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By Mingyang Li, Yan Lv, Xiaolong Ma, Xudong Gao, Jie Zhao, Yingyi Zhang

This study aims to investigate the reduction thermodynamics of ilmenite and pre-oxidized ilmenite, and reveals the isothermal reduction kinetics of pre-oxidized ilmenite concentrate by carbon monoxide. The results indicate that the ilmenite concentrate and pre-oxidized ilmenite concentrate can be selectively reduced by controlling the temperature. The pre-oxidation process leads to the breakage of complex mineral structure, and the formation of porous simple oxides, which is an effective method to increase the reduction and leaching rate. 

By B. K. Cantrell

The use of diesel equipment in underground coal mines is controversial because "whole diesel exhaust" is regarded as "a potential occupational carcinogen" by the National Institute for Occupational Safety and Health (NIOSH). Threshold limit values (TLVs) are recommended for the gaseous pollutants; CO, CO2, NO, NO2, SO2' and some hydrocarbons emitted in diesel exhaust. There is, however, no TLV recommended for diesel exhaust aerosols (DEA) nor is there a standard method for sampling these aerosols. The University of Minnesota and the Bureau of Mines have collaborated to develop a personal diesel exhaust aerosol sampler (PDEAS) which utilizes size selective, inertial impaction and gravimetric analysis. During the field tests of this sampler, numerous air quality measurements were conducted in underground coal mines using diesel equipment. The objective of this report is to present these data and to assess the impact of diesel face haulage equipment on mine air quality.

Jan 1, 1991

By Anthony Iannacchione, Tim Miller, Nicole Evanek

The Subtropolis Mine is a room-and-pillar mine extracting the Vanport Limestone near Petersburg, OH. In February 2018, mine management began implementing a new mine layout to better control the negative effects of excessive levels of horizontal stress. Almost immediately, the conditions in the headings improved. Conversely, and as expected, stress-related damage was concentrated within crosscuts. Over the last 18 months, the mine operator has diligently experimented with different techniques/methods to lessen the impact of the instabilities in the outby crosscuts. The range of controls used by the mine operator include angled crosscuts, crosscut offsets, increased distance between crosscuts, arched crosscuts, cable-bolted crosscuts, altered blasting pattern, and windows. A window is used to resist roof deformation by leaving a strong brow of roof rock within the crosscuts.

By B. W. Cavender

Innovative mining and metallurgical operating techniques or processes can be identified and developed by systematically analyzing change as it occurs within the mine, plant, technology, or industry. Sources of change to be monitored for innovative opportunities include unexpected successes or failures, incongruities between perceived and actual events, process needs, changes in perceptions, and the development of new knowledge. Innovation can be effectively organized, practiced, and managed. The perception of change as an opportunity rather than a threat is mandatory, as is the systematic measurement of innovative performance. Innovation is enhanced by specifically-designed policies regarding organizational structure and staffing, daily management practices, and compensation and incentives.

Jan 1, 1994

By N. Arbiter

If two fluid phases are brought into contact with a solid, one fluid may completely wet the surface to the exclusion of the other, or both may wet it, forming a three-phase line of contact. These relative wetting tendencies are quantified by the contact angle 0 which is related by Young's equation (1,2) [12 cos? = 13 ? 23] [to the three interfacial tensions (3). No contact angle for the first fluid, indicating that it does not wet the solid in the presence of the second, means that the difference between the two solid-fluid fluid surface tensions, - 8 is greater than (or just 13 -23 equal to) the fluid-fluid tension 12; a finite angle indicates that the difference is less.*]

Jan 1, 1964

By C. Roos

Tradicionalmente en la industria minera, el flujo principal del proceso funcional para la evaluación de recursos y reservas procede de geólogos que elaboran el modelo geológico, de allí a los geólogos que hacen la estimación de los recursos (los modeladores) quienes estiman los grados, y a los ingenieros de mina que desarrollan el diseño de la mina y su calendario. La interfaz entre estas tres disciplinas no está siempre exenta de baches. Las presunciones hechas durante una etapa del proceso no siempre son comunicadas a los demás, a pesar que la mayoría de las empresas mineras tienen procedimientos y protocolos establecidos para promover la comunicación a lo largo de las distintas disciplinas. Estos procedimientos no siempre logran su propósito debido a una variedad de razones que incluyen restricciones de tiempo, no tener disponible a las personas apropiadas, o a una falta de entendimiento de lo que las otras disciplinas requieren, y el proceso de traspaso puede degenerar en el envío de archivos a la siguiente disciplina en el flujo de proceso. Este artículo se ocupa de la interfaz entre la estimación del recurso y las disciplinas de la ingeniería de minas y el esquema de algunas de las presunciones comunes hechas al generar un modelo del recurso y los riesgos que los ingenieros podrían correr al elevar los grados de corte, optimizar calendarios o realizar predicciones. Los casos de estudio presentados se centran en depósitos de oro a cielo abierto, pero los conceptos deben ser aplicables a toda la industria. Aquí también proveemos un resumen de preguntas clave y recomendaciones.

Jan 1, 2014

By Jon A. Hummer, MICHAEL R. SHAHAN, Aleksandar D. Bugarski, Shawn Vanderslice

A study was conducted in an undergroundminewith the objective to identify, characterize, and source apportion airborne aerosols at the setup face and recovery room during longwall move operations. The focus was on contributions of diesel- and battery-powered heavy-duty vehicles used to transfer equipment between the depleted and new longwall panels and diesel-powered light-duty vehicles used to transport personnel and materials to various locations within the mine. Aerosols at the setup face were found to be distributed among diesel combustion-generated submicrometer and mechanically generated coarse aerosols. According to the data, the submicrometer aerosols downstream of the setup face were sourced to diesel exhaust emitted by vehicles operated inside and outside of the panel. Depending on the intensity of the activities on the panel, the outby sources contributed between 12.5 and 99.6% to the average elemental carbon mass flow at the setup face and recovery room. Extensively used light-duty vehicles contributedmeasurably to the elemental carbon concentrations at the setup face. The number concentrations of aerosols downstream of the setup face were associated with aerosols generated by combustion in diesel engines operated in the shield haulage loop and/or outside of the longwall panels. Entrainment of road dust by diesel or battery-powered load-haul-dump vehicles operated near the measurement site appears to be the primary source of mass concentrations of aerosols. The findings of this study should help the underground mining industry in its efforts to reduce exposures of miners to diesel and coarse aerosols.

Apr 14, 2020

By Yi Yang, CHENGLONG XU, HAORAN LI, YALI FENG, JINRONG JU

Steel slag is an industrial byproduct of steelmaking that is mainly composed of calcium, iron, silicon and magnesium. In addition, depending on the different raw materials entering the furnace, steel slag contains a certain amount of vanadium that is the main source of vanadium production, accounting for 69 percent of the species of the total vanadium raw material [1]. From experience, the production of one ton of steel will generate 1.0 to 1.5 tons of steel slag [2]. However, the utilization efficiency of steel slag is less than 30 percent, and a large amount of steel slag is identified as waste and stacked in tailings. The random stacking of steel slag not only wastes large amounts of limited steel and land resources but also exerts pressure on the environment [3], making it imperative to research the effective utilization of steel slag and recycling of metal resources.

By L. Andrews, G. Smits, M. D. Adams, E. A. Viljoen

A new approach has been developed that is capable of ascertaining the ore component that is responsible for the preg­robbing of pregnant pulps. Many gold mines are currently treating ores containing a component that is detrimental to the recovery of gold, in that they "preg-rob" the pregnant pulp by adsorption of some of the dissolved gold. The identity of the preg-robbing component in this type of ore has been the subject of considerable debate over a lengthy period, th various suggestions including amorphous carbon, chlonte, chalcopyrite and layered silicates, such as the phyllosilicate minerals pyrophyllite, kaolinite, phlogopite and illite. A means is now available to identify and characterize the preg-robber in gold ores. This new approach consists of contacting the ore with a synthetic aurocyanide solution, identifying the mineral grains by optical microscopy and analysing each grain individually using high-sensitivity electron microprobe analysis. The approach is exemplified in this initial study by identifying the preg-robbing component in an active sample of gold-bearing shale to be an amorphous carbonaceous phase consisting of discrete particles of about 5 µm diameter interspersed with shale particles and agglomerated into grains of up to 100 µm diameter. Microanalysis of these grains as well as other mineral particles revealed that the gold content of some of the carbonaceous grains was close to 7000 g,lt, with no gold being detected in any of the other mineral phases that were found to be present (e.g. quartz, chlorite, muscovite, pyrophyllite, etc). Bulk analysis of the sample for carbon and gold confirmed that gold loadings of around 7000 g,/t would be expected if all of the gold were adsorbed onto the carbonaceous component. The carbonaceous constituent is probably also responsible for the anomalously high surface area measured for the material. It probably acts in a similar fashion to activated carbon, and the correct choice of organic blinding agent will decrease the extent of preg-robbing by lowering the activity of the material for gold, without causing any downstream problems such as fouling of the activated carbon used for gold recovery

Jan 1, 1993

By J. A. Marts

Reservoir properties including porosity and permeability distributions in longwall coal mine gobs have direct application to modeling the flow patterns and gas distributions in the gobs. Proper assessment of these distributions is required to assess gob gas hazards such as spontaneous combustion and explosive methane mixtures and to optimize gob gas venthole operation and nitrogen inertization. Determining the reservoir properties is difficult given that the gob is inaccessible and direct measurements cannot be easily taken. Several techniques have been used by previous researchers and will be discussed. This paper will present the methodology used to model the gob compaction by simulating the sequential extraction of coal. Two Western US coal mines were used for case studies. By determining volumetric strain, the porosity and permeability distributions in the gob can be calculated. The geo-mechanical model predicts an axisymmetric volumetric strain distribution with a steeper slope near the start-up room and a shallower slope near the active face.

Feb 23, 2014

By SUMANT KUMAR SAMAL, BHAGIRATHA MISHRA, MANOJA KUMAR MOHANTY, SUBASH CHANDRA MISHRA

Steelmaking consumes the majority of chromium and manganese ferroalloys for purposes such as to impart various properties to steel. The quality of ore governs the process kinetics as well as the process economy of the ferroalloy industry. The present study demonstrates the thermal transformation behavior of chromite and manganese ores with varying compositions. Simultaneous thermal analysis (differential thermal analysis/thermogravimetry, DTA/TG) was conducted on these ore samples, where the transformation of mineral phases was correlated with the thermogram characteristics and quantified. Phase, microstructure and compositional analysis results of individual ores corroborated with thermal analysis are in good agreement. Chromite samples are ferruginous with goethite and gibbsite contents, whereas manganese ores vary in composition and also exhibit multiple and/or overlapping transformations.

By JOHN HOMER, KATHLEEN STABRYLA, JACOB L. CARR, JONATHAN K. HRICA, JENNICA L. BELLANCA

Given the recent focus on powered haulage incidents within the U.S. mining sector, an appraisal of collision avoidance/warning systems (CXSs) through the lens of the research literature is timely. This paper aims to evaluate the maturity of CXS technology through the application of a technology readiness assessment (TRA) to research literature identified by systematic search methods. Results indicate that much of the evidence for CXS performance is at lower levels of maturity: that is, components and prototypes tested in a laboratory and in relevant environments. Less evidence exists for CXS performance at higher levels of maturity — that is, systems evaluated within operational environments — despite the existence of commercial products in the marketplace. This lack of evidence at higher maturity levels within the scientific literature highlights the need for more peer-reviewed research to evaluate CXS technologies. Additionally, results of the review reveal that most of the literature relevant to CXS technologies is focused on vehicle-to-vehicle interactions, which contrasts with haul truck fatal accident statistics that indicate most are due to vehicle-to-environment interactions, such as traveling through a berm. Lastly, the relatively small number and segmented nature of relevant studies suggest there is a need for more incremental research that would better facilitate the improvement of CXS technologies. This progression could be achieved through continued long-term interest and support for CXS technology research.

Mar 1, 2023

By A. A. El-Midany, R. M. Farag, A. M. Salem, S. E. El-Mofty

Bentonite is one of the main players in the stability of drilling mud. Its particle size and particle size distribution significantly affect drilling mud’s rheological properties. Although the Specifications for Drilling Fluids Materials report on Oil Companies Material Association (OCMA)-grade bentonite states that the API recommended powder having 2.5 percent mass fraction as the maximum value of residue of diameter greater than 75 μm, there is no other information on the specific size distribution for API bentonite. It was found that API bentonite has a specific size distribution with specific mixing weights. It is important to investigate why that mixture represents the optimum properties of drilling mud and how each individual size fraction has a specific function in the mixture. To clarify the effect of individual size as well as the collective effect of the size distribution, API bentonite was classified into different size fractions, with each tested separately for controlling properties such as filtration loss, plastic viscosity, gel strength, cake thickness and packing density.

By Liming Yuan, Wei Tang, RICHARD THOMAS, JOHN SOLES, DAVOOD BAHRAMI

Mine equipment fires remain as one of the most concerning safety issues in the mining industry, and most equipment fires were caused by hot surface ignitions. Detailed experimental investigations were conducted at the National Institute for Occupational Safety and Health’s (NIOSH) Pittsburgh Mining Research Division on hot surface ignition of liquid fuels under ventilation in a mining environment. Three types of metal surface materials (stainless steel, cast iron and carbon steel), three types of liquids (diesel fuel, hydraulic fluid and engine oil) and four air ventilation speeds (0, 0.5, 1.5 and 3 m/s) were used to study the hot surface ignition probability under these conditions. Visual observation and thermocouples attached on the metal surface were used to indicate the hot surface ignition from the measured temperatures. Results show that the type of metal has a noticeable effect on the hot surface ignition, while ventilation speed has a mixed influence on ignition. Different types of liquid fuels also show different ranges of ignition temperatures. Results from this work can be used to help understand equipment mine fires and develop mitigation strategies.

Oct 1, 2022

By S. A. McGhee

ASARCO Incorporated embarked on a modernization and expansion program to improve overall operating efficiencies and to more effectively develop the large mineral reserve at the Ray Complex Open-Pit Mining operation located near Kearny, Arizona. Major elements of this Ray Modernization and Concentrator Expansion Project included engineering and construction of a 54,400 MTPD (60,000 STPD) In-Pit Crusher and Overland Conveying System. and a 24,200 MTPD (30,000 STPD) Copper SAG Concentrator and Tailings Disposal System. Detailed engineering, procurement, and construction management were initiated in November 1989 under contract with Bechtel Corporation. Field construction commenced in May 1990 leading to mechanical completion and start-up during February 1992.

Jan 1, 1993

By R. L. Taylor, S. D. Abbott

"INTRODUCTION Mines are filled with a mixture of gases, some of which are toxic, flammable, explosive. Others can be early reporters of potential problems. It has previously been shown that analysis by gas chromatograph can the most accurate conventional analytical tool for common mine gas mixtures when used correctly. There are some other detection methods (e.g hand held sensors), but they do not detect many situations which are immediately dangerous to life or health (IDLH). Examples include explosive hydrogen mixtures, toxic carbon dioxide levels, and some explosive mixtures of methane with oxygen. (Reference our previous paper). There are several reasons for mines to consider onsite GC analysis. (1) Timeliness of results. Samples can be taken and analyzed immediately. Samples do not have to be shipped to a lab and wait for results. (2) Ability to run greater number of samples a lower for the same cost. This allows mine to increase the number of samples taken to be more informed about the gases/conditions of the mine without the worry of financial constraints. (3) Fewer sample media needed, and there is no wear and tear or cost from shipping them offsite. When samples are shipped offsite, those sample media cannot be used to take until the lab returns them when the analysis is done onsite, the sample media can be used again almost immediately. However there are several challenges associated with using GC to analyze mine gas samples onsite. To date there has been a clash of the requirements for a successful analysis, the capabilities of the technology, and the practicalities of implementation. The purpose of this paper is to discuss some of the difficulties in getting accurate reliable data and doing so in an economic way. This whole measurement activity is a cost center for a mine, so there are economic concerns for the mine to address. These concerns are mainly staffing costs, capital costs, maintenance, and consumables costs. A properly staffed and equipped analysis lab, including burdened overhead, costs about $500K per year. At a sampling rate of 10 per day, this is about $140 per measurement for a proper onsite lab."

Jan 1, 2016

By Justin R. Patts, Andrew B. Cecala, A. KYLE LOUK, Emily J. Haas

The U.S. National Institute for Occupational Safety and Health (NIOSH) and the former U.S. Bureau of Mines (USBM) have put significant effort over the past four decades into researching and developing engineering controls and interventions to reduce mine workers’ dust exposures during the bagging and palletizing of industrial minerals. Workers who perform the manual bagging and palletizing of 50- to 100-lb bags typically have some of the highest dust exposures of all workers at mining and mineral processing operations. This paper provides an overview of available dust control technologies for bagging operations and presents the findings of a recent case study conducted at four industrial sand operations to identify the current types of bagging and palletizing technologies being used and to evaluate their effectiveness in reducing workers’ exposures to respirable crystalline silica dust. An evaluation is also performed to determine if further reductions in respirable dust levels can be achieved by incorporating additional modifications or improvements into the existing technology.

By Iga Trisnawati, Fitria Puspita, Himawan Tri Bayu Murti Petrus, Gyan Prameswara, Idi Amin, Andi Nurfaadhilah Ulfah

Laterite ores, rich in essential metals like nickel, iron and cobalt, are a crucial resource for modern technology. However, the extraction of nickel from laterite ores is a complex process due to their intricate mineral compositions and low nickel concentrations. This paper presents the results of a study to understand the leaching behavior of preroasted laterite ore and the impact of roasting on leaching kinetics. The ore was subjected to roasting at 280 and 610 °C for a duration of three hours, followed by leaching in sulfuric acid (H2SO4) under atmospheric conditions. The results show that preroasting the ore at 610 °C significantly improved the recovery of nickel during leaching, with recovery rate of up to 93 percent, and the leaching process of the preroasted ore was primarily controlled by diffusion through the ash layer. The activation energy values were found to be 20.97 kJ/mol for the ore roasted at 280 °C, and 18.97 kJ/mol for the ore roasted at 610°C. These findings suggest that preroasting can enhance the leaching performance of laterite ore, potentially paving the way for more efficient and sustainable nickel extraction processes.

Aug 1, 2024

By A. Chieregati

"A heterogeneity study was conducted at Erdenet Copper Mine in Erdenet, Mongolia, to determine the fundamental sampling error associated with blasthole sampling. Using a custom designed sector sampler, six large blasthole samples were collected to perform the test that was developed by Pierre Gy, to estimate the constitutional heterogeneity factor for several types of ore. The study investigated the entire sampling protocol, from mine site to analytical laboratory, and quantified the contributions to fundamental sampling error (FSE) of the various stages of sampling and sample preparation. The total relative standard deviation (RSD) of sampling error was determined to be ±32% and ±49.4% for copper and molybdenum respectively. A classical statistics analysis conducted on the data confirmed the level of RSD. About 95% of the sampling error was produced from only one step in the sampling protocol: when the 1 kg sample was reduced to 50 g sample for chemical analysis. Therefore, it is recommended that the 1 kg sample be reduced to 50g using a slightly different protocol to minimize the FSE. The 1 kg sample should be first crushed to 0.2cm size. A 250g split should then be taken and fine ground. A 50g split should then be taken from the 250g fine ground split. These two simple steps will reduce the FSE to ±7.9% and ±17% for copper and molybdenum respectively. The modified sampling protocol effectively reduces the probability of misclassification of low grade ore to zero. INTRODUCTION The Erdenet copper-molybdenum open pit mine is located in Erdenet, in Orkhon province, Mongolia. The Erdenetiin-Ovoo copper-molybdenum deposit is between 1.5 and 3 km wide, and about 25 km in length (Erdenet Mining Corporation, 2016). Chalcopyrite, bornite covellite and chalcocite are among the major minerals found in the deposit. The mine processes approximately 26 million tons of ore annually. A study was conducted to evaluate the fundamental error associated with the blasthole cuttings and sampling protocol at the mine. The open pit mine uses 215mm diameter Russian drills to drill 17.5m holes for 15m benches. The total weight of blasthole cuttings for a 215mm diameter hole and 15m bench height is between 1.5 and 2 tonnes. This amount of sample is difficult and time consuming to collect and analyze. Therefore, a sector sampler was designed for the Russian drills to collect large samples that were representative of the blasthole cuttings (Ganguli et al., 2016). In order to eliminate the delimitation and the extraction errors, researchers consider sector samplers to be ideal for sampling blastholes (Pitard, 2008; Chieregati and Pitard, 2009). This method was intentionally more rigorous than the blasthole sampling protocol at the mine to ensure that the blasthole cuttings were properly sampled. This study was part of a broader study that also looked at the relationship between particle size and grade. The samples collected by the custom designed sector sampler were very large (195 kg on average), and therefore, sufficient for both studies. The relationship between particle size and grade has been reported in Ganguli et al. (2016)."

Jan 1, 2017

By Davar Abi-Zadeh, Cillian Brown, Deepak Kandra

"Grout backfill strategy for a particular subsurface concrete tunnel (~4.9km long, 3.5m in diameter, carrying 20” gas pipeline) was based on achieving 1:100 slope of the fill in order to progressively fill the tunnel, in a series of 350m section. Grout rheology, particularly its non-Newtonian and thixotropic behavior, determines the final fill slope for given backfill strategy. The objective of this study was to simulate the two-phase grout mix backfill process using Computational Fluid Dynamics (CFD) and determine the slope of the fill to validate and optimize the backfill strategy. Three dimensional CFD study showed that for a 500m long tunnel section with a single injection point of grout, given its rheology, it will likely keep flowing without filling the 500m section height wise. Design optimization for filling was carried out using two dimensional studies to make the backfill process “slope independent” by incorporating a 2.5m high bulkhead at ~1,000m. INTRODUCTION As part of a gas field development a 20” onshore gas pipeline is required from the landfall site to the processing terminal some 8km inland. At the landfall site the gas pipeline is routed in a ~5km underground tunnel underneath a bay. For operational reasons and planning consents as well as to mitigate environmental impact based on an environmental impact study, once the gas pipeline and the associated services and spares have been installed, the subsurface gas tunnel will be fully grouted. There will be no permanent access to the tunnel after construction is completed and the site compounds have been reinstated once works are complete. One of the key requirements is that “full grouting of the tunnel” is desired. The grouting material used is a non-Newtonian and thixotropic fluid mixture of bentonite, cement, plasticizer, retarder/stabilizer and water. The tunnel is filled progressively in 350m sections using a combination of existing and new pipework assuming the grout rheology will yield a fill slope of 1:100 in a 350m section. The proposed grouting system used one pump at the grouting compound to pump the grout into the tunnel using the existing tunneling pipework. For the longer runs a second booster pump was used in series to pump the grout to its final discharge location. The filling process is controlled via a system of flow meters, pressure transmitters and a tunnel CCTV system."

Jan 1, 2016