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By David C. Byrne

PURPOSE: Evaluate practical technological advances in hearing protective devices for use in different mining environments. RESEARCH SUMMARY: Previous NIOSH research shows that miners develop hearing loss much more quickly than nonoccupationally noise-exposed individuals and that miners experience a greater severity of hearing loss than would be expected for nonoccupational noise-exposed persons of the same age and sex. As described in the National Occupation-al Research Agenda, problems created by occupational hearing loss include(1) reduced quality of life due to social isolation and unrelenting tinnitus,(2) impaired communication with family members, the public, and coworkers, (3) diminished ability to monitor the work environment (i.e., warning signals, equipment sounds, etc.), (4) lost productivity and increased accidents resulting from impaired communication and isolation, and (5) expenses for workers’ compensation and hearing aids. Although eliminating hazardous noise is the long-term solution to the noise problem, miners will likely need to rely on personal hearing protection in certain situations for quite some time. However, it is well known that noise attenuation provided by hearing protectors as they are worn during everyday use is usually quite different (i.e., worse) than when tested under lab conditions. In addition, workers may refuse to wear their hearing protection for any number of reasons. This project was initiated to evaluate practical technological advances in hearing protectors, with an emphasis on optimizing the balance between effectiveness, comfort, over protection, and communication ability. The recently completed auditory research facility is now under-going the accreditation process conducted by the National Institute of Standards and Technology under the National Voluntary Laboratory Accreditation Program. Experiments are planned to investigate the factors that affect a miner’s ability to hear hazard and warning sounds (e.g., roof working, alarm signals, spoken communications, etc.). A service contract has been initiated to record and digitally store samples of typical warning sounds heard in an underground coal mine. This information will be analyzed in the lab to develop recommendations that can be offered to the mining community regarding correct earplug/earmuff usage to maximize there cognition of hazard and warning sounds while adequately protecting the miners’ hearing.

Jan 12, 2001

PURPOSE: Evaluate practical technological advances in level-dependent hearing protectors and inexpensive personal acoustic monitors. RESEARCH SUMMARY: The results of previous NIOSH research show that miners develop hearing loss much more quickly than nonoccupationally noise-exposed individuals and that miners experience a greater severity of hearing loss than would be expected for nonoccupational noise-exposed persons of the same age and gender. Using hearing thresholds at 4,000 Hz as an indicator, coal miners experience hearing loss 2.5 to 3 times greater than would be expected for persons not exposed to occupational noise. At age 50, 90% of coal miners and 49% of metal/nonmetal miners were found to have a hearing impairment. In comparison, only 9% of a nonoccupationally exposed control group had a hearing impairment at age 50.

Jan 1, 2000

By Frank P. Frandina, Michael J. Loehr, Paul E. Gabryszak

The Heartland Corridor Clearance Improvement Project is part of a regional Public-Private initiative to allow double stack container trains a direct route from the Port of Norfolk through Virginia, West Virginia, Eastern Kentucky and into Central Ohio. In the Preliminary Engineering stage, 30 existing tunnels were assessed and 28 were found to need clearance improvements to allow the use of double stack trains. Alternative tunnel enlargement methods were developed to achieve the desired clearance improvements, while maintaining structural integrity and minimizing disruption to train traffic. This paper summarizes the geometric and condition investigations of the existing tunnels, as well as describes the preferred methodologies to achieve the desired clearance. The clearance improvements will be implemented beginning in the summer of 2007.

Jan 1, 2007

By Frank P. Frandina

The Heartland Corridor Clearance Improvement Project is part of a regional Public-Private initiative to allow double stack container trains a direct route from the Port of Norfolk through Virginia, West Virginia, Eastern Kentucky and into Central Ohio. The project involves clearance improvements to twenty-eight tunnels, twenty-one of which require structural modification. With construction of the first Package of tunnels just underway at press time, this paper summarizes the program implementation from design through the initial stages of construction.

Jan 1, 2008

By A. De, J. S. Zuback, T. Mukherjee, T. DebRoy

For successful commercial applications of additive manufacturing, metallic parts need to be defect free, structurally sound and reliable. However, additively manufactured metallic parts are susceptible to distortion, lack of fusion defects and compositional changes. Methods to measure susceptibilities of various alloys to these defects are needed but not currently available. Here we show that the necessary theories can be developed based on a well-tested numerical heat transfer and fluid flow model and decades of research in the field of welding. The proposed theories are validated with experimental results reported in the literature.

Jan 1, 2016

By Antti Roine

Sulfidic zinc concentrates are usually roasted in a fluidized bed furnace into sulfur-free oxide form. Metallic zinc is produced from this oxidic calcine using hydrometallurgical leaching, solution purification and electrowinning stages. The roasting step is necessary because zinc oxides are easier to dissolve using traditional leaching methods than zinc sulfides. The Kokkola Zinc smelter uses various types of zinc concentrates and secondary materials as feed mixture. This makes it difficult to find optimum process parameters for the roaster when the composition and particle size distribution of the feed mixture varies even on a daily basis. Certain conditions may even cause difficult accretion problems or increase the amount of calcine in the process off-gas line excessively. A thermochemical heat and material balance model was developed for process advisor, in order to estimate the effects of different process parameters (temperature, process air coefficient, concentrate feed, oxygen enrichment, water feed, etc.) on the heat balance, roasting temperature and calcine composition. This model was constructed using the heat balance module of HSC Chemistry 4.0 software. The prevailing chemical compounds in the concentrate and calcine were verified using mineralogical analyses and equilibrium calculations. The roasting process seems to operate near chemical equilibrium conditions, if the behavior of the main components is considered. This paper describes briefly the basic principles of the calculation model and outlines the results with several diagrams and discussion. The calculated results were in reasonable agreement with the recent process air oxygen enrichment and water feed test campaigns carried out at Kokkola in 1999.

Jan 1, 2000

Au airway hteat and moisture exchange .,Jgorithm is described which is generalised to suit most mining situations and can be run separately on a microcomputer or used within a network simulation. The main difference between this technique and other simplified methods is that a non-uniform boundary condition is allowed for. This permits radiative heat transfer between surfaces of different wetness in addition to evaporative and convective heat and mass transfer.

Jan 1, 1988

By I. Longson

As a longwall coalface advances a caved goaf or waste region is left behind. Air flow takes place through this permeable goaf due to the pressure differentials existing across it and en route this leakage air picks up both heat and moisture. A marked deterioration in climatic conditions occurs in the face area at all points downstream of where this leakage air rejoins the main air-stream. This goaf heat source can make a very significant contribution, typically 30-40% to the rate of total heat pickup on an advancing UK longwall coalface with a VST of 40°C and hence on the climatic conditions that prevail at the return end and in the return gate of the face. The magnitude of the rate of heat collection from the goaf depends on a number of factors but it has been established that it is particularly influenced by the prevailing virgin rock temperature and the total flow rate of the leakage air. This paper proposes a model for the goaf based on a packed bed analogy and other assumptions required in order to evaluate the rate of heat pickup are identified. The outlet condition of the leakage air predicted by the model have been shown to correlate with underground measurements taken for a range of different production patterns with the face cutter at various locations on the face. The sensitivity of these predictions to variations in the input data has been tested and is commented on. At this stage of the development the capabilities and predictive limitations of the model are discussed. Further areas of investigation are suggested in order to improve the predictive ability and to extend the versatility of the model.

Jan 1, 1989

By T. Kho, W. Zhang, M. E. Reed

The control of flash furnace heat balances is critical. Suspension smelting control and stability comes from stable operation of the heat balance, and this leads to a stable reaction shaft exit temperature. A number of flash furnace operations have been reviewed to determine if the application of this approach is beneficial for their operation. The cause and effect relationship between reaction shaft exit temperature with uptake and throat buildup is being enhanced with this work program. Our operating personnel are exposed to the operational hazards of cleaning this buildup from the throat and it is imperative that as an industry we continue to look for repeatable solutions. WorleyParsons has reviewed operational data from a number of flash furnaces and looked at the possible improvements that can be made to decrease variation in the reaction shaft exit temperature. The data assessed for each operation illustrate the need to fully understand the process inputs to the particular operation and to ensure that the control changes are correctly impacted. In the plant data that have been assessed for a number of operations combinations of feed changes and inappropriate process decisions have lead to changes in reaction shaft exit temperature which impact the overall furnace operation and the uptake shaft condition, and ultimately the boiler. INTRODUCTION In 2016 WorleyParsons jointly prepared a paper outlining the effects of heat balance control on the Olympic Dam flash furnace (Reed et al, 2016). That paper investigated the importance of heat balance control in flash furnaces and demonstrated the changes made at the Olympic Dam operation to control the heat balance in the furnace and the impact that change had. The operation is still using the tool to assist in trouble shooting performance and pinpointing problems that may lead to issues in the furnace throat and Waste Heat Boiler (WHB). As a result of the interest in the methodology and due to the issues surrounding safety and process performance caused by WHB throat buildup and damage, WorleyParsons approached a number of flash furnace operators to discuss the application of the approach at their operations.

Jan 1, 2019

By M. Kawakami, K. Suzuki, T. Takenaka, S. Yokoyama

Molten NaNO3-NaNO2-KNO3mixture is used as a heat transfer medium at high temperature. One of the most important properties of this mixture is the heat capacity. In the present work, the enthalpy change with temperature was measured by the drop calorimetric method to evaluate the heat capacity. The results are summarized as follows: The enthalpy of the mixture increased linearly with the temperature. From the slope of the line, the heat capacity was evaluated. The heat capacity of pure NaNO3, NaNO2and KNO3was 0.129,0.110 and 0.142 kJ/mol/K, respectively. These values are in fairly good agreement with the published data. In the binary and ternary systems, the molar additivity of heat capacity, which is well known as Neumann-Kopp’s law, was obtained. The heat capacity of HTS1and HTS2, which are well known ternary mixtures of practical use, were in the range of published data.

Jan 1, 2004

By Ignacy A. Lipiec

The advantage of microorganisms used in bioleach systems to conventional chemical reaction systems is that these apply the available energy more precisely where it is needed, either directly onto the mineral of interest or by efficiently catalyzing the production of a reactant. The literature cover the range from empirical models used in describing macro heat balance in heaps to detailed studies relating the micro heat effects of bacteria adhesion energy to the surface of minerals. In this paper, the heat effects are reviewed in a general way describing bioleaching in two macro systems, heap leaching and slurry bioreactors. The micro scale heat effects is the reactions and conditions at the microorganism scale, including the mechanism of leaching and bacterial behavior.

Jan 1, 1998

By Alan M. Jessop

This paper discusses the distribution of frozen ground in the zone of discontinuous permafrost in relation to the pattern of surface temperature. The importance of understanding permafrost in relation to surface construction and open-pit mining operations is stressed.

Jan 1, 1972

By A. J. Dickson, A. M. Starfield

This paper reviews the progress made to date in the development of computer models of heat and moisture transfer from rock surfaces to the ventilating air in deep-level mines. The application of these programs to ventilation planning and design is discussed.

Jan 1, 2014

By J. Jorge, J. Mariño-Salguero, B. Álvarez-Rodriguez, J. M. Menéndez-Aguado, J. J. de Felipe

"This work focuses on the characterization of heat generation during dry fracture by direct impact of a tantalum ore. Moreover, an attempt was made to quantify the heat energy loss to the environment during the grinding process of a ball mill. The study was carried out using mineral samples from a Spanish mine that were characterized by measuring their density and specific heat. During the experiments, increases of temperature ranging from 5.9 to 7.3 °C after the fracturing process were observed. A numerical model was then applied to calculate temperature distributions through the mill wall. Three possible combinations of heat transfer coefficients were analyzed, from (1) Kapakyulu and Moys, (2) Duda and (3) the heat transfer laboratory of Universitat Politècnica de Catalunya. The models with the coefficients from Kapakyulu and Moys and the heat transfer laboratory of Universitat Politècnica de Catalunya were found to provide results that were in best agreement with the experimental data. IntroductionEvery year, several billion tons of metallic ores, minerals, cement and other solids used in the ceramic and chemical industries are subjected to size reduction in ball mills around the world. The U.S. Department of Energy (2005) reported that in the United States about 29 percent of the total energy used by the mining industry, or 0.4 percent of total U.S. energy consumption, is used in comminution. In Canada and Australia, comminution is responsible for about 2 percent and 1.5 percent of total energy use, respectively. In nonindustrialized countries where mining constitutes higher fractions of their industrial sectors, comminution costs represent a significant contribution to mine operating costs. The specific energy consumption values for the grinding of these materials typically range from 5 to 50 kWh/t. Thus, a significant amount of electrical energy is consumed in the ball mill grinding operation (Aguado et al., 2006; Gupta and Sharma, 2014). Grinding can represent up to 50 percent of the direct operating cost in a mineral processing plant, especially as comminution devices operate in highly inefficient ranges of 4 to 8 percent (Wang, Yang and Yu, 2012)."

Jan 1, 2017

This paper presents a review of heat illness in mining, including reference to several recent investigations by the author. Heat illness is a collective term, covering the conditions of heat stroke, heat exhaustion, heat cramps and miliaria rubra. Heat stroke is life-threatening and is by far the most serious condition. It is rare in mining, if appropriate control measures are instituted. Heat exhaustion is primarily due to hypohydration, following prolonged sweating in hot conditions. Symptoms include fatigue, headaches, dizziness, anorexia, nausea, vomiting, shortness of breath, or brief syncope. Confusion, ataxia, prolonged unconsciousness or convulsions are strongly suggestive of heat stroke. Heat cramps are painful involuntary contractions of skeletal muscle associated with work in hot conditions. The limbs are usually involved and the spasms typically last a few minutes, during which the affected part of the body is incapacitated. Heat cramps tend to occur in heat exhaustion, when hypohydration becomes marked. Miliaria rubra is a skin rash caused by extravasation of sweat into the skin, as a result of obstruction of the sweat glands. It occurs after prolonged and profuse sweating in hot environments. It can take three to four weeks of sedentary duties, in an air-conditioned surface environment, for the condition to resolve. Heat illness would be unlikely in underground mining, if the thermal environment was sufficiently well controlled by ventilation and refrigeration. This is however, often not practicable. Where engineering controls alone cannot provide sufficient control of risk, the residual risk can be assessed using an appropriate heat stress index. While procedural controls may further reduce the residual risk, it is important to remember that these are less reliable than engineering controls and cases of heat illness may still occur. Procedural controls include the application of heat stress limits, education, hydration, self-pacing, early symptom reporting, medical advice, acclimatisation procedures, air conditioned accommodation, support to achieve a healthy body mass index, and an effective emergency response capacity.

Jan 1, 2005

By M Olsen, L van den Berg

Bowen Basin coalmines suffer from hot and humid ambient conditions during the summer period. The ambient conditions combined with high VRTs, increasing depth of working and significant equipment heat loads results in heat issues underground. Coalmines operate under heat stress management plans as required by legislation with associated trigger action response plans (TARPs). Some mines also employ refrigeration as part of their heat management strategy.A recent case study was conducted on a mine producing about 4.5 Mt/a from their longwall and experiences summer surface ambient temperatures of about 23.5ºCwb. The expected virgin rock temperature is 46ºC at 300 m depth. The mine currently introduces a modest amount of surface cooling at the portal using ‘off-the-shelf’ air conditioning units. This system does not effectively manage face temperature primarily due to positional inefficiency.Underground conditions remain hot in summer and work is typically undertaken in accordance with the Heat TARP. This has a direct impact on the productivity of crews, worker comfort and also negatively impacts the workforce morale. The mine commissioned a study to determine a refrigeration strategy aimed at maintaining underground conditions below TARP levels 90 per cent of the time.The ventilation network model was calibrated against actual temperature data to simulate the heat loads including longwall, conveyor system, strata and auxiliary diesel fleet. This model was then used to determine the cooling requirements for bulk surface cooling, bulk underground cooling, surface district cooling and underground district cooling strategies.These estimates were used to undertake a total owning cost trade-off for the different strategies. The study concluded that a chilled air shaft has the lowest technical risk but the highest total owning cost due to shaft development needs. Introducing chilled water to an underground cooler via boreholes offered the lowest total owning cost and was therefore recommended.CITATION:van den Berg, L and Olsen, M, 2017. Heat load assessment and mine cooling strategies for a longwall coalmine, in Proceedings Australian Mine Vent Conference 2017, pp 231–236 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 28, 2017

By Chonghun Han, Tae-Hwa Choi, Young-Hwan Chu

"A statistical optimization method is proposed to maintain stable operation in a blast furnace with stave coolers. The objective of this study is to find the operating condition which maximizes productivity as well as minimizes the heat load on the stave coolers. In this method, we first analyzed historical data and calculated the heat flux of stave coolers and the burden distribution by mathematical models. In this approach, we determined the variables to optimize and manipulated variables to adjust these response variables. Next, we collected the necessary data for the data variables after preprocessing such as removal of noise and outlier. Finally, we constructed empirical models describing the patterns of response variables in terms of manipulated variables by partial least squares regression method, and then these models were used as objective functions for entire optimization problem. By using appropriate optimization algorithm, we determined the compromised optimum operating condition considering all response variables from the past operating conditions.IntroductionBlast furnace operation which is accompanied by complex physical and chemical phenomena is an essential process for steel industry. In this process, iron ore which is charged into the blast furnace from the top goes downward. It is reduced to iron by CO gas and is melted by the heat of combustion of coke and pulverized coal. The pig iron is tapped at the bottom in liquid phase after removing the slag, which floats on the pig iron.The cooling equipment of the blast furnace wall is changed from the plate type to the stave cooler recently. In order to cool the shell uniformly and eliminate shell spray cooling, Pohang No.2 blast furnace of POSCO (Pohang Iron & Steel Company) was equipped with 11 rows of stave coolers. These staves are only 350mm-thick including the 170 mm-deep refractory on the hot face."

Jan 1, 2001

By R Moreby, J Kok, L van den Berg

The high production rates achieved from mass mining methods such as block caving, sublevel caving and longwall mining require large conveyor belts, trucking loops (diesel/electrical) and rail systems for ore handling. However, the ore handling systems used in mass mines introduce a significant amount of heat into the overall ventilation system, which may be problematic at depth or in mines located in hot climates.In particular, the heat load from a conveyor system is not always well understood and consists of various components, including frictional heat from idlers, heat from electrical motors, heat from the drive train and heat from broken rock transported on the conveyor system. This paper presents results from a study that investigated the heat introduced to the ventilation air from a large conveyor system. The conveyor system transports ore with a maximum virgin rock temperature of 41°C from a depth of over 1 km. Air, belt and rock temperatures were measured in the conveyor system to evaluate the distribution of heat loads.CITATION:van den Berg, L, Moreby, R and Kok, J, 2015. Heat load estimation from conveyor systems in mass mines, in Proceedings The Australian Mine Ventilation Conference, pp 63–70 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By Jane Li, Kevin Tom

"Research has shown that broken rock on conveyor transport systems can contribute upwards of 50% towards the overall heat load in underground mines. However, few studies have made significant efforts to predict the temperature distribution of the ore and air simultaneously, which can help implement heat management strategies. The present investigation explores a transient, analytical heat transfer model to track ore-pile temperature distributions, along conveyor systems in an example underground mine. Production rate, ambient conditions, ore pile thickness and belt velocity are adjusted to evaluate the effect on dry and wet bulb temperatures.INTRODUCTIONWith an ever increasing demand on Earth’s resources due to a multitude of factors like population growth and step changes in technology, pressure on the mining industry to bring out more ore with improved margins is a persistent challenge. Typically, high-volume producing mining methods (i.e., exceeding 5000 tons per day (tpd)) such as sublevel and block caving, room and pillar, and longwall shall utilize belt conveyors instead of trucks as the primary haulage method to surface to save on operational costs (de la Vergne, 2014). However, studies have shown that when such material transport systems are installed at mine depths with virgin rock temperatures (VRT) above 40oC, the heat dissipated by the conveyed ore can account for over 50% of the underground heat-load (Pareja, 2000; Bluhm, Jones, Moreby, & von Glehn, 2012; van den Berg, Moreby, & Kok, 2015).Unlike other types of heat sources encountered in underground mines, such as diesel machines, strata, electrical devices, and autocompression, heat transfer by conveyed broken rock is much more difficult to estimate. The seminal work of McPherson (1993) states that broken rock heat transfer is a function of its surface area, and the air’s psychrometric condition. It is additionally a function of the VRT, its specific heat, production rate, heat transfer coefficient and the residence time (Bossard, 1997; Ross, Tuck, Stokes, & Lowndes, 1997). Consequently, few studies have attempted to analytically quantify the significance of ore heat flow."

Jan 1, 2019

By Pan Gu, Zhen Zhang, Jiang Diao, Bing Xie, Hongyi Li

Furnace refractories are in most cases chemically incompatible with smelter slag, which leads to a steady erosion in their thickness over time. Once too thin, refractory walls become mechanically unstable and catastrophic failure can result. Historically, external shell cooling was applied to generate a freeze lining of slag and thus prevent refractory erosion. Many modern high intensity smelting furnaces instead maintain their physical integrity by the use of internally cooled wall panels, plates or finger coolers. An initial refractory lining is often installed inside of the coolers, such that the furnace originally operates with a temperature (insulated) rather than a heat flux (freeze lined) boundary condition. This paper examines the change in slag-wall heat transfer coefficient and slag superheat as a function of process intensity. The implications of the changes in heat transfer on residual brick thickness are explored using analytical modelling.

Jan 1, 2016