Search Documents

By Pramod C. Thakur

Coal is a major source of energy in the world today and will, undoubtedly, continue to be so for the next few centuries. Naturally, a great number of studies has been made of its physical and chemical properties. Unfortunately, the work on technical properties which influence the mining of coal and the consequent yield of inflammable gases and respirable dust particles has not progressed at a comparable pace. Coal is a brittle material. Irrespective of the mechanism of breaking coal, some dust is always produced. In mining parlance dust is defined as solid particle, smaller than 100 microns (micron = 10-6 meter), in size Coal dust, when raised into a cloud, creates two well known hazards in mines, namely, the coal dust explosion and Coal Workers' Pneumoconiosis (CMP). The latter is, perhaps, the greatest environmental hazard in U.S. coal mines today. In this context it is not only natural but also necessary to investigate the proneness of a coal seam to respirable dust production. It has been established that the amount of dust produced is a function of two groups of variables (1), (2), viz. (1) Material dependent variables, e.g., moisture content, compressive strength, hardness, etc. (ii) Breaking mechanism dependent variables, e.g., type of machine, depth of cut, etc.

Jan 1, 1973

By R. J. Zagrocki

Rekindled public concern about lead toxicity has intensified the awareness of lead-bearing materials in contact with the environment and the human population. Lead's common association with other metals makes the increasingly restrictive lead standards a primary concern for a large number of metal and metal-related industries. In commercial scale demonstration tests with lead-bearing wastes, the HRD Flame Reactor process has a demonstrated ability to separate and recover over 95% of the lead as a recyclable oxide, while rendering the remainder of the material as vitrified, non-leaching, and nonhazardous co-product. Recent Flame Reactor process tests and preliminary cost data for secondary lead soda slag are highlighted.

Jan 1, 1992

By D. Hong

The leaching behavior of rhenium in ammonium iodide solutions with iodine as oxidant has been studied. Experiments were carried out in an autoclave. The effect of stirring speed, temperature, pH of the solution, iodine and iodide concentrations on the dissolution of rhenium was investigated. It was found that high temperature and high pH of the solutions were essential for the efficient leaching of rhenium. The dissolution rate was found to be dependent upon the concentration of iodine and iodide. It was concluded that the dissolution of rhenium under the conditions studied was controlled by mass transfer of iodine with an apparent activation energy of 15.77 kJ/mole.

Jan 1, 1997

By Terry McNulty

There are many potential pitfalls in the commercialization of innovative technology. The failures often are remembered longer than the successes, thereby serving as deterrents to subsequent attempts. The mineral industry's future depends on effective innovation. So it is essential that the causes of failure are understood. Innovation can be examined equally well in the context of geophysics, geology or mining. However the author's experience has been in mineral processing and chemical engineering. So the following discussion is limited to processes and/or plants for producing mineral concentrates, metals or inorganic chemicals. More of what follows has to do with underachievement or failure than success. But this article demonstrates that there is a strong element of predictability in the former. Furthermore, it is a credit to the minerals industry and to the engineering profession that a very high percentage of projects succeed in achieving design capacity and forecast operating costs. Innovation means the introduction of something new. In this article, the words "innovative technology" are used broadly. They include new processes and novel combinations of established unit operations, as well as novel types of processing equipment or largest-ever equipment models. The discussion of project outcomes is based on personal experience or on published information. Citations are given for technical publications that provide either project information or insights into the methodology used to analyze project performance. However, specific projects have not been identified due to the rather negative connotations of some of the conclusions drawn about the less favorable outcomes.

Jan 1, 1998

By V. M. Johnston

The most abundant fuel resource in the U.S.A. is also the most under-utilized. Proven reserves of bituminous coal, sub-bituminous and lignite constitute from 60% to 90% of our total fossil fuel reserves -- dependent upon the parameters used by the analyst making the estimate. Despite this ample supply, bituminous coal provided only 20% of U. S. energy consumption in 1967 and 1968, this dropping to 17.57 in 1971 and 1972. By 1978, according to my projections, 16.7% of the Nation's mechanical energy will come from bituminous coal. However, our energy needs are growing at such a rate that the 20.6% provided by bituminous in 1967 equalled 480 million tons while the 16.7% of U. S. consumption visualized for 1978 will require nearly 650 million tons. In order to view coal's position with perspective in this developing energy crunch, it is necessary to examine the total energy situation. To this end, I have prepared a couple of tables which you should have before you. I chose this procedure rather than slides because I would need to utilize an entire wall to make the data visible to an audience. Therefore, I refer you to the long sheet entitled "U. S. Energy Consumption - Trillion Btu - 1967-1978." As you can see from the heading, I am confining my treatment of the problem to the intermediate term. In the long run, if we are willing to pay the cost, we can do a lot of things, including the complete conversion of coal into a sulfur-free fuel.

Jan 1, 1973

By Ernest Y. Baafi

The technique of linear kriging as a grade estimation method of mining blocks is reasonably established in the mining industry. Because of the nonbias condition imposed in kriging which requires that the kriging weights (?i) add up to one, negative weights are sometimes used in kriging. The use of negative weights is not justifiable from the practical standpoint. Also, negative block grades can be obtained in some extreme situations which makes no practical sense. To guarantee non-negative weights an additional constraint is required in the kriging system of equations. Unfortunately, the nonnegative weight constraint results in a set of non- linear system of equations. In this paper, a derivation of the resulting set of nonlinear equations is presented and a numerical algorithm is developed for the solution of the equations. Because the algorithm developed does not remove negative weights arbitrarily, optimal nonnegative weights are always guaranteed. Results obtained using the developed algorithm were compared with those using the standard linear kriging, in terms of computer time and the estimation results. Both the computer time and the kriging variance were found to be higher with nonnegative constraint, as expected. However, some systematic pattern was observed in the kriged values (i.e., over or under estimation) with or without the nonnegative constraint. The study also demonstrated when one should generally expect negative kriging weights in practice, and what practical impact the negative weights can have on the kriging estimates.

Jan 1, 1984

A parametric study was conducted to establish the optimum operating conditions for the column flotation of fine coal. The parameters examined in this investigation included collector and frother dosages, feed solids content, and the volumetric flow rates of feed slurry, air and wash water. Despite the wide range of conditions studied the experimental data were found to fall along single grade-recovery curves, just below the maximum separation predicted by the release analysis technique. The deviation of the parametric test data from the release curve was attributed to the nonselective entrainment of mineral matter associated with poor froth washing. The operating point on the characteristic recovery-grade curve was found to be primarily determined by feed rate and aeration rate.

Jan 1, 1992

By V. Srivastava, T. Ghosh

The modeling and simulation of semiautogenous (SAG) mills have been widely used in the design and optimization of mill performance in terms of its power draw, processing capacity and product size distribution. However, these models are solved under steady approximation and do not provide any information on mill charge distribution in real time. 7KLVSDSHUDWWHPSWVWRFKDUDFWHUL]HPLOOFRQWHQWVE\VROYLQJ:KLWHQ¶V¿UVW RUGHUFRQWHQW EDVHGPRGHOLQWKH0$7/$% Simulink environment. The parameters in the model, such as breakage rate constant, discharge rate and appearance function, were estimated using process and design data collected from a gold mine operating in Alaska coupled with a nonlinear parameter estimation scheme. This model was then used to predict the dynamic responses of other key operational variables, such as mill power, bearing pressure, charge level and product size distribution. The transient response of mill behavior with respect to changes in feed size distribution, tonnage and mill feed water is also presented. This dynamic simulation approach can be used for practicing different control strategy and training purposes. The observed response of mentioned variables was validated using dynamic response data from the plant to encompass operational characteristics of SAG mill behavior.

By F. S. Knoll

The high tension process which separates materials based on relative differences in surface conductivity has been very successful in recovering non-ferrous metals from municipal waste. Aluminum is by far the largest constitutent of the total non-ferrous metal fraction; accounting for >95% in most localities. Wire and insulation mixtures from industrial wastes have been treated commercially for several years by a high tension process initially developed for use in the iron ore industry. The wire and insulation application was a forerunner of municipal waste dry treatment technology. In the past eighteen months the rotating-drum-type electrostatic separator has undergone extensive testing and development in order that the process might be efficiently adapted to the recovery of aluminum from municipal waste.

Jan 1, 1974

By MARK J. VANARELLI

Estimating groundwater inflows in rock deep tunnels is critical to the safety of personnel constructing the tunnel and the cost of construction. This paper presents two case studies for estimating steady-state groundwater inflows into deep rock tunnels. The case studies included the Chattahoochee and Nancy Creek tunnels. In this paper, statistical methods were applied to packer test data obtained from exploratory borings during geotechnical site investigations. A semi-empirical procedure was utilized for estimating groundwater inflows into these deep rock tunnels. The Chattahoochee and Nancy Creek tunnels are deep rock tunnels which exhibit radial flow conditions. For the radial flow condition, a statistical analysis presented in this paper indicates that the semi-empirical procedure works well; however, variations in the procedure and/or an insufficient amount of testing could lead to underestimations of the inflow quantities. Packer test data plotted in histograms were observed in all cases to be log-normally distributed for the radial flow condition. Modeling using Monte Carlo simulations was observed to be an effective tool for removing irregularities in the distribution of the data and incorporating high-end permeability data to derive reasonable groundwater inflow estimates.

Jun 13, 2021

By P. Munjal

"Usage of Supercritical CO2 in place of high pressure freshwater has proven to be a potential breakthrough in the technique of fracturing. Tapping of carbon footprints from feasible sources like industries can be used to manufacture Supercritical CO2 required for fracking. Supercritical CO2, being less viscous than water, creates complex and coherent micro-fractures which can connect many more natural fractures greatly, increasing maximally the fractures’ conductivity leading to an increment in production. The better clean-up property of Supercritical CO2 provides auxiliary benefits of immediate evaluation of fracture zones, usage of an optimized quantity of mesh proppant and elimination of the need of swabbing. Also, Coal has a stronger affinity for CO2 than for CH4. When CO2 is present, CH4 on coal is replaced by CO2. This also ensures rigorous recovery of gas from the coal beds. Use of Supercritical CO2 will obliterate many problems as the CO2 used for fracturing is either sequestered beneath the crust or is recovered at the surface and reused. Therefore, injecting CO2 into coalbeds achieves not only enhanced CBM recovery, but also greenhouse sequestration underground. INTRODUCTION Coalbed Methane At various times in the geologic past, earth had dense forests in low-lying wetland areas. Due to natural processes such as flooding, these forests were buried underneath the soil. As more and more soil deposited over them, these dead plant remains were compressed. As the process continued the plant matter was protected from biodegradation and oxidation, usually by mud or acidic water. Under high pressure and high temperature, dead vegetation was slowly converted to coal. The omnibus process of formation of coal, thus, comprises of conversion of dead plant matter into peat, followed by its conversion to lignite, then sub-bituminous coal, after that bituminous coal, and lastly anthracite. This process of enrichment of coal as it is progressively forced deeper into an ambience with higher temperature and pressure involves biological and geological processes that take place over a long period and is called coalification. During coalification, large amounts of methane-rich gas are generated and stored within the coal on internal surfaces; hence comes coalbed methane. Coalbed methane (CBM), a gas formed as part of the geological processes that are responsible for the generation of coal, is adsorbed into the solid matrix of the coal during its formation process. Coalbed methane is distinct from a typical sandstone or other conventional gas reservoirs, as the methane is adsorbed and not absorbed. The methane is in a near-liquid state, lining the inside of pores within the coal. The open fractures in the coal that result from the liberation of volatile materials (and subsequent contraction due to the liberation) from the coal due to the high temperature and pressure conditions encountered, called cleats, may also contain free gas or can be saturated with water."

Jan 1, 2015

By David A. Newman

The Geomechanics Classification (Bieniawski, 1979) was modified for entry and roof support design in underground room-and-pillar coal mines. Adjustment multipliers were introduced to incorporate the influence of strata weatherability, high horizontal stresses, and the roof support reinforcement factor into the existing classification system. Sixty-two case histories of both standing and fallen mine roof were collected from two mines in the northern Appalachian coalfield. Twenty-seven engineering and geologic parameters were recorded for each case. A partial correlation analysis was carried out on the cases to establish which parameters have a significant impact upon the supported stand-up time of coal mine roof. Survival analysis, a statistical technique used in medical research to assess the effect of a drug or treatment on a patient's life expectancy, was conducted together with stepwise multiple regression to derive values for the adjustment multipliers. A practical example is included to illustrate the application of the modified Geomechanics Classification to underground coal mine design.

Jan 1, 1985

By C. G. Anderson

The treatment of materials for the recovery of the precious metals imposes many processing and environmental challenges. Sunshine Mining and Refining Company has developed hydrometallurgical technology for recovery of values from refractory precious metal materials. At Sunshine, the industrial focus of these processes has been for the direct recovery of silver without cyanidation. However, recent work has indicated that these technologies can provide a means for treating complex, refractory gold concentrates. This will be the focus of this paper. The practice of pretreating ores and concentrates to make them more amenable to cyanidation is becoming more common. Several pretreatment options for sulfide concentrates containing gold include roasting, bio-leaching, direct pressure oxidation and nitrogen species catalyzed pressure oxidation. The industrial use of nitrogen species catalyzed pressure oxidation has been limited to the Sunshine refinery where its focus has been for the treatment of silver concentrates. Much of the reluctance, outside of Sunshine, to use this type of technology may be based on the perception that high costs are associated with using nitrogen species (e.g. nitric acid, sodium nitrite) to leach. Also, the use of nitrogen species catalyzed pressure oxidation on an industrial scale is unfamiliar to most metallurgical professionals. A summary of pressure leaching processes which utilize nitrogen species as a catalyst is presented in Tables 1 and 2.

Jan 1, 1996

By Robert N. Morris

Ladies and Gentlemen: It is a distinct pleasure and honor to appear before you representing the railway industry as I do, but there is a much closer personal relationship. I am a graduate Mining Engineer and worked in the coal industry for 15 years prior to becoming a railroader only 4 ½ years ago. I have been a member of AIME most of my adult working life and am currently active in the Washington, D. C. Section. While having been in the railway industry only a short time, I have become involved during the recent period of innovation and development of the new railroad technique known as unit train service. I have had the privilege of helping to work out a number of unit train movements to both electric utility companies and to a major steel concern, handling coal from mines on the Southern Railway to the consuming plants. On Southern, our unit trains are all of what I shall describe as shuttle train operations whereas within the railroad industry today several types of service are characterized as unit train service and many don't offer comparable efficiencies.

Jan 1, 1968

By Joseph W. Mussey

Bio-epigenetic sulphur deposits occur in Pecos, Reeves and Culberson Counties of far West Texas. Sulfate reducrng bacteria, utilizing hydrocarbons as energy, transformed gypsum into replacement limestone and hydrogen sulfide. Hydrogen sulfide, retained in the porosities of the replacement limestone, was subsequently oxidized by highly oxygenated groundwaters, and native sulphur precipitated. West Texas sulphur was first recognized at surface exposures by William P. Blake, a geologist attached to the Captain Pope Military/ Scientific Expedition of 1854. Attempts were made in the early 1900's to mine these sulphur vent exposures by a retort method, but the ventures met with little success. In 1967, Duval discovered a large sulphur deposit near some of the old sulphur works in Culberson County. Duval also extended a small sulphur deposit in Pecos County. The Frasch process, developed for producing sulphur from Gulf Coast salt domes, proved successful in West Texas type sulphur deposits also. However, modifications of the process were necessary to provide economical and efficient sulphur recovery from the varied ore modes. West Texas conditions and logistics require the ultimate in productivity to be competitive in the domestic and foreign sulphur markets. Several companies, in addition to Duval, are producing or have produced sulphur in West Texas. As of the first of June 1984, a total of 29.4 million long tons of sulphur had been produced west of the Pecos -aver. Duval produced more than 88 percent of that total.

Jan 1, 1984

By R. L. Stone

By means of laboratory balling tests and a procedure for determining bentonite concentration in a green ball the present study revealed that the bentonite savings by mulling concentrate and bentonite prior to balling was sufficient to warrant installation of a full-size unit in a pellet plant. On the basis of this work, a muller was put on stream at Bethlehem Steel Corporation's Cornwall pellet plant in June 1969, and has operated continuously since then. Plant tests showed that the use of the muller resulted in bentonite savings of about -502 without any loss of green, dry, and fired ball quality. Virtually no maintenance problems have been encountered. This information is important to future pelletizing operations both from the standpoint of product quality and economics.

Jan 1, 1971

By S. Pollak, J. Rickard

The Long Baseline Neutrino Facility Far Site in Lead, South Dakota is currently under construction and involves drill and blast excavation of the largest and deepest caverns in North America. This paper will review how the geotechnical risks are being managed through careful consideration of excavation sequence, completion of exploratory pilot tunnels, implementation of a robust instrumentation and monitoring program, and validation against the design. Aside from having a cross section of 5,900 square feet and being situated at a depth of one mile, the caverns also employ a unique permanent rock bolt solution which underwent a significant pre-production pull testing program involving varying installation methods and being subject to blast vibrations. The behavior of the schistose rock mass and performance of the ground support are being continually monitored throughout the construction phase.

Jun 13, 2023

By Richard J. Lewandowski

Corrosion and product contamination have been difficult problems for extractive metallurgy industries in the U.S. because of the highly active chemicals used. During the past twelve years, other industries, particularly the chemical and paper segments, began to combat this problem with some degree of success using newer materials of construction, including reinforced plastics. These materials are made by combining a corrosion resistant thermosetting resin with a glass fiber reinforcing material and are used to con¬struct hoods, stacks, blowers, tanks, towers, pipe, and equipment of the most complex configurations. For service in contact with aggressive chemicals, the equipment is most often fabricated with the bisphenol-A fumarate polyester resins because of their resistance to corrosive attack. Data from both laboratory work and case histories of field applications are presented-for many common chemicals found in extractive processes. Information is also presented concerning design standards and recommended construction procedures

Jan 1, 1970

By Leons Kovisars

Two-thirds of the world copper produced in 1979 incurred cash costs between $0.35 and $0.89 per lb, averaging $0.62 per lb. North American costs are higher at $0.48, $0.88, and $0.68 per lb, respectively. Variable cash costs are $0.20, $0.58, and $0.39 per lb for the world; $0.29, $0.63, and $0.46 per lb for North America. Cash costs are relevant for comparing existing operations and evaluating market pricing during periods of excess supply. Analysis of full costs of production (cash costs plus income taxes, profit, and non-cash items) becomes relevant in evaluating the incentive price required to develop new production plants. In mid-1979 this cost (incentive price) was about $1.10 per lb; it is expected to approach $2.00 per lb by 1985.

Jan 1, 1979

It was shown previously that chalcopyrite could be floated without using a collector when the ore samples were treated with small amounts of sodium sulfide (Na2S). The role of this reducing agent was considered to be one of a cleaning agent to remove the hydrophilic surface oxidation products. It was later found, however, that the collectorless flotation could be obtained only under slightly oxidizing conditions. This might suggest that collectorless flotation is not due to the clean surface but to the elemental sulfur which may be present as an incipient oxidation product. Therefore, a search for the presence of elemental sulfur has been made by means of ESCA, mass spectrometry, and solvent extraction followed by W spectrophotometric analysis. On the basis of these results, the mechanisms of collectorless flotation are discussed.

Jan 1, 1983