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By Stuart F. McTavish

Mechanically suitable grinding mills became available to the mining industry in 1908. Since then, mill operators have been searching for the best material and design with which to line the mills. These liner systems had to fulfill several criteria. Most important, they had to last long enough in an operating mill to protect its structure from the abrasive wear of the ore and the grinding media. In addition, they had to be capable of efficiently transferring the energy from the mill to the mill charge in order to facilitate the grinding process. And these liners had to be easy to install and remove. The first liners used were generally made of cast white iron, Hadfield manganese, unalloyed high-carbon steel and composites of steel and concrete or cemented in flint blocks or natural stone. In the early 1920s, pieces of solid rubber truck tires were used as emergency repairs for broken cast metal liners. Thus was rubber first introduced as a mill liner material. The first patent for rubber mill liners was awarded in 1921 to James Denny and Rolla Watson, both of the Coniagas Mine in Cobalt, Ontario, and to Dale Barnum of the Comstock Lode in Virginia City, NV. This original design was covered under US Patent No. 1470597. It had a fabric backed rubber that was bonded to the shell of the mill.

Jan 1, 1990

By R. Mensah-Biney

The NC State University Minerals Research Laboratory (MRL) and Waste Reduction Partners (WRP) of the Land of Sky Regional Council joined efforts in 2000 to initiate a technically sound and practical program for the management of high-volume coal combustion by-products (CCBs) in North Carolina. The accumulation of CCBs from coal burning boilers throughout the state of North Carolina posed a substantial storage problem, and the area was overripe for an effective management program, which would be environmentally sustainable. In particular, the public utility generators had filled storage ponds on their properties, and the storage overload had grown to critical proportions. Much the same situation existed for paper mill biosolids, which were stored on site in landfill cells along with daily output of CCBs from the mill boilers. A conversion process via the patented pyro-process12 (US Patent No. 5,342,442) to produce synthetic light weight aggregates (LWA) from CCBs and paper mill sludge was conceived to process large quantities of both these waste materials. MRL and WRP initiated and formed a consortium that brought together academia, private industry and state agencies to evaluate the production of LWA by the pyro-process. The industry partners included representatives from the power companies, industrial ash generators, expediters for coal ash products, as well as concrete block manufacturers. It was important to welcome interested parties from not only the western North Carolina area and other parts of the state but also from neighboring states including Tennessee, South Carolina and Georgia. Membership of this consortium evolved during the intervening years to include the following participants and supporters: Progress Energy Carolinas; Duke Energy; Santee Cooper; Full Circle Solutions; Land-of-Sky Regional Council; NC Department of Pollution Prevention and Environmental Assistance; Ecusta Business Development Center; Blue Ridge Paper Products; Jackson Paper and Manufacturing Company; Miller Perlite; Appalachian Products; General Shale Brick; Metromont Materials; Small Business Technology Development Center of the University of North Carolina system and North Carolina State University The initial development program conducted at the Minerals Research Laboratory (MRL) was to formulate an acceptable LWA product, which fulfilled user specifications for light weight concrete block and structural concrete application. Support work and program coordination efforts were furnished by retired technical volunteers in WRP. The work advanced steadily, using proven technologies well established in the mineral industry, to generate a very satisfactory LWA. The consortium then concluded that a more comprehensive CCB conversion program would have more appeal for full scale manufacture and commercialization, if a variety of products from CCB separation were generated. This product assortment would include bottom ash, low carbon fly ash, recovered carbon of high purity, as well as the synthetic LWA. The bottom ash would serve the concrete block market, the fly ash was in demand for ready-mix concrete, and the high carbon product could be pelletized and used as a fuel for reburn or by the steel industry, and the LWA was a sought-after component for light weight concrete applications. After scouting all these potential markets and finding them to be viable, the consortium then inaugurated an integrated pilot plant program for the CCB separation and conversion. The plan was organized in three (3) parts: (1) Phase I ? bench scale evaluation studies (2) Phase II continuous pilot plant evaluation and (3) Phase III ? conceptual commercial plant design including marketing efforts and attraction of business entrepreneurs to build a full scale manufacturing plant. Phase II would serve to validate the process in a continuous mode and produce substantial quantities of products for preliminary marketing efforts and for demonstration-of-use purposes. The consortium agreed to the name, CAROLINA ASH PRODUCTS, (CAP), for the integrated pilot plant program. The products generated might be designated with the CAP label as: bottom ash would be named CAP Granules, low carbon fly ash would become CAP Ash, recovered high carbon product would be CAP Carbon, and LWA would have the name CAP Stone. Phase II of the program processed 20 tons (18 t) of ponded ash from Progress Energy storage at a rate of 600 lb (271 kg) of raw ash per hour with favorable results. PRELIMINARY STUDIES Prior to committing laboratory research and development effort as well as support and coordination activities to this program, it was necessary to determine (1) the level of need for a freshly launched CCB reutilization program in this state and (2) what degree of versatility was necessary for such a process. State agency records and a survey of recent boiler operations indicated that in the state of North Carolina at least 77 facilities manage CCBs from their boiler operations. Despite continuing development efforts in more eastern parts of the state, the use of CCBs for commercial applications has not increased to a level which alleviates the need to store vast quantities in private monofills on the generator?s property. More than 1.25 million tons (1.13 million t) of CCBs are landfilled in NC annually, with 300,000 tons (271,985 t) per year generated in western NC alone. Many different boiler types, which span both very old units and those that are modern and efficient, were to be found. These included stoker-fired units, pulverized coal boilers, slag-tap furnaces, and fluidized bed combustion boilers covering a range of sizes. Any systems designed to separate CCB components from all these sources and convert them to useful secondary products would need broad processing latitude and flexibility. Up to the present there has been a paucity of research done in the western part of the state to find productive alternatives to storage in landfills. With tipping fees in our largest landfill now approaching $40 per ton ($44 per t) and escalating transportation fees (about $200 per truckload up to 40 tons, traveling a distance of 25 miles), the problem has become urgent both economically and ecologically. A well-designed, integrated wet process for CCB separation into value-added products had much potential to be less expensive than landfilling as well as to provide saleable materials with acceptable profit margins. These preliminary investigations also revealed that other major waste streams, in particular paper mill sludge and municipal and animal waste biosolids were important candidates for priority attention. Since these biosolids could furnish the organic component of a synthetic LWA product, they could be consumed as part of the same program. This added interest value to a growing list of partners to support and participate in the program.

Jan 1, 2009

By J. D. Miller, C. L. Lin

Appropriate software and hardware necessary to adapt a x-ray CT analyzer for determination of coal washability has recently been developed and sucessfully tested for well characterized samples under laboratory conditions. Evaluation of the CT-based analyzer under simulated on-line conditions is also presented to verify the on-line capabilities of the newly developed x-ray CT analyzer for the control of coarse coal cleaning circuits. The investigation shows that the data obtained from CT washability analyses compare favorably with experimental sink-float data. Further, image frequency was considered to evaluate the CT-Based coal washability analyzer for simulated on-line conditions. Specifically the number of observations (image spacing) needed for accurate sampling and the total time required to perform the calculations for a representative data set were determined.

Jan 1, 2001

By J. G. Davis

The St. Peter Sandstone is typically a well-sorted, friable, ultra-pure, fine- to medium-grained, quartzose sandstone with silica content higher than 99 weight percent in places. The sand grains are well-rounded, highly spherical and characteristically frosted. Their size typically varies from 2 millimeters diameter (No. 10 U.S. Standard Sieve Series size) to less than 0.08 millimeters diameter (No. 200 U.S. Standard Sieve Series size). A freshly exposed surface of the formation is commonly white with shades of pink and green. Weathered surfaces are a dirty gray or brown and are case-hardened at many localities. Bedding is characteristically indistinct, and the formation usually appears massive throughout. The rock is cross-bedded and ripple-marked locally. The formation is generally porous, permeable and rarely fossiliferous in Missouri. The St. Peter is continuously present in the subsurface in the northern half of the state and along the southeastern edge of the state. The St. Peter crops out in a narrow band that starts in western Montgomery County and runs southeastward, along the Missouri River, to just west of St. Louis and continues south, just west of the Mississippi River, through Scott County. The outcrop belt varies from less than one mile wide to over ten miles wide, and it is over 150 miles in length. The formation dips into the subsurface radially away from the outcrop band. A notable isolated outcrop occurs in Lincoln County to the north of the main outcrop band. The St. Peter is discontinuously present in the subsurface along a band in the west-central portion of the state. It is not present at the surface or in subsurface in the remainder of the state. The formation averages 80?100 feet thick. There is an estimated 3.8 trillion short tons of St. Peter in Missouri. Sieve analyses on drill cuttings indicate three subsurface locations in northeastern Missouri where the St. Peter is greater than 10 percent by weight of sand falling in the 20?40 U.S. Standard Sieve Series size range. The St. Peter was first produced in Missouri in the 1870s for the manufacture of glass. Since that time it has been used as a paint additive, filler material, polishing compound, filtering media, and recently it is commonly used as a fracture proppant in oil and gas wells. The St. Peter is currently quarried and produced in Missouri from four sites located in St. Louis, Jefferson and Perry counties. In the same area there are at least nine abandoned historic mine sites.

Feb 27, 2013

By M. A. Reyes, L. Yan

Heat and humidity buildup within refuge alternatives (RAs) may expose occupants to physiological hazards such as heat stress. The Mine Safety and Health Administration (MSHA) regulations require RAs in underground coal mines to provide a life-sustaining environment for miners trapped underground when escape is impossible. RAs are required to sustain life for 96 h while maintaining an apparent temperature (AT) below 95 °F (35 °C). The National Institute for Occupational Safety and Health (NIOSH) tested a 10-person tent-type RA, a 23-person tent-type RA, and a 6-person metal-type RA in its underground coal mine facilities to investigate the thermal environment over a 96-h period. The test results showed that mine air and mine strata temperatures surrounding an RA occupied by simulated miners (SMs) increased over the 96-h test period. The test results suggest that RA manufacturers should consider this increase in temperatures when calculating and evaluating RA components during surface and laboratory tests. The findings can equip stakeholders with additional considerations for calculating the interior heat and humidity temperature profiles for occupied RAs not tested in situ

Nov 22, 2019

By B. Gigas, M. Preston, M. Giralico

Optimized mixer settler designs will now handle total flows of over 6,000 m3/hr.Computational Fluid Dynamics (CFD) is a timely and predictable tool for design development. Lightnin has the capability of using numerical analysis methodology to evaluate flow patterns and phase separation. CFD can show performance differences between changes, in mix tanks, in settler geometry, and in liquid depth, against variable flow rates. Understanding the differences allows the development of optimized designs. This paper focuses on the major design components of the mixer settler and how technological advances will lead to further improvements, when designing for today’s largest flow plants.

Jan 1, 2004

By George A. Mealey

Caving mining methods that are based on a planned caving of rock above and/or at times surrounding the material being mined can be classified in three broad categories: longwall mining, sublevel caving, and block caving. Each of the three methods involves a distinct technology as well as art of operation. Each requires a relatively large, regular, and predictable ore body. As a rule, the effect of mining results in some form of impact or change on the surface. Operationally, underground caving methods are characterized by high productivity as well as a high percentage of extraction of the mineral being mined. A key element for the productivity of this form of mining is the ability to standardize the various elements of work taking place underground. Therefore, work-men may perform a specialized role rather than function as all-around miners. Further, the nature of the mining methods lend them to a high level of mechanization. Operations and manpower can be centralized into a relatively small area where supervision can be concentrated and therefore be more effective. Productivity as well as safety benefits thereby. The caving method is unique in that the exploitation openings are deliberately destroyed by the process of mining. Rock mechanics principles focus on the ensurance and the propagation of the cave as well as the continuance of the mine openings designed to extract the broken ore. As a rule, production operations are designed to maintain a steady, continuous flow of ore from the extraction areas. This steady flow rather than an intermittent flow tends to promote good caving action as well as reduce hangups.

Jan 1, 2008

By O. N. Sikazwe

The Nchanga Cu-Co ore deposit of the Zambian Copperbelt, is hosted in Neoproterozoic siliciclastic-carbonate sedimentary rocks, and it consists of two orebodies: the Lower Orebody (shale) and the Upper Orebody (arkose). Refractory Cu ores present in the Upper Orebody comprise 150 Mt with average 0.87% Cu, and are characterized by inadequate recovery of copper by leaching. This materials characterization study, conducted on refractory ore samples from the Upper Orebody using optical microscopy, QEMSCAN®, and microprobe, has shown that copper occurs mainly in biotite, phlogopite, malachite, pseudomalachite and goethite. QEMSCAN® has quantified the abundance of each phase and total Cu deportment in each phase.

Jan 1, 2008

By A. W. Dickerson, G. Hollier, F. A. Bartley

Following on from many years of research aimed at improving the effectiveness of truck haulage operations in mines operated by BHP Minerals, BHP Research developed a concept for an Innovative Large Mining Truck, (ILMT) which has the potential to significantly improve the cost effectiveness of rear dump mining trucks. The ILMT concept reduces the empty vehicle weight dramatically, greatly reduces unequal rear tyre loading and improves ride and handling characteristics. The concept has been taken to the "proof of concept" prototype truck stage with the cooperative efforts of BHP Coal, BHP Research. Liebherr Mining Truck, Inc., Liebherr-Australia and Birrana Engineering. Testing of the prototype truck commenced at a coal mine in Queensland, Australia during May, 1996. Preliminary results from the testing program are very encouraging. Expectations are being met and in some cases exceeded.

Feb 24, 1997

By Bill Cain, R. John Caulfield, D. Scott Kieffer

The East Bay Municipal Utility District is undertaking seismic upgrades of the Claremont Tunnel in the San Francisco Bay area. The tunnel carries treated water across the active Hayward Fault to supply a major metropolitan area. Studies indicate the tunnel could be severed by fault offset during a major seismic event. A design approach to achieve limited operation of the tunnel following fault displacement has been established and design details are currently being evaluated. This paper describes the project, the design approach, and summarizes significant construction constraints.

Jan 1, 2001

By David M. Jurich, Randy J. Essex, Alex de Aboitiz

An Automated People Mover (APM) transit system is planned for the growing Phoenix Sky Harbor International Airport. The APM will improve passenger movements between the terminals, and provide a link to parking facilities, a new rental car facility, and the planned metro Light Rail. The underground works will include shallow twin bored tunnels, taxiway crossings, and underground stations constructed beneath critical airport facilities. Challenging soft ground conditions will require extensive underpinning and ground improvements. Design is underway, and construction is scheduled to begin in 2007 with project completion in 2015. The owner’s planned delivery method for the APM Project will be Construction Manager at Risk (CMAR) with a Guaranteed Maximum Price.

Jan 1, 2005

By William R. Yernberg

The combined 80th Annual Minnesota Section of SME Meeting and 68th Annual University of Minnesota Mining Symposium was held April 17 and 18, 2007, in Duluth, MN. About 350 mining industry professionals attended the conference, including engineers, executives, mining managers and suppliers from the United States, Canada, Australia, Finland and Brazil. This year’s theme was “Consolidation – Growth – Technology.” The 80th Annual Minnesota Section of SME meeting included concurrent technical papers sessions, a keynote session that featured two distinguished speakers and a general managers session in which taconite mine operators provided updates on their operations. The Minnesota Section meeting also offered an SME short course titled “Control the Feed, Control the Mill.” More than 50 individuals at-tended the short course.

Jan 1, 2007

By H. Do, R. Yoon

Mineral flotation is effective over a relatively narrow particle size range of approximately 10 to 100 µm. If the upper particle size limit can be increased, however, a run-of-mine ore may be coarse ground, and only the middlings are ground further to achieve required grades. This will result in significant energy savings and increased throughput. In this communication, methods of increasing the upper particle size limit will be discussed on the basis of a flotation model that can predict flotation from both hydrodynamic and surface chemical parameters. An example of increasing flotation recovery by control of a chemistry parameter is given.

Jan 1, 2007

By J. Chae, D. Pecha, R. Andrews

The Henderson/ML King CSO Project is a major combined sewer overflow (CSO)reduction project for the Department of Natural Resources and Parks of King County, Washington. The central element of the project is the 3100 lineal feet long, 14'-8"diameter 42nd Ave S Storage/Treatment Tunnel. During the course of the project, the owner and consultants evaluated numerous elements of the tunnel including the alignment, geotechnical conditions, tunnel liner, and settlement monitoring requirements. The contractor utilized innovative shaft construction methods for the tunnel portals, and adhered to strict contract requirements in successfully constructing the tunnel. This paper provides an overview of the design and construction elements of the 42nd Ave S Storage/Treatment Tunnel that led to the successful completion of the project.

Jan 1, 2005

By R. P. Sloan, A. S. Whitford

In November 1999, CCI's Empire Iron Mining Partnership and MinnovEX Technologies Inc. developed an expert system for advanced control of their Empire IV Grinding Section. Empire IV is comprised of three autogenous Primary Mills and six autogenous Pebble Mills, with a single Pebble Crusher and high pressure Roll Press. The challenges of controlling and optimizing three distinct grinding lines that are inter-woven by a pebble crushing circuit were met with innovative and unique solutions. This paper will detail the approach employed at Empire and will focus on the aspects that make this application unique.

Jan 1, 2001

By R. A. Gee, G. B. Ashton, S. T. Warren, P. N. Groves

Northside Storage Tunnel provides 500 megalitres (Ml) (130 million gallons) of storage capacity to capture stormwater/sewage overflows into Sydney Harbour. The6.6 m diameter TBM driven tunnel traverses Middle Harbour 85 m (280 ft) below sea level and through a sandstone/shale rock mass, highly disturbed by stress relief, 20 m(65 ft) beneath the base of the sediment filled palaeochannel. Target limits for inflow, groundwater drawdown and settlement of the valley beaches were achieved by systematic forward grouting from the TBM. Support included rockbolts, sets and shotcrete to carry rock loads, control block instability and spalling and to provide durability and serviceability. This paper describes the tunnelling and grouting works and their effectiveness.

Jan 1, 2001

By Y. Q. Zhang, S. S. Peng

Numerical modeling was used to design the pillars and bolting plan for a mine with weak roof and multi-seam stress condition. Previous mining experience, pillar/roof yielding and in-situ horizontal stress were considered in the models. By modeling the upper seam yielding and vertical stress transfer, a multi-seam influence zone was obtained. Appropriate pillar sizes were designed for conditions with and without upper seam stress influences. Roof support for the track and belt entries, using fully-grouted resin bolts and cable bolts, was proposed and implemented in the model. The bolting plan was evaluated under the weak roof condition.

Jan 1, 2004

By Thomas D. Kelly

In 1900, the average U.S. citizen’s average life span was 47 years. He traveled about 1,900 km (1,200miles) in a lifetime and resided in a home with an ice-box for food storage and oil or gas for lighting. He communicated by mail, telegraph and crude telephones with limited availability and range. By 2000, the average citizen’s life span was 77 years. He traveled an average of 19,000 km/a (12,000 miles/year) by automobile alone. He resided in a home with many electrical appliances, including refrigerators and electric lights. And he communicated almost instantaneously with any other part of the globe by several widely available means, including portable phones and e-mail.

Jan 1, 2002

Minerals contribute to the U.S. gross domestic prod-uct (GDP) at several levels?mining, processing and manufacturing finished products. In 2008, the estimated growth rate for the real GDP of the United States was 1.1 percent and the nominal GDP was about $14.3 trillion (Table 1). Trends in various sectors of the domestic economy are often reflected in mineral production and consumption rates. For instance, continued declines in the U.S. housing market during 2008 were reflected in further reductions in the production and consumption of cement, clays, construction sand and gravel and crushed stone (mineral commodities that are used almost exclusively in construction), and those associated with the related manufacture of goods, such as ceramic tile, heating and air conditioning equipment, paint, plumbing and sanitaryware, roofing, wiring and wallboard ? all used by the housing industry. The widespread effects of the slowing domestic economy became more apparent in the last three to six months of 2008 when prices for many mineral commodities declined sharply after reaching record highs earlier in the year, indicating significantly lower demand for those materials or products containing them.

Jan 1, 2009

By A. K. Majumder

Particle motion in fluids is a subject of considerable practical importance to engineers working in fields such as hydraulics, river mechanics, chemical engineering and mineral processing. Many mathematical models have been proposed to predict the terminal settling velocities of particles in a fluid medium. The selection of an appropriate mathematical model has, therefore, become a challenging task for practicing engineers. This paper reports on an attempt to identify some of the useful models found in the literature for predicting particle-settling velocities in a fluid under free- and hindered-settling conditions. From this study, it was concluded that there is no well-accepted model validated by experimental data available for predicting particle hindered-settling velocities in a suspension of polydisperse and polydens particles. Collective efforts should, therefore, be made towards developing a hindered-settling model, as this is an absolute prerequisite for many model structures in mineral processing and other engineering disciplines.

Jan 1, 2007