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By M. Westendorf, T. Banerjee, S. Kaushik, D. Tinney

"The Copper Mountain Mine is located in Princeton British Columbia, Canada and produces 80 – 90 million pounds of copper annually, as well as gold and silver by-products. The ore processing plant has a conventional SAG/ball mill circuit with inline pebble crushing, followed by flotation. At most plants, much time is spent evaluating and optimizing the comminution and flotation circuits. The cyclones are a key contributor to the effective operation of the plant: They define the circulating load in the comminution circuit and provide the classification that ensures liberated material is passed through to flotation. If the cyclones are not performing as they should, the results are often a combination of lost recovery, grade, capacity and reduced throughput in flotation. For such an impactful unit operation, cyclones have historically been under-instrumented. Consider as well that the cyclones are typically located at the highest elevation in a plant, and it becomes clear why they often underperform. Copper Mountain Mine recognized the critical role that cyclones filled in their plant and worked to optimize their operation through the implementation of a Portage Cyclone Detection (PCD) system to identify plugging and roping incidents, Portage Pumpbox Control (PPC) to manage the flow to the cyclones, and AwaRE to control the grinding circuit. As a result, cyclones overflow stability has increased, switching out a roped or plugged cyclone now happens within seconds rather than many minutes, and both the grinding and flotation circuits perform better. INTRODUCTION Cyclones are one of the most extensively used pieces of equipment within the mineral processing industry because of their simplistic operating and maintenance philosophies. The cyclones are commonly used as classifiers within the comminution circuit to control the grinding product particle size for satisfactory performance of downstream operations. The cyclones are a key contributor to the effective operation of the plant and have a significant impact on the mineral processing plant operations. If the cyclones are not performing as they should, the results are often a combination of lost recovery, grade, capacity and reduced throughput. Similarly, an inefficient cyclone operation may also lead to low or high recirculating loads that impact the efficiency of the comminution circuit. This highlights the importance to have proper stability in cyclone operation while implementing any plant-wide optimisation strategy."

Jan 1, 2015

By W. D. Monaghan

One of the major ignition sources of fires and explosions in underground U.S. coal mines is flame cutting and welding. On May 20, 2006, a flame-cutting operation at the Darby Mine No. 1 led to an explosion that resulted in five fatalities. On Jan. 22, 2003, another explosion caused by flame cutting at the McElroy Mine resulted in three fatalities and three serious injuries. On June 22, 1999, a flame-cutting and welding operation at the Loveridge Mine caused a fire that required sealing the mine for an extended period. On March 19, 1992, an explosion initiated by welding at the Blacksville No. 1 Mine resulted in four fatalities. These examples of mine incidents demonstrate the need to conduct research to develop best practices for safely conducting flame cutting and welding in underground coal mines. The National Institute for Occupational Safety and Health (NIOSH) conducted a study on fires and explosions in underground U.S. coal mines that were caused by flame-cutting and welding operations to determine the root causes of these types of incidents. The methodology included interviewing mining personnel who perform flame-cutting or welding operations in underground U.S. coal mines and visiting mines to observe these operations. In addition, MSHA reports of investigations and accidents statistics were analyzed. The findings were used to identify and compare differences between flame-cutting and welding practices and techniques in small and large mines, eastern and western mines, low-seam and high-seam mines, room-and-pillar and longwall mines, and between experienced miners and new miners. As a result of this study, best practices were developed to reduce the number of ?res and explosions caused by flame cutting and welding. This paper provides a summary of this research.

Jun 1, 2010

By Rongjie Kong, Shiwei Wang, Guomin Wei

Owing to the selective oxidation and uneven combustion that occur on the surface of carbon anode, some carbon particles detach and form carbon residue, which is defined as spent anode slag (SAS). The highly graphitized and toxic impurities such as fluorite ( CaF2), corundum (α-Al2O3), and cryolite ( NaAl11O17) are crucial components of SAS resource but are difficult to separate from graphite. This study developed a method of using water-soluble (emulsified) kerosene to separate the carbon particles from the toxic impurities in the SAS resource. The flotation purification approach of utilizing conventional kerosene was experimentally investigated and compared with that of using water-soluble kerosene. The results showed that with the use of emulsified kerosene, the maximum combustible matter recovery of the carbon particles was 89.86% while that of using traditional kerosene was 80.30%. The emulsified kerosene was comprehensively examined by various instruments to clarify its adsorption mechanism on the carbon particle surfaces. Because of the superior dispersibility of emulsified kerosene, it effectively envelops carbon particles with a smooth surface, oxygen-containing functional groups, and hydrophilic C–F bonds, thereby increasing the surface hydrophobicity and flotation responses of targeted carbon particles.

Feb 6, 2024

By Ma Fangyuan, Li Min, Xu Bing, Xian Yushuai, Zhao Tonglin

The study explored a new combination amine collector (XK-28) that can obtain better flotation index and defoaming rate for magnetic iron ore. A pure quartz mineral test indicates that dodecylamine, XK-I, or XK-II has good collection effect on quartz and their best flotation pH is in the range of 6–7. The experimental results of a combination collector (XK-I:XK-II = 2:8.) show that the separation effect for quartz and magnetite is better than that of a single collector. The single factor for actual mineral test shows that when the combined reagent is used as the collector, the best conditions are pH = 7, 90 g/t dosage, and XK-I:XK-II = 2:8, which is consistant with the pure mineral test. The difference for dodecylamine as a collector is that the optimal dodecylamine dosage is 60 g/t. Under the best conditions of actual ore test, dodecylamine and XK-28 are respectively used as the collector to compare the flotation indexes. Study results indicate the magnetite grade using XK-28 as the collector is higher by 3.02% than that of using dodecylamine, recovery is increased by 1.92% over that of using dodecylamine. Based on the measurement results of zeta potential, uses of XK-28 can slightly increase the zeta potential difference of quartz and magnetite to enhance the flotation effect. The mechanism of action between the XK-28 collector and the actual ore from the Gongchangling plant is physical adsorption, and this adsorption also has hydrogen bond formation. Contact angle results shows that XK-28 improves the hydrophobicity of quartz better than dodecylamine. Compared with dodecylamine, XK-28 is more sparsely arranged on the surface of the foam. The foam produced by the XK-28 collector has better air permeability and it is more likely to merge and disappear with bubbles.

Jul 21, 2021

By Sanja Zlatanic, Michael P. Della Posta

New York State’s Metropolitan Transportation Authority (MTA) has undertaken the largest transportation project in New York City. The East Side Access Project (ESA) will introduce MTA’s Long Island Rail Road (LIRR) service to the East Side of Manhattan, to a new terminal located beneath the existing, landmark Grand Central Terminal(GCT). Construction of the Manhattan Segment of the project will affect overlying operating facilities of two other MTA entities, Metro-North Railroad (MNR) and New York City Transit (NYCT) and major Midtown Manhattan buildings. The paper describes the evolution of the GCT concept at Manhattan from a shallow alternative proposed by a Major Investment Study (MIS), that would require extensive underpinning of multi-story buildings and have considerable impact on MNR and NYCT operations, to a deep alternative with lesser risk and potential for disruption.

Jan 1, 2001

By Siddhartha Roy, Hemant Agrawal, Ram Madhab Bhattacharjee, Devi Prasad Mishra

Heat stress in underground coal mines is a major threat to the health and safety of the miners. Hence, managing heat and prediction of heat stress in advance is essential for maintaining a safe, healthy, and productive underground mine environment. In this study, an extensive ventilation survey has been carried out in three different deep and mechanized underground coal mines. The ventilation survey data are used to develop 3D simulation models with the VentSim™ software to predict the conditions that could cause heat stress in underground mine workings. The developed 3D models predicted well the wet-bulb globe temperature (WBGT), a recognized indicator of potential heat stress, with a coefficient of determination (R2) of 0.986, 0.994, and 0.993 for Mine-A, Mine-B, and Mine-C, respectively. Moreover, through 3D modelling, the applications of auxiliary ventilation and spot coolers to reduce the wet-bulb globe temperature (WBGT) for improving the underground workplace environment have been explored. The study demonstrated that auxiliary ventilation and spot coolers can help in significant reduction of heat stress conditions in an underground mine environment. By application of auxiliary ventilation, to increase air volumes, and spot coolers, the WBGT index in mining faces is reduced by 1.2–1.4 °C and 3.9–5.4 °C, respectively. Therefore, it is concluded that the spot coolers are more effective in reducing the heat stress conditions in hot and humid underground mine environments in comparison with auxiliary fan that is used to increase the air volume and velocity. This study opens up a new horizon of 3D simulations for heat stress management in underground mines. The outcome of this study will be useful for the researchers, mine operators, and environmentalists understanding the heat stress contributors and their control in underground mine environment.

May 10, 2023

By Robert L. Russell

The Bunker Hill Mine, located in the Coeur d'Alene Mining District at Kellogg, Idaho, has been a major producer of lead-silver-zinc ores since its discovery in 1887. The mine has produced over 29 million tons of ore from some 20 to 25 veins and ore zones, and now covers an area approximately one mile in length and one-half mile in width. The active section of the mine extends from 2500 ft above sea level to 1600 ft below sea level. Production is presently at the rate of about 1700 tons of ore per day. A two-mile adit, the Kellogg Tunnel, at the 2500 elevation, provides access to the main shaft area. Ore is hoisted to the adit level through a 5000-ft, 500-inclined shaft, extending to the lowermost haulage level 1200 ft below sea level. Primary shaft service for men and materials is supplied by three major internal, inclined shafts equipped with double-drum hoists. Present production requires ten levels to serve for mainline track haulage. These range up to 5000 ft in length and are either 200 or 400 vertical feet apart. Also, many intermediate levels exist throughout the mine. The conventional and autoloader mechanized square-set and cut-and-fill mining methods used throughout the mine have been the subject of a recent paper(l). One-third of current production is from vein-type ore bodies which are long distances from main shaft areas. Such veins generally dip about 450, have relatively narrow widths of from 3 to 20 ft, and usually contain less than 500,000 tons of ore. For many years, ore bodies thus situated have been developed by means of a separate inclined, timbered service shaft-raise connecting two or more main haulage levels. These commonly range from 400 to 1000 ft in vertical extent and are equipped with 25 to 50 hp electric, single-drum hoists. Intermediate levels are driven as conventional track drifts at 100-ft vertical intervals between the haulage levels. Ore and waste from the intermediate levels are trammed to orepasses for delivery to the lowermost haulage level servicing an ore body. The final result may be visualized as a number of small mines within a large mine. The problems of high development costs and high total development time, and the large amount and high cost of providing materials handl ing and ore haulage service while producing from this isolated type of stope block, made it desirable to consider totally new approaches in developing and mining a number of similar areas.

Jan 1, 1971

By A. Mertzanis

The way and methods used for the surface mining of bauxite until the end of the twentieth century in the area of Ghiona, resulted in a significant burden to the natural environment, especially in the cases where it covered extended parts of forests and forest areas as well as important geomorphological formations. The impacts from the surface mining of bauxite which in fact constitute the object of this study relate mainly to the interruption of the natural continuity of the land relief and the alteration of the natural geomorphological activities and are due to: a) the alternating excavations with fronts of great heights, b) the depositions of large volumes of waste materials which originate from the revealing of the ore and c) the dense road network constructed in order to get access to the mine locations.

Jan 1, 2006

By Ewan Alexander

"As human beings, we have managed risk since the dawn of the ages and have been adept at doing so. In order to survive, we hunted or gathered. If we did not take enough risk, we died. If we took much risk, we died (Fig. 1). As individuals and tribes, risk had to be optimized to maximize our chances to thrive, as individuals and as tribes.In today’s world, the risks are vastly different, but in order to thrive, these must be managed. And no industry knows this as much as mining. In fact, the International Council of Mining & Metals (ICMM) has proposed the Critical Risk Model (Fig. 2) as a means of identifying critical risk, critical controls and associated performance standards. The ICMM focuses on sustainable development performance in the mining and metals industry. It has 23 members, representing some of the largest mining companies in the world.This approach is going to help the mining industry. But it must be applied effectively, with the acknowledgment that the system alone cannot be effective. We can say this confidently, as even companies known for the strength of their risk and safety management systems continue to experience significant incidents, and, in some cases, catastrophes. Why does that happen when all safety metrics, including injury rate, are pointing in the right direction? In the view of the author, it is only when leadership, culture and systems work in complete harmony that the resilience of an organization to manage its significant risk is at an optimal level. It remains an ongoing leadership challenge to maintain that balance and the optimal mindset in the organization. So how do you maintain that special balance?Let’s start with a basic premise. Leadership, supported by simple effective systems, creates culture which creates outcomes. Everyone going home safely is an outcome, as is cost effective operations, and to achieve those outcomes efficiently, the organization must focus on the inputs. And those inputs include effective leadership, effective systems (for the purposes of this article, risk and health, safety and environment (HSE) systems), good planning, stable operations and competent workers. This article will focus on gaining maximum performance from your risk management system."

Oct 1, 2016

Caterpillar unveiled a new dozer, the new Cat D10T2 dozer, that builds on the success the company has had with its D10T model. The newest version of the dozer includes refinements to its power train, automated controls and structures. The result, the company said, is high productivity with superior fuel efficiency, reliable operation with long-lived structures, as well as enhanced access for service technicians and operators. The D10T2 uses the latest load-sensing hydraulics technology combined with Cat advanced engine controls to maximize the amount of material moved for every drop of fuel burned. Improved filtration protects the fuel system, hydraulic system and power train oil system to help ensure high reliability and minimal machine downtime. Refined large structures, such as redesigned track roller frames, deliver longer service before rebuilds. Improved access and egress features enhance safety and productivity of technicians and operators, and optional powered access systems and platforms enable configuring the D10T2 for the site. Caterpillar offers the D10T2 with two variations of the Cat C27 engine with ACERT Technology. One version is U.S. Environmental Protection Agency (EPA) Tier 4 Final certified, and the other is capable of achieving emission levels equivalent to EPA Tier 2 standards. Both engine configurations produce net power of 447 kW (600 hp) in forward gears and 538 kW (722 hp) in reverse gears. The engine controller automatically adjusts power output based on the direction of travel. With the new system, the D10T2 has about 20 percent more power in reverse compared to its predecessor model. The result is faster cycle times and greater productivity in certain applications. The D10T2 is suited for a variety of applications including mining, heavy construction and bulk materials handling.

Mar 1, 2014

By C. Clark, R. Pakalnis, B. Seymour, L. Martin, M. Stepan, M. Roworth, C. Caceres

The National Institute for Occupational Safety and Health (NIOSH), Office of Mine Safety and Health, Ground Control Engineering Branch is investigating the use of shotcrete in weak rock mass mines with the objective of reducing fatalities and injuries resulting from rock fall accidents. When shotcrete is used as part of a multielement ground support system, there is a need to know the support characteristics that the shotcrete contributes to the overall system. To quantify the support provided by the shotcrete, flexural strength tests were conducted with two common, commercially available fiber-reinforced shotcrete (FRS) mixes using the round determinant panel (RDP) test method, ASTM C 1550. A portable RDP test machine developed by NIOSH researchers was used to determine the peak flexural load and residual load capacity for a steel FRS and a synthetic poly FRS that were sprayed using dry mix procedures and equipment. Besides the flexural strength and loading behavior determined from these tests, a method was also developed for measuring the width of cracks exposed on the underside of a shotcrete panel during a RDP test and relating these measurements to residual load values. Quantifying the peak flexural load and residual loads of a shotcrete mix through on site testing at a mine and visually assessing the loading cycle and load-carrying capability of the shotcrete applied to underground workings will improve mine safety by providing a better assessment of the stability of shotcrete supported entries.

Jan 1, 2010

By W. K. Utt

This report discusses U.S. Bureau of Mines' research involving modem vehicle position determination techniques in surface mining. The applications would include haul trucks, power shovels, and drilling rigs. Accurate position determination of these vehicles in near real-time is expected to result in safer and more efficient mining operations. The requirements for a vehicle position monitoring and warning system were determined. After screening several concepts, the global positioning system (GPS) and a radar positioning system were selected for further evaluation. A state-of-the-art GPS receiver was taken to a surface mine to assess the feasibility of receiving the satellite signals. A state-of-the-art radar positioning system was evaluated with regard to accuracy.

Jan 1, 1995

By Elisa Comis, David Chastka, Miriam Piemontese, Maria Chastka

The Lower Olentangy Tunnel (LOT) Project involves the construction of a 17,000 ft (5,200 m) long, 12 ft (3.65 m) internal diameter Combined Sewer Overflow (CSO) tunnel. The tunnel is excavated by using an Earth Pressure Balance (EPB) machine designed to cope with soft ground, weak rocks and water pressure. The project is located in the city of Columbus, Ohio and the main geotechnical hazards are related to the heterogenous soils and the low overburden in an urban environment. This paper focuses on the performance of the EPB first drive and the comparison between the design assumptions and the actual TBM performance during construction.

Jun 23, 2024

By M. R. Shahan, W. R. Reed, S. Klima, T. W. Beck, Y. Zheng

Testing was conducted to determine the ability of foam to maintain roof coverage in a simulated longwall mining environment. Approximately 27 percent of respirable coal mine dust can be attributed to longwall shield movement, and developing controls for this dust source has been difficult. The application of foam is a possible dust control method for this source. Laboratory testing of two foam agents was conducted to determine the ability of the foam to adhere to a simulated longwall face roof surface. Two different foam generation methods were used: compressed air and blower air. Using a new imaging technology, image processing and analysis utilizing ImageJ software produced quantifiable results of foam roof coverage. For compressed air foam in 3.3 m/s (650 fpm) ventilation, 98 percent of agent A was intact while 95 percent of agent B was intact on the roof at three minutes after application. At 30 minutes after application, 94 percent of agent A was intact while only 20 percent of agent B remained. For blower air in 3.3 m/s (650 fpm) ventilation, the results were dependent upon nozzle type. Three different nozzles were tested. At 30 min after application, 74 to 92 percent of foam agent A remained, while 3 to 50 percent of foam agent B remained. Compressed air foam seems to remain intact for longer durations and is easier to apply than blower air foam. However, more water drained from the foam when using compressed air foam, which demonstrates that blower air foam retains more water at the roof surface. Agent A seemed to be the better performer as far as roof application is concerned. This testing demonstrates that roof application of foam is feasible and is able to withstand a typical face ventilation velocity, establishing this technique’s potential for longwall shield dust control.

Jan 1, 2017

By M. R. Shahan, W. R. Reed, S. Klima, T. W. Beck, Y. Zheng

Testing was conducted to determine the ability of foam to maintain roof coverage in a simulated longwall mining environment. Approximately 27 percent of respirable coal mine dust can be attributed to longwall shield movement, and developing controls for this dust source has been difficult. The application of foam is a possible dust control method for this source. Laboratory testing of two foam agents was conducted to determine the ability of the foam to adhere to a simulated longwall face roof surface. Two different foam generation methods were used: compressed air and blower air. Using a new imaging technology, image processing and analysis utilizing ImageJ software produced quantifiable results of foam roof coverage. For compressed air foam in 3.3 m/s (650 fpm) ventilation, 98 percent of agent A was intact while 95 percent of agent B was intact on the roof at three minutes after application. At 30 minutes after application, 94 percent of agent A was intact while only 20 percent of agent B remained. For blower air in 3.3 m/s (650 fpm) ventilation, the results were dependent upon nozzle type. Three different nozzles were tested. At 30 min after application, 74 to 92 percent of foam agent A remained, while 3 to 50 percent of foam agent B remained. Compressed air foam seems to remain intact for longer durations and is easier to apply than blower air foam. However, more water drained from the foam when using compressed air foam, which demonstrates that blower air foam retains more water at the roof surface. Agent A seemed to be the better performer as far as roof application is concerned. This testing demonstrates that roof application of foam is feasible and is able to withstand a typical face ventilation velocity, establishing this technique’s potential for longwall shield dust control.

Jan 1, 2018

By Xiaoyan Luo, Congcong Dai, Gaipin Cai, Xin Liu, Lu Zong

To overcome the difficulty of accurately judging the load state of a wet ball mill during the grinding process, a method of mill load identification based on the singular value entropy of the modified ensemble empirical mode decomposition (MEEMD) and a probabilistic neural network (PNN) classifier is proposed. First, the MEEMD algorithm is used to decompose the vibration signals recorded under different load states to obtain the intrinsic mode components, and a correlation coefficient threshold is used to select the sensitive mode components that characterize the state of the original signal. Second, singular value decomposition is used to obtain the singular value entropy. Finally, the load state of the wet ball mill is judged based on the magnitude of the singular value entropy. A characteristic mill load vector is constructed from the singular value entropies of the cylinder vibration signals recorded under different load conditions and is used as the input to a PNN, which then outputs the predicted ball mill load state; in this way, a load state identification model is established. Grinding experiments are presented to verify the effectiveness of the proposed method, showing that the method can accurately identify the load state of a wet ball mill. ()

By Z. H. Xie, D. S. He, W. M. Xie

China has rich phosphate rock resources, but with their continuous depletion, the rich ore resources have become increasingly scarce, which makes the exploration of collophane more important. Medium- and low-grade phosphate rock cannot be utilized until their impurities have been removed through mineral processing. However, due to the similar physical and chemical properties of dolomite and phosphorus minerals, the separation of dolomite from phosphate

By J. J. Komadina

Since the advent of resin-in-pulp (RIP) technology for treatment of uranium-bearing ores in the 1950?s to current carbon-in-pulp (CIP) processing of gold values, metallurgies and operators alike have wrestled with the problem of interstage screening. Early gold CIP plants such as at Homestake utilized externally mounted vibrating screens in conjunction with air lifts to effect carbon-pulp disengagement. Other operations world-wide have likewise adopted this technique with varying degrees of success. Subsequent development of in-tank launder screens both in South Africa and the United States have been of the air cleaned variety (EPAC)

Jan 1, 1988

By Nicola Della Valle

The Singapore Land Transport Authority (LTA) is currently expanding capacity by extending their Metro system from South of the city to the North East end of the island. The scope of Contract 704 involved excavating a long reach of tunnel which had a complex rock/soil interface comprised of fresh granite overlaid by clayey sand. Two 6.5 m diameter Earth Pressure Balance (EPB) TBM’s were used to bore the tunnels. These machines were designed so that both hard and soft rock could be excavated. The cutter head was equipped with a combination of both rippers and disk cutters. Soil conditioning was achieved by delivering foam through a multiple port injection system. This very irregular profile of the interfaces posed many challenges to the equipment and the people.

Jan 1, 2001

By C. W. Schultz

Earlier publications from The University of Alabama have indicated that column flotation performance is improved when operating at low pulp levels and when the feed is directed into the froth phase. To validate these early observations a series of tests were performed in which the position of the feed entry to the column and the pulp-froth interface were systematically varied. The optimum grade-recovery relationship was achieved with high feed entry (WA) of column height) and very low pulp levels (<10% of column height). The position of the pulp-froth interface appears to be the more critical variable. When operating in this mode (1. e. at low pulp levels) column flotation becomes. in reality. a froth separation process.

Jan 1, 1991