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By Terry W. Engelhart

"A computer-based approach to online supervisory control and operations management of bulk materials handling terminals". This paper describes an integrated computer facility supporting the functions and responsibilities of shift operations, scheduling, maintenance and management using real-time interactive techniques. The functions and responsibilities as related to coal export terminals are specifically addressed, although these functions would be equally applicable to other terminal configurations and other commodities. A discussion of the resulting benefits are presented: - throughput efficiency - long-term planning and scheduling, using simulation - operations monitoring and protection - demurrage/despatch optimization - preventative maintenance - operational productivity

Jan 1, 1982

By Larry Taylor, Thomas Zdeb, Brian Jacobs, Dennis Jensen

Subway tunnels proposed for the Los Angeles County Metropolitan Transportation Authority (LAMTA) East Side Extension are to be excavated below the groundwater through an area of Los Angeles, California with dissolved hydrogen sulfide concentrations in excess of 200 mg/L. To address unique construction and worker safety issues, bench scale and field pilot test studies were conducted to evaluate various mitigation alternatives including in-situ oxidation by chemical injection, slurry pH adjustment to suppress H2S evolution, and chemical treatment to remove the H2S from the slurry and muck material. The results provided the basis for detailed hydrogen sulfide control specifications for the contractor.

Jan 1, 1999

By R. M. Smailer

Detailed description of the development of the FIOR process1 and, subsequently, other technical papers relating to the operation and start up of the FIOR plant2,3 are available in the technical literature. The Fluidized Iron Ore Reduction (FIOR) process plant constructed in the Matanzas region of Venezuela represents the first commercial application of this technology. The FIOR process was developed by Exxon Company during the 1950's and 1960's; and the facility in Venezuela was designed and constructed by Davy McKee with the plant start up in 1976. While there is a minority government ownership in the company, FIOR de Venezuela operates as a private sector company with the majority of the ownership being private capital.

Jan 1, 1981

By P. Worley

With Utah Power & Light Mining Division's commitment to operate the safest and most productive mines possible, a decision was made to purchase and install mine-wide monitoring systems for use in the mines. After review of several different systems the Conspec Senturion 200 system was chosen. Three separate systems were ordered to fulfill the monitoring requirements of the six mines in operation: one system for the Deer Creek Mine one for the Wilberg/Cottonwood complex, and one for the Deseret, Beehive and Little Dove complex.

Jan 1, 1989

By Adrian C. Dorenfeld

The lesser developed countries (LDC's) may be classified into two categories: 1) oil producers, and 2) non-oil producers. The non-oil producing LDC's, as a class, are at present in very difficult financial straits. (1) Since the quadrupling of world market crude oil prices in 1972, an ever greater share of the LDC's export earnings have gone to pay for oil imports, in-stead of national reinvestment. The LDC's inter-national debts--much of it to pay for oil--have soared to record levels, with consequent limits for future credits. (1) Again, this inhibits future national investments, and there does not seem to be an end to the future increase of Organization of Petroleum Exporting Countries (OPEC) prices. Indeed, some of the economic difficulties in some metal markets--particularly the imbalance of production vs. markets for copper, can be traced indirectly to the OPEC cartels' heavy-handed impact on copper producing LDC's which must produce copper at any price to meet their oil bills. (2) Among the major oil importing LDC's are the Philippines and South Korea. 50th nations have substantial cement industries. The South Korean industry is geared for major export markets in the Far East. Both nations have ambitious plans for economic growth in order to accommodate burgeoning populations with ever increasing expectations for high standards of living. These plans had some success, more or less, until the high OPEC oil cartel charges had to be borne. Now, in common with all oil-deficit areas, the Philippines and South Korea are seeking lower cost sources of energy. Both countries have coal deposits. In the case of the Philippines, the reserves are in scattered, relatively small deposits. Most of the coal deposits are faulted, folded and, in general present formidable production problems for limited reserves. Nonetheless production has been on the order of about 70,000 to 150,000 tons per year in the last 30 years. Prior productions (1920-1941) varied between 9,000 Co 150,000 tons per year. (13)

Jan 1, 1978

By C. McDonald, S. Slottee

Deep "paste" thickeners have been used in the alumina industry for several decades to improve chemical recovery and allow “stacking” of the red mud for disposal. These paste systems have eliminated many traditional tailings ponds in addition to providing better tails washing and better water recovery. This technology is not widely used or understood in other mineral processing applications. However, there is growing worldwide recognition of the advantages of concentrating mill tailings to a “paste”, i.e. a solid suspension that does not settle or segregate. This technology offers several alternatives to the traditional tailings pond such as “stacking” or mine backfill. More water recovery is possible than with high rate thickeners. Process benefits come in the form of better chemical and metals recovery through better washing in counter current decantation (CCD) applications. Obtaining a true paste (non-segregating suspension which exhibits a yield stress) and understanding the handling characteristics for applications outside alumina, are recent developments. Achieving all of the benefits available from a paste system requires careful design that takes into account the specific requirements of the disposal application along with the peculiar difficulties in producing and handling paste. In fact, design of a paste system is markedly different from a conventional system. Project design usually requires the cooperation of experts in several interrelated specialties including geotechnical, thickener design, pumping and discharge design and controls. A successful project must coordinate all activities to ensure that the overall objectives for the project are achieved. This paper describes the properties of paste, reviews the applications, and discusses the design of a complete paste deposition system.

Jan 1, 2003

By K. A. Natarajan

The relative significance of corrosive and erosive wear in magnetic taconite grinding is examined. The influence of different types of aeration, namely, nitrogen, air and oxygen on ball war was established for mild steel and high carbon low alloy steel balls. Ball wear data from dry and wet grinding tests are compared with those obtained in the presence of an organic solvent that does not promote electrochemical corrosion. 'Marked ball grinding, tests along with electrochemical measurements involving ball material and magnetite electrodes indicate that contribution from oxygen towards wear (corrosive wear) is relatively small and abrasive wear appears to be significant. Rheological properties of the slurry-appear to have an important bearing on the abrasive wear of grinding balls.

Jan 1, 1983

By Joseph L. Walker

INTRODUCTION In looking over the diversity of the papers that are being presented during this meeting on The Industrial Practice of Fine Coal Processing one cannot help but be impressed with the progress the industry has made in beneficiating fine raw coals, and in the number of innovations that are under study to increase recovery and to improve the quality of the finest size particles produced at a preparation plant. Those who are not in our industry, who look at the technical program, might be confused, when they see that the papers include such topics as cleaning to zero and heavy media cyclone cleaning 28M x 100M; application and performance of fine coal jigs, tables, hydrocyclones, spirals, and flotation; filtration, dewatering and thermal drying; and ancilliary aspects such as fines handling, instrumentation and process control plus screening and liberation. This is an observation and not a criticism of the diversity of papers being presented. The program fits within the parameters of fine coal preparation as the term "coal preparation" is defined, but perhaps not as the term "fine coal" is defined. Admittedly these definitions are sometimes loose. However, each should be made more definitive if a meaningful fine coal preparation overview is to be possible. COAL PREPARATION DEFINED In the opinion of the writer, the term "coal preparation" should be defined as including all work activities that are performed on all components of a run-of-mine coal from the time it leaves a surface reserve or an underground portal, until all components are either ready for shipment or are stowed on, or in the earth in an environmentally acceptable manner. This definition excludes the work that is performed to improve coal quality or handleability inside the mine or pit. This work is commonly called "face" or "pit" preparation. FINE COAL DEFINED The term "fine coal" means different things to different people. In the past, anthracite finer than No. 3 Buckwheat (3/16 in.) was considered fines which often were discarded from the breaker as an unsalable by product; and bituminous coals finer that about 1/4 in. (slack) were either discarded or sold at cost to prevent an accumulation of "no bills" which referred to a product having no immediate sale. Although a standard definition of "fine coal" is yet to be accepted by the industry, a designation of coals by particle-size range has evolved through the wide use of three-circuit flowsheets, wherein the optimum size range by washer type determines the size fractions: a coarse-coal circuit for the plus 3/8 in., a -11- coal circuit for the 3/8 in. x 28 Mesh, and a fine-coal circuit for the remaining 28 Mesh x 0. Logically, the term "fine coal" should refer to some resultant size fraction or some top size by zero. This definition should include a 28 Mesh x 0 feed to a flotation cell but should exclude a 28 x 100 Mesh size fraction fed to a heavy media cyclone. Failure to include the resultant sizes in the definition precludes accounting of the full range of particle sizes present in the feed to the plant. Since the 28 Mesh x 0 fraction is treated in the final circuit of the three discreet washing circuits, now almost always used in U.S. commercial applications, and since it contains all of its resultant sizes, in the writer's opinion, it should be designated "fine coal". FINE COAL CLEANING Cleaning coal fines, which in the past was at best marginally profitable, is now an essential part of coal preparation strategy for a number of reasons : 1. Raw coals now cost more to produce and

Jan 1, 1988

By L. R. Todd

Gold Fields' Mesquite mine, located in southeastern California, heap leaches low grade gold ore at an annual rate of 2.7 Mt (3 million st). Ore is crushed in a two stage open circuit and belt agglomerated prior to loading on the leach pads. Since initial heap construction in October of 1985, a number of operating practices have been modified and several agglomeration techniques have been tested in an effort to improve percolation and reduce leaching time. Findings to date are discussed.

Jan 1, 1987

By S. Gering, R. Ruiz, C. H. Calderon-Arteaga, J. Barrios

"INTRODUCTION Located in the northeast corner of Zacatecas State, Mexico, the Peñasquito Operation is comprised of the Peñasco and Chile Colorado (Brecha Azul) deposits. Open pit mining (pre-stripping) began in 2010 and full production commenced during 2011. The open pit mines feed both a sulphide concentrator (mill) and a heap leach pad. The project is owned by Goldcorp, Inc. Penasquito is a poly metallic deposit with Au, Ag, Zn and Pb being recovered as payable metals. As a consequence of lower grade ores expected with advancing mine-life Peñasquito is facing a declining metal production profile. To maximize returns and asset value plant modifications including the addition of a carbon pre-float circuit and a pyrite leach circuit to improve recovery are currently being undertaken. This carbon pre-float circuit will enable the recovery of precious and base metals from carbonaceous sediments. This material is currently being stockpiled. With the associated increase in complexity in the process circuit, the requirement of the ore control system to accurately predict ore feed characteristics is critical to maximizing metal recovery at the Penasquito operation. The addition of the carbon pre-float circuit was also a key driver in allowing the Chile Colorado open pit to be developed. These conditions alongside Goldcorp’s drive to increase profitability, and maximize net asset value has created challenges. These challenges are numerous and are multifaceted, however the ability to accurately route materials from the ore control system is critical to site success, and some of these challenges have been overcome by the adoption and implementation of a new ore control (OC) technology. Examples of these technological innovations in the ore control program are discussed in this paper and include improvements in geo-modeling, material routing and reconciliation. Successful implementation of these elements has led to significant improvements in selectivity, performance, and data management, while reducing the variance between planning and execution, thus helping to drive overall improvement across the operation."

Jan 1, 2018

By F. Milton Lewis

In this paper an attempt has been made to review the cost trends in producing copper by conventional milling. smelting and hydro-metallurgical means during the last five years. The primary objectives of this cost analysis are to provide a base for future projections as well as to indicate which cost items are more volatile in their influence on overall cost of producing copper.

Jan 1, 1977

By Warren G. Burres

or more than 50 years the Portland Cement Association has represented the United States cement industry in matters relating to the technology and use of cement and concrete. Interestingly enough, PCA?s emphasis has been on concrete and its uses rather than on Portland cement. The cement industry realized long ago that cement is basic and serves its fundamental purpose as an ingredient in concrete. Cement could never be successful if concrete were not. Work with the users and specifiers of concrete had to be done at its end point of application--in a building, bridge, dam, highway or home. PCA, over its half century of existence, has been dedicated to this job. I should like to talk to you today on the less technical side of concrete--what it has been--what it is today--and what it can offer in future construction. Concrete, in many forms, has a long background extending from such notable historic times as the Roman Empire. Here, concrete made from pozzolanic cement from the slopes of Mt. Vesuvius was used to construct the Coliseum, home of the Roman circus; for the Appian Way, the ancient forerunner of the Interstate system; and the miles of aqueducts throughout Europe, many of which still carry water. In 1811 Joseph Asppin, an English bricklayer, made the first modern cement by the artificial mixing of pulverized limestone and clay materials. Ht,

Jan 1, 1971

By O. A. Bascur

Current competitive demands on the process industries stimulate the need for improved operating efficiencies and compliance to stricter governmental regulations. Emerging information technologies allow narrowing the gap between management business objectives and the process control level. Benefits come from enhanced energy management, operating costs reduction, enhanced scheduling of activities, reduced quality giveaway, enhanced market driven production and enhanced decision making. Plant management systems integrate economic performance monitoring by controlling the business rather than just throughput and product quality. Sound business based decisions about how to operate the plant can be achieved by adequate dynamic performance monitoring at the plant level and the enforcement of the desired targets at the process control level. This paper describes some of the key requirements to implement a process management system to meet stricter process performance standards. Extensions are made to facilitate conforming with regulations established by various governmental and industry monitoring agencies.

Jan 1, 1993

By David A. Zegeer

Since 1980, more than 40 miners have lost their lives by being trapped and suffocating in stock-piles, bins, silos, and similar facilities. Mine Safety and Health Administration (MSHA) is concerned about these accidents, most of which could be prevented if management and miners appreciated the hazard. In February 1986, the coal industry had a suffocation accident that drew national attention. A group of engineers were standing on a coal stockpile. It gave way under their feet. Five of the engineers were buried in the coal and suffocated. As with all fatal accidents, MSHA investigated the cause of this tragedy. I also asked my staff to look into the history of similar accidents. I found out it is rare to have multiple fatalities due to suffocation in material. But, over the years, there has been a long series of individual fatalities from this type of accident. Here are some examples. In Oct. 1985, a coal mine employee in Virginia entered a hopper to collect a coal sample. The feeders were started while he was standing in the hopper. He sank into the coal and suffocated. In Sept. 1985, an employee at a Texas sand company climbed onto a surge pile, to check a problem with sand flow. When other employees found him, the sand had swallowed him. Only his face and one hand were showing. Though the victim's face was clear of the sand, he suffocated before rescuers could free him. Many people do not realize you can suffocate in this kind of situation, though your head is free. Every time you exhale, the material has room to shift and press harder against your chest. Then you have less room to inhale. If this goes on long enough, it gets to the point where you cannot inhale at all. That is what happened to the victim in this accident. In May 1985, a plant operator at a Wisconsin sand and gravel operation purposely slid into the drawhole of a surge pile. He tried to break up large rocks that were clogging the drawpoint. Material piled on the side of the surge pile slid down and buried him. The operator was wearing a safety belt and line. But he was covered by 3 to 3.7 m (10 to 12 ft) of material and could not be pulled free. This incident illustrates another point. A safety line can help. But it is not enough. Workers should never put themselves in a position where loose material can fall on them from above. In Jan. 1985, a young Utah coal miner was waiting for a ride home from a co-worker whose job was at the tipple. A jam developed in the coal bin. The men could not clear the jam from the outside. So the young miner jumped into the bin. He started digging with a shovel at the toe of the coal pile. It caved in on him and he suffocated. The young miner had only three months of mining experience. He had not been trained for work around the coal bin. Since 1980, 16 coal miners and 26 nonmetal miners have lost their lives in loose-material suffocation accidents. Suffocation accidents occur in many areas around mines - bins, hoppers, stockpiles, surge piles, and silos, among others. One recent accident occurred at a surface coal mine in Illinois. The victim was walking over an area that had been drilled and blasted the week before. He fell into a void that had been crusted over with earth. He too suffocated. And many materials have been involved in suffocation accidentscoal, crushed stone, sand, salt, different kinds of ore, ammonium nitrate pellets used in blasting, and a powdery byproduct of iron ore milling called calcine. In addition to fatal accidents, there are near misses. We do not know how many. Most of them are not reported. A person who gets trapped in material, but is rescued, is usually unhurt. MSHA sometimes hears about these accidents by chance, or because they are reported in the local media. We do know that near misses are happening far more often

Jan 1, 1987

By William J. McCutheon

This paper presents some personal observations obtained during the course of visits to Europe, Africa, Latin America and the United States to talk with senior decision-makers in the copper industry about their views of markets, prices and the future of copper. The industry's future has never been particularly easy to define; with the changes of recent years, prediction has become even more difficult. The author's personal assessments of the present and future are offered for comment.

Jan 1, 1986

By A. M. Galperin

Back analysis is a very important procedure for proper understanding of physical processes. Back analysis can be used to establish the role of different factors, define parameters to be calculated and formulate the behavior of natural or physical processes based on field experimental results. It is evident that, in order to obtain the necessary data for back analysis, field observations are required. For the Michailovsky region (Kursk Magnetic Anomaly, KMA) the long-term strength characteristics of the clay covering the quarry slopes were established with the help of back landslide calculations. The obtained data allowed quantification of the shearing resistance parameters at the presence or absence of intermittent dips of discharge in the pit bank massif structures. Based on the results of investigation for material composition, strength and deformation of finely dispersed (clay-chalk) deposits in the Kursk Magnetic Anomaly including measuring of the settlements of filled structures, complex probing and laboratory determination of water-physical and mechanical properties of "man-made" soils, engineering-geological zoning of filled structures was carried out.

Jan 1, 2005

By Roy M. Fleming, Christine B. New

The federal standard for limiting exposures to miners from radon daughters was reduced from 12 working level months (WLM) per year to 4 WLM per year in 1971. However, even at that time some researchers were concerned that the new limit would eventually be shown to result in an excess risk for lung cancer mortality in miners. The National Institute for Occupational Safety and Health (NIOSH) is now engaged in a comprehensive review of this topic. As the lead agency in this project, NIOSH has developed a work plan and established a work group to implement this plan. The procedure and specific considerations are outlined in the work plan for developing a comprehensive ionizing radiation standard recommendation for all miners, underground and surface. Such a recommendation will not only include estimates of health risks at various levels of exposure, but also appropriate recommendations for medical monitoring, sampling and analytical methods, sampling strategies, posting, engineering controls, personal protective equipment and recordkeeping. The work group has twenty-four members. Eleven members are NIOSH personnel representing six divisions of the Institute. The remaining thirteen members represent other federal agencies, specifically the Bureau of Mines of the Department of the Interior, the Mine Safety and Health Administration and the Occupational Safety and Health Administration of the Department of Labor, the Office of Radiation Protection of the Environmental Protection Agency, and the Bureau of Radiological Health of the Food and Drug Administration, Department of Health and Human Services. Several factors contributed to the decision to initiate this project. First, the efficacy of the current standard was considered. An initial study group was formed in the spring of 1980 by NIOSH to identify and evaluate articles that contained information on lung cancer mortality risks at and below the present permissible exposure limit. The conclusion drawn from their evaluation was that a two-fold excess risk of lung cancer mortality at and below 120 cumulative working level months (CWLM) of exposure to radon daughters is evident. This composite indication from selected studies was of sufficient magnitude to justify further evaluation. The study group, however, recognized that other studies and information must also be considered in a quantitative risk assessment which would form the basis for recommending an acceptable and feasible permissible exposure limit. A second factor in the decision to pursue further evaluation was the gaps in the current standard that had previously been identified by the Mine Safety and Health Administration (MSHA). These included lack of medical monitoring of underground miners and absence of regulations for surface miners. The seriousness of the health hazard relative to other hazards in mining was also considered. Along with exposures to silica and asbestos fibers, radiation was judged to be one of the major health hazards in mining, These combined factors constituted the justification to develop criteria and recommendations for improved mandatory health standards. The development process begins with a survey and review of the available world-wide information on the topic, including data and information developed by NIOSH. The end product of this review is to be a document that will contain an evaluation of the collected information and support for any recommendations that are made. To develop this document, the present work group has been divided into five task groups with the following emphases: Health Effects, Medical Aspects, Monitoring, Environmental Exposures, and Engineering Controls and Work Practices. The Health Effects task group is to evaluate the evidence from epidemiologic and animal studies of adverse health effects associated with all forms of ionizing radiation encountered in mining and milling operations. The "weight-of-evidence" of the results of all relevant and useful studies will be summarized, with the reasons for emphasizing the cited studies. The critical cells or tissues and the factors that should be considered in estimating the dose to these areas from various types of radiation will be identified. An evaluation will be made of the possible impacts of smoking and exposure to diesel exhaust on the determination of health effects related to radiation. The implications of biologically redundant dose in terms of the time between tumor initiation and death will also be analyzed. The Medical Aspects task group is to review the generally-accepted and the state-of-the-art medical technology for the detection of adverse health effects from ionizing radiation exposure. An evaluation will be made of the accuracy of urine and fecal analysis, wholebody counting, chromosome analysis and nose blows, as well as their usefulness for early detection of adverse health effects. Early detection is of little utility to the affected individual unless subsequent medical care can improve the prognosis. Recommendations for screening tests will be made after carefully considering the accuracy of the diagnostic procedures and the usefulness of early detection. Required recordkeeping and transfer rights will also be addressed. The Monitoring task group is to consider the state-of-the-art technology for the monitoring of occupational radiation exposures. Instrumentation, sampling strategies and analytical procedures will be reviewed for both personal and area sampling. The implications of the associated levels of confidence for non-compliance decisions will be evaluated. The discussion will also include an evaluation of the feasibility of replacing present monitoring systems with recent technology and the impact that a possible lower permissible exposure limit would have on monitoring requirements. The Environmental Exposure task group is to investigate the field procedures and mathematical methodologies which have been used to quantitate exposure levels to the various kinds of ionizing radiation. The magnitude and direction of the possible biases in past exposure assessments will be estimated. Specific attention will be given to the controversies concerning the quantification of the biological dose equivalent and the feasibility of recommending standards for mixed radiation exposures which use "rem" as the unit of measurement. The Engineering Controls and Work Practices task group will analyze the advantages and limitations of

Jan 1, 1981

By D. C. Yang

A packed column jig has been developed for sharp separation of fine particles--150 down to 1 micron--having different densities. The packed jig is a column filled with corrugated packing. A slurry of mixed particles is fed into the middle of the column. Water enters near the bottom of the column as both a steady state and a pulsating flow. The pulsating water sets up a jigging action that interacts with the packing causing the dense particles to sink and exit the bottom of the jig and the lighter particles to rise and exit the top of the packed jig. The result is a sharp, environmentally friendly, gravity separation machine with low operating costs. Grades and recoveries of iron ore exceed that of known devices. Grades as high as 95 percent purity with concomitantly high recoveries are common for iron ore concentration. Low silica, sulfur and phosphate are common. This paper is the first to unveil the packed column jig technology in detail and presents its physical model with performance data. The purification of iron ores and coal is the paper's focus.

Jan 1, 1997

By K. Rajamani, I. Shah

The development of liquid-level control algorithms, based on sets of linguistic rules expressing human operator's "intuitive" control strategies, have been reported. The main objective of the present paper is to illustrate the implementation methodology. The experimental work was done with a 28.3Lflotation cell. The control variable (height of pulp in the cell) was controlled by manipulating the outflow rate. The controller algorithms were programmed and implemented using an Applelle computer and a Keithley das Series 500 measurement and control interface. It is pointed out that the scheme of fuzzy controllers is simple to use and powerful enough to handle complex and nonlinear systems.

Jan 1, 1987

By J. M. Keating, R. L. Wiegel

Those processing plants which depend on flotation for their mineral separations are always looking for reagents which are cheaper, more selective or in some other way may provide improved economic performance. This paper describes the rationale for and some results from applying a statistically based approach to reagent testing in those flotation plants which still rely on experienced operators for manual flotation control.

Jan 1, 1986