Search Documents

By Bruce H. Mason

Lightweight aggregates are classified as those minerals, natural rock materials, rock-like products, and byproducts of manufacturing processes that are used as bulk fillers in lightweight structural concrete, concrete building blocks, precast structural units, road surfacing materials, plaster aggregates, and insulating fill. Other uses include architectural wall covers, suspended ceilings, soil conditioners, and other agricultural uses (Mason, 1989). One unusual agricultural use recently reported was for bedding on a crocodile farm on the south coast of Natal. It seems that female crocodiles became upset because there was no vermiculite in which to lay their eggs due to the late arrival of a consignment of vermiculite. The vermiculite was being used as a substitute for river sand to nest crocodile eggs (Griffiths, 1989). The various lightweight aggregate materials may be classified into four groups as follows: 1. Natural Lightweight Aggregate Materials-prepared by crushing and sizing natural rock materials, such as pumice, scoria, tuff, breccia, and volcanic cinders. 2. Manufactured Structural Lightweight Aggregates-prepared by pyroprocessing shale, clay, or slate in rotary kilns or on traveling grate sintering machines. 3. Byproduct Lightweight Aggregates-prepared by crushing and sizing foamed and granulated slag, cinders, and coke breeze. This group of lightweight materials, with the exception of slag, has become less significant and will not be discussed in this chapter. Other lightweight aggregates are beginning to appear in the marketplace. Some are the result of manufacturing processes on industrial byproducts and/or waste products, such as fly ash and incinerator residue (Bigner, 1992). 4. Manufactured Insulating Ultralightweight Aggregates-pre- pared by pyroprocessing ground vermiculite, perlite, and diatomite. The application of diatomite in brick and in extruded and aggregate forms has declined in recent years (Kadey, 1983) and will not be considered in this chapter. Lightweight aggregates for structural concrete and concrete masonry units, according to the American Society for Testing and Materials (1986) consist of "aggregates of low density used to produce lightweight concrete, including: pumice, scoria, volcanic cinders, tuff and diatomite; expanded shale, clay, slate, perlite, vermiculite or slag; and end products of coal or coal combustion" (Mason, 1989). Lightweight aggregates are distinguished from other mineral aggregate materials by their lighter unit weights-1 281 to 1 602 kg/m3 or less for loosely packed lightweight aggregates-as com- pared to 2 002 kg/m3 or more for crushed stone, sand, gravel, air-cooled slag, and other common mineral aggregates. The specific gravities of these lightweight aggregates are also used to classify them for use in concrete; they range from the extremely light materials, used for insulative and non-structural concrete to expanded shale, clay, slate, and slags used for structural concrete. Vermiculite and perlite are sometimes referred to as super light- weights. Insulating concrete (non-load bearing) weighing as little as 240 kg/m3 can be made with these aggregates. Natural aggregates such as pumice, pumicite, and scoria are normally made into concrete weighing about 400 to 480 kg/m3. Expanded shale, clay, and slate produced in a rotary kiln make structural concrete ranging from 1 201 to 1 842 kg/m3. Expanded shale and clay produced by sintering make concrete that ranges from 1 442 to 1 922 kg/m3. Air-cooled slag produces concrete ranging from 2 162 to 2 403 kg/m3. The low density lightweight aggregates are used primarily for insulating purposes. They have relatively low compressive strength. The middle density aggregates are used for insulation and for fill. Those at the upper end develop excellent compressive strength and are used in many structural applications (Anon., 1971). In recent years, the production of lightweight aggregates in the United States for all uses (including insulation and construction materials) has averaged about 19 Mtpy (Table 1). The production and consumption of lightweight aggregate is closely tied to the fortunes of the construction industry and the need to construct energy efficient buildings. Recent years have seen the production of lightweight aggregate approach the levels of the early 1970s. The period of 1979 to 1981 was a low point in production levels. The low levels of production were caused by significantly higher plant energy costs due to the large amounts of fuel and energy used in the production of most types of lightweight aggregate. Lower levels of construction activity also affect production levels. This chapter focuses on the use of natural lightweight aggregates and manufactured insulating ultralightweight aggregates, and on both the production and use of manufactured structural light- weight aggregates. Some additional comments are made on byproduct materials. Separate commodity chapters on vermiculite, perlite, pumice, and volcanic cinders are elsewhere in the volume. Discussion of the commodities covered elsewhere in the book will be limited to observations on their utilization and relation to other lightweight aggregate materials.

Jan 1, 1994

By C. J. Bise, P. Bucks

Central Appalachian coal reserves are a valuable natural resource in high demand, both domestically and internationally, justifying efforts to increase percentage recovery through pillaring. Unfortunately, the challenge associated with pillar extraction introduces additional safety risks during the activity. Although pillaring developed prior to mechanized mining, current technology and mining practices have made this form of mining highly modernized. However, current fatality trends suggest that work still needs to be done to control the residual risk that is not controlled by modern practices, such as those having a personnel-performance-based component. This paper investigates the application of modern coal pillaring techniques and will present a risk-management-based strategy that targets personnel-performance-based risk, in order to improve the ability of safety engineers, managers and trainers to provide training programs addressing the needs of pillaring sections.

Jan 1, 2012

By John J. Dran

Large mining companies use a number of sophisticated analytical techniques for introducing the element of risk into the valuation of mineral reserve sites. These methods include, but are not limited to, sensitivity analysis, computer simulation, conditional probability, and portfolio theory. Such techniques enable the managements of these large companies to have an awareness of the many possible ramifications of their investment decisions. On the other hand, small mining companies and individuals in the mining business, due to limited financial and technical resources, still rely primarily on single point estimates of the value of mineral reserves. These small miners introduce the aspect of risk only through the application of an appropriate "speculative" discount rate. This paper illustrates the application of a technique for the introduction of risk into investment analysis. The method appears to be most suitable for use by small mining companies and individuals contemplating a large investment in a new mineral reserve site.

Jan 1, 1974

By William F. Hahn

It is a pleasure to speak to this group about special crusher installations which are in the bauxite and phosphate rock processing industries. The installations to be discussed demonstrate the variety of conditions, materials, and results desired which must be evaluated before a selection is made from the specialized crusher technology available today. Those of you who are closely involved with phosphate rock and phosphate products processing will find some of this information a bit interesting and perhaps alien to your own descriptions or every day references. It is given from a "crusher" manufacturer's viewpoint and therefore is infused With our flair and language. General features of six (6) different crushers will be shown in cross-section With slides and will be discussed in the same order.

Jan 1, 1978

By AJIT SWAIN, SUNATI MOHANTY

The abstract discusses the importance of predicting the dewatering performance of industrial hydrocyclones from laboratory models. It highlights the challenge of scaling up design and operating parameters for efficiency estimation. The paper describes experiments with a 2-inch and 4-inch hydrocyclone using silica sand. It details the development of a model using the Nageswararao hydrocyclone model and a simulator to estimate model parameters. The model is validated with experimental data, and a new model is developed using 4-inch hydrocyclone data. The technique is then extended to predict dimensions for a full-scale dewatering cyclone operating at higher throughput and solid concentration.

Mar 30, 2022

By Roger L. Hulette

Mt. Newman Mining Co. is now completing an expansion program, begun even before initial construction was complete, which will result in facilities with the ability to ship over 30 million tons of iron ore per year by early 1973. Confidence in such rapid future growth was evidenced by careful planning for the future expansion of those facilities provided for initial operation of the project which first shipped ore on 1 April 1969. Ore sales contracts totaling more than 300 million tons have been negotiated, thus justifying the optimism which led the joint venturers to provide over $200 million in initial investment and a like amount in capital required to finance the continuing expansion program. Members of the Mt. Newman Joint Venture are: Amax Iron Ore Corporation - 25% (a subsidiary of American Metals Climax) Pilbara Iron Ltd. - 30% (a subsidiary of Colonial Sugar Refining) Dampier Mining Ltd. - 30% (a subsidiary of Broken Hill Proprietary) Seltrust Iron Ore Ltd. - 5% (a subsidiary of Selection Trust Ltd. of London) ? Mitsui C. Itoh Iron Ore Pty. Ltd. - 10% Mt. Newman Mining Co. Pty. Ltd. manages the project on behalf of the five companies which make up the joint venture.

Jan 1, 1972

By David Jurich, Ed Perko, Jacob Prezkuta

Numerous Colorado mountain tunnels that date to the late 1800s convey water to the farming and urban communities of the eastern Front Range. Repairs to these remote facilities, often located in public lands at altitudes of 11,000 feet or more, require detailed planning, close coordination with multiple agencies, and creative execution. Issues and solutions discussed include designing repairs in undocumented ground and support conditions, logistical challenges, work in a short summer construction window, stabilization of historically signicant structures, and proect delivery strategies. xamples that illustrate early contractor involvement, exibility in design, and construction solutions are presented.

Jun 23, 2024

By M. Z. Mubarok, Z. T. Ichlas, A. T. Sugiarto, K. Sukamto

The use of ozone as an oxidant for the direct leaching of zinc sulfide (sphalerite) concentrate in sulfuric acid medium under atmospheric pressure was explored. The influence of acid concentration, feed gas injection rate, particle size distribution, stirring speed, temperature and slurry density on zinc extraction efficiency was examined. The experimental results showed that the leaching efficiency depends on all of these operating parameters except for stirring speed. It was found that essentially complete dissolution of zinc from the concentrate with the present method can be achieved in only about seven hours under the conditions of sulfuric acid concentration of 2 mol/L, particle size smaller than 74 µm, slurry density of 50 g/L, stirring speed of 420 rpm and feed gas injection rate of 1 L/min at ambient temperature. The experimental results suggest that the dissolution reactions produce independent elemental sulfur that is readily floated and can be easily separated rather than forming a layer on the surface of the reacted particle, as usually observed in a system with ferric-sulfate as oxidizing agent. It was therefore determined that the dissolved ozone play a key role in improving the rate of zinc dissolution from the concentrate. Analysis of the leaching kinetics indicate that the leaching rate follows the shrinking particle model, and the overall dissolution rate of zinc is controlled by a surface reaction.

By Jerome F. Sheldon

The earliest recorded history in the use of belt conveyors in the United States is in O. Evans' "Miller's Guide" published in Philadelphia in 1795. Evans defines a conveyor as a "broad endless strap of thin pliant leather or canvas revolving over two pulleys in a case or trough." (Ref. 1) In this definition, pulleys are being used in a bulk material belt conveyor application. Pulleys used in belt drives can trace their origin back to 1200 A.D. In fact, Engineers had considerable experience designing them into drives transmitting greater horsepower than those used in the early belt conveyors. In belt conveyor application, a pulley's purpose is primarily three-fold, 1) support the belt in directional changes, as designed in the conveyor, 2) transmit driving power to the belt, and 3) guide or train the belt. There are various types of pulleys used in belt conveyor systems and these are thoroughly covered in "Belt Conveyors For Bulk Materials" prepared by CEMA, 1966. For our discussion, however, the most common used in belt conveyors are drive pulleys, snub pulleys, head pulleys, tail pulleys, takeup pulleys and bend pulleys. The drive pulley imparts the driving force to the belt and may be located at the head or discharge end of the conveyor, in return strand, or at the tailor loading end of the conveyor. A snub pulley is located near the drive pulley to provide more arc of contact between the belt and pulley for maximum

Jan 1, 1971

By Eva K. Fernandez, Paul Y. Louie, Derek S. Adams, Renée L. Fippin

The Folsom Area Stormwater Improvement Project is part of SFPUC’s flood resilience efforts under the Sewer System Improvement Program. This 4,000-foot-long, 12-footinside- diameter tunnel will help reduce the risk of flooding in San Francisco’s low-lying Inner Mission neighborhood. The project is in a high seismic hazard zone and extends through a complex geologic corridor that includes full-face soft, compressible Bay Mud, Colma Sands, and full-face rock with several stretches of mixed-face conditions. Additional challenges include removal of 99 piles beneath an existing box sewer, tunneling under commuter rail tracks, and an underground tie-in. This paper examines these challenges and how they are being addressed.

Jun 13, 2023

By Rao Balusu, Bharath Belle, Krishna Tanguturi

A collaborative research project is undertaken by Anglo American Coal and CSIRO to develop appropriate strategies for gas and spontaneous combustion management of longer panels. Extensive computational fluid dynamics (CFD) modelling studies have been conducted and calibrated using operational longwall goaf gas data to obtain a fundamental understanding of goaf gas flow patterns in longwall panels of 1.0-km and 3.0-km lengths and a detailed investigation of the effect of various mining and operational parameters on goaf gas flow patterns. The modelling studies have also been used to investigate the performance of various gas drainage and proactive inertisation strategies during various stages of longwall panel extraction. Simulation results indicated that apart from tailgate (TG) side goaf holes, gas drainage from maingate (MG) goaf holes and the mid panel start-up goaf holes would be useful for flat seam field conditions. Operation of 8–10 goaf holes is recommended for field site conditions with high goaf gas emissions of 6000 L/s. The modelling results indicated that the traditional inert gas flow rate of 500 L/s currently used in some mines would be insufficient to achieve effective goaf inertisation in long panels. Results indicate that 3.0- km-long panels would require 1500 L/s of inert gas and there is a need for multi-point inert gas injection strategy for effective goaf inertisation. In this paper, details and results of modelling investigations and recommended strategies for gas and spontaneous combustion management in 1.0-km- and 3.0-km-long panels are presented.

In this paper, a number of novel hypotheses that provide a fresh perspective on the characterization of strata movements associated with longwall mining are developed by analyzing subsidence measurements with an influence- function-based computer program. With this influence-function technique, easily obtained surface displacements can be used to determine some of the complicated, expensive, and difficult to measure movements of the immediate roof strata in a longwall panel. The primary hypothesis developed by this analysis proposes the existence of an area of partial roof caving near the edge of a panel called the "edge effect." A second hypothesis, interrelated with the first, promotes the importance of the effect of gate-entry closure on the observed strata movements. Both the primary edge effect hypothesis and the secondary hypothesis concerning gate-entry closure are justified and quantified in an extensive analysis of surface subsidence that uses supporting information from related theories, design criteria and insitu measurements. Next, the edge effect and the gate closure hypotheses are extended further and used to provide an explanation of the complex subsidence interaction of adjacent longwall panels in what is termed a "redisturbed" effect. Finally, in the conclusions of this paper, the importance of accurately understanding these longwall strata movements for proper subsidence prediction or gate design is stressed.

Jan 1, 1986

By Bruce Kennedy, Charles Bruce

MINERAL EXPLORATION 'The Function of Exploration Mineral exploration aims at locating the presence of economic deposits and establishing their nature, shape, and grade. As all ore bodies are finite, exploration is essentially the lifeblood of the mining industry. It is divided into two phases, reconnaissance and target investigation. It involves geological mapping, geophysical prospecting (aerial and ground or both), geochemical surveys, prospect drilling, and/or exploratory under-ground workings. Successful exploration is followed by development drilling, mine development, and eventually operation. In underground mining, the term "ore" is applied rather loosely to metalliferous rock that can be profit- ably mined, but nonmetallic industrial minerals and energy related materials constitute a large and growing portion of the tonnage extracted by underground methods each year. It is appropriate, therefore, to consider exploration as the search for any useful substance occurring in the earth or in the oceans that is of sufficient value as to volume, grade, chemical and physical com- position, and location as to make extraction by mining commercially profitable for the investment required. The Selection Process The search for ore includes hundreds of mineral commodities. The more successful exploration organizations tend to restrict the search to the mineral commodities for which they have strong exploration expertise and which have a high probability of being concentrated in areas open to exploration and development in sufficient volume, grade, and proximity to the surface to warrant the large expenditures of risk capital in finding an ore body. Special expertise is needed to engage in mineral exploration and development for the extended periods required for success. Individual prospectors continue to discover mineral occurrences, but it generally takes an organization with strong financial resources to carry the exploration process forward to the point of developing "ore." Still greater corporate resources in the form of management, engineering, and sales capability are needed to develop an ore body into an operating mine. In the past, companies other than those engaged in mining rarely conducted exploration, since they lacked the technical skills and know-how to bring a mine to fruition. A notable trend in recent years has been the success of other resource-oriented firms, such as petroleum companies, that have not only acquired the necessary skills to engage in exploration for hard minerals, but are doing so on a far more intensive scale than known in the industry heretofore. The desire to diversify from increasingly regulated oil and gas, the potential for the discovery of a bonanza, and the large scale of mining projects for these capital-intensive firms are the attractions. US government and certain international organizations, such as the United Nations, have fielded sizable exploration programs in the past decade on behalf of Third World countries wherein many of the world's higher grade deposits and scarce mineral resources are located. The level of overall mineral exploration in the industry is, regrettably, closely geared to the business cycle. Accelerated search during the periods of strong demand, shortages, and high prices, together with the long lead times necessary to develop mineral finds, often creates surges in supply which invariably are followed by a collapse in prices. The trend is, therefore, to exploration funding by larger better-endowed firms having the staying power to weather the cyclical nature of mining. Tax incentives, tariff policies, and other incentives have a decided impact on the level and nature of exploration. Surface mining regulations and environmental forces have fostered a renewed interest in under- ground development despite the lower average costs of surface mining. Spiraling inflation has caused mining costs to outpace prices for many mineral substances. Organizations increasingly are directing their search away from high- grade but limited tonnage occurrences toward low-grade disseminated bulk tonnages amenable to mining on a vast scale. Mining continues, therefore, to grow even more capital-intensive with half-billion-dollar mine-mill- smelter complexes now commonplace, compared with the hundred-million-dollar projects of a decade ago. Reconnaissance Exploration Having elected to search for specific mineral commodities, the exploration company narrows its focus to a reconnaissance of those regions offering the best potential. A working hypothesis which is constantly up- dated concerning the geologic controls for ore occurrence guides the search. The possibilities for discovery are best in areas of existing mines and known ore bodies, where the probabilities are high for additional ore occurrences. In such areas, published data on the trends and geologic controls of known mineral occurrences aid the search. Even in some remote territories, a variety of geologic data is available to the explorationist. The major sources of basic geologic data are the libraries of the US Geological Survey (USGS), the state geological surveys, the American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME), the US Bureau of Mines, and various institutions such as Colorado School of Mines. Overseas, virtually all of the countries have their own geologic survey groups which are associated directly, or indirectly, with their respective ministries of mines. The objective of reconnaissance exploration is to narrow the search by pinpointing target areas having interesting mineralization. These favorable areas are then investigated in detail to delineate potential ore bodies.

Jan 1, 1982

By Raul A. Deju

This paper shows how one can relate the chemical reactions between water and a silicate bed to the equations of flow. First the reaction mechanism is studied both theoretically and experimentally. Once the reaction mechanism is established, the equations of flow are solved and a solution (under physically reasonable side conditions) is obtained. Experiments to substantiate the solution are also presented.

Jan 1, 1969

By Anthony M. Bauer

It is the nature of mining to reshape the landscape. Mining is an earth moving process with many of the same activities associated with the regrading of a site for a shopping center, drainage channel, housing project or ballfield. The difference exists only in purpose and duration of activity. The purpose of mining is to, produce a valuable product. The purpose of regrading for construction of a project is to create a predetermined landscape for a specific end use. In both situations the objective is to move earth materials as efficiently as possible. The question is then raised, if similarities exist, can mining operations be directed to shape predetermined landscapes as an integral part of its earth moving activity. This paper will explore the opportunities and issues of shaping sand, gravel and hardrock construction aggregate sites for productive end uses. It is based upon the premise that, as an earth moving operation, the process of extracting sand and gravel includes an inherent capability to shape productive lands as an integral part of the mining operation. In the course of any mining operation non-commercial materials, including overburden, fines and excess sand are handled to extract and process the commercial products. This activity exists regardless of whether or not there is a plan to reclaim the land. Moving this dirt is a basic operational cost. This cost need not be significantly increased when the material is deposited to shape land rather than be stock- piled just to clear the way for mining the deposit. Moving of dirt to create useable land can be guided by the same criteria used to remove the dirt from the deposit: for example, limiting the- hauling distance. Over a period of time earth handling costs can be reduced by minimizing the need to transport the stockpiled material a second time to the new landform location.

Jan 1, 1984

By Edward T. Koch

With the dramatic increase in world demand for basic raw materials, open pit mining is proceeding at an unprecedented rate. A viable demand is the ever tempting Siren's song for increased production or new facilities. When the Siren's lure is viewed against the panorama of today's world economic milieu the concomitant Scylla and Charybdis are seen in the form of high capital cost and high operating cost. If the economic realities of present day open pit mining are to show a proper return on investment, a clear and penetrating eye must be cast upon the area of mine planning. This paper deals with the problem of overburden removal. In almost every open pit mining operation overburden removal is a significant part of the capital cost and operating cost of the total operation. This paper deals with a new and unique method to affect economical overburden removal. Well known to all are the parameters surrounding draglines, shovels, and bucket wheel excavators. All of these machines require a reasonably stable soil to support them and the shovel and bucket wheel excavator require a reasonably stable bank in which to operate. Their reliability, portability and rate of production per dollar of invested capital are good.

Jan 1, 1975

By Miguel Reyes, Bruce Whisner, Joseph Bickson, Lincan Yan, David Yantek, Justin Srednicki, Nicholas Damiano, Eric Bauer

Built-in-place (BIP) refuge alternatives (RAs) are designed to provide a secure space for miners who cannot escape during a mine emergency. Heat and humidity buildup within RAs may expose miners to physiological hazards such as heat stress. To minimize the risk of heat stress, Title 30 Code of Federal Regulations (CFR), or 30 CFR, mandates a maximum allowable apparent temperature (AT) for an occupied RA of 35 °C (95 °F). The National Institute for Occupational Safety and Health (NIOSH) has conducted extensive research on the thermal environment of occupied RAs intended for use in underground coal mines. NIOSH research has demonstrated that a fully occupied BIP RA can exceed the AT limit by more than 5.6 °C (10 °F) in mines with elevated mine strata and air temperatures. In this circumstance, an RA cooling system could provide a solution. This paper provides an overview of test methodology and findings as well as guidance on improving the performance of a cryogenic air system prototype by optimizing the flow rate, increasing the tank storage capacity, and improving the efficiency of the heat exchanger of the cryogenic system. This may enable BIP RAs to meet the 35 °C (95 °F) AT limit in mines with elevated temperatures. The information in this paper is useful for RA manufacturers and mines that may choose to implement a cryogenic air system as a heat mitigation strategy.

By Tom Michaud, Rob Albinger, Ian Turner, Michael Rispin

Data transmission, communication, tracking, and the connection of equipment such as gas detectors, cameras, and collision avoidance systems in today's tunnel industry are critical pieces of the constructor's infrastructure. Reliability, flexibility, redundancy, and cost-effectiveness are key in selecting and implementing inte- grated systems. Both wired and wireless components are used to deliver custom solutions and can involve interconnectivity between backbones. Systems integration is important as industry adopts proven technologies from other industries. Case stud- ies are given showing how tailor-made approaches deliver needed functionality, with varying degrees of com- plexity, in various classifications of environment, in order to meet a project need.

Jun 23, 2024

By S. S. Klima, H. Jiang, T. W. Beck, Y. Zheng

Researchers at the National Institute for Occupational Safety and Health (NIOSH) performed a series of lab tests to evaluate the respirable dust removal capacity of an industrial air-cleaning fan. Limestone and coal dust were tested separately in NIOSH’s full-scale drill table simulator at the Pittsburgh Mining Research Division (PMRD). Gravimetric samplers with Dorr-Oliver Cyclones and 37-mm filters were used at two upstream and four downstream locations inside and outside of the drill shroud chamber. There were six tests performed for both the limestone and coal dust experiments. In the limestone tests, an average respirable dust concentration of 98.86 mg/m3 was achieved upstream of the air-cleaning fan. The filter results show that the averaged respirable limestone dust reductions were 7.84%, 8.81%, 10.94%, and 18.02% at the four sampling locations downstream of the fan. In the coal tests, upstream samplers achieved an average of 129.03 mg/m3 of respirable coal dust. The averaged dust reductions were 9.54%, 9.83%, 18.54%, and 19.21% at the four downstream sampling points. The results indicate limited cost benefits of using this technology because of the relatively low dust reductions determined from this laboratory study.

Feb 1, 2023

By James W. Baxter

State geological surveys promote sound procedures for evaluation of mineral resources before development-procedures that protect the environment and accrue maximum benefit to citizens. Sophisticated laboratories have been equipped for geophysical, geochemical, petrographic, and mineralogic characterization of materials to assist citizens in land-use planning and optimum development of natural resources, activities clearly within purview of the state. Proper use of these facilities in support of exploration in a competitive, free-enterprise system should be based on achieving ultimate benefits to the public, but, in general, should not entail competition with commercial laboratories.

Jan 1, 1982