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By S. A. Saki, J. F. Brune

"INTRODUCTION Longwall coal mining leaves large areas where the coal has been made removed and the roof rock strata collapse, forming a zone of broken rock rubble called the gob. Figure 1 shows a typical longwall gob area along with the gate roads. The ventilation pattern for progressively sealed longwall panels follows a simple “U” pattern where fresh air is coursed inby to the headgate, flows along the face and exhausts through the outby tailgate as shown in figure 1(a). An important variation of this pattern is the back return (BR) arrangement where the exhaust air from the face is drawn inby and around the nearest open cross cut before it turns in the outby direction towards the exhaust fan. Figure 1(b) illustrates the use of back return. This arrangement moves the point of low pressure from the tailgate corner up to 60 m inby and thus maintains fresh air in the tailgate region that could otherwise be contaminated with gob air.The gob area may contain remnants of unmined coal or parts of overlying coal beds that continue to release methane, eventually filling the gob area with methane in concentrations far above the explosive range of about 4.5 to 15%. Many gob areas must be equipped with gob ventilation boreholes (GVBs) to extract methane, and GVBs often exhaust methane at concentrations from 50% to 90% (Saki, 2016). Due to oxidation processes occurring in the gob, the oxygen content is reduced to a low level, with nitrogen and CO2 making up the major remaining components of the gob atmosphere. FORMATION OF EXPLOSIVE GAS ZONES IN GOBS Since the longwall face area is ventilated with fresh air below 1% methane and the face and gob areas are not separated, an explosive fringe will form where the methane content lies within the explosive range and oxygen content remains above 12%. Figure 2 shows a typical development of such an EGZ. This figure is based on a computational fluid dynamics (CFD) model developed by CSM researchers to analyze gas concentrations and flow patterns in longwall mining. Figure 2(a) shows the formation of EGZ in the gob with a U type ventilation scheme, where EGZ lies right behind the shields in the tailgate corner. Figure 2(b) shows the formation of EGZ in the gob combining U type ventilation scheme with BR, where EGZ is pushed away from the face deep into the gob. The CFD modeling parameters and boundary conditions have been verified with field data from two cooperating, active longwall mines (see Worrall 2012, Marts 2015, Gilmore 2015 and Saki 2016). Other mine geometries, methane inflow rates and gob permeability distributions can be modeled to establish representative gob atmospheric conditions. Two GVBs were operating in the model, extracting 0.165 m3/sec each. The methane in the working areas and returns was kept below 1%. Methane flowing into the model from a rider coal bed above the mined seam was at the rate of 0.55 m3/sec."

Jan 1, 2017

By Omar A. Muhtadi

Brohm Mining Corporation, in conjunction with Geobiotics, Inc. has nearly completed a pilot heap biooxidation test on sulfidic ore from the Gilt Edge Mine near Rapid City, South Dakota. Some results from the pilot testing have shown the correlation between the extent of biooxidation and the increase in cyanide gold recovery seen in the laboratory. Bench scale testing showed approximately a 1: 1 correspondence between percent biooxidation and percentage increase in gold recovery. The economics of large scale biooxidation were also evaluated in terms of increased gold recovery versus the time and cost of biooxidation. In the pilot test, the rate of biooxidation became limited by the acid water neutralization system. Later in the test, measures were taken to overcome this problem. Results from bench scale column bioleach testing showed that the Gilt Edge sulfide ore is quite amenable to biooxidation with a substantial increase in gold recovery with just partial biooxidation. Direct cyanide gold recovery of 51 % on ore crushed to -3/8" was enhanced to 82-85% after oxidation of37% of the sulfide as measured by iron. Laboratory experiments also showed that the slow rate of biooxidation of this ore could be accelerated by removal of metal sulfate build up from the leach liquor. The combination of these normally non-toxic metals became inhibitory to biooxidation if not removed by the neutralization circuit.

Jan 1, 1995

By William B. Schmidt

In July of 1974 a study team comprised of the authors was formed by the Department of the Interior. It was supported in part by funding from the National Science Foundation. The purpose of this study group was to visit coal mines and research and manufacturing facilities in England and Germany, to review the status of mining in these countries, and to identify mining technology which might have application to U. S. mining conditions. The duration of the visit was 18 days. The first week of the trip was spent in England. Time does not permit a complete recitation of the team's impressions but a few of the more interesting technologic developments will be discussed. These fall into the following categories- High Speed Development Ground Support Chainless Haulage and Face Conveyors Nucleonic Steering of Shearers Miscellaneous

Jan 1, 1975

By Martin G. Casto

Mixer-settler extractors, among the oldest forms of extraction equipment, have been used since the beginning of this century. Over the past years, a very large number of mixer-settler devices have been designed and operated. Both batch and continuous flow mixer-settlers have been used. The continuous flow mixer-settler extractor offers a great number of advantages over other extraction equipment. The main advantage of the continuous flow mixer-settler is that it is a compact device. A large number of stages can be assembled in a relatively small area, and more stages can be added fairly easily. Many improvements have been made in the design of mixer-settlers. These improvements occurred in almost every phase of mixer-settler' operation; interface control, mixer design, intrastage pumping, interstage flow of the two liquid phases, and stage construction. It is believed that Barstow1 used one of the first continuous mixer-settler extractors. This mixer-settler had concurrent flow within each stage and countercurrent flow overall. The flow for both phases took place by gravity. The Barstow device and other early mixer-settlers had no separate interface control for each stage, therefore, "tilting" of the stages was necessary. In 1934 Holley and Mott2 designed a mixer-settler in which the heavy phase was recirculated within each stage by the use of a valve controlled central line instead of by a pump. Gordon and Zeigler3 in 1939 were among the first to use an adjustable valve to control the interface levels in a mixer-settler, making tilting of the extractor unnecessary. In 1952 Coplan et al. 4 used a modification of the Holley-Mott idea to build a highly improved mixer-settler with flat common walls, and with the

Jan 1, 1971

By M. Robson

Water & Earth Technologies, Inc. (WET), Habitat Management, Inc. (HMI) and Chevron Mining, Inc. (CMI) together developed a solution for reclaiming steep southwest facing slopes in mining Area 12C that have historically been prone to excessive erosion, low vegetation establishment and continuing maintenance. Area 12C is located in the east wing of the Chevron McKinley Coal Mine, 27 miles northwest of Gallup, New Mexico, on Navajo Nation land administered by the Office of Surface Mining (OSM). Mining in this area was completed in May of 2007. Challenges encountered for this reclamation project included the need to reclaim graded material on a slope of 18-35% with southwest facing aspect, the presence of undisturbed rock outcropping that needed to be avoided during reclamation, the operational need to limit bulldozer pushes and the inability to import or export additional materials for construction. Two different reclamation alternatives were considered for Area 12C. The first alternative would use a traditional reclamation approach including three levels of draining terraces designed to convey water on a 3% slope to a single riprapped down drain. Terracing and down drains have been used to reclaim areas with similar terrain conditions elsewhere at the McKinely Mine and have failed to adequately control erosion (Williamson 2006). Terrace overtopping and down drain blowouts have been issues in maintenance and functionality for the mine. Maintenance routines consist of cleaning out terraces where they have filled in with sediment and repairing damaged or blown out terraces and down drains.

Jan 1, 2010

By Ehsan Alavi, Eren Kusdogan

The City of Toronto’s Coxwell Bypass Tunnel is currently being constructed by North Tunnel Constructors ULC, a joint venture of Jay Dee Canada, C&M McNally Tunnel Constructors and Michels Canada. This project includes construction of approximately 10.5 km of 6.3 meter finished diameter rock tunnel, five 20 meter diameter storage shafts and eleven tunnel connection drop shafts, along with associated deaeration and adit tunnels. This paper describes progress on the project to date and reviews the risk mitigation measures utilized on the project to move the project forward through tough geological conditions during shaft excavation and tunneling phase of the project.

Jun 13, 2023

By P. Tsang

The stability of longwall chain pillars depends not only on the mechanical properties of coal and surrounding rocks, but also geological and mining conditions. In order to evaluate the effects of each, variable, the orthogonal experiment design was employed in this study for significance analysis. The study concluded that the stability of longwall chain pillars is mainly controlled by the ratio of pillar stress to pillar strength, the ratio of Young's moduluds of the roof to coal and floor to coal, entry width, pillar width and the internal friction angle of coal. Additionally, horizontal stress, panel width and mining height also play a significant role.

Jan 1, 1994

By Ihsan Berk Tulu, Gaobo Zhao, Deniz Tuncay, Syd S. Peng

Longwall mine instrumentation for measuring abutment stress distribution, mining induced immediate roof stress change and deformation, and primary/secondary support loads and deformations provides critical guidance for the design of gateroad chain pillars and roof support. Field measurement results are also recognized as the best way to calibrate numerical models that have been used to study the failure and support mechanisms. International Conference on Ground Control in Mining (ICGCM) started in 1981 and since then, there were 26 papers published in the proceedings discussing the stress and load measurements as the face advanced using various field instrumentation techniques. The focus of this paper is on summarizing the analyses of the data published in these papers. Stress/load change monitoring included the following categories: gateroad chain pillar, abutment pressure, bolt load, and pre-driven recovery room. The data shows that the magnitude of stress changes as the face advances varies considerably from panel to panel and mine to mine. However, regardless of types of stress changes, pillar stress, abutment pressure, and bolt load, there exists a rough trend of stress increase as the face advances, generally consisting of three stages, i.e., stress/load (1) initially increases steady or slowly, (2) increases rapidly, and (3) increases reaching the peaks and dropping down slowly or sharply. The stress/load increases start earlier during the second panel mining and are larger than the first panel mining. This review makes it easy for the interested persons to find valuable data for other similar projects.

By Robert O. Vernon

The discussion of water and pit mining together is most appropriate. In fact, water can be considered a mineral and a well a narrow pit. Thus, of all the mineral resources mined, water is probably the cheapest, most valuable and least valued. The delivered price, including mining, transportation, storage and marketing rarely exceeds ten cents per ton, and our economy would cease without it. The time has come when the public must recognize that the extraction of a mineral resource from the land is a necessary and inevitable result of the industries? attempt to meet the demands of a growing economy. In so much of Florida, the lands mined can, with forethought and planning, be left as improved real estate, water conservation and management lands. On the other hand, the mining industries must face up to the need for the reclamation of land and compact with themselves, appropriate governmental agencies and with the mining states to restore mined lands to usefulness. Of limestone, sand, and clay 90 to 100 percent of the mined material is used, but with planning and specing, these pits, if they penetrate the water table, become valuable as real property. Phosphate, which returns about 70 percent of the mined materials to the pit, can reclaim the land for many purposes.

Jan 1, 1966

By Bob Katsiouleris

Having passed through the worst of times for industrial minerals demand, there are signs that the best of times lie ahead. If the downturn was the result of unsustainable economic policy, the path forward has everything to do with sustain-ably meeting the demands of more people enjoying higher standards of living than ever before. Minerals producers must be poised to understand and meet their requirements well into the next decade. Successfully marketing industrial minerals - the building blocks of a growing and increasingly urban world population - will depend on producers? ability to respond nimbly to a rapidly changing and regionally evolving macroeconomic environment. A renewed focus on energy conservation, sustainable agriculture and building practices and consumer demand for products with a smaller environmental footprint will drive product and market segmentation strategies. These trends will not only shape the way industrial minerals producers do business, but also the type of skills and people they will require to run those businesses.

Jan 1, 2011

By R. G. Reddy

Spent potliner is generated in the electrolytic process of reducing alumina to make aluminum metal using molten fluoride electrolytes. Spent potliner (SPL), obtained at the end of the pots life contains a small amount of cyanide and fluoride which present environmental problems. SPL became a listed hazardous waste under RCRA (K088) in July, 1990. One of the possible uses of spent potliner is as a substitute for Calcium Fluoride (CaF2) as a fluidizer in iron-and steel making and in the glass industry. A low viscosity and a low melting point are prime requirements for accomplishing the above. In the present study, viscosity measurements were performed. Effect of various additives, such as sand, limestone, dicalcium silicate dust, and MgO baghouse dust on the viscosity of SPL was studied. The results showed that with the addition of sand and limestone, very high fluidity of SPL melt can be obtained at significantly low temperatures. The results suggest that spent potliner mixed with additives could potentially be used as a substitute fluidizer.

Jan 1, 1999

By S. Partney

Waste clay ponds are a necessary part of the phosphate rock beneficiation process. They are large, averaging a square mile in size; unsightly, in that they protrude 20 to 50 feet (6 -15 meters) above natural grade; stabilization and reclamation is slow; and they have had a history of catastrophic failure. The State of Florida has never published a specific rule regarding the configuration or height of these ponds, but has enforced numerous policies along these lines. The current rules are given and interpreted, along with the reasoning for current policy. In addition, an overview of the history of the policies, and an attempt at explaining the reasons for the changes that have occurred is given. The industry has been forced to make major monetary decisions, having effect for decades on mine economics, in a constantly changing regulatory environment. The Bureau of Mine Reclamation is confident that a direction of regulation has been solidified, but changes are still to be anticipated.

Jan 1, 1998

By Miche1 Dagbert

In most open pit operations mining porphyry type deposits, production planning rests on an are reserve inventory block file which is derived from diamond drill hole data. With such a practice, the way by which block values are generated is critical and in the recent years many studies deal with the comparison of different estimation methods for block grades (Mueller, E. (1), Knudsen et al (2) (3), Barnes, (4), Williamson and Mueller (5). Typically in such studies, one selects a bench or a group of benches where there is a "sufficient" number of blast holes (BH) with assay values in each of the blocks (generally 30.5 x 30.5 m (100 x 100 ft) or 15.2 x15.2 m (50 x50 ft). Then the arithmetic mean of the BH values in each block is computed and it is assumed to represent the real block grade against which different estimated values are compared. However it is sometimes observed that the variation of these BH values within a block is high and that their arithmetic average may significantly differ from the real average grade of the block (Barnes (4). The problem of the precision of the mean BH grade in a block has been examined by Williamson and Langlois (6) in an experimental way. They strove to find a better estimate of the average block grade than the mean BH grade but their results were not conclusive. The purpose of this study is to investigate the same problem within the frame of geostatistical models (David (7). Besides practical results obtained with these models, two general points are emphasized and illustrated in the text. First, "good results" are obtained if "good geostatistics" is done (David et al (8).

Jan 1, 1978

By Daniel Roy, Danielle Bouffard, Antoine Berton, Simon Gariépy

Commissioning a mineral processing plant has always been a challenging task. The process includes pre- operational verification, dry and wet commissioning, and a gradual ramp-up to full production, all of which must be executed within the shortest possible timeframe, requiring numerous highly interdependent tasks to be conducted concurrently. This phase is under scrutiny by shareholders, corporate management, and other stakeholders who are keen to see a return on investment as the operation starts yielding results. Despite extensive documentation in the literature highlighting its significance, the impact of the commissioning phase remains underestimated in contemporary mining projects. This paper provides an overview of the commissioning process and its associated challenges before focusing on a critical success factor: building a dedicated commissioning team with the required competencies and personality profiles. The roadmap to achieving an efficient plant start-up is outlined. Drawing on over 15 years of experience with more than 20 concentrator commissioning and start-ups, a general framework is presented to maximize success. This method emphasizes the crucial role of the operation and metallurgy team in supporting these projects. Finally, insights from Soutex’s involvement in multiple start-ups are shared, offering lessons learned that emphasize best practices and challenges encountered in expediting the ramp-up process while maintaining high Health, Safety, and Environment (HSE) standards.

Feb 1, 2025

By Lloyd M. English

Accurate knowledge of the gas content of coal seams has always been important, according to the work of W. P. Diamond and J. R. Levine, 1981, but is becoming increasingly important for several reasons: Excessive gas emissions in the mine can create explosion hazards. Depletion of shallower coal reserves is forcing underground operations to greater depths where coal gas content is often greater. Natural gas prices and the need for new energy sources make naturally occurring coal gas a potential resource of economic interest. Information on coal gas content will impact mine designs, mine ventilation system specifications, and the effectiveness of methane control procedures used. Accurate resource assessment is needed for projecting and designing potential gas utilization enterprises. The emphasis upon methane hazards in mining operations, and upon potential methane utilization, has led us to improve upon the procedures used to determine coalbed methane levels.

Jan 1, 1984

By C. R. McClung

"Molybdenum, in the form of molybdenite, is a common byproduct of many copper mining and concentrating operations. While the recovery of most copper sulfide minerals is principally liberation controlled, the recovery of molybdenite is much more complex, with fully liberated particles commonly lost to tailings.A geometallurgical investigation was undertaken of molybdenite from the Bingham Canyon deposit with the aim of determining what effects, if any, mineralogy and the mineralogical attributes of morphology, angularity, liberation and size have on molybdenite recovery in the processing circuit. A set of samples was collected from the ores and products of Rio Tinto Kennecott’s Copperton Concentrator. The samples were analyzed by normal polarized reflected light microscopy, X-ray diffractometry, and scanning electron microscopy using a Mineral Liberation Analyzer, revealing the presence of two distinct types of molybdenite, which are the two polytypes: hexagonal (2H) and rhombohedral (3R). The 2H polytype occurs as textbook-shaped particles in quartz-molybdenite veins located in the core of the deposit, while the 3R polytype occurs as disseminated, ball-shaped particles with a dull or frosted appearance along the margins of the mineralized intrusive body or central core. Each polytype exhibited metallurgical properties consistent with those reported in the literature. The 2H polytype is easily ground, kinetically “faster” floating and displays surface attributes that are amenable to higher rates of recovery. This commonly results in the production of a high-quality molybdenum concentrate under normal operating conditions at most copper concentration operations. The 3R polytype is difficult to grind, kinetically “slower” floating and displays surface attributes that are less amenable to recovery. Therefore, in deposits with higher concentrations of the 3R polytype, modifications to operating parameters may be necessary to improve the recovery of molybdenite.A preliminary investigation into the metal budget of porphyry copper and molybdenum deposits indicated a possible positive correlation between total economic metal budget and polytype content. Higher concentrations of the 3R polytype appear to be more prevalent in gold-enriched porphyries than in molybdenum-enriched porphyries. This may help explain why it is easier to obtain higher rates of recovery in molybdenum ± tungsten-rich deposits, which contain little to none of the 3R polytype. There is a potential for the metal budget of a porphyry deposit to be used as an indication of the molybdenite polytype present as well as its impact on the economics, in terms of exploration, and the processing circuit, in terms of plant design."

Jan 1, 2016

By C. Braux

The aim of this study was to develop an integrated approach to enable identification of areas favourable for the presence of massive sulphide deposits in a given region (Las Herrerias, Spain). It is based on geochemical soil exploration, geophysical surveying (ground gravimetry), detailed geological mapping and a knowledge of the deposits of the South Iberian Massive Sulphide Belt. The multi-dataset approach consists, in the first instance, in standardizing and combining all the geochemical data with reference to their geological setting. Next, the "heavy" anomalies are extracted from the gravimetric survey, regardless of the surrounding context (heavy or light). The results from these two stages are then crossed, so that areas where heavy anomalies are associated with geochemical anomalies can be identified and classified. Crossing the geochemical and geophysical data enables a much tighter selection of anomalies than does the manual superposition of data provided by each method (geology, geophysics, geochemistry).

Jan 1, 1994

Laboratory testing by the Federal Bureau of Mines has shown that the removal of insoluble slimes using selective flocculation and flotation is a viable method for treating low-grade potash ores which have a high content of water-insoluble impurities. Results indicated that up to 85 percent of the insoluble slimes could be removed from sylvinite ore containing 5 percent water insolubles and 13 percent K20 using nonionic or cationic polyacrylamide flocculants and cationic, anionic, and/or nonionic collectors. Subsequent potash flotation recovered up to 88 percent of the potash in rougher concentrates containing 47 to 57 percent K20. Sizing and cleaner flotation of the rougher concentrates upgraded the products to 60 percent K20. Filtration of the insoluble slimes flotation concentrates recovered 87 to 0 percent of the brine. Flotation concentrate filtration rates were 7 times faster than the filtration rates of mechanically deslimed products.

Jan 1, 1977

By A. Cecala, J. Noll, J. Hummer

"NIOSH has observed that many control rooms and operator compartments in the US mining industry do not have filtration systems capable of maintaining low dust concentrations in these areas. In this study at a mineral processing plant, to reduce respirable dust concentrations in a control room which had no cleaning system for intake air, a filtration/pressurization system originally designed for enclosed cabs was modified and installed. Eighty-seven percent of submicron particles were reduced by the system at static conditions, meaning that greater than eighty-seven percent of respirable dust particles should be reduced. The particle size distribution for respirable dust particles are greater than for submicron particles, and filtration systems usually are more efficient in capturing the larger particles. A positive pressure near 0.02 inches of water gauge was produced which is an important component for an effective system and minimizes particles (e.g. dust) from entering into the room. The intake airflow was around 118 cfm, which is greater than the airflow suggested by ASHRAE for acceptable indoor air quality. INTRODUCTION Chronic overexposure to respirable silica dust (particle diameter < 10 microns) leads to a progressive lung disease known as silicosis. Workers who develop silicosis have an increased incidence of lung cancer and pulmonary disorders. In June 1997, the International Agency for Research on Cancer (1) found sufficient evidence to declare that inhaled crystalline silica in the form of quartz and cristobalite is carcinogenic. Mining is one of the leading industries for occupational exposure to silica dust (2-7). Control rooms located in dusty areas in some mines are of particular concern (8). Many mineral processing operations utilize operator’s compartments and/or control rooms to house workers who are performing particular job functions. Most industrial processing mills have rooms where a worker looks out over the facility and has direct control over the product flow throughout the entire building. In addition, primary crusher operators are often located in a compartment from which they are able to view the primary crushing function. Their job is to control when trucks dump into the primary jaw crusher and the rate of feed of the ore from the hopper into the crusher. Many of these control rooms and operator booths do not have filtration systems capable of cleaning air entering the control room or booth, which can result in elevated concentrations of dust in the room or booth. To reduce the dust concentrations in these rooms, it would make sense to clean the entering air with filtration/pressurization units similar to those proven to provide a clean environment in enclosed cabs."

Jan 1, 2016

By K. J. Ma, L. Ma, J. Stankus

The paper’s intent is to evaluate pumpable foamed cementitious mine seal material by determining the shear strength of a generic foamed cement in the laboratory. The tests were conducted on three scales: small-size specimens, consisting of cylinders 4 in. in diameter or 3-in. prisms; double shear medium- size specimens, measuring 13 in. by 10 in.; and large-size specimens, measuring 6 ft by 4 ft by 4 ft. The small-specimen shear tests resulted in average peak and residual shear strengths of 128 psi and 56 psi, respectively. These values are fairly consistent with published shear strengths of foamed cementitious material. However, the other two types of shear tests did not achieve the shear strength of a typical pumpable foamed cementitous mine seal material. Based on the test results, the paper concluded that the structural analysis of cement foam seals should be based on their residual shear strengths, approximately 20 psi, determined from small laboratory-scale tests of the cement foam/concrete or rock interface, and not be based on their peak strengths.

Jan 1, 2015