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By NILAMADHABA SAHU, Gajanan U. Kapure, Pankaj Kumar, Sunil Kumar Tripathy

Chromite ore processing tailings and low-grade manganese ores are typically considered waste due to their limited or negligible utility, leading to environmental and storage concerns. Researchers globally have explored various methods to utilize or upgrade these wastes, particularly because dumping chromite ore has been linked to severe health issues through Cr(VI) leaching. Individually, these ores lack economic value, and there has not been research on simultaneously reducing both low-grade ores. In this study, the focus lies on smelting these ores together, aiming to create a precursor alloy for 200 series stainless steel scrap. Initial research indicated the potential for scrap formation, validated through lab experiments with varying coke rate, basicity, and holding time. The investigation discovered that smelting this combination could yield a metal product comprising 59% Fe, 24.93% Cr, 7.56% Mn, 0.62% Ni, and 0.93% Si. The optimum basicity was found to be 0.6 with 80% recovery. Notably, this process eliminates intermediate steps in 200 series stainless steel production, potentially reducing overall CO2 emissions. This proposed method represents a cleaner, sustainable approach to repurpose these two waste ores, projecting a net profit of USD 330 per ton.

Jan 10, 2024

By Manoj Khandelwal, Jian Zhou, Yingui Qiu, Peixi Yang, Pingan Peng

Rockburst prediction is crucial in deep hard rock mines and tunnels to make safer working conditions. Due to the complex interaction of many factors involved in rockburst prediction, such as multi-variable and multi-interference factors, three hybrid support vector machine (SVM) models optimized by particle swarm optimization (PSO), Harris hawk optimization (HHO), and moth flame optimization (MFO) are proposed to predict rockburst hazard level (RHL). The RHL is determined according to four kinds of microseismic characteristic parameters including angular frequency ratio, total energy, apparent stress, and convexity radius. Then, six types of microseismic characteristic parameters are taken as input variables in 343 sets of data, including angular frequency ratio and total energy, etc.. And the RHL is taken as the output target of rockburst prediction. The classification performance of PSO-SVM, HHO-SVM, and MFO-SVM hybrid models is evaluated by accuracy (ACC), precision (PRE), and kappa coefficient. Findings reveal that the MFO-SVM model performs best in terms of accuracy, with ACC, PRE, and kappa coefficients reaching 0.9559, 0.9063, and 0.9094 respectively, while PSO-SVM and HHO-SVM have similar performances. However, the PSO-SVM, HHO-SVM, and MFO-SVM all perform better than the unoptimized SVM model. This confirms that the three optimization algorithms significantly enhance the rockburst prediction capacity of the SVM model to help mine practitioners apply machine learning methods to rockburst prediction problems appropriately.

Feb 3, 2023

By J. Starwood

Post-super-cycle mining executives must exploit every aspect of the value chain to deliver continued value to stakeholders. Integrating enterprise-wide information technology with value-chain-wide operational technology, known as IT-OT integration, is essential to extracting optimal results from the value chain. Mining companies trail other industries with respect to IT-OT integration across the value chain. Manual data consolidation and value chain optimization using spreadsheets and human intelligence are widespread practices within the industry. Increasing automation with smart devices and controllers means the volume and velocity of data will soon increase beyond human abilities. Enterprise Architecture provides a method for aligning information technology with the business operating model to successfully implement IT-OT integration. A Value Realization Framework (VRF) provides a means for predictable traceable value realization from IT investments and assets. With these principles, frameworks, models, methods, and techniques, mining organizations can accomplish IT-OT integration that provides their executives with a strategic value-chain-aligned platform for sustained value realization over the long term.

Feb 23, 2014

By Staff

"In 2018, the total estimated value of nonfuel mineral production in the United States increased by 3 percent from 2017 to $82.2 billion. The estimated value of metals produced domestically decreased by 4 percent, and the estimated value of indusrial minerals produced domestically increased by 7 percent (Table 1).Some idle U.S. metal mines and processing facilities restarted in 2018, including two primary aluminum smelters in Indiana and Missouri, a rare-earths mine in California and a zinc mine in New York. In contrast, four iron ore mines in Minnesota and a pelletizing plant in Indiana were shut down. Increased oil and natural gas drilling activity in 2018 led to increased production of some industrial mineral commodities that are used for oil and gas drilling, including barite and industrial sand and gravel. Production of industrial minerals primarily used in infrastructure and residential construction — including, cement, construction sand and gravel, crushed stone and gypsum — increased in 2018. Overall, mining activity trended upward for the second consecutive year because of increases in oil and gas extraction and industrial mineral mining (Table 2).Mineral industry performanceDiscussion of mine production is commonly segmented according to the type of materials produced within the broad categories of metals and industrial minerals (also known as nonmetallic minerals). Industrial minerals can be further subdivided as natural aggregates and other industrial minerals. Metals tend to have higher unit values but very low production quantities compared with those of industrial minerals, such as crushed stone or construction sand and gravel, which have higher production quantities but are lower-valued materials. Therefore, for discussion and analysis of the performance of the nonfuel minerals industry, the value of production is used rather than the tonnage produced. Tonnages of natural aggregates are orders of magnitude larger than those for most other mineral commodities, thus making direct comparisons based on weight meaningless (Fig. 1)."

May 1, 2019

By Mark C. Russell, Charles T. Russell, Brooke Colburn, Parker Bailey, Desiree Bernhard, Kaito Durkee, Tristen Cutshall, Rob P. H. Urselmann

Hypersonic tunnel boring (HTB) uses directed, high velocity projectile impacts to remove rock. HTB is highly independent of rock strength and targets hard, abrasive rock and variable rock environments. This paper discusses history, theory and presents test (2×2 m and .75×.5 m tunnels) field trial results and technical and economic evaluation. The HTB tests are compared against the historic ‘project REAM’ and the concept against tunnel boring machines and drill & blast in design studies for full-scale 12 m and 4.5×5.5 m tunnels. The positive results indicate that under these conditions HTB can replace Drill & Blast and Tunnel Boring Machines.

Jun 13, 2021

By R. Adsero

The volume of data produced by operating mines has increased substantially over the last 10 years. However, the volume of data and analytical capability has been negatively correlated to equipment productivity for at least the last seven years. In simple terms, as the volume of data has increased equipment performance has declined. Table (2010) tells us that ?The calamity of the information age is that the toxicity of data increases much faster than its benefits?. More data does not guarantee improving productivity; but more data is also not the cause of declining productivity. Similarly, when equipment performance does start to improve, (it must ? there really is no option if mines want to remain competitive), it will not be the data nor analytics which causes it; it will be the people using the resources at their disposal; including the data. Data and analytics can help if the toxicity of the data can be managed. The simplest form of business improvement using data is benchmarking. The objective of benchmarking is to understand and evaluate the current position of a process in relation to ?best practice? and to identify areas and means of performance improvement. The application of benchmarking involves four key steps: (1) Analyze and understand in detail existing processes; (2) Analyze and understand the processes of others; (3) Compare your own performance with that of the others analyzed; and (4) Design and implement the changes necessary to close the performance gap(s). There are however, many in the mining industries who have shunned equipment benchmarking because they believe that, ?every mine is a pilot?. In other words, the differences between mine operations make comparisons between them of little value. This paper will present a valid approach to benchmarking equipment performance and reliability, accounting for the differences and similarities between operations, producing a result which can be used to add value to mines around the world.

Feb 23, 2014

By Yakup Cebeci, Leyla Kalender, Ceylan Yarluğkal Altınışık, Hikmet Sis

The abstract highlights the challenges in concentrating complex and non-sulfide lead-zinc ores and emphasizes the importance of froth flotation for their beneficiation. The study focuses on using process mineralogy to understand the flotation behavior of these ores from the Görgü region. The ore samples were characterized using various techniques, revealing oxidation and carbonation of primary minerals. The flotation results were interpreted in light of the mineralogical data, explaining the poor outcomes due to the complex nature of the ore, poor liberation, and lack of hydrophobicity.

Mar 22, 2022

By Yao Yevenyo Ziggah, Victor Amoako Temeng, Solomon Evans Kweku Koomson

Tyre hours/life deficit is a major operational challenge facing the mining industry which adversely affects materials production and costs. An accurate forecast of the tyre life is key in addressing this menace. This study for the first time employed the hybrid intelligent technique by utilising three metaheuristic optimisation algorithms, including particle swarm optimisation (PSO), genetic algorithm (GA), and whale optimisation algorithm (WOA), as trainers for the parametric weights and biases to optimise multilayer perceptron neural network (MLPNN) for enhancing prediction of on-site dump truck tyre life in the mine. Four hybrid models known as PSO-MLPNN, WOA-MLPNN, GA-MLPNN, and BP-MLPNN were developed using a total of 157 tyre dataset records obtained from a surface mine in Ghana. In assessing the prediction performances for the models developed, five statistical performance metrics of variance accounted for (VAF), Nash–Sutcliffe efficiency index (NASH), coefficient of determination (r2), mean absolute percentage error (MAPE), and correlation coefficient (r) were utilised. Moreover, ranking, uncertainty analysis and Bayesian information criterion (BIC) techniques were utilised to establish the most effective hybrid model, whereas sensitivity analysis was conducted on the input parameters. Results achieved showed that PSO-MLPNN was the best for prediction because it had the least MAPE value of 1.196% and relatively high values of VAF (99.642%), NASH (0.996), r2 (0.996), and r (0.998). Besides, PSO-MLPNN had the best selection criteria values of 6, 7.1725, and 444.834 for the ranking, uncertainty analysis and BIC respectively. Hence, PSO-MLPNN is recommended for the prediction of on-site dump truck tyre life for the studied mine.

Mar 11, 2024

By Charles T. Ford

In 1971, Bituminous Coal Research, Inc~ established a program to provide the coal industry with the necessary information and technical capability to investigate and evaluate potential problems concerning trace elements in coal and coal-related materials. The initial efforts at BCR in developing or adapting analytical procedures for the precise determination of trace elements in the parts per million to parts per billion range were detailed in a report titled "The Development of Analytical Methods for Determining Trace Elements in Coal and Coal-related Products." A subsequent reports contained descriptions of reliable analytical methods refined by BCR for determining mercury in coal and coal ash and also in coal mine water. his paper reports initial progress in applying recently-acquired trace-element analytical capabilities to solving potential coal industry problems. In this case, the effect of a coal-cleaning process on the distribution and removal of potentially harmful trace elements in coal was evaluated. Coal cleaning offers the possibility of controlling potentially harmful emissions resulting from combustion of large tonnages of coal by removing the pollutants prior to combustion.

Jan 1, 1977

By Rong Lu, Hao Wu, Bing Dai, Guoyan Zhao, Li Cheng, Weizhang Liang

Affected by the disturbance of blasting activities, deformation instability and rock dynamic disasters are prone to occur in deep hard rock roadways. Thus, it is particularly necessary to understand the failure behavior of rocks and roadways under dynamic loads. In this study, a series of impact loading tests were carried out on sandstone samples with and without a circular cavity by a modified split Hopkinson pressure bar (SHPB) test system. The mechanical properties and energy evolution of the samples were systematically investigated, and the effect of cavity size was analyzed. The results showed that the presence of the cavity in the samples weakens the dynamic compressive strength by more than 10%, and the peak strain and brittleness are also reduced to varying degrees. Under dynamic loading, spalling cracks occur first on the roof and floor of the cavity, and then different numbers of shear cracks are formed on the sample diagonals. The eventual shear failure mode is the result of the connection of the shear cracks and the cavity. As the cavity radius increases, the dissipated energy density and fractal dimension both grow accordingly, leading to smaller and smaller rock fragments. The dynamic failure behavior of the circular cavity can be well explained based on the dynamic stress distribution law. Overall, this study can provide a reference for the study of the mechanism of rock burst in deep roadways.

Feb 18, 2021

By Ruichen Ren, Xu Han, Caixia Li, Zengchuan Yue

In this paper, the size-density distribution of coarse middling coking coal (CMCC) with different grinding fineness and flotation concentrates was investigated. Then, the flotation behaviors and liberation characteristics of different size-density fractions in ground CMCC were analyzed, and the different size-density fractions were divided into five categories: mostbeneficial, secondary-beneficial, poorly liberated, insignificant-pollution, and serious-pollution. Based on the content of particles with different liberation characteristics, an evaluation index of the liberation characteristic of ground CMCC, namely, the liberation perfection index (LPI), was proposed. The results indicated that grinding changed the size-density composition of CMCC, which affected the flotation performance. Insufficient grinding and overgrinding were not beneficial to flotation. Insufficient grinding caused a higher content of poorly liberated particles and a lower content of most-beneficial particles. Overgrinding increased the content of serious-pollution particles and reduced the content of most-beneficial particles. The size order of the LPI values of different ground CMCC was consistent with the flotation efficiency, and the LPI values of the other two similar samples were overall positively correlated with their flotation performance, suggesting that the method is universal.

Feb 14, 2023

By J. F. Brune

This is a shortened version of the paper ?The Methane-Air Explosion Hazard Within Coal Mine Gobs published in the 2013 volume of SME Transactions (Brune, 2013). This paper analyzes the explosion hazard resulting from the formation of methane-air mixtures in the mined-out gobs of underground longwall coal mines. Evidence from numerous mine explosions suggests that explosive methane zones can form within longwall gobs. Explosions and fires resulting from these methane accumulations have led to severe and fatal injuries to the miners, including the explosion of the Upper Big Branch mine in West Virginia, where 29 miners lost their lives. The paper also reviews current research on numerical modeling of gas flows in longwall gobs and outlines how targeted injection of nitrogen into gobs can effectively reduce the volume of such explosive methane zones. The paper concludes that comprehensive monitoring of gas compositions along the accessible fringes of the gobs along with inertization, improved ventilation schemes and further research are necessary to control this explosion hazard and make mining operations safe.

Feb 23, 2014

By J. Kretschmann, H. Mischo, O. Drusche, S. Krause

Mining is and will be inevitable in spite of the increasing implementation of circular strategies. The energy transition and population growth will boost the demand for critical raw materials. It is the opportunity for miners to reinvent their business models. Generating attractive new business cases with sustainability-oriented innovations meets investor and stakeholder expectations from the beginning. This contribution guides managers on their pathway towards sustainable success. Contextual sustainable business model patterns will be presented that can be adjusted individually, regardless of actor’s size. It will also point out, how sustainable value creation can be measured on business model level.

Feb 1, 2023

By C. Feng, W. Song, B. Moudgil, P. Zhang, W. Xiao

Separation of dolomite from phosphate is the most challenging problem in phosphate mineral processing. Over 50% of the future phosphate reserves in Florida contains too much dolomite to process using the current industry practice. The FIPR Institute has collaborated with worldwide experts in the field to address this issue. As a result, the industry is now offered with three feasible options. Optional 1 involves crushing and grinding of high-dolomite phosphate pebbles followed by dolomite flotation at slightly acidic pH using a new collector that does not require phosphoric acid as a phosphate depressant, achieving a final concentrate analyzing less than 0.9% MgO at about 87% P2O5 recovery. Option 2 offers three methods for reducing MgO content in the concentrate from the Crago process, including adding a dolomite depressant in the rougher flotation step, dolomite flotation of the cleaner concentrate, and scrubbing the cleaner concentrate in quartz sand. These methods could reduce MgO content in the final concentrate by 20-40%. Option 3 is a gravity separation technique using an innovative separation jig, and may well be the ultimate solution to the problem. INTRODUCTION Magnitude of the Dolomite Problem With the depletion of the higher grade, easy-to-process Bone Valley deposits, the central Florida phosphate industry has moved into the lower grade, more contaminated ore bodies from the Southern Extension. The phosphate deposits in the Southern Extension may be divided into two zones: an upper zone and a lower zone. The upper zone is readily processable using the current technology, but the lower zone is highly contaminated by dolomite. Geological and mineralogical statistics (Hassan and Bogan, 1994) show (Table 1) that more than 50% of the phosphate resource would be wasted if the lower zone is bypassed in mining, and about 13% of the resource would be wasted if the dolomitic pebbles in the lower zone were discarded.

Jan 1, 2019

By Saurabh Kundu, Shakuntala Tudu, Indrajit Paul, Chandra Sekhar, Manikanta Nallamilli, Shaik Mahaboob Basha, Neha Gupta, Srinivas Dwarapudi, Dhiraj Madhukar Kadhe

Iron ore pelletizing using compressive and shear action on wet mixture feed has been studied. The physical properties, namely, moisture content, drop strength, green compressive strength (GCS), dry compressive strength (DCS), porosity, and cold crushing strength (CCS), have been studied. Pelletizing tests were carried out on four different types of ore, namely, hematite ore, magnetite ore, goethite ore, and sinter return fines. The inference of shear forces on silica distribution index in dry pellet has been studied using optical and scanning electron microscopy. Significant improvement in physical strength was observed due to compressive and shear forces on the pellet mixture feed. However, decrease in moisture content and ball porosity has been observed. Silica distribution index improved by 1.72 times for hematite ore, 1.47 times for magnetite ore, and 1.68 times for goethite ore. It has been found that bubble cavity has been reduced which is good indicator in terms of physical properties.

Jan 29, 2022

By Frederic Souche, Andrew R. Klaetsch, Brian Hann, Nick Goodenow

This paper describes support of excavation (SOE) design and construction for three large diameter shafts excavated through glacial soil and controlled blasting in complex sedimentary rock formations. SOE in soil consists of unreinforced secant pile rings designed to resist lateral pressure in circumferential compression, eliminating costly steel core beam reinforcing. Controlled blasting at the shafts, adits, and tunnels in densely populated neighborhoods requires managing risks to the public, buildings, and utilities. Controlled blasting approaches limited adverse impacts to receptors nearby while achieving adequate production and fragmentation. A site-specific observational approach was used to adjust blasting parameters, limiting the impact on local stakeholders while maintaining daily progress and managing overbreak.

Jun 13, 2023

By J. R. Goode

The first part of this paper comprises a general discussion on refractory gold ores and their mineralogy processing methods now in use are reviewed and test procedures for the important methods are discussed. Factors determining the selection of a process are outlined. The paper includes a survey of production plants using pressure oxidation, roasting and biological oxidation to process refractory ore. The status of processes under development is briefly reviewed.

Jan 1, 1993

By Tassos Grammatikopoulos, Mike Johnson, Niels Verbaan

Seabed polymetallic nodules, which contain significant quantities of metals key to electrification (nickel, cobalt, copper, and manganese) can be processed using several different metallurgical processing options, including direct smelting and subsequent hydrometallurgical refining of the copper/nickel matte, ammoniacal leaching (gas reduction or Cuprion), and acid leaching (often reductive). Many of these approaches suffer from reduced cobalt extraction, difficult physical performance, or overall circuit complexity in general, leading to increased risk to the overall project. SGS has considered pressure acid leaching of nodules for further investigation, as publicly shared data on this processing route stems from the 1970s and 1980s and is not always easily accessible. This paper will detail the series of tests conducted and provide updated results obtained (high Ni/Co/Cu recovery with limited Mn/Fe), as well as comment on the potential treatment options on the product solution and residue.

Feb 1, 2025

By P. Bissert, M. Klein, L. Yan, D. Yantek, R. Matetic

"U.S. Mine Safety and Health Administration (MSHA) regulations require underground coal mines to use refuge alternatives (RAs) to provide a breathable air environment for 96 hours. One of the main concerns with the use of mobile RAs is heat and humidity buildup inside the RA. The accumulation of heat and humidity can result in miners suffering heat stress or even death. MSHA regulations require that the apparent temperature in an occupied RA not exceed 95 °F. To investigate this, the U.S. National Institute for Occupational Safety and Health (NIOSH) conducted testing on a 23-person tent-type RA in its Experimental Mine in a test area that was isolated from the mine ventilation system. The test results showed that the average measured air temperature within the RA increased by 9.4 °C (17 °F) and the relative humidity approached 94 percent at the end of a 96-hour test. The test results were used to benchmark a thermal simulation model of the tested RA. The validated thermal simulation model predicted the volume-weighted average air temperature inside the RA tent at the end of 96 hours to within 0.06 °C (0.1 °F) of the average measured air temperature. IntroductionIf an accident occurs in an underground coal mine, miners who fail to escape from the mine can enter a refuge alternative (RA) for protection from adverse conditions, such as high carbon monoxide levels. One of the main concerns with the use of mobile RAs is the potentially adverse thermal environment inside an RA from the metabolic heat of the occupants and the heat released by the carbon dioxide (CO2) scrubbing system. Moreover, the humidity within the RA will increase through occupants’ respiration and perspiration, and from the chemical reaction within the CO2 scrubbing system. The accumulation of heat and humidity can result in miners suffering heat stress, heat stroke or even death."

Sep 1, 2016

By Tassos Grammatikopoulos, Mike Johnson, Niels Verbaan

Seabed polymetallic nodules, which contain significant quantities of metals key to electrification such as nickel (Ni), cobalt (Co), copper (Cu) and manganese (Mn) can be processed using several different metallurgical processing options, including direct smelting and subsequent hydrometallurgical refining of the copper/nickel matte; ammoniacal leaching (gas reduction or Cuprion); and acid leaching (often reductive). Many of these approaches suffer from reduced cobalt extraction, difficult physical performance, or overall circuit complexity in general, leading to increased risk to the overall project. SGS has considered the pressure acid leaching of nodules for further investigation, as publicly shared data on this processing route stem from the 1970s and 1980s, and are not always easily accessible. This article details the series of tests conducted and provides updated results obtained — high Ni/Co/Cu recovery with limited manganese/iron (Mn/Fe) — as well as comments on the potential treatment options on the product solution and residue.

Sep 1, 2025