of metallurgy."

Jan 8, 2017

By T. W. Camm

"We hear all the time about the value of hard work and perseverance, and the part they play in the professional life of successful people. What we do not hear so much about are the many professionals who work hard and persevere, yet never seem to quite reach the level of success they aim for. Some current authors are beginning to give more attention to the part luck/black swans/outliers play in success. This is not a new phenomenon, Machiavelli had a lot to say about it back in the Renaissance. So how can knowledge of this dynamic help in a modern organization? INTRODUCTION Work hard and you will succeed. Go to the right school, major in the right degree, study hard, and get a good job. Look at the lives of successful people, and do what they do. Be all that you can be. You can be anything you want to be. Really? Those who are successful always get attention, people want to know what they did to reach such a high position. Invariably, at least part of their narrative will include hard work, wise insight, taking advantage of opportunities, etc. If they are of a more generous nature, they might also allow that building the right friendships and collaborations also played a role. All of this may be true; what we do not often hear are the stories of those who did all of these very same things, but did not find success. An example from pop culture: The Voice. I have watched this show occasionally the past couple of years. One of the things I like about the show is that the initial screening of contestants is based solely on their singing voice (hence the name of the show), and not on their appearance. At the time of this writing (early November), the judges have just finished elimination rounds for their final teams to go on to the live shows. Here is my point—in almost every case the judges agonized over choosing who would go forward and who would be eliminated. And the reason is because all of them are really talented singers. It is impressive how gifted they are. At the end of each season, only one is declared a winner, out of that gifted pool of singers. When you hear their stories, they are all talented, hard-working individuals sacrificing for their art. And as far as I know, none of them has ever become a star. Hard work, dedication, sacrifice, talent—sometimes it is enough, sometimes not. I will be looking at the part uncertainty/luck/black swans play in our lives, but I want to make it clear at the beginning that I am not saying everything that happens to us is out of our hands or beyond our control. Taleb makes this same point (2007, p. 52): “This problem is chronic: if you tell people that the key to success is not always skills, they think that you are telling them that it is never skills, always luck.”"

Jan 1, 2017

By Gabriel Böde Jimenez Leon, Michael Karmis, Christopher Newman, Zach Agioutantis

"When utilizing high recovery underground mining methods, such as longwall or high-extraction room-and-pillar mining, the movement and deformation of the overburden propagate toward the surface and may affect the integrity of overlying surface streams (Peng et al, 1996). Published studies cite three major mechanisms of subsidence as most likely to impact streams: displacement, slope and strain. While subsidence-induced vertical displacement cause little structural damage to the stream bed, it may create adverse drainage and stream flow issues as the subsidence trough allows for ponding (Dawkins, 2003). Subsidenceinduced changes to the slope, or tilt, of a stream may have adverse effects on water flow. As the stream enters the subsidence trough, the gradient increases providing potential erosion control problems. When exiting the subsidence trough, a reduction of the gradient may inhibit stream flow, causing localized ponding (Peng, 2008). While vertical displacement and tilt both may have detrimental effects to surface streams, the resulting strains have been documented as being the most damaging to surface streams and structures causing distortion, fractures, or failure (Singh, 1992). When stream beds are subjected to high tensile strain, tensile cracks may form at the surface level allowing for the direct loss of stream flow through fissures. When stream beds are located in areas of high compressive strain, rock layers forming the stream bed can fail as the stream bed ruptures, upward, blocking stream flow or having the stream diverted into the fracture zone at the base (Iannacchione, et. al., 2010).Recent investigations on the effects of underground mining on surface bodies of water suggest that to determine the degree of stream impact one must also consider the geologic structure and thicknesses, surface topography, watershed drainage areas, width of river bed and rate of mining. Due to the complex nature and number of parameters affecting surface streams, subsidence modeling tools and software packages should be implemented throughout all stages of subsidence planning, prediction and control. The Surface Deformation Prediction System (SDPS) utilizes the influence function for the calculation of final subsidence deformations with respect to the angle of influence, supercritical subsidence factor as a function of the percent hard rock, edge effect offset distance, and surface topography. Developed more than 25 years ago, SDPS has been continually updated with new analysis and prediction features, providing a reliable and versatile program for subsidence management methodologies. Most recently, the program has been updated to evaluate the effect of varying surface topography in the prediction of horizontal displacements, referred to as ground strain, allowing for the accurate three-dimensional representation of surface deformations in mountainous terrain (Agioutantis and Karmis, 2014). Ground strain has become one of the predominant deformation indices used in the evaluation of potential damage to surface structures (Karmis et al., 1995). Ongoing work with SDPS software seeks to investigate the calculation of ground strain in SDPS and its ability to accurately and realistically predict damage to surface streams due to underground mining operations."

Jan 1, 2015

By S. Perla

Two of Peabody Western Coal Company's mine operations are the focus of this paper ... Black Mesa Mine and Kayenta Mine, both located in Northern Arizona. These two locations are unique for a variety of reasons. ? The two mines have only two customers, both power plants, one the Southern California Edison's Mohave Generating Station near Laughlin, NY, the other the Navajo Generating Station near Page, AZ. Close in proximity, these two locations ships nearly 12 million tons of coal per year. ? Material is shipped to these customers two ways: via a 273 mile underground slurry pipeline, which by the way is longest in the world, and by a 17 mile long conveyor to four storage silos. Product is then shipped via train from the storage silos to the plant sites.

Jan 1, 1995

By VIVEK KUMAR HIMANSHU, PK SINGH, AK MISHRA, MP ROY, RAVI SHANKAR

Underground blasting has many challenges. The primary aim of blast designers is to optimize drilling and blasting parameters to deal with the associated challenges. Optimizing these parameters is currently based on various rules of thumb, which have many site-specific limitations. Accordingly, computation of these parameters using empirical rock fragmentation predictors can be useful for blast designers. This paper presents the results of work on burden-spacing determination by back-calculation from the empirical Kuz-Ram model for underground stope ring blasting.

By S. McAlister

This paper outlines the development of the Falcon enhanced gravity separator. Design objectives included continuous operation with sharp separations, mechanical simplicity, minimization of process water demand, the ability to apply a centrifugal field up to 300G's, unit capacity in excess of 100 t/h within a footprint of 10 square meters, a capital cost below $US 4,000 per t/h capacity, and total operating costs of less than $US 0.40 per tonne. A parallel development has been inexpensive, effective, semi-continuous equipment for recovery of precious metals in the free metallic state. These objectives have been largely met. There are significant opportunities for the technology in many mineral processing applications.

Jan 1, 1998

By A. B. Cecala

The Bureau of Mines performed a study to determine optimal locations for longwall face methane monitoring equipment. Longwall face ignitions continue to be a concern to the U.S. coal mining industry. Gains in ignition control technology have been somewhat negated by advances in longwall productivity. More reliable, heavy-duty longwall face systems generate higher production rates and increase methane liberation rates. These rates will likely continue to rise in the future as further coal production increases occur. Efforts will continue in the areas of methane drainage, methane containment, and methane dilution. In addition, more effective face methane monitoring is needed. As technology continues toward automated longwall panels, the importance of monitoring for methane at the shearer becomes even more significant. Since the primary face ignition source is the shearer mining machine, the Bureau ran tests to determine the best location to take methane readings on the shearer. This information, in conjunction with data obtained from field studies, provides a knowledge base for selecting optimum face methane monitoring locations.

Jan 1, 1993

By Biswajit Samanta, Pranjal Pathak

This article presents a customized genetic algorithms (GA) with new crossover and mutation operators to solve the short-term production scheduling problem of multi-mine mineral value chains (MVC). The preceding problem consists of determining the extraction sequence and destination allocation of blocks from all the mines collaboratively while closely meeting the quality and quantity requirements of the processing units subject to relevant technical and operational constraints. The short-term production scheduling is carried out at shorter scales wherein the operations are modeled in a great detail with large number of constraints. This makes the industry-scale instances of the problem computationally intractable for standard mixed-integer programming (MIP) solvers. Thus, a GA-based heuristic approach is developed to obtain nearoptimal solutions to the large-scale instances of the problem in a reasonable amount of computational time. Computational experiments show that the developed GA-based method is a promising way to handle industry-scale instances of the problem. Moreover, the sensitivity analysis on various parameter combinations of crossover and mutation operators indicates that the customized global mutation operator, when used in combination with the customized crossover operators, took on average 12.5% less time than the customized local mutation operator to converge to a solution.

May 21, 2022

By J. G. Russell

The valuation of known mineral re-serves entails the economic evaluation of the mining enterprise and the valuation of other assets employed, including mining and processing plant and intangible assets. A case study approach analyzes two reserve situations: ownership of reserves (phosphate rock), and leasing of reserve lands (kaolin). The appraisal of the physical property is outlined, along with the economic analysis of the operation. The discounted net cash flow approach is used to value the enterprise, leading to value of the reserves after correlation with other assets employed.

Jan 1, 1989

By John L. Halls

Modern business practice dictates that in order to ensure the economic optimization of investment, the size of any investment venture must be such that every increment of capital invested in such a venture yields at least a corporate minimum acceptable rate of return. This practice is based on the premise that alternative investment opportunities capable of yielding the minimum corporate return are immediately available. If a mining corporation is to make the maximum use of its investment funds, any capital investment in a mining property must comply with the above practice. The most important parameter in estimating ore reserves is the cut-off grade which is used to separate material into ore or waste. The cut-off grade is calculated on the basis that material of cut-off grade produces sufficient revenue to cover the estimated costs of mining and processing through to sales, including depreciation and produce a pre-determined profit. Ore reserves so estimated are adequate for determining the magnitude of an orebody but do not provide a sound basis for determining plant size and therefore capital investment in a new property or for expansion consideration on an existing property. From a financial analysis of this one ore reserve it is impossible to ascertain whether each increment of capital investment is providing the minimum acceptable rate of return, Other difficulties associated with the calculation of a cut-off grade including the determination of depreciation and the amount of pre-determined profit to be included in the cut-off grade calculation are outlined in the text. The proposed solution to determine optimum ore reserves and plant size for new properties avoids the complication of calculating a cut-off grade by computing a series of ore inventories using arbitrarily selected cut-off grades. A comparison of the cash flows generated by production from such ore inventories using incremental financial analysis clearly indicates the ore reserve and plant size which will best serve the corporation's investment and metal production goals. Incremental financial analysis of a corporation's operating mines and prospects assists management in assessing the comparative expansion and investment possibilities of each property for increasing or maintaining metal production on a long term basis.

Jan 1, 1969

By Kenneth J. Miller

A novel two-stage froth flotation process to remove pyritic sulfur from fine- size coal is described. The process consists of a first-stage, standard coal flotation step in which high-ash refuse and some of the pyrite are removed as tailings. The first-stage clean coal froth concentrate is then repulped in fresh water, and a coal depressant, a pyrite collector, and a frother are added to float the remaining pyritic material. Laboratory and pilot plant flotation results with coals from the Lower Freeport and Pittsburgh beds are given. The pilot plant test results show that up to 80 percent pyritic sulfur reduction was achieved with the Lower Freeport bed coal and up to 50 percent with the Pittsburgh bed coal. Laboratory and pilot plant results were in excellent agreement, indicating that the process is a viable means of removing much of the sulfur from some coals.

Jan 1, 1974

By T. Negeri

Flotation is the most efficient and preferred solid-solid separation method in mineral processing. However, enhanced production of high-grade concentrates at sufficiently high recovery still poses technological challenges to-day. A novel flotation method to produce final-grade concentrates from finely-ground ores in a single step is being developed and tested by CANMET. For the complex sulphide ores tested, grades are superior while recovery is considerably improved. Furthermore, concentrate production rates, at similar recoveries, are faster than for the conventional rougher-scavenger-cleaner configuration. This paper discusses the physical operating parameters affecting Cu-Zn flotation metallurgy.

Jan 1, 1995

By C. Flores

The most common experimental approach of studying one variable at a time while holding all others constant is extremely inefficient. Use of statistical methods enables engineers and scientists to obtain meaningful information with the fewest experiments, reducing cost and wasted effort. In particular, the Taguchi method can be more efficient than traditional full factorial experiment designs, as it can study more variables with fewer nuts, and it is more robust against process "noise." Taguchi designs are also simple to formulate and the results can be analyzed by simple PC spreadsheets. The role and benefits of using the Taguchi method in experiments to develop and optimize processes is discussed.

Jan 1, 1998

By Richard A. Thomas, III JAMES H. ROWLAND, Liming Yuan

This paper presents the results of large-scale fire experiments on evaluating the performances of carbon monoxide (CO) and smoke sensors at low ventilation velocities. Experiments using three different combustibles — conveyor belt, coal and diesel fuel — were conducted in the experimental mine at the U.S. National Institute for Occupational Safety and Health (NIOSH) Bruceton Research Facility. A total of eight sensor stations were located downstream of the fire with each station containing sensors for CO, smoke, carbon dioxide (CO2 ), oxygen (O2 ), humidity, barometric pressure and temperature, as well as two airflow sensors. The airflow velocity ranged from 0.22 to 0.26 m/s (44 to 51 fpm) in the tests. The response times were recorded for the CO and smoke sensors at each sensor station when smoke and gaseous products of combustion from each burning combustible reached the station. The response times of the CO sensors were used to determine the appropriate sensor spacing in the belt entry with a low air velocity. The performance of the smoke sensor was found to be affected by the high humidity in the experiments. The results on proper selection of sensors and the determination of sensor spacing at a low ventilation velocity can be helpful for ensuring sufficient early fire warning for underground workers, thereby improving the health and safety of miners.