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By A. Warczok

Metal losses in discard slag are the main factor determining overall recovery. The metals are present both in dissolved form and as matte or metallic inclusions, varying in size from 2 to 1000 µm. Pyrometallurgical slag cleaning usually consists of heating the slag, reduction of oxides and settling of matte/metal droplets. Heating the slag decreases viscosity and accelerates reactions. Reduction of magnetite liberates inclusions and facilitates co-reduction of dissolved metal oxides. A significant amount of the matte and metal is present as very fine metallic inclusions, too small for settling. The coalescence of these matte or metal inclusions is required to remove them from the slag. The developed new concept of slag cleaning combines DC furnace technology with an extra magnetic field for vigorous slag stirring, enhancing mass transfer to the reductant surface, accelerating the rate of reduction, and destabilizing the emulsion of matte or metal inclusions. Intensive slag stirring increases the probability of collision of inclusions, will accelerate their growth and will therefore improve settling. The process is carried out in a patented DC channel furnace, where the liquid metal or matte layer acts as a cathode and the floating coke bed on the slag surface is the anode. In the first part of the furnace, a superimposed magnetic field induces a Lorentz's force causing the slag to start an intensive circular motion. The next furnace zone does not experience any stirring and is dedicated for quiet sedimentation of the inclusions. A mathematical model of gravitational coalescence combined with forced slag motion showed the possibilities of effective removal of copper matte inclusions. The results of laboratory pilot scale tests of continuous slag cleaning showed fast slag reduction and confirmed the improved matte removal from the slag. Conceptual analysis shows the potential use of the technology in various other non-ferrous industries, like for example nickel plants. It is also possible to use this technique batch wise.

Jan 1, 2007

By S. J. Schatzel, J. D. Addis, V. Gangrade, L. L. Chasko, C. A. Hollerich

A ventilation study using tracer gas was conducted at a western US coal mine. The objective of the study was to evaluate the movement of longwall face air exchanges between the face and worked-out area and to document the presence or absence of face airflow pathways between these locations. The mine operator uses a bleederless longwall ventilation system with a back return and a blowing mine ventilation system. The study was conducted on an active panel and included both underground and surface monitoring sites. The study used sulfur hexafluoride (SF6) released as a slug on the longwall face and in the front of the gob inby the face. The velocity of the tracer gas movement in the gob was 0.019 m/s (3.7 fpm). The rate of movement for the overall tracer gas slug averaged about 0.0091 m/s (1.8 fpm). A separate tracer gas test initiated with the release of SF6 into the legs of the first shield showed the existence of more than one pathway of face air in the general direction from the headgate towards the tailgate corner. Maintaining adequate ventilation air on longwall faces is important for worker safety and for the dilution of methane emitted from the face and caved gob. A more detailed characterization of longwall system air and gas movement allows a mine to better assess its ventilation design for controlling gas on the face and in the gob.

By JOHN R. HEBERGER, MAHIYAR F. NASARWANJI, Jonisha P. Pollard, Lydia M. Kocher

nt in the mining industry, and identifying factors associated with these injuries is critical for developing prevention efforts. This study identifies nonfatal injury incidence rates, nature of injury, work activities, glove usage, and sources of hand and finger injuries in the U.S. mining industry, as reported to the Mine Safety and Health Administration (MSHA) from 2011 to 2017. Hand and finger injuries occur at a rate of 6.53 per 1,000 full-time employees, which is nearly double the rate of the next highest affected body part, the back. Most of the hand and finger injuries were classified as cuts/lacerations/punctures (53 percent) followed by bone fractures/chips (26 percent). Materials handling and maintenance/repair were common activities at the time of the incident with miscellaneous metals — such as pipe, wire and guarding — and hand tools as the primary sources of hand and finger injury. Although the information on glove use was limited, leather gloves were most often worn when an injury occurred.

Errors in ore reserve estimation can occur during drilling and sampling, sample preparation and analysis, geological logging and modelling, database construction, statistical or geostatistical evaluation, selection of economic parameters, selection of ore reserve method and assessment of mining constraints. Core sample recovery can be a major source of error, and it is proposed that the modelling of grade, metal accumulation and thickness should be accompanied by the modelling of core recovery (or core loss) so that for each ore block a weighted block recovery factor is obtained. This gives a good indicator of the reliability of a reserve estimate. It is suggested that a resource reliability rating (RRR) system be established to quantify what is meant by geological assurance and to combine this with an estimate of the precision of estimation as gained by geostatistical analysis. Proven and probable minable reserves would be those with an RRR better than 50% and a precision of estimation better than 20%

Dec 1, 1996

By M. G. Driessen, H. E. Criner

Possible applications of cyclone thickeners for: (1) clarification of the washery water and, (2) recovery of fine coal from the plant bleed. The paper shows: (1) that it is possible to remove all particles including the very finest, from the circulating water, thus obtaining a closed water system and, (2) that reduction of the ash content of the solids of the plant bleed is feasible by means of cyclone thickeners. Performance data for different size cyclones is given in the form of graphs.

Jan 1, 1950

By Christian Hoyme, Jochen Maurer, Hans Regler

Up to today, it has been very difficult to obtain qualitative and quantitative information about the status and production process of a construction site. It is becoming more and more important to be able to analyze this process so as to notice bottlenecks and interruptions on the site early on. The high costs of each shift in special foundation industry mean that making the wrong decision and/or interruptions can put the financial result at risk. Previously, keeping reliable data meant manual process documentation. This was done either by an additional staff member (incurring high additional costs for training, education, etc.) or by the equipment operators. The latter is critical, because they have to initiate every process step change, leaving no time to log data separately. Studies have shown that there are considerable deviations from the actual process steps. In this paper, a seamless, automated method will be introduced to analyze the construction process. This method recognizes each process step from the equipment data. The main purpose of the data recorded by the piling rig is the need of quality reports and now basis for the presented analysis. Here, a method was successfully transferred from theoretical computer science (compiler construction field) to find application for process recognition. Because the execution of works in special foundation construction can always be defined sequentially and therefore also practiced sequentially, recognition can occur step-by-step. Our method always recognizes the next step, so it does not have to monitor as much data at the same time. Individual trigger points are easier to define. Unlike solutions that are based on a global approach and allocate suitable process steps to data patterns, thereby also creating gaps, the presented method is always seamless. Furthermore, this method can be applied regardless of time or location provided that the necessary machine data is available, which is normally the case with production data logging. This means that construction sites even from the past can also be analyzed and the results used for comparisons. The first results from the analysis of a complete continuous flight augering (CFA piles) installation process of a construction site will be presented.

Sep 8, 2021

By Robert S. Warfield

Eight samples of high-volatile bituminous coal, each large enough for a study of its coking properties by the Bureau of Mines, were obtained from a location along the Kukpowruk River, Arctic Northwestern Alaska. Bench scale and pilot plant carbonization studies with several patterns of coal blending were conducted. The data from these tests were compared to data from similar tests on a coking blend used by the Kaiser Steel Corporation at Fontana, Calif. The majority of the samples representing the 20-foot seam was found to have significant coking properties, and produced coke approaching metallurgical quality when blended with selected coking coals. Although oxidation effects were evident in the samples representing upper portions of the seam, it appears that the whole seam could be used.

Jan 1, 1966

By McKenzie P

The techniques of geological control developed by the Coal Geology Sections of the Broken Hill Proprietary Company Limited and Australian Iron and Steel Proprietary Limited in providing geological service in the coilieries operated by these associated companies cover the provision of geological control for both planning and production in each of which the significance of geology has in the past been only poorly appreciated by the coal mining industry.While the adoption of similar techniques is well within the capacity of major companies there is considerable scope for the development of government geological services providing specialized assistance of this nature for smaller scale producers.INTRODUCTIONThe coal mining industry in Australia can instance many notable mistakes caused by failure to obtain sufficient geological information or by incorrect interpretation of available geological evidence both before the commencement of mining and during the progress of operations. Substantial development undertaken in, areas with insufficient or inferior coal reserves, difficult mining conditions caused by failure to adjust operations to geological circumstances, and the irregular development of mine workings caused by unexpected geological features, all bear witness to the lack of geological foresight by the industry.Along with the more widespread general use of applied geology, an increasing acceptance has developed during the past ten years of the valuable contribution which can be made by this science to the exploitation of coalfields. In spite of the advances which have been made, there is still a wide scope for further detailed application of geology throughout the coal mining industry in Australia.

Jan 1, 1963

By O. C. Blade

Total sales of diesel fuel in the United States continue to Increase. This growth is due primarily to two causes: More conversion to diesel units by the rail-roads In recent years, and the greater use of diesel engines in trucks, busses, and tractors. Following are some figures on the distribution of the fuel computed from data issued by the Bureau of Mines.2/ [ ] Deliveries of diesel type fuel from refineries totaled 91,522,000 barrels during the first six months of 1955,3/ corresponding figure for 1954 was 91,170,000 barrels. Information on the properties of this engine fuel is very important to the petroleum industry, engine manufacturers, and consumers. To supply such information the American Petroleum Institute and the Bureau of Mines, United States Department of the Interior, under cooperative agreement, are conducting annual surveys of diesel fuel oil produced in refineries in this country.

Jan 1, 1955

Reduce respirable dust exposure of workmen operating auger-type continuous mining machines. Approach: An auger miner was fitted with an exhaust system which draws dust laden air through a [scruber] and discharges it behind the line curtain. How It Works: Dusty air is drawn into the space above the coal conveyor and through a scrubber, by two fans mounted side by side above the conveyor. Exhaust from the fans passes through a duct to the side of the auger miner, and into tubing that runs back and into the air return passage formed by the line curtain. See Figure 1. Of the 5,000 cubic feet per minute of air normally entering the working place, 4/5 is drawn out through the dust exhaust system. The system was installed on a Wilcox Mark 20 Miner and tested underground by personnel of the Bureau's Pittsburgh, Pa., Mining and Safety Research Center, under a cost sharing

Jan 1, 1976

By Gerald L. Stolarczyk

Safe and efficient coal extraction requires advanced radar subsystems that can be mounted on cutting drums of coal cutting machines. A look-ahead radar (LAR) must solve the radio geophysics problem of transmitting an electromagnetic (EM) wave through at least 20 feet (6.1 meters) of coal to an air- or water-filled void. The reflected EM wave must be processed in the radar electronics to determine the physical distance to the void. Horizon sensing enables selective cutting near the undulating sedimentary rock boundaries of the coal bed to address coal quality and ground control issues. Both sensors require subsystems for dynamic electric power generation, real-time measurement of drum rotation angle, detection of reflected EM waves, and processing to determine distance through coal and RF modem transmission of measured data to the mining machine. This paper describes the development of the subsystems and field test results.

Jan 1, 2006

By S Jeffrey, S Mundell, F Arboleda

In the current cycle of low commodity prices and rising costs, mine managers continue to focus on optimising mine performance and productivity. A critical component of strengthening performance and productivity is ensuring material is routed correctly and efficiently through the core mine production activities of drilling, blasting and grade control.By the time a blast is planned, an enormous amount of intellectual property has been invested in the exploration, resource development, feasibility studies and mine planning activities. The value of that knowledge is either realised or diminished during mine production. Efficient execution of the process is critical and is reflected by the quality and timeliness of the information produced.Multiple teams are involved in the mining extraction process. These teams are all under time pressure to keep the mine equipment operating. One of the root causes of this pressure is the dependency between the teams. They do not operate in isolation, but are a link in a chain depending on the outcomes of each activity. It is essential communication is efficient so tasks can be completed according to the production schedule. Unfortunately, communication fails when unintegrated systems are used because of:- different teams seeing different data, hence there is not an overall, up-to-date view of progress and priorities- lack of cross-functional visibility of data leading to failure to identify errors in time to address or correct issues- teams tending to be siloed and focusing on their part of the process rather than the overall objective.With different systems used for the parts of a common goal, supervisors and managers lack visibility of the process. This makes it difficult to identify process improvement opportunities.Streamlined communications help consolidate all data and activities resulting in improved cooperation between mine production teams. This outcome increases the confidence and efficiency of material routing decisions. It also reduces potential impact to mine performance from errors in early stage tasks like drilling and grade control. Having everyone collaborating off the same trusted data, helps teams identify with common goals and find business improvement opportunities as they appear.CITATION:Arboleda, F, Mundell, S and Jeffrey, S, 2016. Driving mine performance through communication, in Proceedings International Mine Management Conference, pp 117-124 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By Hiroyuki T. Takeshita

Ca-Ni based alloys were investigated on structures, hydrogenation properties and the effect of additive elements on hydrogenation properties. CaNi, samples were decomposed to form a new hydride with a CsCl-type structure on the constituent metal atoms at high temperatures such as 673K in a hydrogen atmosphere. The candidate of the third element which was added to stabilize the original compound was investigated by using the Miedema's semi- empirical model and, as a result, Pd was chosen. The hydrogenation of CaPd was conducted with a Sieverts' type apparatus and the synthesis of Ca-Ni-Pd ternary alloys was performed by high frequency heating.

Jan 1, 2002

By Steve Massman, Edward Wipf, Gary Beerkircher

"As mine size and tonnage continues to increase, material handling/processing equipment has also increased in size with 400 MT haul trucks, 2000 KW crushers, 12 M SAG/AG mills, 8.5 M ball mills, 3000 M3 flotation cells and 12.5 MW HPGR’s all with planned designs to increase in size further. Related equipment including vibrating screens have also increased in size with screens seeing feed rates of 3000 MTPH. Open circuit SAG Pre-Crush and closed circuit HPGR flowsheets are becoming more common with large screening requirements. Large multi-slope (banana) or horizontal screens are commonly used for these applications, however as the size of these screens has increased, the number and size of the brute force/overhead exciters has increased but with limitations. An example is a SAG discharge screen that will see surges of material from the SAG mill which overload the screen, reducing the screen stroke or throw causing a large reduction in screen efficiency with excessive fines & moisture in the screen oversize feed to the pebble crushing circuit. This paper will present some actual examples of the use of Two-Mass screens as a solution to these overloading problems and the advantages of Two-Mass screens in other high tonnage applications.Brute Force Drive Compared to Two Mass Drive Vibrating ScreensThe standard single mass screen as depicted by figure 1 is generally recognized in the mining industry. It is characterized by the screen body – labeled as the single mass (Mt) that is supported by isolation springs (Kiso). The stroke needed to process material is obtained by incorporating large eccentric wheels and/or drive boxes (Fb) directly mounted to the screen body via a drive tube."

Jan 1, 2017

By A. Bhattacherjee

The Shewhart [X]?and R charts are still the most popular control charts in use today for continuous monitoring of quality data. However, for these charts to function properly, the underlying assumption of normality and independence of data must be satisfied. When either independence and/or normality of data are not present, which is a common feature of ore quality data, an application of the conventional Shewhart [X]?and R charts may introduce false alarms in the analysis of the data. To address these issues, a guideline is proposed for construction of appropriate univariate and multivariate control charts for a variety of situations. A use of this guideline to a bauxite mine suggested the construction of special cause control chart for the analysis of individual variables namely, Al2O3% and SiO2%; whereas, the multivariate T2 chart based on residuals is proposed for the bivariate analysis of the variables. The case study clearly revealed that without considering the data correlation, one may be in a state of false impression about an out of control condition while using the Shewhart [X]?and R charts for univariate and the Hotelling T2chart for multivariate analysis. To compare the effectiveness of the control charts, specifically the Shewhart [X]?and the special cause control charts, a simulation study was conducted. It was found that the conventional Shewhart chart provided lower probability of coverage than the special cause control chart. It was also revealed that the quality specification of Al2O3% is met as the variation of Al2O3% is well within the specification limits; whereas, it is difficult to meet the quality specification of SiO2% on a regular basis.

Jan 1, 2002

By S. Asokan, D. Rathod, Ch. V. G. K. Murty

Tata Steel, a steel arm of Tata Group, is Asia's first and India's largest integrated private sector steel company. Tata Steel’s turnover in fiscal 2004-05 was nearly US$ 3.25 billion. As part of its vision to grow in related industries, Tata Steel is poised to enter the Titania businesses in the Indian state of Tamil Nadu. The Titania project will involve mining, separation of ilmenite & other co-minerals, beneficiation of ilmenite to synthetic Rutile and further maximum value addition to Titanium metal. This paper outlines the journey from the concept to current findings of the Bankable Feasibility Study in developing Sattankulam Heavy Mineral Sands Deposits in the State of Tamil Nadu, India by Tata Steel.

Jan 1, 2005

By Thomas F. Anderson

(Measurements of stable isotopic variations (sulfur, carbon, and oxygen), supplemented by chemical, mineralogical, and petrographic analyses have been used to investigate the processes responsible for : (1) the incorporation of sulfur in coal, and (2) the (development of permineralized peat zones ("coal balls"). Sulfur isotopic results indicate that there are two principal sources of sulfur in the Pennsylvanian coals from the Illinois Basin: (1) "primary" sulfur assimilated by plants (low-sulfur coals), and (2) "secondary" sulfur produced by reactions involving H2S that was produced by the anaerobic reduction of sulfate in seawater which permeated the peat during post-depositional marine transgressions (the dominant source of sulfur in high-sulfur coals). Sulfur isotopic compositions of low-sulfur coals in Several Tertiary basins of Wyoming are consistent with a plant sulfur source. However, the inverse correlation between content and isotopic composition of sulfur observed in coals from the Powder River Basin suggest some "secondary" additions to these low-sulfur coals. Seveeral Quaternary (freshwater pears which were submerged by sea-Level rises during deglaciation over the past 30 ka have sulfur contents and isotopic compositions similar to high-sulfur coals. Carbon and oxygen isotopic compositions of calcareous coal balls from North America and Europe suggest that (1) the carbonate was derived from variable proportions of oxidized plant matter (typically predominant) and inorganic carbonate, and (2) the carbonate minerals were precipitated from fresh-to-brackish waters. Local geochemical and hydrological conditions were apparently more important than regional depositional environments in controlling the source of carbonate and the development of coal balls.

Jan 1, 1983

By Thomas E. Marshall, Michael Dunn, L. J. Prosser, Anthony T. Iannacchione

During the past few years, the Pittsburgh Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) examined and characterized conditions at a majority of the underground stone mines in the United States. Observations at these mines revealed a limited degree of roof monitoring beyond visual inspection and sounding. When monitors are used, they typically require the miner to measure movement at the roof. If conditions are unstable, the mine rmay be in a hazardous situation while recording data. Based on this scenario, researchers surmised that a simple, inexpensive monitor with the capability of recording data at a distance from the mine roof would be a safer way to gain the information. Additionally, more widespread use of monitors could potentially lead to better understanding of roof movement in general. A monitor to meet this need was designed, tested, and subsequently improved as experience was gained in its’ use at a number of underground stone mines. The Roof Monitoring Safety System (RMSS) can provide an initial indication of movement in roof beams. By understanding and measuring roof movement in underground mines, the potential for injuries and fatalities to mine workers from falls of ground can be reduced. Also, officials at a mine with a history of data are better prepared to make a decision on remedial actions in the event of ground falls. This paper will outline the evolution of the RMSS and how it can be used in a comprehensive proactive ground control safety program. Also included is a case history describing how the RMSS was used in an evaluation of the effectiveness of a mechanical impact scaling machine at an operating limestone mine.

By Neil T. Davie, Thomas K. Blanchat, Thomas C. Togami, Joe R. Weatherby, Dale S. Preece, Robert A. Benham, James J. Calderone

"Geotechnical structures ,such as underground bunkers, tunnels, and building foundations aresubjected to stress fields produced by..the gravity load on the structure and/or any overlyingstrata. These stress fields may be.. reproduced on a scaled model of the structure byproportionally increasing the gravity field through the use of a centrifuge. This technology canthen be used to assess the vulnerability of various geotechnical structures to explosive loading.Applications of this technology include assessing the effectiveness of earth penetrating weapons,evaluating the vulnerability of various structures, counter-terrorism, and model validation. Thisdocument describes the development of expertise in scale model explosive testing ongeotechnical structures using Sandia’s large scale centrifuge facility. This study focused onburied structures such as hardened storage bunkers or tunnels. Data from this study was used toevaluate the predictive capabilities oft existing hydrocodes and structural dynamics codesdeveloped at Sandia National Laboratories (such as Pronto/SPH, Pronto/CTH, and ALEGRA)."

Jan 1, 1998

By Yingxin Zhou

Virtually every coal seam in Appalachia will at some time be subject to multi-seam interaction (Wu et al, 1987). Many such problems result from seams which lie in close proximity or have split and lie within thirty feet vertically of one another. Existing techniques for multi- seam design have concentrated on conditions where the entire inner burden is not the failing member and are unsuitable for ultra-close multi-seam design. Structural integrity of the inner burden must be maintained if two superimposed seams are to be mined separately and under- standing possible failure mechanisms of the inner burden is an essential first step in the design process.

Jan 1, 1989