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By Liming Yuan, Isaac Zlochower, RICHARD THOMAS, Thomas H. Dubaniewicz, Teresa Barone

Mining vehicle manufacturers are developing lithium-ion (Li-ion) battery electric vehicles as an alternative to diesel-powered vehicles. In gassy underground mines, explosion-proof (XP) enclosures are commonly used to enclose electrical ignition sources to prevent propagation of an internal methane (CH4) air explosion to a surrounding explosive atmosphere. Li-ion batteries can create pressurized explosions within sealed enclosures due to thermal runaway (TR). Researchers at the National Institute for Occupational Safety and Health (NIOSH) measured TR pressures of lithiumiron phosphate (LFP) cells as a function of free space within sealed enclosures and observed an inverse power relationship. A well-confined cell produced 294 bar (4260 psia) of pressure during a TR, far exceeding minimum pressure containment specifications for conventional XP enclosures. Results indicate that adding enough free space surrounding LFP cells can reduce TR pressures to levels below that expected for CH4-air ignitions. Measured TR temperatures were below the minimum autoignition temperature of CH4-air.

Nov 6, 2020

By Z. Jin, D. DePaoli, P. Zhang

"Phosphate beneficiation in Florida generates more than one tonne of phosphatic clay, or slime, per tonne of phosphate rock produced. Since the start of the practice of large-scale washing and desliming for phosphate beneficiation, more than 2 Gt of slime has accumulated, containing approximately 600 Mt of phosphate rock, 600 kt of rare earth elements (REEs) and 80 million kilograms of uranium. The recovery of these valuable elements from the phosphatic clay is one of the most challenging endeavors in mineral processing, because the clay is extremely dilute, with an average solids concentration of 3 percent, and fine in size, with more than 50 percent having particle size smaller than 2 µm, and it contains nearly 50 percent clay minerals as well as large amounts of magnesium, iron and aluminum. With industry support and under funding from the Critical Materials Institute, the Florida Industrial and Phosphate Research Institute in conjunction with the Oak Ridge National Laboratory undertook the task to recover phosphorus, rare earths and uranium from Florida phosphatic clay. This paper presents the results from the preliminary testing of two approaches. The first approach involves three-stage cycloning using cyclones with diameters of 12.4 cm (5 in.), 5.08 cm (2 in.) and 2.54 cm (1 in.), respectively, to remove clay minerals followed by flotation and leaching. The second approach is a two-step leaching process. In the first step, selective leaching was conducted to remove magnesium, thus allowing the production of phosphoric acid suitable for the manufacture of diammonium phosphate (DAP) in the second leaching step. The results showed that multistage cycloning with small cyclones is necessary to remove clay minerals. Selective leaching at about pH 3.2 using sulfuric acid was found to be effective for removing more than 80 percent of magnesium from the feed with minimal loss of phosphorus.IntroductionFlorida phosphate ore, or “matrix,” as it is called locally, contains three different mineral groups that have to be separated from each other: (1) phosphate minerals, (2) clay minerals and (3) quartz, or sand. As mined, the phosphate and sand particles are embedded in compacted mud, or clay-balls. Before separation can begin, all of the particles must be liberated from the matrix of mud. The very first unit operation in the beneficiation process is to disaggregate the various particles. This actually starts while the matrix is flowing through the multimile pipeline from the mine to the beneficiation plant. While in the pipeline, the matrix is exposed to shear forces as it passes through the various centrifugal pumps along the pipeline. These intense shear forces cause a significant percentage of the sand and phosphate particles to be liberated from the clay-balls by the time they arrive at the plant. Once they reach the plant, the first goal is to finish disaggregating the clay, and follow that by making a size separation at 1 mm. This processing is conducted in the washer, consisting of a large rotating trammel screen and a few stages of log washer, screens and hydrocyclones. In all of the currently operating beneficiation plants, the washer is a large structure that receives the matrix, screens it and then discharges a pebble phosphate product sized larger than 1.0 mm and a slurry of liberated clay, sand and phosphate particles that are smaller than 1.0 mm."

Jan 1, 2017

By J. L. Ellenberger, T. Miller

"A limestone mine in Ohio has had roof instability problems that have led to massive roof falls extending to the surface. This paper describes a collaborative study of these events undertaken by the National Institute for Occupational Safety and Health and the mine owners. The study focuses on the roles that weak, moisture-sensitive floor and weak bands in pillars play in a general instability that led to roof falls at this mine. The NIOSH Stone Mine Pillar Design software (S-Pillar) does not include analysis for weak floor or weak bands and recommends that when such issues arise they should be investigated further using a more advanced analysis. It is important to recognize that without the impact of the floor or weak bands, the calculated inherent stability factor for these pillars is within the recommended design range. Therefore, to further investigate the observed instability occurring on a large scale at the Ohio mine, FLAC3D numerical models were employed to help determine the failure mechanism. Roof-to-floor extensometers were also installed in the areas predicted to have further instability. This case study will provide important information to limestone mine operators regarding the impact of weak floor causing the potential for roof collapse, pillar failure, and subsequent subsidence of the ground surface. This recent case demonstrates that weak floor can be a significant factor in pillar stability and should be assessed during the design stage of the mine.To an area-wide failure (Zipf, 2001). In that case, it appears that the pillars had actually remained intact. However, moisture-related yield of the weak floor caused deformations which passed through pillars and into the roof, triggering roof collapse around the intact pillars (Esterhuizen et al., 2011). This previous case and the case presented in this study, while not identical, both demonstrate that weak floor and/or bands within pillars can be a significant factor leading to instability."

Jan 1, 2015

By Daniel W. Kappes

Testing ores for heap leach operations traditionally follows a progression of bottle roll tests, bucket and column leach tests, and very expensive large field leach tests. Enough data is now available to streamline the procedures. Data from five different operations shows that recoveries from large field leach tests can be predicted from the bucket tests. Initial recovery times in large field leaches are longer than in bucket tests- a typical response is eight days versus twenty days to the same recovery percentage; but the ultimate percent recoveries (after 60 days) are normally very close. Methods of mining and stacking can radically affect recoveries from clay-rich ores. Leaching of uncrushed ores provides special testing problems, since accurate samples smaller than several tons cannot be taken.

Jan 1, 1981

By Richard C. Travis, Edward C. Dowling

A detailed kinetic study of the flotation installation at the Metcalf Concentrator revealed a rougher flotation circuit operating under less than optimal conditions. Based on these results, a project was initiated to approximately double the rougher flotation capacity by increasing the installed volume from 780 cubic meters to 1,560 cubic meters. This project, which was completed in early 1991, replaced the existing cells with larger capacity cells. A comprehensive analysis of results demonstrates significant metallurgical benefits. INTRODUCTION/BACKGROUND The Metcalf Concentrator is located in Morenci, Arizona and is part of Phelps Dodge Morenci, Incorporated. Sumitomo Metal Mining of Arizona is a minority partner in the operation with 15% interest. The Metcalf Concentrator is the newer and smaller concentrator and operates in conjunction with the Morenci Concentrator. Operating capacity at Metcalf is currently 48,000 TPD of ore on a 365 days per year basis. The Metcalf Concentrator was commissioned in 1974 at a 30,000 TPD operating rate for the purpose of treating ores originating in the Metcalf Mine. The mine takes its name from the former town of Metcalf which was named for Robert Metcalf who was credited with discovery of the mineral district. The predominant ore mineral is chalcocite which occurs as a secondary enrichment closely associated with iron pyrite. The host rock is largely granodiorite and quartz monzonite. The original rougher flotation circuit consisted of a total of six rows of Wemco 8.5 cu. meter (300 cu.ft.) flotation machines treating pulp from the two grinding sections (Sections A and B). Each row was configured in a 4-4-4 arrangement. Shortly after startup the throughput rate was increased significantly without sustaining a recovery loss. This increase was achieved by raising the target value for the particle size of the cyclone overflow which is the rougher flotation feed. Shortly thereafter, the capacity of the pump and cyclone began to restrict further increases in throughput. After testing, two 66 cm. (26-in.) cyclones and a 12-in. X 12-in. centrifugal pump replaced the original classification equipment. As a result of these modifications, the grinding section could routinely process in excess of 42,000 TPD. Due to the increased tonnage rates, limitations in the rougher flotation circuit performance were observed. In an effort to improve the performance of rougher flotation with this higher throughput, the speed of the flotation mechanisms was increased from 230 RPM to 250 RPM. This change improved the suspension of the coarser feed and induced additional air into the pulp. It did, however, apply additional strain to the motors, shortening their life. At these elevated processing rates, it was found that the dart valves operated almost entirely at the top end of the control range and could not efficiently handle upsets from the grinding section. This was remedied by lowering the end overflow weir and allowing some of the tailings to overflow the end weir. However, in order to obtain acceptable recovery levels, the flotation pulp was maintained at a high level, adversely influencing the rougher concentrate grade.

Jan 1, 1993

By Jürg Künzle

Underground construction is a matter of dealing with the inherent uncertainty of subsurface geology. If the encountered conditions are less favorable than the expected ones, the execution of excavation, support, ground treatment or lining works is likely to require more or different efforts than anticipated, thereby delaying the works and increasing the costs. The 2019 first edition of the FIDIC Emerald Book model contract (FEB) addresses many of the issues to which underground works give rise, including those related to differing site conditions (DSC). This paper examines how under the FEB disputes arising from or in connection with DSC could or should be avoided.

Jun 13, 2021

By L. A. Khan

This paper first discusses the physicochemical cleaning methods used to process fines followed by an analysis of the subprocesses of froth flotation and the adverse effects of slimes and particle oxidation. These subprocesses include the phenomena of interception, contact, adhesion and levitation. Preventive and corrective measures to combat the generation of fines and their effects are suggested. Preventive measures include controlled grinding, limited liberation, flotation at coarser sizes. Means of preventing oxidation and/or removing oxidation products are a1 so discussed. Corrective measure to increase recovery include intensive aeration, aggregation of particles, intensive mixing, increased retention time, and reduction of detachment. Measures leading to improves selectivity involve means to reduce slime coating, achieve selective mineralization of bubbles and minimize entrapment.

Jan 1, 1986

By J. D. Miller

The sedimentary western phosphate deposits of Idaho, Montana, Utah, and Wyoming tend to be calcareous and generally carry a significant amount of dolomite along with collophanite. In some cases, such as the Smokey Canyon Mine, Afton, Wyoming, the ore will also contain mudstone, and in this case the aluminosilicate minerals (clay, feldspar, etc.) together with some dolomite are floated from the collophanite in column flotation cells with an amine in order to meet product specifications (31 % P205) (Service et al.). In other cases, such as the SF Phosphates Limited Mine, Vernal, Utah, the ore is treated by traditional fatty acid flotation of the collophanite with mechanical flotation cells (Weber, 1986). Preliminary tests have now been conducted to evaluate air-sparged hydrocyclone (ASH) technology for the flotation of western phosphate ore. For this preliminary study, samples were taken from the hydrosizer overflow stream (18-21 % P205) at the SF Phosphates Limited Plant in Vernal, Utah for scavenger flotation testing with the 2-inch ASH system in laboratories at the University of Utah. Selected design and operating variables are being studied, and the initial results show that satisfactory separations can be achieved by high-capacity ASH flotation at appropriate operating conditions. For example, with single-stage ASH flotation 80% recovery can be obtained with a scavenger concentrate grade of about 26% P2O5. These results are comparable to, or better than, those obtained at SF plant operations with conventional flotation cells and suggest that ASH flotation technology can be used to good advantage in the phosphate industry. Of course, research should be continued to consider other process streams, optimize the separation efficiency, and evaluate larger diameter ASH units.

Jan 1, 1993

By G. Purcell

When coal in an oil/water slurry is ground to minus-200-mesh in a ball mill, some of the mill energy, normally wasted as heat, can be usefully recovered to help emulsify the oil. If the discharge flows onto a suitable sized trommel screen, water and ash material are rejected through the screen while coal and oil ball together to give a clean coal product. A small (6-lb/hr) continuous plant has demonstrated the feasibility and the limitations of this process for New Mexico coals.

Jan 1, 1980

By C. A. Summers

The U.S. Bureau of Mines applied process mineralogy to investigate a lead and zinc deposit located near Story Creek, Colville Mining District, Alaska. Mineralization is hosted by the Kayak Shale in veins, veinlets, and breccia. Sphalerite and galena, with supergene anglesite, occur in symmetrical quartz veins and between breccia clasts. The study sample analyzed 2.11 percent Pb, 5.37 percent Zn, 0.014 percent Cu, and 1.2 oz/ton Ag. Analyses of crushed products showed that 33 percent of the sample weight, and more than 50 percent of the Pb and 65 percent of the Zn, are in the minus 850 µ m fraction. Liberated grains of sphalerite and galena were found in crushed products finer than 300 µ m. Beneficiation tests indicate the material is amenable to processing by traditional gravity and flotation techniques.

Jan 1, 1993

By Michael Jatczak

The San Vicente Tunnel Project is an 11-mile water tunnel constructed for the San Diego County Water Authority. One of the many challenges of the project included tunneling a 22,000-foot single-heading tunnel on the western half of the job in varying geology using a 3.66m (12ft) diameter open shield excavator or ?digger shield.? This paper will discuss the design considerations for the temporary liner, the tunneling, and ancillary equipment. It will also highlight the challenges faced while mining this geology, explain the methods implemented to drive this section of tunnel, and discuss the experiences while performing mechanized tunneling in an extensive and varied San Diego geology.

By C. Gregory Knight

Adequate planning for the development, operation, and reclamation of a surface mine requires attention to present and future uses of land, both on the mine site and in the mine vicinity. This paper outlines land use implications of surface mining, and suggests procedures that could link mine planning, mine operation, and reclamation to more general land use concerns. Mining is viewed as a temporary use of land that may irretrievably commit land resources away from some future activities, but may allow other uses, some of which may have been impossible without mining. The paper accepts the premise that surface mining should attempt to minimize environ-mental damage and to maximize future alternative uses of land by appropriate reclamation. I. The Effect of Surface 1'1ining on Land Use Surface mining is a temporary utilization of the land most often criticized because the disturbances it creates are of far greater duration than the actual extractive operation, Resource recovery disrupts existing activity on the land, at least temporarily, and

Jan 1, 1977

By X. Shi

This paper presents design and implementation details of a fuzzy-behavior-based controller for an automated excavator. The robotic excavator is equipped with sensors, actuators and an embedded control system. The excavator controller uses neural-networks to interpret forces and torques gathered during the excavation process from bucket-mounted force sensors. Implementation details card experimental results using the fuzzy-behavior-based excavation controller are given for several excavation tasks. These excavation tasks demonstrate some of the complex skills that are essential for an autonomous mining-excavator controller.

Jan 1, 1997

Column flotation has been successfully implemented on a production scale in the Athabasca oil sands. In this application, bitumen is recovered and mineral matter is simultaneously rejected from a middling stream originating from a primary separation vessel. Exploiting the natural hydrophobicity of bitumen, the middlings streams have traditionally been processed utilizing conventional, mechanical flotation cells. Although these cells offer adequate bitumen recovery and mineral rejection rates, operating costs are high due to the required maintenance of the wetted mechanical components. In comparison, column flotation provides superior metallurgical performance while offering a lower maintenance demand. Both metallurgical and mechanical characteristics of column flotation are discussed to demonstrate the benefits of this technology for the recovery of bitumen from oil sands.

Jan 1, 2012

By J. P. Brady

A major spontaneous combustion incident occurred in the sealed goaf of the SL3 Panel; Southland Colliery in 2003 resulting in the loss of a longwall and sealing of the mine. The most important issue for the new owners, Yancoal Australia Pty. Ltd, was to effectively manage the atmosphere in the fire affected sealed area. This atmosphere comprised of flammable gases, the products of combustion and excessive levels of oxygen due to pressure differentials across the panel isolation seals with a potential ignition source associated with the residual spontaneous combustion event. The challenges were met in the first instance by the erection of pressure balance chambers with limited success. The problem was not solved until the pressure chambers were pressurized using a Floxal Nitrogen Plant supplied by Air Liquide Australia. Given the success of this approach on a small scale, a higher capacity Air Liquide Floxal Unit was acquired to manage spontaneous combustion at the recommencement of longwall mining operations. This provided the ability to pressurize pressure chambers that were installed in the Maingate Seals behind the face of the adjacent Longwall Block effectively preventing the ingress of oxygen and permitting the goaf to self inert in a reasonable time period. This paper summarizes a new proactive method of mitigating the risks associated with active and sealed goaves. Proactive management of these areas using low flow nitrogen into pressure chambers to maintain a positive pressure has eliminated typical reliance in explosion proof or explosion resistance seals as the primary control.

Jan 1, 2009

By R. B. Elver

The St Lawrence Seaway, a deep-water canal system between Montreal and Lake Ontario, was opened for navigation on April 25, 1959. Prior to the opening of the new Seaway, small boats known as canalers and a few deep-sea carriers, primarily from Norway since World War II, were the only ships able to journey past Montreal into Lake Ontario through the old Canadian St. Lawrence canal system. Thus it was necessary for many tons of bulk and general cargo to be shipped all-rail to and from Atlantic ports or to be transhipped to and from canalers. With the opening of the new Seaway, large Great Lakes bulk carriers and a much larger percentage of the world's shipping fleet are now able to sail directly from the sea to the heart of industrial North America. In this paper, the historical events leading up to the construction of the Seaway and the physical nature of the Great Lakes transportation system are briefly reviewed. Following this, an attempt is made to evaluate the effects of the new Seaway on Canada's mineral industry. Because the Seaway has been in operation for only one season, this paper must be considered only an interim report. Because of the importance of the Seaway to iron ore, this commodity will be dealt with in detail, although the effect on other mineral commodities such as coal, petroleum, nonferrous ores, iron and steel will be mentioned. At this time the author wishes to thank the various company and government officials who provided both factual information and critical opinions.

Jan 1, 1960

By F. N. Kissell, C. D. Litton

This study predicts the level of smoke that miners might meet while trying to escape a coal mine fire and describes how smoke would impede their safe escape. For this study, the authors assumed that miners exit through an escapeway adjacent to the burning entry, that some air would leak from the burning entry to the escapeway. The following conclusions were made: • A very low amount of air leakage to the escapeway can produce a critical level of visual obscurity from smoke. This shows that intake airways may be as susceptible to smoke visibility problems as return airways. • This critical level of smoke obscurity is reached much before a critical level of carbon monoxide is reached. • Small fires can cause a severe sensory irritation that further limits vision. Thus, reliable eye protection is very important. These results show that methods to guide miners through dense smoke will contribute greatly to saving lives during mine fires.

Jan 1, 1993

By J. L. Whitlock

A mutant strain of Pseudomonas paucimobilis is utilized to effectively degrade and or remove 90-98% of cyanide, thiocyanate, toxic heavy metals and ammonia from a cyanidation mill process and mine discharge maximum of 21,000 m3/d (5.5 MGD). Homestake Mining Company?s biological wastewater treatment plant has been in full scale operation for over 2 years at the Homestake Mine in Lead, South Dakota.

Jan 1, 1987

By W. D. Elston, A. E. McLaughlin, G. B. Hampton, W. L. Barham, J. F. Murphy, W. H. Cundiff, J. W. Mulloy, R. G. Breuer, J. W. Shaffer

Introduction Alumina (aluminum oxide) is the material from which all the world's aluminum is produced. In the Western World, all the alumina is made from bauxite by the Bayer process. In the nearly 150 years since aluminum was first isolated by Oersted, the metal has grown from a laboratory curiosity to a position of major importance in the world's commerce. In terms of annual production rates aluminum is first among nonferrous metals. Oersted's discovery-reduction of aluminum chloride with potas¬sium amalgam-was improved on by Ste. Claire Deville, whose so¬dium amalgam reduction of aluminum chloride led to the commercial production of aluminum in France in 1855. Ste. Claire Deville's method prevailed until 1886 when Charles Martin Hall and Paul T. Heroult each invented a process for the production of aluminum by the electrolysis of alumina dissolved in molten cryolite. The inven¬tion by Karl Josef Bayer in 1888 of an economical process for making very pure aluminum oxide (alumina) from bauxite established the necessary link between known ores and the Hall-Heroult reduction process. Bayer's work completed the scientific base-the ore bauxite refined to alumina by the Bayer process (U.S. Patent No. 515,895), the alumina reduced to aluminum in the Hall-Heroult cell (U.S. Patent No. 400,766--upon which today's aluminum industry is founded. Small-scale production of aluminum in the U.S. began in 1888 utilizing the Hall cell. By 1903, bauxite properties and a Bayer process refining step had been incorporated into the production activities. On this base the aluminum industry in the U.S. has grown at an annual compounded rate of 15%. Since 1946 the annual growth rate has been 10%.1 The rapid growth of the industry is the result of many factors among which are the existence of widespread bauxite ore deposits; a sound and economic production technology; and the properties of the metal-lightness, strength, ductility, good electrical and heat con¬ductivity, and pleasing appearance, which lead to ever greater de¬mands for aluminum in an industrializing society. At the inception of the industry, the only market that could be found for aluminum was in the production of cooking utensils. How¬ ever, the rapidly accelerating industrial and technological development of the Western World soon created new needs for aluminum, and today aluminum is marketed in a broad range of industrial, commer¬cial, and consumer applications. The principal uses for aluminum are:' building and construction, 22%; transportation, 18%; electrical, 13%; packaging, 11%; consumer durables, 10%; machinery and equipment, 7%; other, 19%. The 1974 production of primary alumi¬num in the world was 14.5 million short tons, which at an approximate ingot price of 40¢ per lb puts a value of $11.6 billion on the industry product prior to fabrication. While aluminum is widely distributed in the earth's crust and is a major constituent of many rocks and soils, to date no method of extraction of aluminum from such nonbauxite material has been brought to commercial practice in the Western World. In the USSR alumina is produced by the complex processing of nepheline syenite, but elsewhere all commercial production of alumina is from bauxite. A brief discussion of recent developments and other processes for alumina is included in the subsection "Other Processes for Alumina," page 19-15. In early 1973, a major U.S. aluminum producer announced the successful development of processes for the production of aluminum from aluminum chloride. This achievement promises to exert a major influence on the future of the aluminum industry. In the initial com¬mercial application of this new technology, Bayer alumina will be chlorinated, and the aluminum chloride then reduced by electrolysis. Important claims for the new processes are lower energy requirements (one-third less than obtainable in Hall cells) and reduced labor costs. Capital costs are said to be no greater than for conventional plants. While the announced intention is to produce the aluminum chlo¬ride from Bayer process alumina, the new chloride reduction process will eliminate the other raw materials, carbon and fluorides, required by the conventional Hall cells. The electrodes in the chloride cell will not be consumed on the reduction process and the electrolyte will have, as the name indicates, a chloride rather than a fluoride base. 2. Bauxite Definition and Origin. Bauxite is a naturally occurring raw material composed principally of a mixture of one or more of the hy¬drated aluminum oxide minerals gibbsite (Al2O2 3H2O), boehmite (Al2O3 H2O), and diaspore (Al2O, - H2O), and impurities of silica, iron oxide, titania, and other various elements in trace amounts. It is an end or near-end product of chemical weathering. Depending on the amount of iron impurities, the color of bauxite varies from dark red and brown to pink to white. Some bauxite is finely divided, free digging earthy material, while other forms are dense and rocky, requiring explosives in mining. Many gradational forms exist. It is one of the most variable of mineral raw materials in chemical composition and physical appearance. It is generally believed that bauxite deposits resulted from intense chemical weathering of aluminum-bearing rocks or formations under tropical or subtropical conditions with alternating wet and dry sea¬sons. Topographic conditions were favorable for drainage and the in-situ accumulation of aluminum, iron, and titanium oxides. There was low to moderate topographic relief with a minimum of erosion during long quiet periods in earth history.2 The occurrence of bauxite is widespread and it has been found on all continents except Antarctica. Production was reported from 27 countries in 1974, at which time total world production was over 79 million metric tons. Of this production 76% was from seven coun¬tries-Australia, Jamaica, Surinam, Guinea, USSR, Guyana, and Greece-which ranked in that order of production. In Table 1 are shown typical compositions of bauxite from some

Jan 1, 1985

By Mark Kuchta, Hans Engberg

The Swedish mining company LKAB operates two of the largest underground mines in the world today that together produce around 35 Mton of iron ore per year. During the 1990s, the company embarked on a massive effort to computerize its mine planning system. The goal was to combine various mine planning operations including mine surveying, geologic modeling, mine layout, production planning, and production follow-up into one modular based integrated system. The system was built around a large Oracle database and the Microstation CAD system. This overall design strategy and the various system modules are described, and some experiences gained using the system are discussed.

Jan 1, 2002