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By M. C. Bétournay

Hydrogen fuel cells are a known technology, having been applied to stationary (e.g. equipment, buildings, and power plants) and vehicle applications (e.g. transit buses and space shuttles). There is currently a growing need to provide alternate power systems to diesel fuel for underground mining vehicles to improve underground air quality and reduce production costs and greenhouse gas emissions. To date, however, fuel cells have not been exposed to underground mine air and physical conditions. A testing program was carried out to provide information on the vulnerabilities of fuel cells as part of a number of proof-of-concept projects to apply hydrogen power to underground mining vehicles. The fuel cell type of choice for the industry, the proton exchange membrane, would function at the range of surface operations, and use hydrogen that is stored under low pressure and risk. A small fuel cell stack was tested in a cooperative project between CANMET, the Fuelcell Propulsion Institute, Inco, the Ontario Ministry of Labour, Sandia National laboratories, and H-Power. This article will review the tests carried out to measure the effects from high humidity, mineral dust, diesel emission gasses and diesel particulate matter, as well as from shock and vibration provided to the unit in underground conditions at Inco?s 175 Orebody minesite and Stobie mine. The test results provided will show that the unit was not affected by the underground conditions; physically and electrically, the unit performed without any reduction in operation or adverse effects imposed

May 1, 2005

By G. Bonnell, W. Lidkea, M. C. Bétournay, E. Edwardson

"Hydrogen fuel cells are a known technology, having been applied to stationary (e.g equipment, buildings, and power plants) and vehicle applications (e.g transit buses and space shuttles). There is currently a growing need to provide alternate power systems to diesel fuel for underground mining vehicles to improve underground air quality and reduce production costs and greenhouse gas emissions.To date, however, fuel cells have not been exposed to underground mine air and physical conditions. A testing program was carried out to provide information on the vulnerabilities of fuel cells as part of a number of proof-of-concept projects to apply hydrogen power to underground mining vehicles. The fuel cell type of choice for the industry, the proton exchange membrane, would function at the range of temperatures encountered in underground and surface operations, and use hydrogen that is stored under low pressure and risk.A small fuel cell stack was tested in a cooperative project between CANMET, the Fuelcell Propulsion Institute, Inco, the Ontario Ministry of Labour, Sandia National laboratories, and H-Power. This article will review the tests carried out to measure the effects from high humidity, mineral dust, diesel emission gasses and diesel particulate matter, as well as from shock and vibration provided to the unit in underground conditions at Inco’s 175 Orebody minesite and Stobie mine. The test results provided will show that the unit was not affected by the underground conditions; physically and electrically, the unit performed without any reduction in operation or adverse effects imposed."

Jan 1, 2005

By P. Bester, G. J. van der Linde

Foskor operates a mine in the Northern Province of the Republic of South Africa exploiting the igneous complex at Phalaborwa. It produces about 3 million tons of phosphate concentrate per year by means of froth flotation from 26million tons of ore of which 16 million is mined and milled onsite. The remaining 10 million tons originate at the Palabora Mining Company and is pumped as a slurry to Foskor. Two types of ore are mined and milled namely Foskorite and Pyroxenite. (The main mineral content of this ore is Apatite, Phlogopite and Diopside.) After three stages of crushing the ore is milled using 24 rod mills and 5 verti mills. The apatite is then recovered using four stages of froth flotation. The stocks of Foskorite ore are rapidly being depleted and the PMC tailings will also fall away by the year 2002 so that the whole mining operation will then be centred around the Pyroxenite ore. This will lead to substantial increases inproduction costs. The recoveries achieved in the flotation plant are largely dependent on the successful operation of the comminution section. Parts of this plant are now 35 years old and the advantages of re-engineering, new technology and automation can only be applied to a limited extent in an effort to reduce costs. It was then decided to investigate alternative milling methods, both wet and dry.

Jan 1, 1999

Jan 1, 2001

This paper provides an overview of possible approaches for structuring the ventilation systems for mines that will become operational within the next decade. Features addressed in the paper include: aspects of airway design and layout in the absence of centralized vertical return shafts, the impact of using diesel-powered trackless equipment in conjunction with conveyor belts in the development and production phases of the project, and the need to balance increasing electrical power costs against the requirement for reduced capital expenditure. The paper provides brief descriptions of the strategies employed in real-life situations and presents an overview of various operational parameters affecting the design of ventilation systems that will be used as ?platforms? for much deeper mines in the future.

Jan 1, 2007

By Carlos Soria

El presente texto describe los Sistemas de Gerencia de la Información y su aplicación en la industria minera con el objetivo de optimizar la gestión total de la empresa. Dichos sistemas manejan información del proceso y sus valores de producción, cálculos, consumos de energia, emisiones de plantas, tiempos de funcionamiento de equipos, eventos, alarmas, mediciones de laboratorio y control estadístico, etc. De forma que dicha información pueda ser reunida y consolidada, convirtiéndose en materia de significado y relevancia disponible en base a análisis, reportes, listas, tendencias y gráficos para que el usuario final de una planta o en sus oficina pueda tomar mejores decisiones.

Jul 17, 2000

By F. W. Bowdish

A theoretical and experimental laboratory study has shown that the rate of breaking of oversized particles in a ball mill is proportional to 1) the concentration of such particles, and 2) the area of the balls, provided that the balls are larger than a certain size relative to the particles. If all undersized material were removed as formed, the rate of breaking would be almost independent of the quantity in the mill. Rate equations are given which are similar to those for zero, first, and second order reactions. Deviations of small balls from the equation for a second order phenomena are quantified by a factor called "nipping efficiency." Some data are correlated by a dimension-less equation, which is used to estimate nipping efficiencies from data not in the correlation. The investigation described here was undertaken after a literature survey revealed that little was known concerning the mechanism of breaking of particles within a ball mill and the effect of this mechanism upon grinding rates. One paper, by Roberts1 , offered a theory concerning the mechanism of breaking, and a rate equation for the breaking of particles larger than some size to particles smaller than that size. That paper provided the starting point for a theoretical and experimental investigation of grinding under carefully controlled conditions. THEORETICAL CONSIDERATIONS In his paper on the probability theory of ball mill grinding, Roberts theorized that "... a given expenditure of power leads either to a certain number of point to point blows per bp-hr or to a certain distance of line contact per hp-hr ..." He assumed that the balls touch each other during each blow or during moving contact. Then he said that a volume of pulp, dependent upon the size being considered, would be covered per minute within which all oversized particles would be crushed to particles smaller than that size. Naturally, the higher the concentration of oversized particles in the pulp, the higher the rate of which they would be broken. From this reasoning Roberts obtained the differential equation -dC/dt = k hp/ton C (1) where k is a constant for any size of particle, density of particle, and moisture content of pulp. C is the percentage of oversize in the material to be ground, t is the time, and hp/ton is the power input per ton of material in the mill. He then integrated the equation to log Co/Ct = k/2.3 hp/ton t , where Co and Ct are the percentage of oversize at time zero and t respectively. By always using the same quantity of material in a mill and assuming that it required constant power to run the mill, he was able to combine the horsepower per ton factor with the other constants to give an equation for a first order rate.

Jan 1, 1961

By Theodore James Kurela

Analysis of adverse technical issues has traditionally relied on a snapshot of the state of the operation complemented with both the melt shop’s archived data and eyewitness accounts of adverse events. The GrafTech ArchiTech System is helping EAF shops solve problems faster by combining continuous analysis of information with statistically based alerts of process deviations. After one year of system implementation, a number of cases have been detected and communicated to melt shops worldwide. The objective of this paper is to examine a few of these cases; the early detection, statistical analysis, deviation reporting and the resulting countermeasures implemented.

Aug 17, 2017

By J. P. Gous, J. J. Sutherland

"Transalloys is a silicomanganese (SiMn) producer located in South Africa, and uses only local manganese ores to produce SiMn alloy. The plant operates five open submerged arc furnaces (SAFs) with an annual capacity of 180 000 t of saleable SiMn.Maintaining tap-holes is critical for effective furnace operation, allowing proper drainage of the furnace with minimal operator interference. Using a claygun and drill arrangement installed at each furnace, tapping occurs every four hours. Tap-holes are maintained through mickey replacement and brick repairs. Three furnaces have SiC tap-holes and two have graphite tap-holes.This paper gives a review of SAF operation, furnace and tap-hole design, daily tapping operation, and maintenance practices for repairing tap-holes.IntroductionDefining tap-hole life cycle, Steenkamp et al., (2016) highlighted four main steps: installation during furnace relines, day-to-day operations, tap-hole maintenance, and tap-hole repair. The authors argued that the design of the tap-hole area should allow for all four stages in the tap-hole life-cycle. Design principles for each stage were presented using silicomanganese (SiMn) production as a case study. Here we present a further analysis of the case study by providing practical examples of how the tap-hole life-cycle is managed at Transalloys during the design, operation, and maintenance of submerged arc furnaces (SAFs) applied in the production of SiMn.BackgroundTransalloys is the largest producer of SiMn in Africa. Its smelter complex is based outside the town of eMalahleni, in the Mpumalanga Province of South Africa. Transalloys was commissioned in the mid- 1960s as a high- and low-carbon ferrochromium plant based on the Perrin process. In 1967 the plant was converted to SiMn production because of constraints in the ferrochrome market (Basson, Curr, and Gericke, 2007; Bezemer, 1995). Today, the installed production capacity is 180 000 t of SiMn annually. Plant operations consists of five SAFs (see ratings in Table I), operating 24 hours a day, 365 days a year (including maintenance), involving 280 permanent employees, with up to 120 contract employees on site at any given time."

Jun 1, 2019

By Roland C. Walker

Traditional headed rebar has existed in the mining industry as a ground support product for many years. The head of a rebar bolt is most commonly produced by hot upset die forging. Upset die forging produces a rugged, simple head that performs well. Certain elements of the head must comply with regulatory standards, such as ASTM F432-95, which offers a standard test procedure to ensure quality of the product. The head style produced by all major manufacturers has been optimized to reduce manufacturing costs, provide greater miner safety and provide an excellent performing product. Observations were made in some mines of heads failing under in-situ loading. These observations could not be replicated according to the ASTM testing method. This paper highlights the problem and how a solution was developed. The development includes pictures of in-situ failures from the underground operations, laboratory replication tests indicating how this loading occurs, and then the use of this calibrated test method to validate the new design created.

Jan 1, 2009

By B. Hilscher, P. Nayak, N. Yoon

"The mining industry is currently facing challenges with declining feed grades and is struggling to find solutions to improve the project’s economic value. By means of pre-concentration, ore sorting aims to separate the barren material from the valuable ore to reduce energy consumption and tailings generation, while increasing the feed grade, concentrate grade, mill recovery, and revenue. In addition, ore sorting allows the modification of deposit geometallurgy in order to allow the creation of an optimal mill feed.This paper evaluates the applicability and challenges of ore sorting by utilizing the results from four different mines, and reviews them in detail. The mines include two underground and two open pit mines that are base metal and precioius metal operations. In order to understand the applicability of ore sorting in these operations, initial rock-by-rock test results and different types of assays (atomic adsorption [AA], inductively coupled plasma [ICP], and fire assay) are utilized. Using the assay results, the grade recovery curves for ore sorting are generated and they are further improved by using and developing an ore sorting algorithm, which is discussed in this paper. The application and evaluation of ore sorting in greenfield and brownfield properties will also be discussed.The state of the art ore sorting technologies for both rock-by-rock and bulk sorting are reviewed in this paper. The future technologies on the horizon, including different combinations of sensors, are explained. The sorting technologies include, X-ray transmission (XRT), X-ray fluorescence (XRF), colour, infrared, electromagnetic, and laser induced breakdown spectroscopy (LIBS).IntroductionOre sorting is a sensor-based sorting technique introduced between the excavation stage and processing stage, where the unwanted waste is diverted to the waste dump and only the ore is sent to the mill for further processing. As a result, the quality of the material entering the mill is improved and the dilution of the ore is reduced. In greenfield projects, sensor-based ore sorting provides an opportunity to reduce the capital cost of the project and increase the return on investment (ROI). With most operations currently facing the challenge of finding a high grade deposit, having a sorting unit provides several advantages while keeping the cost at minimum."

Jan 1, 2017

By J. C. Johnson, W. G. Pariseau, D. F. Scott, F. M. Jenkins

In situ stresses are important input data for the design of safe, stable stope layouts and extraction sequences. However, it is commonly assumed that normal and shear stress gradients in a stress field are negligible and, consequently, that stresses are uniform throughout the region of analysis. To evaluate these assumptions and to provide input data for an analysis of a shaft pillar mining plan, in situ stresses were measured at the Homestake Mine, Lead, SD, using overcoring on hollow inclusion cells and borehole deformation gauges. These measurements were used with conventional least squares, best fit data reduction schemes. The results showed that normal stresses within the shaft pillar were less than, but comparable to, those estimated from finite-element modeling. Shear stresses were an order of magnitude less than normal stresses and varied considerably from site to site. Possible causes of this variability include effects of scale, elastic moduli, anisotropy, and axial strain. Because of the variability, it is not possible to determine the magnitude of horizontal stress gradients.

Jan 1, 1993

By T. R. A. Davey

The fundamental principles by which bismuth may be removed from lead by pyrometallurgical processes are enumerated. Qualitative discussion of the phase diagrams concerned is followed by presentation of quantitative diagrams. Brief mention is made of the practical aspects. Data presented show how chemical lead (<0.005 pct Bi) may be produced by the Jollivet, Dittmer, and Kroll-Betterton processes. BISMUTH is an element whose properties are very similar to those of lead, and its minerals are associated to a greater or lesser extent with nearly all the major lead ore deposits of the world. In consequence, the lead produced contains bismuth unless a special debismuthizing process is practiced. There does not appear to be any published comprehensive review of the effect of bismuth as an impurity on the properties of lead, and there is some uncertainty as to the beneficial or detrimental effects of small amounts of bismuth in lead used for particular applications. Standard specifications of most countries stipulate a maximum bismuth content of 0.005 pct for chemical lead. With one exception, this specification is met only by lead producers whose ores are relatively bismuth-free, or whose refineries are electrolytic. In lead for certain applications a higher bismuth content is preferred by some fabricators.&apos; In contrast to the refining for silver, copper, and antimony, the refining for bismuth does not usually result in a large overalil economic gain from the sale of byproduct. Thus, debismuthizing is customarily practiced only if market conditions demand a lead with a bismuth content lower than that produced by classical refining; i.e., softening, desilverizing, and zinc refining. Until this century, debismuthizing was carried out only a:; an incidental result of desilverizing, as later described. This century has seen the development of the Betts electrolytic process—the only successful one of many electrolytic processes proposed and patented —and a number of precipitation processes based on the pioneering work of Kroll,&apos; although only one of these, the Kroll-Better ton process,&apos; is in wide commercial use today. It is proposed in this paper to deal only with the pyrometallurgical processes, excluding those based on aqueous electrolysis. Historical Background Prior to 1833 silver (and incidentally bismuth) could not be removed from lead. To recover silver from rich bullion, the only course available to lead refineries was to cupel the bullion, forming a slag of litharge. The first slag tappings or skimmings, on reduction, yielded soft lead of very low silver and bismuth contents. Intermediate skimmings yielded a lead of somewhat higher silver and bismuth contents, which could if desired be recupelled. The last skimmings yielded a litharge very high in bismuth, which could by successive oxidation and reduction cycles be separated into high purity bismuth, and lead returns. This oxidation reduction process, with modern operating techniques, can still be used today to produce a portion of a lead refinery&apos;s output of very low bismuth content, as discussed later. In 1833 Pattinsone discovered that lead bullion could be purified of silver and bismuth by fractional crystallization, the primary lead crystals formed by partial freezing being purer than the melt. Repeated processing in pans produced a lead containing as little as 0.02 pct Bi. The simple explanation of this

Jan 1, 1957

By Gene R. Reid

The contract objective is the development of an Automatic Fire Control System for Mobile Underground Metal Mining Equipment. The Phase I Report, which described the projected data handling plan, was published on July 24, 1975. The Phase II effort covered the period from July 24 through December 2 and accomplished the following objectives: ? Acquisition of data in accordance with the project data handling plan. Data were acquired through visits to twenty mine sites in ten states and Canada; visits to Bureau of Mines and MESA facilities; visits to mobile equipment manufacturers; and an extensive literature search. ? Analysis of accumulated data which provided the following specific types of design inputs: selection of the type of mobile underground equipment found to represent the greatest overall fire hazard; typical operating conditions for the vehicle; characteristics of the reported fire experiences; and performance, cost and maintenance factors affecting potential purchases of automatic fire control systems for underground mining equipment. ? Development of the AFCS design concept. Utilizing the data analysis results and considering the state-of-the-art of fire control system components, a recommended design concept was developed with particular emphasis placed on the need for a low cost and reliable system. Design trade-off studies are provided for the recommended system and for four alternate system concepts.

Jan 1, 1975

By A. A. Angelov

This paper presents a unique method of monitoring the effectiveness of the planning process as well as the execution of mine plans. The method primarily determines the degree of deviation from the original mine plans by comparing actual mined areas to initially planned mining areas. The performance of mining operations is also measured by comparing actual and planned tonnages for a particular period. Once the degree of deviation from mine plans has been established the cause/s of the deviation can be determined through a simple fault tree analysis. Accurate identification of the reasons of deviation can aid the mine in selecting possible methods to correct the deviation. It is, however, beyond the scope of this paper to discuss the methods employed in correcting such deviations, as each mining operation will have unique causes of plan deviation and methods of remedying them. Deviations from the plan greatly affect the yields obtainable, which in turn affects the life of mine, thus having negative economic and financial implications. Accordingly, this paper presents a project management method which aims to reduce risk by improving planning systems to ensure optimum overall extraction of coal reserves.

Jan 1, 2010

Significance of Ion Interactions in Flotation in Saline and Brine Solutions

Sep 13, 2010

By A. D. Prokop, J. P. Rider

Along with increased production from longwall units has come the likelihood of increased worker noise exposures. In recent years, equipment has become larger, more powerful, and noisier than its predecessors. For these reasons, the Mining Division of the National Institute for Occupational Safety and Health (NIOSH) is investigating worker noise exposure on longwall faces and researching possible solutions to reduce this exposure. Part of this research effort involves studying the effect of covering the underside of longwall shields with acoustical material to reduce reverberating noise along the face. Experiments using acoustical absorptive insulation to cover the undersides of the shields, shearer body, and the shield supports were conducted at the full scale simulated long-wall test facility located at the Pittsburgh Research Center. Sound levels were recorded every 1.5 m [5 fl] along a 15.2 m [50 ft] section of the simulated face for all of the conditions tested. The analysis of the data indicated that a 2.0-3.0 dBA noise reduction was achieved between the shearer drums and a 4.0-5.5 MA attenuation was attained upwind of the headgate drum.

Feb 24, 1997

The Subtropolis mine is a room-and-pillar mine extracting the Vanport Limestone near Petersburg, Ohio. In February 2018, mine management began implementing a heading reorientation to better control the negative effects of excessive levels of horizontal stress. The conditions in the headings improved, but as expected, stressrelated damage concentrated within crosscuts. The mine operator has worked to lessen the impact of the instabilities in the outby crosscuts by implementing several engineering controls. With the implementation of each control, conditions were monitored and analyzed using observational and measurement techniques including three-dimensional (3-D) LiDAR surveys.

Jan 7, 2020

By Lennart Mukka

The Kiruna Mine in Sweden currently has three ventilation systems. The first two (a new and old system) serve the production areas. The third system is used for the facilities on the former main haulage level 775. That area includes offices and workshops for load haul dumpers (LHD) and drill rigs. The third ventilation system also covers the crushing and haulage on level 1045. At the present time, the total airflow for the mine is 1,600 m3/sec(3.4 million cfm). The current system serves the levels above the 775 level. The new one is for the levels between 775 and 1,085 m (2,540 and 3,560 ft), which are needed for the new ore body. When all of the production is below level 775, the old ventilation system will be closed down.

Jan 1, 2002

By Simon St J Tose

The objective of this paper and presentation is to review the different criteria and methodology used by AEL and other organisations to create a pre-split design which delivers a stable highwall for the life of that part of the mining operation. It will look at the need to adapt and change the way, size and direction of the production blasts as the mining phase approaches the highwall position for which a pre-split has been created. Key Words: Pre-split: Design; Highwall; Perimeter

Jan 1, 2006