Search Documents

By D. J. DeLeo

In recent years the hue and cry of American industry concerning the pressure of foreign competition on the domestic marketplace has become all too familiar to most of us, as we are all well aware, the steel industry has not been exempted from this pressure, reduced production levels, work force cutbacks, and in some extreme cases, plant closings and company liquidations have resulted, new regulations governing imports and quotas have been enacted, foreign trade agreements reached, and more strict regulation enforcement practices undertaken, despite these, and other measures, the impact of aggressive foreign competition has not lessened, the concensus of numerous management consultants is that in order to successfully cope with these problems we must draw on all available technology to provide the tools which will enable us to enhance our management effectiveness, one area requiring particularly close attention in any mining operation is that of managing critical resources - namely time, energy and equipment in a fast and efficient manner, In mining, with critical resources deployed over a large geographical area, any degree of success involved with resource management is dependent upon knowing the current status of all work related activities, if we, as mine operators, are to be more successful in this area, additional tools are a necessity and modern technology has provided a multitude of new options from which to choose.

Jan 1, 1985

By J. A. Herbst

Fine coal cleaning by froth flotation has become common practice in the U.S. with more than 80,000 tons treated in this way per day. In spite of this large tonnage, developments in the automatic control of coal flotation circuits have lagged significantly behind those for mineral systems. One reason such developments have been limited is that instruments have not been available for the on-line measurement of carbon or ash and another critical variables in coal slurries. A second reason is that the influence of the operating variables on coal flotation has not been completely understood. During the last few years some of the required instrumentation has been developed and an improved knowledge of the flotation process itself has occurred through mathematical modeling; as a result certain control strategies for coal flotation are beginning to emerge. This paper attempts to evaluate several control strategies using a detailed flotation dynamic simulator, DYNAFLOAT. After constructing a process matrix for the system of interest, promising alternatives for linking manipulated and controlled variables have been analyzed. In order to develop combined grade and recovery control strategies, the authors found it necessary to construct a grade/recovery map with the aid of the simulator to drive the system to known final, feasible grade/recovery operating conditions. Finally, an advanced strategy which uses an on-line model to identify disturbances and take control actions is proposed.

Jan 1, 1983

By P. T. Bissert, L. Yan, M. D. Klein

"Since 2008, the U.S. Mine Safety and Health Administration (MSHA) has required the installation of refuge alternatives (RAs) in underground coal mines (MSHA, 2008). MSHA requires that RAs provide an environment with breathable air for entrapped miners for a 96-hour period. Heat buildup inside an occupied RA is a serious concern. Without a means to dissipate the heat and humidity generated by the occupants and the carbon dioxide scrubbing system, the temperature and humidity inside RAs could lead to severe discomfort or heat stress depending on the mine ambient temperature before and during occupation of the RA. In its 2006 report, the West Virginia Mine Safety Technology Task Force (2006) recommended an apparent temperature limit of 35 °C (95 °F) for RAs. In Title 30 Code of Federal Regulations Part 7.504, or 30 CFR 7.504, MSHA specifies a maximum apparent temperature of 35 °C (95 °F) inside an occupied RA (MSHA, 2016). The apparent temperature is calculated using both air temperature and relative humidity (Steadman, 1979).Calculations can be used to deter-mine if the air within an occupied RA will reach the apparent temperature limit. In these calculations, the mine temperature could be assumed to re-main constant. With this assumption, the effects of the mine strata thermal mass and thermal conductivity on the heat buildup in an RA are ignored. Re-search conducted by the U.S. National Institute for Occupational Safety and Health (NIOSH) shows that the mine air and strata temperatures surrounding an RA increase when subjected to the heat of an occupied RA (Yantek, 2014). Thus, calculations performed with the assumption that the mine temperature is constant would underpredict the resulting dry-bulb temperature and apparent temperature for a given RA occupancy. The mine air temperature has been used as the basis for RA temperature calculations. However, there has been no research to confirm that the mine air temperature is the appropriate basis."

Apr 1, 2017

By R. J. Sheets

"What is the primary responsibility of geo-engineers in mining? Early in my career, I was asked this question by an experienced engineer. After explaining some various tasks, I was informed that the main responsibility was to monitor. Although this proved true for many cases, I came to understand that monitoring is merely one means to achieve the primary responsibility of a geo-engineer — ensure the safety of all personnel. The potential for groundwater to impact stability allows this responsibility to be shared with hydrogeologists as well. Inherently, we monitor to identify risks; we analyze designs and develop models to mitigate risks; and we are provided opportunities to explain to supervisors the geo-risks to personnel and mine plans that will result from particular courses of action. A couple years ago, I took an opportunity to share experiences from the first several years of my career as a geotechnical engineer with junior geoengineering staff within my company. The intent was to share situations that were a part of my development, so they could learn and understand their responsibility to the safety of all personnel. Similarly, the purpose of this article will be to share these thoughts with new geo-engineers in the industry in order to help prepare them for the challenges they will face.What is our purpose?A senior hydrogeologist shared an experience that occurred in their career. The experienced hydrogeologist had spent some time with the hydrogeology staff, most of them relatively new to the mining industry, to understand how they viewed, and carried out, what they perceived as their responsibility at an active mining operation. After a couple months of observing and mentoring, the senior hydrogeologist met with everyone and posed the question “What is our purpose?” I am sure that most junior geo-engineers would start explaining different tasks or projects that they must complete. The list would include monitor ground water levels, track slope movement, evaluate designs, build models, oversee drilling programs, etc. These individuals did as well their supervisor. After going around the room allowing each individual to answer, the experienced hydrogeologist provided them the real answer to the question: Safety. If you examine the root intent of nearly every responsibility geotechnical engineers and hydrogeologists have, it is to apply our professional skills to ensure the safety of our workforce. When the objective of safety from the geotechnical and hydrogeology disciplines is achieved, inherently accomplishing the mine plan should follow suit, or it should significantly minimize the impact by gravity or ground water."

Jan 9, 2018

By Donald E. Steif

The Tower Mill is a vertical stirred mill using steel balls or pebble grinding media. This device is designed for fine grinding at significant power savings when compared to conventional tumbling mills. This paper describes the machine, its operation, application, and performance for wet grinding.

Jan 1, 1984

By P. B. Altringer

The Bureau of Mines conducted laboratory tests to develop a process for recovering a marketable grade of tungsten from the brine of Searles Lake, Calif. The brine contains only 56 parts per million of tungsten (70 ppm WO3). Using ion exchange resins synthesized by Bureau chemists, 98 percent of the tungsten was extracted from the brine and 92 percent of the tungsten vas recovered as a marketable iron-tungsten concentrate containing 44 percent tungsten as tungsten trioxide. Although major technical problems have largely been resolved, research is progressing to escalate testing in a process investigation unit to provide more reliable data for an economic appraisal.

Jan 1, 1978

By K. D. Dill, S. D. Rosenthal

"This project analyzed the efficiency of incorporating the use of directional drilling technology into coal overburden blasting. Directional drilling is currently in use in the petroleum industry and it is believed that it will be a valuable asset in the mining industry. This project has shown that directional drilling can be a viable technology for use in the coal overburden removal process resulting in increased drill utilization and potential for cost savings. Future work regarding blasting and geotechnical evaluation should be performed to solidify the concept. INTRODUCTION Determine the Potential Drill Utilization Improvements and Rock Fragmentation Requirements Using Directional Drilling in a Coal Mining Overburden Highwall Application was a project funded by Atlas Copco Drilling Solutions (Atlas Copco) based in Garland, Texas. The project was developed and researched by Montana Tech of the University of Montana. This project was intended to show how the use of directional drilling can increase drill utilization, while decreasing costs, without sacrificing overburden blasting results. This paper discusses a review of the literature, the methods performed, conclusions and future work Background Atlas Copco theorized that an alternative approach to drilling a cast blast pattern would be beneficial to coal mining operations by increasing drill utilization and therefore, decreasing overall costs. Increasing drill utilization results in an increase in the amount of time the drill is being productive, more drill bit time in ground. Atlas Copco’s theory is that by incorporating directional drilling in the design of a cast blast pattern, a drill rig could drill multiple directional holes, which are the length of the cast blast, from a single drill set up. A drill goes through a series of steps to complete a blast pattern, these steps include: tramming to the hole location, leveling the drill, drilling the hole, cleaning the hole, and retracting the drill steel. This process is repeated hundreds of times until the whole pattern is completed. The most time intensive part of this process is drilling out the blast pattern. Integrating directional drilling into this process could decrease the overall time it takes to drill out a blast pattern by minimizing the amount of time spent tramming and setting up for each subsequent hole. Tramming and drill set up are two aspects of the drilling process where the drill tool is not engaged with the ground and, therefore, not being utilized. A cast blast pattern designed to utilize directional drilling will allow the drill tool to be “in the hole” longer and will improve drill utilization. This change in drill utilization was analyzed. Drilling and blasting is an integral part of the mining process, without it mining would be a slower process and less material could be mined. Drilling provides holes for explosives to be loaded and then blasted. Blasting has been found to be the most cost effective method of fracturing rock in mining for material removal. Blasting is also used as a low-cost method to move the rock in open cast mines, commonly referred to as cast blasting. A cast blast is a large blast designed to allow for the maximum amount of overburden to be removed using explosives in a single blast thereby uncovering more coal at a lower cost. Not all the material is blasted to cast-to-final, which requires that material to be moved with large mining machinery. Material that is considered cast-to-final is material that has been thrown far enough to never be moved again in the coal extraction process, therefore it is in its final resting place. A typical cast profile and cast-to-final area is shown in Figure 1."

Jan 1, 2017

By N. J. Ferguson

An upsurge in demand for Australian coal has seen a much needed programme for a new generation of coal ports. This paper discusses design concepts in planning a large modern terminal, with the 25 Nt/a Port Kembla and the 50 Mt/a Newcastle facilities as practical examples. The need is emphasised for a studied Master Plan, in-built materials handling flexibility and staged development. Trends in bulk ship design and loading methods are noted. Features of these Australian designs include methods of dealing with poor ground conditions, functional civil engineering for environmental protection and optimal marine structure designs.

Jan 1, 1982

By T. Owen

Not since 1917 has a foreign company developed a standalone, grass roots gold mine in Russia. With. Russia's political changes of the late 1980s, development of mineral prospects once again beckons foreign investors. In 1990, Cyprus Amax began aggressively searching for such an opportunity. Early in 1997, production will commence at the Kubaka gold project located in the Russian Far East, near the Arctic Circle. The Kubaka project is a 1,750-tonne per day open-pit operation that will produce more than 300,000 ounces of gold per year. This paper discusses the challenges of locating such a prospect, doing business in Russia, developing supply lines, identifying work force capabilities, gaining government approvals, securing financing, arranging for gold sales and ultimately building a facility in this arctic region.

Jan 1, 1997

By D. M. Davidson

The economics of geologic exploration have changed materially in the past decade primarily due to the change in three basic factors, namely, increased wages and salaries, increased cost of materials, and a greater complexity in methods of exploration. Following the general economic pattern over the past ten years, exploration costs, have, in general, increased, although there is one heartening exception. A comparative picture is complicated because of advances in techniques which ensue from the introduction of new methods and devices largely for aerial exploratory work, Some of these methods were either in their infancy or unknown before World War II. Geological exploration may well be considered as a form of applied research. True, it has peculiarities from this standpoint some advantageous, others disadvantageous, Some of the advantages lie in the fact that exploration success does not involve the production of a new product which necessitates advertising expense and marketing problems. In normal times there is a well established market for the fruits of a successful mineral find. The outstanding disadvantage of exploration lies in the enigma of deciding when to quit if the sought fop prize is elusive. In the search for buried treasure, man?s curiosity is apt to color his judgment. Even the so-called detached scientist may fall 'all too readily into the wishful thinking of the old- time prospector who is lured on by the thought that the next pull from the drill hole, or the next round from the face will reveal a bonanza. It involves mature judgment and experience to ascertain the stage in exploration when further work is not justified.

Jan 1, 1958

By H. H. Murray

Significant changes in ownership and production of industrial clays have occurred since 2000. Clays covered in this presentation are kaolins, ball clays, smectites, (bentonite), and palygorskite (attapulgite)-sepiolite. IMERYS discontinued production of paper coating kaolins at their Cornwall operations and have expanded their kaolin production in Brazil. J. M. Huber sold their kaolin operation in Georgia to KaMin whose headquarters are in Ft. Worth, Texas. BASF purchased Engelhard?s kaolin and attapulgite operations in Georgia. ActiveMinerals purchased Southeastern Kaolin in South Carolina, Wilkinson County Kaolin in Gordon, Georgia, and Zemex Attapulgite in Quincy, Florida. Chemical Lime purchased Spinks Ball Clay Company in Paris, Tennessee. Most of the ball clays used in Italy and Eastern Europe comes from expanded operations in the Ukraine. Bentonite operations have expanded production in Wyoming and Montana because of strong demand for drilling mud, foundries, cat litter, and iron ore pelletizing. The production and exports of palygorskite in China continues to increase. Nanoclays utilizing sodium montmorillonite, palygorskite, and halloysite are actively being developed.

Jan 1, 2009

By Dean R. Gehring

Creating projects to reach a goal is not new to American industry. In fact, all major construction projects, from skyscrapers to bridges, are completed using similar project management techniques. However, modern project management is relatively new. It was not formalized until 1962, when NASA and the US Department of Defense recognized the need to develop uniform project management procedures throughout the aerospace industry (Moder, Phillips and Davis, 1983). This management method was not introduced to the mining industry until the early 1970s (Britton, 1983). Project management typically follows an organized, four-stage process —definition, planning, implementation and control.

Jan 1, 1996

By Sumit Kumar Hota, Asadi Srinivasa Reddy, Ashok Kumar, Ashish Agrawal, Surajit Sinha, Chandra Sekhar, Tanay Ray

In the current operational facility, due to the absence of pellet pot facility, a novel technique is developed wherein the pellets with different chemistries prepared in the laboratory are fired in an induration machine by placing them inside the Inconel baskets. In the present work, an attempt is made to optimize the pellet chemistry by developing 2 different flux pellets, viz., low basicity (B2: CaO/ SiO2 = 0.3) pellets and high basicity (B2 = 0.9) pellets, and further the effects of basicity on pellet properties, viz., cold compressive strength, porosity, swelling index, reducibility index, and softening and melting temperature, are studied. It has been found through the multiple operational trials that increasing the basicity of pellets from 0.3 to 0.9 results into improving the pellet strength, reducibility and softening and melting characteristics. Moreover, it is observed that the swelling index of pellets is reduced by adding 2% MgO to both low and high basicity pellets that could be attributed to the formation of high melting point slag in pellets. The operational trial has resulted into producing pellets that exhibit a combination of desired mechanical strength, improved swelling, and reducibility index and possess better softening–melting behavior among all the chemistries studied.

May 24, 2022

By R. Bhaskar

The control of respirable dust in mines has been given paramount importance due to the health and safety implications associated with fine dust. The understanding of the temporal and spatial behavior of dust has been recognized as essential for increasing the efficiencies of the existing control techniques and for developing new control strategies. Mining-related studies in this area are, in general, limited. They are also mostly experimental. Some mathematical and computer analyses have been attempted. In this paper, first a review of the mathematical studies performed in the last three decades in this area is presented. Second, a mathematical model for analyzing dust flow in mines is proposed. The model takes into account a number of factors affecting dust transport. It incorporates varying dust generation source strengths and dispersion, deposition, and coagulation of dust in mine airways. Finally, application areas for the model are discussed. A computer program based on the mathematical model has been developed. The program will output the dust concentration in the mine atmosphere as a function of time and distance from the source. The amount of dust deposited on the sides, roof, and floor of the airway is also determined.

Jan 1, 1985

By Gill Montgomery

The problems of the domestic merchant fluorspar producers are more or less common with those of many other producers of metallic and non-metallic minerals. For more than ten years the American fluorspar producers have seen an ever lowering price in the market-place for the fluorspar product, while their labor and material costs-continue to mount steadily. This cost-price squeeze has forced out of business all but a few of the merchant producers, and only two captive producers continue to operate, and one of them has announced early curtailment. The prices of domestic fluorspar, of all grades, have declined because of the competition from cheaper foreign imports, principally from Mexico, Spain and Italy. Tariff protection on fluorspar, particularly on the highest or acid grade, has never been sufficient to cover the production cost differential between foreign and domestic fluorspars. Low ocean and barge freight rates have also contributed to the barring of the product of domestic mines from, the major consuming centers along the Gulf and East Coast. Because of the freight disadvantage, all but one or two fluorspar producers in the western states have had to suspend business. More than 80% of the domestic fluorspar is being produced in Illinois and Kentucky fluorspar districts which adjoin on both sides of the Ohio River.

Jan 1, 1964

By T. G. Melkus

A Setaram C-80 heat flux micro- calorimeter was used to study the surface and interfacial properties of fine coal particles in water containing flotation agents via heat of immersion measurements. Heat of immersion (?Himm) is usually a small exothermic quantity and can be used' to characterize a solid in terms of its relative hydrophobicity or hydrophilicity. The effects of coal type, surface oxidation, mineral matter content, kerosene concentration, and pH on the wetting characteristics were investigated. Results obtained from the calorimetry experiments correlated well with results from independent flotation experiments.

Jan 1, 1987

By Aditya Rana, A. K. Mishra, M. M. Singh, N. K. Bhagat

Many cases of derailments, train accidents and traffic interruptions due to the slope failure and rockfall have been reported in the past on Konkan Railway trackline because of unstable rock slopes. The authorities installed stability enhancement measures such as wire netting, rock bolting and shotcreting which were found insufficient. The failed geotechnical measures prompted authorities to excavate the unstable slopes. Rock blasting is generally not preferred for the excavation of slopes along the transportation route. Stabilisation and widening of slopes by blasting need closure of the route for a considerable time. Discontinuing traffic on Konkan Railway route was undesirable as it connects two important port cities Mumbai and Mangalore. The paper presents an innovative directional controlled blasting (DCB) technique for excavating three unstable slopes (i.e. cuttings) in hilly terrain without disturbing the traffic. New empirical formulae for small geometry blasting to estimate burden and throw have been developed. A unique sequence of firing and excavation with powder factor varying between 0.04 and 0.39 kg/m3 irrespective of the actual free face was used for rock blasting. The process controlled the throw of blasted material over the track and resulted in a smooth and stable wall. The slope angle has been changed from 80 to 82° to 45–47° and probability of wedge, planar and toppling failures was eliminated. About 100 such accident-prone slopes (52 km cumulative length, 7% of total route) situated at discrete locations along Konkan Railway route were stabilised using the technique. No incident of rockfall and slope failures along these slopes has been observed after the stabilisation.

By Edwin W. Tooker

Creation of needed new resources will be accomplished mainly by imaginative and diligent geologic exploration because geologic availability is the key determinant of future mineral supply. Adequate resources of most commodities can be made available for the rest of this century and beyond if they are discovered. Thus conversion of hypothetical and speculative resources into available reserves will provide the principal challenge to earth scientists. Additional problems now compete for our attention. First is a challenge to discover more resources than have been found to date for domestic needs as world-wide demands increase exponentially and as easily found high-grade deposits are rapidly being depleted. New ways to find new types of deposits are required. Second, the United States, a resource importer, increasingly is challenged for access to foreign supplies through stiffening competition and economic or expropriation sanctions. Balancing needs for mineral supply and environmental protection is a third challenge. Geologic explorers must consider statutory as well as economic and technologic requirements, controlled access to public and private lands, competition with urban sprawl or wilderness, limitations on discovery, appraisal and mining methods, and restoration of mined areas. Finally, is the challenge to temper public and private attitudes and assure that decisions bearing on resource problems are based on comprehensive credible facts. While striving to maintain and improve the standard of living, many Americans appear to disdain and mistrust those organizations that provide their material where-withal. Meeting these challenges effectively, and in time, will require careful appraisal of the resource system and the joint efforts of industry, university, and government earth science research.

Jan 1, 1974

By Rameshwar Sah, Basavaraja Maribasappanavar, Sangamesh Desai, G. Balachandran, Ravi Kant Sagar

The present research work deals with the effective utilization of hematite ore containing goethite, kaolinite and gibbsite losson- ignition (LOI) phases in pellet making without deteriorating product pellet properties by optimizing the induration cycle especially drying and preheating of pellets. Adequate drying and preheating of pellets before sintering is of prime importance to sustain the desired properties of pellets. Green pellets of + 8 to − 16 mm size were prepared in a laboratory disc pelletizer and indurated by varying drying and preheating temperatures in a laboratory Raising Hearth Furnace (RHF). Produced pellets were assessed for physical and metallurgical properties. Improvement in drying and preheating temperature simultaneously helped in mitigating fired pellets’ property deterioration. Drying at 300 °C and preheating at 750 °C helped in the maximum removal of matrix LOI from the pellets before firing and enabled the production of pellets of desired properties. Laboratory scale findings successfully implemented at existing 4.2 MTPA capacity pellet plant of JSW Steel Ltd. Vijayanagar and high LOI iron ores (IOs) utilised which resulted in reduction of average monthly pellet fines generation by ~2 wt. %.

Jun 4, 2022

By E. Tondu

Separation Technologies Inc.’s (STI) electrostatic separation technology is a dry, continuous process for the separation of discrete particles. This high-volume process does not require any additives nor is any additional waste produced. In December 1993, STI, in cooperation with New England Power(NEP), installed an 18-t/h (20-stph) prototype electrostatic separator at NEP’s Salem Harbor plant. The plan was to convert waste streams of type F fly ash into commercially valuable products. In July 1995, a second separator was installed at NEP’s Brayton Pointplant. Fly ash feed, ranging from 6% to 25% carbon (loss-of-ignition fly ash or LOI), is separated into <3% LOI “clean” ash and sold as a portland cement substitute in the New England concrete markets.

Jan 1, 1996