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By O. A. Velasquez, A. R. Kumar

"Continuous miners are often equipped with a flooded-bed dust scrubber to clean the air from close to an active underground coal mining face. However, its impingement screen is prone to clogging due to an accumulation of dust, thereby lowering the scrubber’s efficiency and potentially exposing the mine workers to higher levels of dust. Fans can compensate for the increased resistance by varying their operating parameters, but the scrubber screen needs significant maintenance which leads to downtime. The authors have proposed a suitably sized Vortecone as an alternative to the conventional flooded-bed dust scrubber system. Water is used as the filter medium, which is replaced and recycled continuously. Preliminary CFD investigations of Vortecone scrubbers have indicated higher cleaning efficacies, especially in the respirable range. This paper presents the results including the flow characteristics and capture efficacies of a full-scale Vortecone. Multi-phase flows, including free-surface modeling and particle tracking methods, have been adopted. ACKNOWLEDGEMENT The authors acknowledge the National Institute for Occupational Safety and Health (NIOSH) for funding this research project. This research is being developed with the support of a NIOSH Grant 200-2014-59922- ‘Coal Mine Dust Mitigation through Novel Scrubber Development and Numerical Modeling’. The views expressed in this paper are those of the authors and do not necessarily reflect those of NIOSH. This project is aimed at designing novel and efficient scrubbing systems for underground mining operations. The authors acknowledge Dr. Thomas Novak of the Department of Mining Engineering, the University of Kentucky for his support and encouragement. The authors also thank Dr. Sunil Vytala, CFD engineer at Cradle CFD for his invaluable inputs to the numerical models.INTRODUCTION Continuous miners are the main production machines deployed in room and pillar mining operations. These miners extract coal by the shearing action of the wethead cutting drums. Strategically placed water sprays on the drum not only cool the bits extending their useful service life, they also suppress the dust at the point of generation itself. A flooded-bed dust-scrubber (Campbell, et al. 1983) is usually integrated onto the continuous miner to arrest dust from close to the active face. These fan-powered scrubbers have an impingement screen flooded with water, which also serves as the filter element. A demister downstream of the screen removes the excess water from the air cleaned. These conventional scrubbers have been found to be very effective in alleviation of respirable dust levels underground (Chao and De-sheng 2000) (Colinet, Reed and Potts 2013). However, the inefficiencies of the flooded-bed dust scrubbers arise out of their internal components. Depending on the mining conditions, the screen may be clogged by the accumulation of the trapped dust particles. The resistance of the scrubber system is increased reducing the airflow. The flooded-bed dust-scrubber system would, therefore, require frequent maintenance of the screen and the demister (Listak 2010). Since any maintenance needs to be carried out under supported roof, this leads to loss of availability of the equipment as well. In addition to this, the continuous miner operators could be exposed to elevated levels of dust when satisfactory airflow at the face is not achieved."

Jan 1, 2018

By Doug Harding

The 3.5 km long Ashbridges Bay Outfall in Toronto, Ontario, Canada was a challenging drive set below Lake Ontario. After a remote machine acceptance due to the global pandemic, an 8 m diameter Single Shield machine launched in March 2021 from an 85 m deep shaft and began its bore in shale with limestone, siltstone and sandstone. During excavation, the TBM and its crew bored a city-wide record of 30 rings in one day, or 47 m of advance. This paper will cover the unique project, from TBM acceptance through to launch, tunneling in difficult conditions, and completion in 2022.

Jun 13, 2023

By P. Schilizzi

The increased impact of mining subsidence in the U.S. coalfields and the recent regulatory constraints legislated by government and state agencies have provoked an intense research effort on this topic by government agencies, coal companies and academic institutions. Subsidence and horizontal strain predictions are a basic requirement if subsidence and its associated effects are to be controlled and contained within acceptable environmental levels. As a result, several such prediction techniques have been proposed or are currently under development to assist coal operators in minimizing the detrimental effects of these surface deformations. VPI&SU has been actively involved in this research effort in the past few years, with particular emphasis on the Appalachian coalfield. During the initial stages of this research a large number of subsidence case studies were collected from the literature, the coal industry and government agencies. In total, data from 32 longwall panels and 60 room and pillar panels were collected. This data bank was used to determine relationships between the basic mining and subsidence parameters, in order to allow the evaluation of the various prediction methods for the Appalachian coal region. Based on this data two subsidence prediction techniques, one based on profile functions and the other on influence functions have been developed. Profile function methods provide a tool for a fast calculation of subsidence on a line across a mine panel. Influence function methods, on the other hand, allow for a more detailed calculation of ground movements, in any mode and at any depth, on a grid or at any specific point. The limitations of the data of the collected case studies, i.e. accuracy of surveys, frequency of monitoring, lack of horizontal movement measurements, etc, led VPI&SU to the initiation of a detailed subsidence and strain monitoring program above a number of active mines, located in three major coal producing counties of Virginia. The aim of this program was to enhance the data base with accurate and complete measurements of surface movements and to allow, therefore, the refinement of the prediction techniques. This paper presents this monitoring program, discusses in detail the results obtained from three specific case studies and provides recommendations for the implementation of the field data in the general prediction methods.

Jan 1, 1986

By George W. Land

For the year 1985, the U.S. coal industry produced 881 million tons of bituminous coal and lignite. Domestic consumption amounted to 814 million tons. The electric utilities consumed 689 million tons, almost 85 percent of total consumption, over 78 percent of production. In May, 1986, the NCA forecast that with moderate growth rate averaging 1.9% per year from 1985 through the year 2000, production could reach 1,176 billion tons and domestic consumption 1079 billion. The estimate for electric utilities indicate 924 million tons for the year of 2000, about the same percentage of production and consumption as now experienced. Before we consider the main topic of this paper, the cost of using high sulfur coal, let us examine the coal use patterns of the last 25 years, the changes in those patterns and consider the reasons for those changes. Table I shows those changes.

Jan 1, 1986

By Jon Kellar, Samuel Kessinger, Prasoon Diwakar

Tantalum (Ta) and niobium (Nb) are extracted from many different ore types. The major economic orebody mined for tantalum and niobium consists of tantalite ((FeMn)Ta2O5) and columbite ((FeMnNb2O5)) in a solid-solution mineral commonly referred to as “coltan.” The largest supplying region, The Democratic Republic of the Congo (DRC), is unfortunately also the most ethically compromised source for this critical mineral. Officially, the U.S. government has deemed coltan ore from the DRC a “conflict mineral” [1]. The lack of pragmatic and effective local mining regulation in Central Africa, when coupled with high levels of violence and corruption, has spawned a widespread, illegal, unethical and, most importantly, unsafe economy. This illicit economy is centered around first, illegally mining these valuable conflict minerals and second, smuggling these minerals into the global supply chain. Handheld spectroscopy devices could provide further transparency to these opaque supply chains, giving miners, traders and refiners the ability to authenticate the provenance of the minerals they encounter, and allowing companies to prove compliance with the regulatory agencies attempting to curtail illicit mining.

Mar 1, 2025

By M. J. Meulendyke

An extensive program of marked ball wear testing (MBWT), laboratory corrosion studies, and worn ball surface analyses has been used to gain insight about the role of corrosion in the overall wear process. In some environments, localized corrosion is observed; the actual wear mechanisms in such cases are pitting/spalling and abrasion. Factors affecting the occurrence of pitting include the abrasiveness of the ore, corrosivity of the slurry, corrosion resistance of the media, and galvanic coupling effects. Elimination of pitting substantially improves overall wear resistance. When pitting is not observed, the contributions of general corrosion are significantly less.

Jan 1, 1984

By R. W. M. Lai

In flotation or hydrometallurgical leaching of minerals, the cumulative metals recovery for a given process condition generally approaches a maximum value or an asymptote as the process time increases. This paper discusses the experimental methods of identifying and obtaining the asymptote of metals recovery through kinetic studies. In flotation, the kinetic asymptote of metal recovery, or ultimate recovery, is a function of grinding and collector dosage, but within a realistic variable range, is not a function of pH or temperature. However, variations in grinding, collector dosage, pH and temperature, all exert noticeable effects on flotation kinetics. Frothers generally have a minor affect on the asymptote, but have a major affect on flotation kinetics. The asymptote from batch flotation is found to be identical to that of a continuous flotation. In hydrometallurgical Leaching, the asymptote of metal recovery for a given leaching system is a function of such variables as temperature, particle size, and acid concentration.

Jan 1, 1983

By D. R. Spears

Conventional round tank thickeners have been widely used in the mining industry for many years. The mining industry was well satisfied with the ability of conventional thickeners to improve minerals beneficiation operations. However, development of improved flocculants (the polyacrylamides) made possible much more rapid settling rates, since polyacrylamides produce large flocs rapidly (unlike starch or inorganics). Traditionally considered to be a slow operation if maximum underflow density was achieved, and therefore there was some justification for the expense. Thickeners required large volumes to permit sufficient time for settling. The oversize not considered a drawback but the initial capital cost was. In high rate thickeners, a bed of thickened material is allowed to build around the feedwell, even above the bottom of the feedwell. The slurry is fed directly into the bed at a velocity that allows the material to be evenly dispersed over the thickener area This more efficient use of settling area allows a higher solids throughput per unit surface area (rise rate). In this paper, high rate thickener rise rates and polymer consumption are compared.

Jan 1, 1998

By M. S. Duffy

To exploit the mineral resources of fine grained ore bodies the minerals processing industry is turning to fine grinding technology, of which tower milling has become an established part. However, compared to other mills relatively little is known about the operating mechanisms in tower mills. In all milling processes one of the keys to understanding how they work is in knowing how their grinding media move. To investigate the ball motion in tower mills a glass unit was therefore constructed and measurements taken of the movement of the grinding media. This paper describes the results from this study.

Jan 1, 1998

By R. J. Miller

Mechanized Roof Supports (MRS) have dramatically improved safety and productivity of retreat pillar mining in coal. Due to low capital cost and greater flexibility, retreat panels have in some cases approached the productivity of a longwall. Because of improved safety and rapid set-up time when compared to conventional timbering, MRS are driving a return to retreat pillar mining in many situations. This paper describes how panel layout can be optimized for safety and operational efficiency when using MRS for retreat pillar mining of coal. The potential for significant unit cost reductions will also be addressed.

Jan 1, 1996

By Erich U. Petersen

Chemical zoning studies of mineralization can be useful in guiding exploration efforts. They permit one to determine the limits of mineralization and to correlate mineralized intervals in drill holes. Fahlore minerals are well suited for zoning studies because they are common minerals found in a variety of deposits, exhibit chemical diversity, and record the chemical evolution of migrating hydrothermal fluids. Zoning information in the form of metal ratios preserved in fahlore minerals was used to determine ore body limits in the Orcopampa precious metal system, Peru, and to correlate between multiple ore horizons in a sediment hosted massive sulfide (SHMS) currently under investigation. The current generations of electron microprobes provide the most efficient, accurate and economic way to analyze the tens to hundreds of sample required to successfully describe and use zoning information at the mine scale.

Jan 1, 1991

By R. J. Sweigard, R. V. Ramani

Three case studies were undertaken to investigate the role of land use potential evaluation in reclamation planning and to determine the impact of regional differences on final land use plans. The three surface mines studied were representative of operations in the Appalachian, Interior, and Northern Great Plains provinces. The scope of the investigations included a survey of regional characteristics, a detailed investigation of the mining operations and site conditions, and an assessment of local land use planning activities in the area of the mines. Special attention was given to key factors that presently determine the use of reclaimed land. Also, for each case study, the postmining land use potential was evaluated using site planning principles. Specifically, the environmental, economic, and social impacts of several potential postmining land use plans were considered.

Jan 1, 1987

By Calvin J. Konya

An investigation was performed to determine conditions which optimize fracture formation between blastholes used for purposes of pre-splitting. Experiments-involved high-speed photography in Plexiglas models and radiographs in sandstone models. Additionail data was obtained from full-scale pre-split blasts. Pre-split fractures between blastholes were found to form as a result of gas pressure and were affected little, if any, by stress wave interactions. Pre-splitting was effective with short period delays of 25 milliseconds or less, and did not require instantaneous initiation of blastholes. Significant reduction of ground vibration resulted with the use of delays

Jan 1, 1980

By Ronald A. Crowson

Detailed stratigraphic studies of the overburden at North Carolina Phosphate Corporation new South Creek Mine have delineated several aquifers and acquicludes within the 30-meter-thick overburden section of late Pleistocene sands and clayey sands. A major aquifer occurs in the 10-meter-thick sequence of shelly sands of the early Pleistocene Croatan Formation. The water-charged Croatan sands thicken into a paleodrainage surface on top of the Pliocene Yorktown Formation, a major aquiclude. A three-phase dewatering program is projected: 1) improve surface drainage around mine perimeter to reduce both flowage into the pit and rainfall recharge; 2) use a wellpoint system to dewater the upper 8 meters; and 3) use recharge wells along the axis of the paleo- drainage to dewater the overburden below 8 meters.

Jan 1, 1983

By Dale R. Ralston, Roy E. Williams, Gerry V. Winter, George L. Bloomsburg

INTRODUCTION The majority of ground water flow models have been developed for large computer systems. Most of these operate under a batch mode of operation, that is, the data are input with a deck of punched cards. The advent of micro- and minicomputers over the last few years opens the possibility of adapting many of these large flow programs to the smaller computers. In general, this adaptation will require more computer time to run the program, but in many cases if the small computer is in-house, the overall cost may be less than that required for a large computer. There are also a number of peripheral devices that can be used to make the data input much easier. As an example, the use of a digitizer with a finite element or finite difference mesh reduces the data input time considerably; the use of a graphics terminal for display of the mesh immediately after it is developed shows immediately whether there are errors in the location of node points. DEVELOPMENT OF AN INTERACTIVE SYSTEM The finite element program, UNSAT2, has been used over the past several years by the authors for several ground water flow problems (Bloomsburg, 1977; Bloomsburg and Wells, 1978; Zahl and Bloomsburg, 1980). In the past these programs have been run on an IBM 370/ 145 computer under the batch mode of operation. One difficulty that has been encountered has been in determining the length of time step that must be specified for operation of the program. The problem is that if the time steps are too large, the program becomes un- stable and operation ceases. If this happens in the middle of the problem, the only alternative is to reduce the length of time step and repeat the entire run. This problem has been alleviated in other pro- grams by using a subroutine that determines the time step automatically. If the solution becomes unstable, the time step is reduced automatically and that portion of the solution is repeated. With an interactive system this can be done by storing the output pressures and restarting the program with the new output pressures. Under the batch mode of operation, there is an option in UNSAT2 that allows restarting of the program from the last point of solution, but this must be specified when originally starting the program. The interactive computer system that we use currently consists of a PDP 1 1 /23 with hard disk drive, CRT terminal, plotter, graphics terminal, digitizer, and printer. The computer has 256 K bytes of core storage and the hard disk drive will accept a 5.2 M byte disk. To run a large program on a computer such as this, some overlaying must occur; that is, subroutines are stored on disk and put into core storage only when they are actually needed for running the program. UNSAT2 required very few changes to run on this computer but some changes were necessary to take advantage of the interactive capabilities of the system. One of these changes consists of the development of a program called DBUILD to build the data file for running the program. This program calls for each piece of data by prompt statement and gives instructions for using the digitizer. The data are then entered in completely unformated form. The node points must be entered in order and the coordinates are determined automatically by the digitizer. The pressure readings or initial conditions on each node point are entered through the terminal. All element information also is entered through the terminal. After DBUILD is run the mesh may be displayed immediately on the graphics scope whereupon any error in node point

Jan 1, 1986

The adsorption of gold onto activated carbon in iodide solutions has been studied. The adsorption rates were determined as a function of temperature, salt concentration and pH as well as activated carbon concentration. A kinetic model was also developed for the adsorption. The adsorption rate was believed to be controlled by a mixed mechanism of film diffusion and pore diffusion, but the film diffusion had a major contribution to the overall rate. Experimental findings were in good agreement with the model developed. The apparent activation energy was found to be 14.9 kJ/mol.

Jan 1, 1993

By Sheldon P. Wimpfen

Sand and gravel has been, and will continue to be, our principal construction material. Most of us are familiar with the patterns of past growth. Today we will examine the present status of this vital industry. We shall also attempt to look into the future to see where it is going and to evaluate the constraints that are being imposed. Natural aggregates are among the lowest in value of all bulk industrial minerals. From the processing point of view, sand and gravel production is relatively simple since the products are sized materials obtained from a deposit of satisfactory physical soundness. They can be used either loose or bound to provide bulk, strength, or protection. One of the main uses of coarse aggregate is in concrete as a filling material. As a general rule, the coarse aggregate constitutes about three-quarters of the volume of concrete. The other main use for aggregate is as a roadstone or roadbase to provide protective and stabilizing bulk beneath the road surface. Also it is used in a mixture with petroleum products as the wearing course on top. The sand and gravel industry is geographically widespread. In general, the output of operations is directly proportional to the amount of construction in any area. A wide variety of other aggregates compete with sand and gravel, including crushed stone, blast-furnace slag, clinker, and artificial and natural lightweight materials.

Jan 1, 1972

By Javad Sattarvand, Milad Ghahramanieisalou

As new technologies are introduced to the mining industry, the challenges related to their safe assimilation and the potential changes they bring to mining techniques necessitate adjustments to the current operations. Predictive simulations are critical to understanding unforeseen scenarios and shifting costly changes from the operational stage to the design. The Digital Twin methodology has gained a lot of attention in recent years. Many industries, from manufacturing to engineering and even social sciences, are adopting this approach to understand better the complex systems they are working with. By considering the enormous expenses and risks related to a pilot project, DT could replace that by acting as a prototype in which realistic tests and simulations are carried out with close to zero cost. DT includes a data hub, simulation and analysis tools, and visualization platforms to enable appropriate designs and monitoring plans focusing on unknown areas. A few examples of DT's application in mining include fleet management, Mine-to-Mill optimization (especially D&B), geotechnical digital twin (gDT), etc. When developing regulations, testing the efficiency of the mine layout, design, and magnitude of the restricted area and its access points, human-machine interactions, risk identification, and management processes, examining the efficacy of control systems, and monitoring, DT could help speed up (or completely replace) the process in the physical world.

Jun 25, 2023

By Siddhartha Agarwal

The mining industry collects a significant amount of operational data. However, gleaning useful information from the terabytes of data is difficult, and not just because of the sheer volume of the data. Therefore, an automated tool was developed at the University of Alaska Fairbanks to go through data and apply sophisticated statistical and neural network techniques in order to identify the data streams that are important to a process. This paper presents results from the tool as applied to SAG mill data from a gold mine. The results were compared to results achieved earlier with available commercial modeling tools. The comparison indicates that there was little or no loss in performance by automating the very complicated process of neural network modeling. Therefore, the intent of the exercise, to examine if complicated modeling tasks can be automated, was realized. Mining Engineering, 2011, Vol. 63, No. 12, pp. 52-54. Official publication of the Society for mining, metallurgy and exploration, Inc.

Jan 1, 2011

By M. C. Williams

The solution of the dynamic population balance model (PBM) of a closed grinding network consisting of a mill, sump, and cyclone is problematic. The fact that the dynamic PBM model equation solution to the Inverse Problem for grinding systems is degenerate or underspecified is demonstrated. Two numerical solution approaches to the Inverse Problem are used. These are: 1) providing additional constraints on breakage selection functions or 2) performing the Arbiter-Bhrany (or other) normalization of the selection functions. Actual experimental anthracite batch grinding data is used to demonstrate the non-unique functionality of the batch dynamic mill selection and breakage functions for a real physical system. The Levenberg-Marquardt algorithm for systems of constrained non-linear equations is used to solve the batch dynamic PBM grinding equations to obtain the grinding selection and breakage rate functions. Different solutions to the same PBM transport equations are provided. The mill, sump and hydrocyclone were modeled as a CSTR operating at various retention times. Batch dynamic PBM data was used to provide the mill kinetic and breakage selection function data. Two different solutions were obtained depending on the numerical solution approach. The severity of the non-uniqueness problem for dynamic grinding is demonstrated. Each solution approach to a dynamic PBM with transport, while giving the same prediction for a single batch grinding time, gives different solutions or predictions for mill composition for other grinding times. This fact makes dynamic nodal analysis and control problematic. The fact that the constraint solution approach gives a solution may suggest that normalization for closed networks is not necessary. Differences in solutions to the PBM cannot be excused away by inaccuracies in the data used to model the grinding phenomenon.

Jan 1, 1995