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By A. J. Plumpton

Centrifugal air classification and li-quid-phase sedimentation are the principal methods of industrially sizing materials of dimensions smaller than those handled by screens. Increasing application of materials such as composites and high performance ceramics has furthered the need for closely-sized, fine, industrial mineral and synthetic products of controlled properties. Sedimentation can be used to separate very small sized particles but introduces problems of liquid-solid separation, de-agglomeration and drying. Some of the advantages and limitations of centrifugal air classification will be discussed and laboratory and plant measurements using centrifugal machines will be presented to support the discussion.

Jan 1, 1990

By Pan Gao, Songyang Yin, Zhibiao Guo, Jinglin You, Yuhui Li

Under the geological conditions of the interaction of upper goafs and lower working face in deep mining, coal seam mining causes a large stress concentration, which may lead to large deformation of the surrounding rock and rock burst risk. The research reported herein is aimed to utilize the FLAC3D software to establish a three-dimensional numerical model and analyze the law of the surrounding rock stress evolution during coal mining under complex geological conditions. The simulation results reveal that the peak abutment stress reaches its maximum value at 20–30 m in front of the working face, about 1.8–4.3 times the original rock stress, and the peak stress is larger in the stable mining stage. Along the dip of the working face, the peak stress occurs about 8–10 m away from the roadway side. The upper barrier coal pillar and the interval coal pillar in order exhibit stress concentration areas of 142 m and 88 m. According to the law of the deflection stress distribution of the surrounding rock in the presence of various widths of the coal pillar, a 10-m coal pillar between the roadway and the adjacent goaf could enhance the stability of the roadway. For the stress concentration area, drilling holes with a depth of 20–25 m are utilized to reduce the pressure, and anti-impact supports are installed in the middle of the roadway. Due to the varying stresses of the rocks around the roadway, partition prevention and control countermeasures are capable of efficiently preventing the instability of the surrounding rock.

Mar 22, 2023

By J. W. Furlan

Due to the time consuming nature of froth testing in a laboratory environment, it is required, due to practical limitations, to develop a method of applying a single set of performance test data (Visintainer & Whitlock, 2012) obtained for a single froth pump at a given speed, to a range of froth pump speeds and sizes, % air contents, and liquid viscosities. Head, efficiency, and flow all vary as functions of both liquid viscosity and air content. As such, it is necessary to develop a technique which can be used to interpolate from existing test data in order to predict froth pump performance for pumps of various sizes running at variable speeds. Details of the technique developed in order to achieve this goal as well as the insights gained from analysis of the resulting regressions are discussed. Additionally, comparisons are made between the performance predictions of this test-derived method and those of the Hydraulic Institute Standard for the effects of liquid viscosity on centrifugal pump performance (ANSI/HI 9.6.7-2010).

Feb 27, 2013

By Bahadir Ergener, Angel Maria Tobar Escudero, Sandra Nowosad

Modern mining companies are increasingly turning to integrate digital technologies and circular economy (CE) principles to increase the sustainability of their operations. The so-called “mine of the future” is envisioned as a smart, integrated system where technologies such as automation, artificial intelligence, digital twins, and real-time data analytics work in harmony with human decision-making and environmental responsibility. Already in 2018, McKinsey and Co. identified that the three drivers that would define a technology-enabled change in mining would be technology, including digital, analytics and automation, management systems able to identify the potential and value of the new technologies, and the culture and capabilities of the organisation, leaning to more agile and responsive organisations. From the three drivers, in the last five years most developments have been centred in the first one. Yet despite rapid advances, the adoption of new technologies across the industry today remains uneven and often slower than expected. Furthermore, it has been identified that the problem on the technology uptake often relay on the lack of operational readiness, process incompatibility or misalignment, and resistance to change within the mining operation. At the same time, leading companies like Rio Tinto, BHP, and Anglo American have each launched major digital transformation programs. Rio Tinto, for instance, operates one of the world’s largest autonomous mining fleets and has integrated digital technologies across nearly all its operations (Rio Tinto, 2025). BHP is actively investing in information and communication technology (ICT) development as artificial intelligence, big data analytics and robotics, and has partnered with battery companies to pursue circular economy initiatives. Only in 2024, their ICT spending reached US$ 438.3 million (Global Data, 2024). Anglo American has rolled out its FutureSmart Mining™ framework, explicitly aligning innovation with circularity and sustainability goals (Anglo American, 2025). The accelerating pace of change across leading mining companies along with the uneven adoption in the technology uptake clearly state how digital transformation is no longer just about implementing new tools, instead it requires a fundamental shift in how people, processes, and culture are aligned. Addressing only the technical layer, while neglecting the human and organizational dimensions, leaves transformation efforts fragile and unsustainable. As the industry must act decisively to close this gap, the true test of transformation is today centred in changing behaviours, mindsets, and systems. Even at the listed leading companies, initiatives have encountered cultural and structural resistance that are relatable to the industry in large: siloed departments fail to collaborate, procurement teams focus on upfront costs rather than lifecycle value, and operators are often excluded from early-stage planning, reducing buy-in. In many cases, a lack of communication or failure to link technology to real operational bottlenecks leads to disengagement at the ground level. This friction reveals a broader issue: mining organizations have historically treated technology and culture as separate domains, when in fact they are deeply interdependent. To address this, the authors propose a systems engineering approach focusing on the mining operations as a complex socio-technical system composed of people, processes, and technologies. Systems engineering offers tools and frameworks for mapping interactions, aligning incentives, designing for feedback and adaptation, and integrating change across organizational boundaries. Specifically, besides technical requirements, it demands treating culture not as an afterthought or side-effect, but as a design variable that must be intentionally shaped alongside infrastructure and workflows. This paper explores how this approach can be applied in practice, by analysing a real-world case scenario where resistance to innovation was overcome not by technical capabilities alone, but through alignment of stakeholder incentives, thoughtful communication, and cultural integration. A particular focus is set on the adoption journey of the Powerbit X, a drill bit technology with significant potential for operational and environmental gains.

Feb 22, 2026

By Y. Zhang, M. Yekich, C. Zhou, C. Jobes, J. Galanko, D. Tuchman, J. Srednicki, J. Carr

The continuous personal dust monitor (CPDM) is an essential instrument for working in hazardous environments, is used to monitor real-time coal dust exposure, and is mandated by the Mine Safety and Health Administration (MSHA) for underground coal mines. Researchers from the National Institute for Occupational Safety and Health (NIOSH) found that it is possible for electromagnetic interference (EMI) between a CPDM and a proximity detection system (PDS) to occur. Various approaches have been taken by researchers and manufacturers to address this EMI issue. Administrative controls were recommended to keep the CPDM six inches away from the wearable PDS device. Shielding pouches were made to contain the electromagnetic (EM) emission from the CPDM. Metal shielding was added to major EM emitting components. EMI filtering with large capacitors was introduced to mitigate EMI. Most recently, a novel magnetic-field-cancellation-based approach was developed and achieved remarkable results. In this paper, we provide a comparison between these approaches. The pros and cons of each approach are presented and discussed, so that mining device manufacturers and operators can best evaluate the technology and controls that improve the health and safety of mine workers.

Feb 1, 2023

By Theophilus Mensah, Kwame Awuah-Offei

Engineers face significant challenges when determining what geometry provides the most profitable and safe stope for extraction. Several techniques and optimization algorithms have been developed in recent years, but most fail to find optimal solutions because they are heuristic or LP-based without efficient geometric constraints. This paper presents a two-dimensional binary linear programming (BLP) model for determining the optimal combination of blocks in a stope that maximizes the economic value of the layout of stopes for a sublevel deposit. The work draws from Queyranne and Wolsey’s (2017 & 2018) formulations of tight constraints for bounded up/down times in production planning problems to formulate novel and efficient geometric constraints along with geotechnical and grade constraints for the BLP stope layout optimization problem. Results from the model indicate that it is possible to formulate efficient shape constraints in LP-based approaches. The model used for the numerical example contained 144 valuable blocks out of 774 blocks, which translates into an economic value of $53.21M. The BLP model selected 60 valuable blocks and 13 waste blocks that met all constraints translating into a maximum economic value of $34.4M in 1.83 hours within a gap tolerance of 0.00%.

Jun 25, 2023

By S. K. Sharma, ANKUSH GALAV, G. S. P. Singh

Providing a suitable protective water barrier pillar (PWBP) is common to reduce inundation hazards in underground coal mines. The imperative factors influencing its performance include the water head acting on the pillar, cover depth, pillar width, strength properties, and permeability characteristics. The mechanical failure of such pillar is a stress-controlled phenomenon, whereas the hydraulic failure is a strain-based phenomenon. A finite-difference numerical modeling approach was developed to study the hydro-mechanical coupled behavior of protective water barrier pillars. The mechanical stability was evaluated in terms of the percentage of failed (ZoF) and intact zones. The influence of the strain-controlled weakening on the permeability of the flow medium was studied through the coupling of the mechanical and hydraulic effects. The coupled steady-state model was used to estimate the outflow rate and its hydraulic stability. The adequacy of the protective pillar was also investigated by assessing mechanical stability and capability to resist hydraulic pressure against the maximum expected water head. A seepage rate-based classification system has also been proposed to evaluate the seepage potential and assess the hydraulic stability. The model has been validated for two case studies at the cover depth of 136–189.5 m and the existing pillar width of 16–42 m against the water head of 25–141 m.

Aug 18, 2022

General. Data for the operating information given in the 15 tables in this chapter was obtained from voluminous questionnaires sent to over 100 operating companies in 1972. There has been a considera¬ble change since then in supply and power costs and many companies have had expansions or revisions since that time, so it must be realized that information is valid for the year 1972. This is true except for the three new properties of Sacaton, Metcalf, and Pinto Valley. These three operations started up since 1972 and all information for them was obtained in 1975. The questionnaires were sent to all major copper properties throughout the world as well as to many smaller units and to some mines that had complex or unusual conditions. Properties for which no information is given did not submit completed questionnaires. Several operations were unable to supply information requested be¬cause of company policy prohibiting it. However, data is presented for 75 different operating properties. The reference number of the left-hand column is the same for all 15 tables of data. If the company had several operating properties as of 1972, then subsequent properties use the same number but a different letter. For example, Anaconda's property at Butte, Mont., is IA, whereas Anaconda's (now Anamax) Twin Buttes property in Arizona is IB. Table I gives general data for the properties including exact loca¬tion, milling rate, pertinent assay values and recoveries, and a brief listing of ore and gangue minerals. It was not possible to obtain any more information from the properties in Chile except that given in Table I. Crushing. Crushing plant operating data is given in Table 2. This table gives data on the crushers, feeders, and screens used at each property. The data obtained on feeders was confusing, but, rather than completely eliminate this information, it was decided to report it as given. The confusion lies only in the description of where the feeder is located. Where a primary feeder is listed it was not possible to determine if this feeder was on primary feed or primary discharge. For secondary feeders it is known that the feeder listed usually is feeding the secondary crushers, but at some properties it is handling the secondary crusher discharge. The same reasoning holds true for tertiary feeders-they handle either tertiary feed or discharge. This table contains a voluminous amount of data. A column giving tons per day per square foot of screen area would have been very informative, but some properties included circulating load in the feed rate and others listed new feed only, so calculations were meaningless. Autogenous Mills. The use of autogenous or semiautogenous mills for any property must be given serious consideration in the future. Table 3 lists data for four properties that are fully autogenous and four more semiautogenous mills that use balls to supplement the chunks of ore. This method of grinding is especially applicable when the ore is of such a nature that crushing problems would be severe, such as when ore is wet or sticky or contains a lot of fines. Paradoxically, it should also be considered when ore is tough and hard and blocky because then the competency of the ore means it can serve well as the grinding media. Where the ore varies greatly in hardness, as at Cyprus Pima and Lornex, semiautogenous grinding has been especially beneficial with capital costs and operating costs both 10-20% lower than could be obtained with conventional crushing and grinding. Rod Mills. For a great many years the standard milling operation used two- or three-stage crushing followed by open circuit rod mills and then ball mills in closed circuit with classifiers of some kind. A surprising number of properties crush to the fine size of about 3/8 in. and then use ball mills only, in closed circuit, with no rod mills. It is difficult to say whether rod mill-ball mill circuits or ball mill only is the best. One can be certain of two things: (1) the argument will go on for a long time and (2) for some mills one method obviously was superior over the other. As ball mills of 14, 15 ft, and larger came into use, more properties like Duval Sierrita (16b ft diam by 19 ft long) and Bougainville (18 x 21 ft) were built with single-stage ball mill grinding. Although there are larger rod mills used, especially in the iron ore industry, the largest rod mills on copper ore are at Twin Buttes (14 x 18.5 ft) and at Gibraltar (13'A x 20 ft). Table 4 lists operating data for rod mills. If a company is listed in Table I

Jan 1, 1985

By F. Rudloff, C. Karageorgos, J. Moyo, I. Boadi, M. Struble, B. Lumsden

Over it’s more than 100-year history, the Kennecott operation has often been at the forefront of innovation; driven by the demands of the lower grade ore-body and the higher costs of operating in the US where wages are generally higher and regulation more restrictive. One way of reducing operating costs in c/lb is to increase the lbs produced at minimal cost. Despite the relatively coarse grind at Kennecott - about 30% >150μm, approximately 20% of the Cu lost to tail is liberated chalcopyrite in the <20μm fraction, and about 30%-40% in the <37μm fraction. In 2020 Kennecott undertook a detailed plant scale test of the magnetic aggregation technology to increase copper recovery by reducing fine copper losses. A paired statistical plant test of magnetic conditioning on one rougher line showed a 1.12% increase in Cu recovery to 97% statistical confidence. The next challenge, unforeseen at the start of the project, was the fabrication and transportation to site of the equipment for the three remaining rougher rows, during the severe supply-chain constraints of the Covid pandemic in 2021. This resulted in delays and unforeseen costs as world-wide transportation became chaotic, particularly transportation via west coast USA. Nevertheless, the project was completed and commissioned, with only minor delays and cost increases, due to a flexible approach to overcoming the hurdles encountered.

Feb 1, 2023

By P. Clifford

FIPR-sponsored research will playa critical role in enhancing the competitiveness of the Florida phosphate industry as ore grade declines and environmental restrictions tighten. FIPR&apos;s program seeks to improve surface mining and pipeline transportation while reducing the energy cost for pumping phosphate matrix. The development of a reliable on-line analyzer and a modern process control strategy will result in improved processing efficiency. Significant improvement in overall efficiency will also be realized as the industry adopts column flotation technology. Economic acidulation of high-Insol rock will allow the industry to adopt simplified flotation flowsheets thereby reducing operating costs. Various applications of phosphogypsum would save the industry millions of dollars in constructing and closing gypsum stacks.

Jan 1, 1998

By D. R. Tesarik, T. C. Trancynger, W. G. Pariseau

The Davis detector cavern was excavated on the 4850 Level of the former Homestake Mine in the mid- 1960s to house a novel neutrino detector developed by Nobel Prize winner Dr. R. Davis. The original cavern was about 9.1 x 16.8 x 9.7 m high, excavated in a Precambrian amphibolite known as the Yates unit and enlarged in 2010. In 2009, the National Science Foundation selected the site for development as a national Deep Underground Science and Engineering Laboratory (DUSEL). This retrospective rock mechanics study of the Davis cavern is intended to inform design of the much larger caverns and laboratory rooms being considered for the same 4850 Level. Provision for rock mass variability, sequential excavation, jointing and wall damage from blasting are included in analyses that were done using two different computer codes and methods (FLAC3D and UTAH3). The results are in agreement with observations and show that cavern stability is indeed the case. The main conclusions are: (1) if conventional scaling of laboratory rock elastic moduli and strengths is done, then 0.25 and 0.50 scale factors are reasonable, (2) measured statistical and spatial variability in rock properties should be incorporated into geomechanical analyses to better reflect reality, (3) discontinuities (“joints”) are essential to reliable analysis of excavation safety and when properly taken into account eliminate the need for empirical “scaling” of laboratory rock properties, (4) major geologic features such as rhyolite dikes and breccia zones may be important to excavation safety at Homestake and should be explicitly represented in analyses and (5) quantifying wall blast damage is important to engineering design of underground excavations.

Jan 1, 2012

By H. Jiang, Y. Luo

The study develops an automated, high-efficiency drilling control system to reduce respirable dust and increase energy efficiency in underground coal mines. It uses specific energy to evaluate efficiency and proposes a comprehensive drilling control algorithm based on laboratory tests. The algorithm optimizes drilling parameters to maintain high efficiency, reduce dust generation, and improve safety.

Feb 12, 2022

By Kurt M. Larson

Future haulage cost projections led Foster Yeoman Limited into developing a fully mobile crushing and conveying system at its Torr Works quarry in Somerset, England. The purpose-built system has an effective throughput of 2,500 tonnes/hour and features an Orenstein and Koppel (O & K) manufactured walking frame, a Fuller-Traylor type 54 X 74 TC gyratory crusher, and unique mobile conveyor modules designed and manufactured by Foster Yeoman. Used in a single-bench operation in this 6 million-tonne per annum limestone aggregate quarry, the system is fed at the production face by 2 Caterpillar 992C loading shovels. The entire system is moved on a daily basis following production face locations.

Jan 1, 1986

By William H. Mount

Since the late 19405, St. Joe has operated rubber-tired, trackless mining equipment underground in its Southeast Missouri Lead Belt operations. At first, the trackless equipment was operated in conjunction with rail haulage equipment in the room-and-pillar operations, but was to later replace rail haulage completely. The first pieces of equipment to travel on pneumatic rubber tires were short-haul shuttle cars of 12-ton capacity hauling rock from the heading to the mainline railroad. Early-model drill jumbos were the next pieces of production equipment to be carried on rubber, along with mobile slusher ramps. Mobile diesel equipment, in the form of conventional rear-dump trucks, made its appearance underground in the early 1950s, introducing the era of relatively high-speed mobile equipment as compared to the electrically powered shuttle cars. Haulage distances for rubber-tired vehicles were no longer dictated by trolley lines and trailing cables and tires were subjected to increasingly severe applications. St. Joe&apos;s first completely trackless mine, the Hayden Creek Mine, was opened in 1952, employing rubber-tired drill jumbos, electric shuttle cars, and for the first time, an articulated diesel truck consisting of the tractor unit of a conventional earthmoving scraper and a rear-dump rock wagon. Those machines rolled on the first true earthmover tires to be used underground by St. Joe. The articulated truck concept proved to be very successful, and constitutes an In- creasing portion of the underground haulage today.

Jan 1, 1975

By B. K. Cantrell

The U.S. Bureau of Mines and others have conducted a number of occupational exposure surveys since the publication of the International Agency for Research on Cancer report of 1989, which labeled diesel exhaust as a probable human carcinogen. These surveys have assessed diesel exhaust exposure using measurement of diesel aerosol and/or specific polycyclic aromatic hydrocarbons as indicators of exposure. This paper reviews present diesel emission standards, available diesel exhaust aerosol measurement techniques, and the results of the occupational exposure surveys. In the surveys, diesel aerosol was emphasized because it is a major component of diesel exhaust, is suspected to contribute to the health hazard, and is readily measurable. Three primary aerosol measurement techniques were used: respirable combustible dust, size-selective sampling, and measurement of the elemental carbon fraction. Occupations surveyed included mine workers, railroad workers, forklift operators, fire fighters and truck drivers. The studies found mean diesel aerosol concentration levels in the range of 0.004 to 1.74 mg/m3? Highest aerosol exposures were in confined spaces such as mines where heavy diesel equipment is used. Polycyclic aromatic hydrocarbons typically are found at very low concentration levels and are not unique to diesel exhaust.

Jan 1, 1996

By Ewald H. Kurt

The story of America&apos;s progressing standard of living is the story of machines. The automobile, the airplane and the telephone for example have made our transportation and communication systems what they are today. Even they depend in turn on another machine -- the rock drill. By making it possible to economically mine and quarry minerals in large quantities, this versatile machine supports virtually every American industry relying on the earth for its buried raw materials. And, like all machines, the rock drill&apos;s mechanical evolution was stimulated by production demands placed upon it. All percussion drills are mechanized versions of the original drilling unit -- man, Figure - illustrates a double jack team at work before the turn of the century. The man with the sledge hammer is the impact device while the man sitting is the rotation mechanism and feed motor. The first drifter drills (Figure 2) performed the same function but with increased mechanical efficiency. A piston controlled by a valve produced impact. A built-in ratcheting mechanism provided rotation and a hand-cranked screw provided feed thrust. As the industrial revolution proceeded into the twentieth century, the demand for raw materials stimulated refinements of all recovery machinery, including rock drills. As drills became heavier and more powerful, a mounting (or carrier) had to be provided to move the drill from hole to hole. This resulted in the development of the wagon drill (Figure 3). Propelled by muscle power, the wagon drill was for years the standard tool of the surface drilling industry (Figure 4). As drills penetrated faster and as labor increased in cost, the time consumed in nondrilling peripheral operations had to be

Jan 1, 1977

By E. Bakhtavar

In this paper, problem of short-term production planning for dimension stone quarries was mathematically modeled using a binary integer programming. The model includes an objective function, which was founded as the minimization of the costs due to the total cutting planes of the blocks. This objective may cause to maximization of the net present value (NPV) in dimension stone quarries. During the mathematical modeling the essential constraints are dimension stone quarry capacities and the market demand, block accessibility for the equipment and the reserve constraints. As a base, an optimal size and shape of extractable blocks should be first assigned according to the available extraction technique and the market demand, in order to create a geological block model. Then an economical block model is provided by assignment of a value of ?one? for ore blocks and ?zero? for waste. Maximum profitability and minimum amount of the ore wastage can be gained using this plan and modeling.

Jan 1, 2012

By J. F. Burr, D. Snyder, W. Calder

This paper provides a determination of the equivalent level of protection of the international standards relative to similar criteria used by the U.S. Mine Safety and Health Administration (MSHA) to approve two-fault intrinsically safe (IS) stand-alone equipment. U.S. mining law requires such a determination for MSHA to use alternatives to existing standards. The primary issue is to demonstrate that the international standards for equipment evaluation will provide at least the same level of protection for miners as the document currently used by MSHA.

Jan 1, 2018

By J. F. Burr, D. Snyder, W. Calder

This paper provides a determination of the equivalent level of protection of the international standards relative to similar criteria used by the U.S. Mine Safety and Health Administration (MSHA) to approve two-fault intrinsically safe (IS) stand-alone equipment. U.S. mining law requires such a determination for MSHA to use alternatives to existing standards. The primary issue is to demonstrate that the international standards for equipment evaluation will provide at least the same level of protection for miners as the document currently used by MSHA.

Jan 1, 2017

By G. Mei

"This study explores froth flotation and selective flocculation methods to recycle waste phosphors containing several rare earth elements, namely, yttrium (Y), europium (Eu), cerium (Ce) and terbium (Tb). The effects of the presence or absence of collector and of flocculant and their dosages, as well as the pH, were investigated. Reverse flotation resulted in concentrates with grade of 27.03 percent and recovery rate of 71.36 percent, while flocculation resulted in concentrates with grade of 31.43 percent and recovery rate of 91.28 percent. The flotation and flocculation behaviors were further analyzed by X-ray diffraction analysis, zeta potential measurements, particle size distribution and other methods. The successful separation of rare earth minerals by flotation was attributed to the selective adsorption of the collector onto quartz, making it particularly recoverable by reverse flotation so as to be separated from the valuable materials. The analysis of the particle aggregation process indicated that its better flocculation performance was due to the selective adsorption of flocculants onto the unwanted materials, enlarging the flocculant sizes by forming aggregations and facilitating the separation of rare earth minerals from waste materials based on different settling rates. IntroductionBecause waste phosphors pose the problems of heavy environmental burden and high risk to human health (Hu and Cheng, 2012) as a result of containing heavy metals such as mercury and manganese (He et al., 2006; Lucas and Emery, 2006), they have received added attention as urban mining resources for extracting rare earth elements (REEs) like yttrium (Y), europium (Eu), cerium (Ce) and terbium (Tb).At present, chemical processes such as acid leaching, alkali fusion, roasting and extraction are the primary methods for recovering REEs from waste phosphors (De Michelis et al., 2011; Li et al., 2012; Li, 2010). With these strategies, phosphors can be effectively decomposed and their REEs extracted. After the removal of impurities, the REEs can be efficiently precipitated by adding an H2C2O4 solution (Porob et al., 2012). Although relatively high recovery rates are achieved, those processes entail high energy consumption and can cause severe environmental pollution."

Jan 1, 2017