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By David A. Heitman

The Buick Concentrator is a highly automated operation which utilizes a process control system for continuous monitoring and control. The process control system development, installation, and application to the concentrator grinding and flotation circuits are presented in this paper. The design and implementation of analog field sensing instrumentation, a continuous on-stream X-ray analyzer, grinding and classfication circuit controls, and a recent digital process control system utilizing a centralized computer are discussed. Emphasis is placed on the project planning and installation of the digital control system including a presentation of future plans for continuing application of computer control.

Jan 1, 1982

By W. X. Wang

In the mining and quarry industries, rock fragments are often transported by conveyor belt. To estimate the qualities of the rock fragments (i.e., size distribution and shape), an operator must take samples from the conveyor and manually perform a sieve analysis, which is time-consuming and tedious. Alternatively, an image-analysis system can be used to monitor the fragment quality on a fast moving conveyor belt. However, images of fragments on a fast moving belt vary to such a degree that the quality of any two successive images are not the same, and some of the images are of such poor quality that they are unrecognizable by human eyes. If poor-quality images are directly analyzed by a segmentation algorithm, the analysis will not be satisfactory. To resolve this problem, it is necessary to use an image-classification pro-gram for the automatic selection of fragment images with good quality. Because of this need, an image-classification program was developed and tested both in the laboratory and in the field. Testing of the system on different types of fragments showed that the system works reasonably well.

Jan 1, 1996

By B. Yarar

The critical surface tension of wetting (?c) of Cu2S, FeS2, PbS, and MoS2 were determined by plotting flotation recovery versus YLV which was arranged by methanol, and Extra-polating to % R = 0. ?c values ranged from 26 dyne cm-1 for MoS2 to 49 dyne cm-1 for PbS and elemental sulfur gave a value of 31.5 dyne cm-1. Minerals exhibiting natural flotability of different extents, could be separated from their mixtures in the absence of conventional flotation reagents, but controlled ?LV. Correlations between non-stoichiometry and degree of natural hydrophobicity for MOS2 are also reported in this paper.

Jan 1, 1983

By S. Kittel, P. Galleguillos, H. E. Urtubia

The rougher flotation at Escondida consists of 80 cells of 100 m3 each, with injected air. Escondida has developed a system of automatic control of the rougher flotation using video cameras, which have been operating since 1997 for remote monitoring and manual control. Since 1999, an image processing software and a group of rules have allowed implementation of an expert system. To date, the expert system controls the superficial speed of each cell by adjusting the air flow and the froth depth of the flotation bank. Preliminary tests of the expert control on two of the eight rows gave 1.2% higher rougher recovery at a 92% degree of confidence. The proven benefits are already sufficient to move towards a complete plant implementation.

Jan 1, 2001

By A. E. Ketler

Optical smoke monitoring fills an important gap in ventilation and fire safety: namely monitoring of smoky, low temperature fires where little CO and heat are generated. Smoke monitoring also avoids the nuisance alarms due to diesel exhaust, battery chargers, blasting and welding. The smoke optical density (OD) fire alarm standard specified by MSHA presents an opportunity for improved safety. Experience of actual mine usage of the SmokeBoss*100 is reviewed, with particular regard to effectivity, maintenance and cost.

Jan 1, 1995

By J. Sammarco

Proper illumination is critical to a miner?s ability to detect hazards in underground mines. Moving hazards are often located in the miner?s peripheral field-of-view, while slip/trip/fall hazards are often located in the forward field-of-view. The objective of the research described in this paper was to determine if light-emitting diodes (LEDs) improve visual performance as compared to traditional incandescent (INC) cap lamps. The research presented focuses on comparative studies of a National Institute for Occupational Safety and Health (NIOSH) prototype LED, a commercial LED, and an INC camp lamp. Thirty subjects participated in these studies; ten subjects in each of the age groups: 18 to 25 years, 40 to 50 years, and 51+ years. Visual performance was quantified by the subjects? speed and accuracy in detecting hazards, while visual performance for disability glare was quantified by the use of contrast sensitivity tests. Results suggest that LEDs with a visible spectrum containing a higher concentration of the shorter wavelengths can enable visual performance improvements with respect to disability glare, the detection of moving hazards in the peripheral field-of-view, and the detection of floor hazards in the forward field-of-view. The NIOSH prototype LED cap lamp provided the best visual performance improvements for the older age groups in every test. Disclaimer: The findings and conclusions in this report have not been formally disseminated by the National Institute for Occupational Safety and Health and should not be construed to represent any agency determination or policy.

Jan 1, 2009

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 J. W. Walkiewicz

The U.S. Bureau of Mines has conducted studies using microwave energy to stress-crack iron ores. In a microwave chamber which simulates a continuous throughput operation, the Bond grindability of a taconite sample was improved by 13 pct at a bulk temperature of 197? C. To further improve the economics of microwave fracturing, higher powers up to 16 kW were used to rapidly heat samples to relatively low temperatures in a continuous belt-fed applicator. A significant enhancement of grindability was obtained with a minus 1.9-cm taconite rod mill feed. At a sample temperature of 130? C, the grindability was improved a maximum of 26.1 pct over the non-microwaved sample.

Jan 1, 1993

By Richard M. Winar

In September of 1988, the United States Environmental Protection Agency (US EPA) published final regulations that effect owners and operators of underground storage tanks (USTs). These regulation include stringent technical requirements for owners and operators of USTs containing petroleum and certain hazardous substances. The technical requirements effect both new (those installed after December 1988) and existing USTs and include notification; performance and operating standards; release detection, reporting, investigation; release response and corrective action; and closure requirements for out-of-service USTs. The USEPA also published final regulations regarding financial responsibility requirements for owners or operators of petroleum USTs in October of 1988. These regulations require owners or operators of petroleum USTs to demonstrate financial responsibility for the costs of corrective action and compensating third parties for bodily injury or property damage caused by releases from petroleum USTs. Like thousands of other industries, the mining industry must become thoroughly familiar with these new regulations in order to properly manage their UST systems, ensure compliance, and understand other ramifications imposed by these regulations.

Jan 1, 1990

In the present study, we have investigated the conditions for the formation of bubble clusters and the effect of well-defined agitation on the stability of clusters. A specially designed cell was used in which bubble clusters could be formed at the surface of a porous block in a fluidized bed of relatively coarse hydrophobic silica particles. The clusters then rose through a flow field of known turbulent characteristics. The size of the clusters before and after passing through the turbulent zone were measured using a high speed camera. The influence of shear rate on the deformation of the bubble clusters was investigated. The results showed that the Kolmogarov microscale was much smaller than the maximum cluster size, suggesting that the breakage of the clusters was mainly due to interaction with clusters in the inertial convection sub-range.

Jan 1, 2009

By T. Patten

A method for stabilizing mercury containing waste for landfill disposal would be a very cost effective solution for industry. A mercury polythiocarbonate material which is made via a metallurgical process passes a traditional TCLP for mercury. The mercury polythiocarbonate material was subjected to a more thorough evaluation, the Integrated Leaching procedures as described in Kossan (1) and Sanchez (2)The procedure involves leaching the mercury polythiocarbonate material at varying pH and sample size to liquid. The procedure had to be adapted for small sample sizes and finely divided materials due to the product characteristics and available material. The leachates were evaluated and found to be stable within common environmental pH values. The performance details on how Inter-Mountain Labs met the leaching requirements of the procedures and the analysis of mercury are presented.

Jan 1, 2012

By W. H. Pomroy

In its 2001 diesel particulate matter (DPM) rule for metal and nonmetal underground mines, MSHA established an interim concentration limit of 400 micrograms of total carbon (TC) per cubic meter of air (400TCµg/m3), and a final concentration limit of 160TCµg/m3, to be phased in over five years. Following a court challenge to the 2001 rule, MSHA, industry and organized labor reached a partial settlement of the litigation under which the agency agreed to issue a proposal to amend the 2001 rule by, among other things, changing the surrogate from TC to elemental carbon (EC), applying MSHA's traditional hierarchy of controls, and revising requirements for one-year special extensions for complying with the final DPM exposure limit. MSHA issued a final rule in 2005 converting the interim concentration limit from 400TCµg/m3 to 308 micrograms of EC per cubic meter of air (308ECµg/m3) based on a miner?s personal exposure. Pending further rulemaking, MSHA retained the final concentration limit of 160TCµg/m3. In May 2006, MSHA issued a final rule that clarified that the final limit of 160TCµg/m3 would be based on a miner?s personal exposure rather than as a concentration limit. The 2006 rule also phased in the final DPM limit in three steps over two years, beginning in May 2006 at 308ECµg/m3, followed eight months later in January 2007 with a limit of 350TCµg/m3, and finally reaching 160TCµg/m3 in May 2008. Also in the 2006 rule, MSHA committed to converting the 160TCµg/m3 limit to an EC limit in future rulemaking. This paper reviews the DPM exposure limits in the context of the MSHA rulemakings and discusses the DPM engineering controls that were utilized by mine operators to attain compliance with each progressively lower limit.

Jan 1, 2009

By R. Mensah-Biney

The aqueous biphase separation process (ABS) has been used to separate ultrafine industrial minerals. The partition behavior ofTiO2, Al2O3, Fe2O3 and kaolin was not pH dependent. The partition behavior of SiO2 was, however, pH dependent. The partition coefficient of kaolin in PEG 3400/ Na2CO3 biphase system was 150 and that of the silica in the same system was 0.02, resulting in a separation factor of 8500 between kaolin and silica. The aqueous biphase separation system was used to separate free silica from kaolin in a raw clay sample from Mexico. The partition behavior of mica, feldspar and clay from North Carolina was also evaluated.

Jan 1, 1999

By İbrahim Gunes, ATILA GURHAN CELIK, Eren Komurlu

This study introduces a new apparatus designed to improve the load-bearing capacities and insertion efficiency of split set type friction bolts. Laboratory and site studies demonstrated the apparatus’s advantages in terms of practicality and prevention of buckling. The apparatus temporarily compresses the split tubes, reducing friction during insertion and increasing normal stresses and friction capacity at the bolt-rock contacts.

Jan 3, 2022

By E. Snyders

Two alternative processes for the manufacturing of zircon products were investigated by the South African Nuclear Energy Corporation (Necsa). These were the synthesis of doped-zircon pigments from plasma dissociated zircon, and an upgrading process to convert an inferior grade of zircon into a superior opacifier for ceramic applications. A solid-state reaction process was used to produce doped-zircon pigments. The influence on the colour intensity of the pigments on a ceramic tile were compared for milled and un-milled plasma dissociated zircon (PDZ) material, prior to calcination. Pr-yellow and V-blue zircon pigments produced from PDZ with different degrees of dissociation, were also evaluated. The second zircon beneficiation process entails the upgrading of an inferior grade of zircon to a superior opacifier for ceramic applications. A calcining process in the presence of mineralizers was used to produce the product in a conventional muffle furnace. A pre-milled inferior grade zircon concentrate, with a relatively high iron and alumina content generally not suitable for high quality ceramic applications, was used in this study. The influence of the upgrading process on the opacifying properties of the zircon material was compared to that of commercially available prime grade zircon opacifier products currently being produced in South Africa. The influence of a calcining step in the presence of mineralizers with regard to the milling characteristics of the treated zircon material was also evaluated.

Jan 1, 2005

By Joseph J. Diehl, Brian B. Khalighi

This paper discusses the Queens Water Tunnel, No. 3, Stage 2, being driven by a new Robbins High Performance (HP) Tunnel Boring Machine (TBM).The paper is divided into four sections. In the INTRODUCTION section, a short overview of the scope of the project is presented. In the GEOLOGY section, the geological condition along the tunnel drive is briefly introduced. The TBM DESIGN section discusses the various design criteria and the resulting machine specifications. The paper concludes, in the TBM OPERATION section, with a case history describing the tunneling operation from start-up to the time of the writing of this paper.

Jan 1, 1997

By Peter Loehr

Full-face tunnelling machines were introduced into German coal mines 12 years ago. It was aimed to utilize these highly efficient systems to drive mine tunnels in rock so that the large demand for development work in some mines could be met. A characteristic feature of coal deposits in Germany - and particularly in the Ruhr Area - is a thick overburden strata. Access is therefore only possible through vertical shafts. A network of horizontal drivages leading from these shafts open the deposits between the different mine levels. The hardcoal-bearing formations are multi-folded and heavily tectonically stressed. Apart from a few extensive fault zones there are many single faults of different natures in the carboniferous strata. During the course of decades coal mining has penetrated to ever increasing depths. Nowadays coal is mined from depths of between 600 m and 1,200 m. The effects of ground pressure in connection with extremely varying rock strengths and high temperatures are particular difficulties which have to be overcome during drivage work. The first full-face tunnelling machines to be applied in the mines had originally bee deigned and developed for tunnelling projects. Not only the machines themselves, but also the back-up equipment had to be adapted to meet the special demands of German coal mines.

Jan 1, 1983

By S. A. Shuey, P. Taylor

The recycling of electronic waste (e-waste) tends to be a rather complex undertaking when considering the intimate bonding of materials in the average printed circuit board. The development of a recycling process is further complicated when considering the wide variety of products being generated under the heading of “electronics” as well as the constant change in materials of construction coupled with the speed at which electronics are changing. CSM researchers have undertaken a survey of the current state of pyrometallurgical processing of e-waste. This base-line will set the stage for the development of new recycling technology at CSM.

Jan 1, 2004

The Mine Safety and Health Administration (MSHA) conducted a respirable dust survey to evaluate the effectiveness of a water curtain utilized for dust control on continuous miner sections. The purpose of this survey was to determine if the water curtain was effective in reducing respirable dust concentrations, since several mines currently use water curtains to control miners? respirable dust exposures. The survey was conducted on a supersection of an underground coal mine, which utilized two continuous miners on the same split of air. Each continuous miner alternated taking a cut so that both continuous miners would not operate at the same time. The underground coal mine is located in Knox County, Indiana. The water curtain evaluated in this survey was located in the last open crosscut between the intake side continuous miner and the return side continuous miner. When the intake side continuous miner cuts coal, its exhaust air would be used to ventilate the return side of the section. The intent of the water curtain was to reduce the intake air respirable dust concentration (generated by the intake side continuous miner) before the air stream ventilated the return side of the section. To determine the effectiveness of the water curtain in reducing respirable dust concentrations, respirable dust sampling pumps were placed on both the intake side and the return side of the water curtain. Additional respirable dust sampling pumps were placed farther downstream from the water curtain to monitor dust levels downstream of the water curtain, but in an area where respirable dust would not be created by anything other than the intake side continuous miner or additional section air. The water curtain and the respirable dust sampling pumps were operated only when the intake side continuous miner was cutting coal. The samples were analyzed for respirable dust and quartz content. The water curtain showed minimal effect in controlling respirable dust and respirable quartz dust, but the reduction was so negligible that this survey could not quantify the reduction. The measured reductions are within the accuracy of the sampling equipment.

Jan 1, 2009

High-pressure grinding rolls (HPGR) are an accepted, but continuously expanding, comminution technology. The copper industry has a growing need to process harder ores with progressively lower grades, more challenging metallurgy and increasing demand for efficient bacterial leaching applications. This has resulted in a major focus on HPGR use in a crushing circuit. If the industry is to increase leach extraction while lowering energy costs in high-throughput hydrometallurgical operations, HPGR will be of inherent significance. The following paper summarizes test work on copper leach ores utilizing the benefits of HPGR comminution, while increasing several critical metallurgical parameters. Based on the current work and previous investigations, it was found that HPGR comminution within a crushing circuit, in specific instances, can result in 2 - >10% increases in cop-per extraction. The tested variables are crush size, rock type and copper mineralogy dependence. Various other process parameters may also be optimized.

Jan 1, 2011