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By Cem Şensöğüt, Özer Ören, Yaşar Kasap

The mining sector, which has an important place in terms of raw material and energy supply, is referred as a sector with one of the highest fatal accidents in comparison with other sectors. In this century, where occupational health and safety awareness has increased, it is important to review the past accident statistics and to determine the current deficiencies by using the information in the inventory. In this study, the Malmquist total factor productivity index (MPI) has been utilized to investigate the changes in the work accidents occurring in the Western Lignite Corporation (Turkey), where underground and surface production methods are applied, and to determine the measures to be taken. According to the results obtained, both the decrease in production amount and the increase in the number of accidents caused inefficiencies during the period in concern due to the expected 10-year economic life of the mechanized system operating in the underground production panel that came to an end in 2007 and the flooding took place in early 2017. Compared with the underground operations, it has been determined that production can be carried out at the appropriate scale despite the heavy working conditions encountered due to the changing climatic conditions and the progress of production in the surface operations.

By Thomas Pea, Heiner Kontrus, Jérôme Steinkühler

In tunnel condition assessment, the trend is towards comprehensive 3D measurement combined with high quality image texture to document and quantify damages to the tunnel surface and to create a cohesive data base of the structural conditions throughout its lifespan. The faster such measurements can be made on site, the less it impacts traffic conditions of the highly sophisticated subway systems. The Dibit high-speed 3D scanning system which is based on Photogrammetry and LiDAR technology enables data acquisition in tunnels at a speed of up to 60 mph. Given the high rate of speed the system can operate, tunnel shutdowns can be drastically reduced, and tunnel safety increased. The photorealistic texturing of the 3D-model allows the identification and analysis of smallest material damage (e.g., cracks ≥0.3 mm wide). The publication illustrates technical details and 3D results of the innovative system from measurements that were performed in the subway tunnels of the Bay Area Rapid Transit System in San Francisco, CA (total length 66.23 km).

Jun 13, 2021

By Richard C. Neavel

Among the many compositional parameters used to judge the quality of a steam coal is the fouling factor of Attig and Duzy1 [% base in ash % acid in ash X % Na20] in ash. The higher the fouling factor, the more likely the heat transfer surfaces of the boiler will acquire a deleterious deposit of sintered ash. While examining the elemental composition of ash from various size and gravity fractions of coals from Illinois, we noticed that variations in the fouling factor were attributable mostly to variations in the sodium content. Further, sodium content was essentially the same in all sink-float fractions from a given coal. In other words, sodium was related neither to the ash nor to the organic material. We therefore concluded that the sodium was most likely in the pore water, which was approximately a constant proportion of all fractions. This led to the supposition that the sodium might be removable through water extraction. This supposition tended to confirm the observations of Daybell,2 Daybell and Gillham,3 and Gluskoter and Ruch4 that much of the sodium in coals existed as water soluble sodium ions. In passing, it should be noted that most sodium in Western U.S. coals (i.e., Wyoming, North Dakota, Montana) is not water soluble, but rather is fairly strongly held in association with the organic material (ion-exchanged).5 Because data reported in the literature were not very conclusive about the typical proportions of sodium that might be removed by water extraction, and because there were few data indicating extraction rates, and finally, because our calculations showed a favorable economic incentive to lower sodium contents, we initiated an experimental program to investigate water extraction of sodium from Illinois coals.

Jan 1, 1976

By Pramod C. Thakur

Methane drainage by cross-measure boreholes on retreat longwall faces can be a viable alternative to the vertical gob degas boreholes under favorable circumstances. The research was done in a mine working Pittsburgh Coal seam in Northern West Virginia under U.S.B.M. Co-operative Agreement No. 14-09-0050-3252. The study was the first application of this technique to Pittsburgh coal seam. A total of fourteen, small diameter, inclined boreholes were drilled over a retreat longwall panel from gate roads, to intersect the overlying coal seams. All boreholes were manifolded to a pipeline and the gob gas was extracted by an exhaust fan on surface. The methane capture ratio was poor at 7 to 18% at various stages of the longwall panel. A vertical gob degas borehole captured an additional 20% gas. Poor results were due to premature failures of the cross-measure boreholes leading to air leakage. For better performance the boreholes should be drilled from a point 30 to 45 m from longwall pillar over the largest chain pillar, the standpipe should be grouted for at least 6 m, and the entry containing boreholes and the pipeline must be supported to ensure access for maintenance, and optimization of methane capture. Coursing the ventilation air around longwall such that it forces methane-migration towards cross-measure boreholes can further improve methane capture. The optimum vertical inclination is 45° ± 10°.

Jan 1, 1983

By M. S. Celik

The principal impurities in some feldspar ores are titanium and iron which impart color and in turn degrade the quality of the ore. The mineralogical investigations indicate that titanium element originates from mainly rutile with small amounts of sphene. Conventionally, fatty acids and particularly sodium oleate are extensively used in the flotation of colored minerals from feldspar ores with reasonable success. In this study, new reagents, oleoyl sarcosine and hydroxamate have been used to float colored impurities before and after magnetic separation. Oleoyl sarcosine is found to exhibit better results compared to fatty acids and hydroxamate. The mechanism of the action is elaborated on the basis of experimental data.

Jan 1, 1999

By H. Shafick Hanna

The beneficiation characteristics of low grade Birmingham red iron ores of the Big Seam and Ferruginous Sandstone seams were investigated using flotation and magnetic separation after reduction roasting. Samples of Bib Seam Ore responded more readily to concentration than the Ferruginous Sandstone ores. The impurities inherent with the iron oxide minerals limit the grade of concentrates recoverable from these ores to a maximum of about 61% Fe if reasonable iron recoveries are sought. Flotation concentrates assaying 60-61% Fe and about 0.1% P with attendant iron recoveries of about 63% were achieved from Big Seam ore charges while those obtained from the low phosphorus Ferruginous Sandstone samples analyzed 54-56% Fe. Reductive roasting and magnetic separation of ground charges of the two ore samples yielded concentrates assaying 60-61% Fe. Iron recoveries were better than those achieved by flotation, but the magnetic products of Big Seam ore were high in phosphorus (0.2-0.3% P).

Jan 1, 1983

By Y. Numata

2-Mercaptobenzothiazole (MBT) is a heterocyclic-mercaptan and belongs to a group of molecules containing nitrogen and sulfur as electron donor atoms. MBT has been employed as a collector in flotation under names of MBT, Captax, and Flotagen. It is a major constituent of reagents in the 400 series of the American Cyanamid Co. Current applications of the reagent include flotation of copper minerals, tarnished or oxidized lead, copper activated sphalerite, and nickel ores. It has been used successfully in the flotation of pyrite in acid circuits in the range of 4 to 5.

Jan 1, 1990

By M. L. Free, N. Dhawan, M. S. Safarzadeh, J. D. Miller, M. S. Moats

"The drum agglomeration of nickel laterite and gold ores has been optimized through the design of experiments (DOE) using a Taguchi L16 (45) orthogonal array to determine the optimum conditions for maximizing average agglomerate size and minimizing the amount of fines. The effects of controllable operating factors including moisture content (nickel laterite ore: 34-37%; gold ore: 7-10%), retention time (2-3.5 min), drum speed (15-45% critical speed), drum load (nickel laterite ore: 8-32 %; gold ore: 6-22%) and acid concentration (150-600 g/L) on the performance of the agglomeration process were studied.For nickel laterite ore, maximum average agglomerate size and minimum percent fines (-1 mm) occurred under the following conditions: drum load (23.7%), moisture (36.5%), time (3 min), drum speed (30% critical speed) and acid concentration (150 g/L). Under the studied nickel laterite ore conditions, the most effective parameters for maximizing average agglomerate size and minimizing the amount of fines were found to be drum load and acid concentration, respectively. Drum speed had a statistically significant effect on minimizing the amount of fines. Maximum average agglomerate size and minimum percent fines (-1 mm) for gold ore occurred under the following conditions: drum load (19.3%), moisture (8.5%), time (2 min 15 s) and drum speed (40% critical). The most significant factors for maximizing average agglomerate size and minimizing the amount of fines for gold ore were found to be drum load, time and moisture.IntroductionSeveral heap leach operations have experienced problems in terms of poor recovery due to percolation issues caused by low-grade complex ores, tailings and clayey deposits. Poor percolation can lead to low metal extraction due to solution channeling or the development of impermeable/dead zones within the heap (Dhawan et al., 2012; Kappes, 2005). Improper heap building practices such as the use of loose agglomerates and inadequate attention toward the presence of clay minerals have been among the main reasons for percolation issues. During the transport of ore material, severe segregation of the material can occur. To overcome percolation problems, a major improvement was made through the introduction of agglomeration prior to ore placement. If the ore particles and agglomerates are of similar size, segregation can be avoided to a great extent (Dhawan et al., 2013; Kinard and Schweizer, 1987; McClelland and van Zyl, 1988). Agglomeration improves the uniform percolation of solution through ore heaps and is applicable to many ores, wastes and milled tailings (Bouffard, 2005; Dhawan et al., 2013). Manning and Kappes (2005) reported agglomeration/ stacking accounts for ~14% of the total heap leaching operating cost. The cost of binder is a primary contributor toward the total cost. Also, the lack of consistent quality control tests for agglomerate often leads to operational problems. The details are mentioned elsewhere (Dhawan et al., 2013). Considering the significant contribution of the agglomeration/stacking step toward the total heap leach operating cost, it is appropriate to study the agglomeration behavior and its optimization for two different ores. The reason to study the same parameters for different ores is the fact that significant variability in the agglomeration behavior of different ores has been reported to exist in industrial operations."

Jan 1, 2015

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 C. W. Baxter

Eveleth taconite company was formed in 1963 to mine and beneficiate taconite on the Mesabi range of Minnesota. Its thunderbird mine is located midway between the cities of Eveleth and Virginia, Minnesota, and the crude ore is transported by rail to its Fairlane plant approximately ten miles to the south of the mine, "figure 1". As is implied by the names of the mine and plant, the ford motor company is the principal owner of Eveleth taconite company, with an 85% interest, Oglebay Norton company holds the remaining 15% interest and also is the managing agent.

Jan 1, 1972

By James N. Orlich

Meridian Gold Company's Royal Mt. King mine (RMK), a subsidiary of FMC Gold Company, is located approximately 40 miles east of Stockton, California on the western edge of the historic mother lode belt. Gold ore at RMK is associated with a series of northwest trending fault zones hosted in either meta-volcanic or meta-sedimentary rock types commonly referred to as greenstone sulfide and carbonaceous phyllite. Mineralogy studies show gold in both ore types to occur primarily as electrum in the form of 1 -20 um inclusions in pyrite with varying amounts of free milling gold. In carbonaceous ores, gold was not found to be closely associated with carbon. At the start of the current mining operation, three major ore resources were identified. North Pit and Gold Knoll pits were the major greenstone reserves while Skyrocket Pit contained over 60% of the total reserves as carbonaceous ore. Since North Pit and Gold Knoll were to be the first areas mined, the mill began operation in February 1989 with a flowsheet designed for greenstone ores with a carbonaceous expansion anticipated after depletion of the greenstone reserves.

Jan 1, 1992

By S. Tandanand

The Bureau of Mines, U.S. Department of the Interior, assessed the geological effects on the ratio of maximum subsidence and extraction thickness, hown as the subsidence factor, to develop a simple method for predicting the maximum subsidence. The study is restricted to the Northern Appalachian Coal basin where data were collected from 13 coal mines. A model previously developed to relate the subsidence factor with the lithology and with the width and depth of working panels was used in the assessment. The result shows the possibility of determining maximum subsidence without resorting to a rigorous method.

Jan 1, 1982

By R. B. Elver

The level of steel consumption per capita is one of the principal indicators of a country's standard of living. It is no coincidence that the materially advanced nations possess viable iron and steel industries to provide a reliable and economic source of steal for the manufacturing industries. No other metal is as dominantly important in manufacturing as steel. The blast furnace - steel furnace complex based on coking coal, ferrous scrap and iron ore - continues to be the principal steel-producing method. Less important is the electric furnace method based on scrap, In recent years, there has been considerable interest in the many direct reduction processes that are not dependent on coking coal but usually produce a product for further refining in steel furnaces. No matter which series of processes are used, iron ore is essentially the only source of virgin iron units. Thus, to such a vital and capital-intense industry as steel, access to a relatively inexpensive, long- term supply of iron ore is essential.

Jan 1, 1964

By R. L. Grayson

As the total cost of labor has significantly increased over the past ten years, older underground mines have found it more difficult to compete- in a limited demand coal market. Many of the older mines were developed extensively into a reserve requiring a large number of workers to maintain and rehabilitate extensive track haulages and/or belt conveyor systems. Often, a large number of fans were required to maintain minimal airflows in areas where poor conditions and huge leakages prevail. This paper focuses upon problems which beset one such coal mine and projects undertaken to restore it to potential profitability.

Jan 1, 1986

By Xiaoting Li, Richard Adasiak, Benjamin Mirabile

Pumpable J-Crib stopping walls and Jennmar high-strength (HS) stopping panel walls are widely used for resisting high-ventilation air pressures and roof support in underground mines due to their installation efficiency, convergence allowance, and better performance than traditional concrete block stopping walls. Based on the different entry dimensions and required maximum ventilation air pressures of up to 36-in. water gauge, 24-, 27-, 30-, and 36-in.-diameter pumpable J-Crib stopping walls, or 18- to 30-in. thick Jennmar HS stopping panel walls can be designed, and their support capacities and convergence allowances are evaluated for better roof control. Pumpable J-Crib stopping walls consist of 0.187-in.-diameter steel wire reinforced, JCrib material-filled bags, and non-wire-reinforced filler bags in between. Jennmar HS stopping panel walls consist of two, 20-gauge (0.04-in.-thick), galvanized, cold-formed steel panels with J-Seal materials pumped in between. Based on the fundamental structural design principles and specifications of ACI 318-19(22), the compression and flexural strength, and shear resistance of the walls can be checked to be compliant with the codes and specifications following the load and resistance factor design (LRFD) method. Specifically, the 0.187- in.-diameter steel wires in the pumpable J-Crib walls and 20-gauge steel panels in the HS stopping walls are integral parts of the walls and are considered to effectively confine the J-Crib or J-Seal materials. These steel elements play a significant role in reinforcing and improving the strength or support capacity of the stopping walls from a structural design perspective. Because of the high ductility of low-density J-Crib/J-Seal materials and steel elements, these walls are good at accommodating or absorbing the roof convergence (≥5% entry height), which cannot be matched by a traditional concrete block stopping wall (Figure 1). Based on the successful design and application of these stopping walls in different mines for improving roof stability and avoiding the air leakage, the authors have formulated the design methodology and verified independently by the finite element analysis (FEA) simulation technique. This design methodology combines the fundamental structural design principles with specific wall dimensions and material properties, facilitating mine engineers and government agencies to understand the in-depth working mechanism of these stopping walls.

Jul 1, 2023

By B. Pina

The conversion of maf coal to pyridine solubles and gas was investigated in a microautoclave batch reactor for two Kentucky washed coal samples (Ky. #9 and Ky. #11). Solvent hydrogen donor strength was controlled by the tetralin content of a mixed 1-methyl naphthalene-tetralin solvent. Primary liquefaction conversions greater than 90% in 10 minutes of reaction time at 427°C were achieved in liquefaction solvents with moderate hydrogen-donor strength (circa 40% tetralin). A modified irreversible first order rate expression, containing a parameter (a) to account for the intrinsic reactives of the maf coal, described the experimental kinetic data rather well. The integrated form of this rate expression is -k1e x = a (a- ß)e (eq. 1) Parameter ß in equation (I) is the pyridine solubility of the starting maf feed coal, x is the primary liquefaction fractional number of conversion, k1 is the specific reaction velocity constant and ? is reaction time. Primary liquefaction rate was found to be quite temperature sensitive and independent of coal when a liquefaction solvent containing 40% or more tetralin was employed. Primary liquefaction rate appears to depend on liquefaction solvent hydrogen donor strength for solvents containing = 40 wt.% tetralin. The intrinsic reactives in the maf feed coal or a appear to depend mainly on the inertinite group maceral content of the coal for the two coals studied in liquefaction solvents containing 3 40wt.% tetralin. In contrast, a appears to decrease in liquefaction solvents of low donor strength., i.e; solvents with less than 40wt.% tetralin.

Jan 1, 1984

By Valérie J. Bertrand, Richard W. Lawrence, Marcos G. Monroy

Two cemented paste backfill (CPB) formulations containing pyritic tailings were leached in deionized water in flooded and alternating air-flooded environments and in a simulated acid rock drainage-type (ARD) solution. Scanning Electron Microscopy (SEM), solid phase chemistry and acid-base accounting measurements documented the weathering characteristics of the CPB samples. Short-term exposures of the portland-CPB samples preferentially dissolved the cement binder to a greater extent than slag-Portland CPB mistures. In all cases, the added neutralizing potential provided to backfill by cement was short-lived and insufficient to neutralize the acid generating potential of the mixture.

Jan 1, 2000

By Rambabu Pothina, MELO EDUARDO PIMENTA DE, Rajive Ganguli

 The mining industry is home to a mass of sensor-generated data that are critical to real-time and long-term optimization. This heavy reliance on sensor data has resulted in an undesirable development. The industry is reluctant to verify the accuracy of sensors as it would mean shutting down important processes. Sensors are typically calibrated once a year, if at all. Errors in sensors go undetected until the next calibration or until errors are so gross as to be obvious

By John Newby, Mahmood Khwaja, Bernard Theron, Janice McGovern, Bernard Catalano, Michael S. Schultz

Launching a full-size pressurized-face Tunnel Boring Machine (TBM) in difficult ground conditions is always challenging. Recently, few projects have innovated the process by scaling the trenchless method of pipe jacking, and modified steel bell approach, to facilitate the launching of a full-size TBM without the need for large and deep trenches, starter/tail tunnels, or for incrementally installing supporting gear as the machine advances. This paper presents three such projects; evaluates the post-bid contractor proposed modifications; details the innovative use of pre-cast pipe segments to facilitate machine launch; and, provides an overall assessment of the benefits, challenges and lessons learned related to the modified approach.

Jun 13, 2021

By John T. Bartlett

During the last decade, the increasing price of gold has renewed interest in the various metallurgical techniques for recovering precious metals. Much of the recent technology advance has been aimed at low grade deposits resulting in more complex processes and the necessity of tighter economic control. These factors along with more stringent environmental constraints have made it necessary to optimize each process to minimize energy and raw material consumption and reduce waste discharge. In most cases, detailed process analysis is required to detect inefficiencies and provide alternative solutions for process improvement. Also during this same period, the computer has become widely accepted and computerized mathematical modeling has been applied to an increasingly broader range of problems. Microcomputer based process modeling and simulation systems are routinely used to analyze and improve communition, hydrometallurgical, and pyrometallurgical processes for the recovery of precious metals.

Jan 1, 1987