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By M. Dobbins

The advent of the more efficient and effective rare-earth roll (RER) separator in the early 1980s began a new era of dry magnetic separation. The RER units quickly became the separator of choice within the materials processing industry. Though RER separators are now commonplace throughout the world, only modest advancements have been made to the original design. This paper details recent, more significant, rare-earth magnetic separation developments. These developments maintain the best features of existing technology while minimizing shortcomings. The discussion includes discerning features that aid in better metallurgical performance. Also discussed are improved mechanical aspects that allow for both easier operation and maintenance. Performance details from various test programs are included.

Jan 1, 2010

By Dan Martz, Bill Moler, David Young, Wally Chen, Matthew Crow, Steve Norris, Tolga Togan

Two 610 m (2000 ft) long tunnels were driven through water bearing silts, sands and clays beneath the Sacramento River using a 4.59 m (15.1 ft) diameter Earth Pressure Balance Tunnel Boring Machine (EPBM). Four sheet pile shored shafts were sunk with and without dewatering. The pre-cast concrete segmentally lined and grouted tunnels were driven down at 6% grades beneath the river flood protection levees, buildings, roads, a railroad and adjacent to a Freeway Viaduct. Details of the schedule, cost, shaft construction, TBM, tunnel construction, and installation methodology for the twin1.676 m (66 in) steel force main pipes and environmental constraints are provided.

Jan 1, 2007

By Y. Q. Zhang, S. S. Peng

Numerical modeling was used to design the pillars and bolting plan for a mine with weak roof and multi-seam stress condition. Previous mining experience, pillar/roof yielding and in-situ horizontal stress were considered in the models. By modeling the upper seam yielding and vertical stress transfer, a multi-seam influence zone was obtained. Appropriate pillar sizes were designed for conditions with and without upper seam stress influences. Roof support for the track and belt entries, using fully-grouted resin bolts and cable bolts, was proposed and implemented in the model. The bolting plan was evaluated under the weak roof condition.

Jan 1, 2004

By Steve Kral

The mining industry has had three difficult years. Commodity prices have remained low and investor confidence in the industry has been shaken. And even though the Asian economy appears to be improving, it will be some time before this improvement will translate into better commodity price conditions for mining. In addition, increased environmental and social restrictions that have been placed on the industry in developed and developing countries have made mining a more difficult proposition. And, if that is not enough, the global mining industry has found itself in fierce competition with Internet businesses for investor capital. Despite that gloomy picture, more than 10,500 mining industry professionals from about 70 countries gathered in Toronto, Ontario March 5-10, 2000 for the Mining Millennium 2000 conference. This meeting was a joint effort between the Canadian Institute of Mining, Metallurgy and Petroleum(CIM) and the Prospectors and Developers Association of Canada (PDAC).The joint meeting also featured two trade exhibitions and more than 150speakers. PDAC’s trade show attracted about 400 exhibitors and an additional 200 in the concurrent Investors’ Exchange. CIM’s exhibition attracted about 600 equipment and service companies.

Jan 1, 2000

By Michele Ashby

The mining industry is facing new risks from peak commodities, the energy and economic crisis and stock market pressures. The Green Mining Industry Initiative is a risk management strategy for the future of the mining industry. Defining the Risks The bad news is peak commodities, energy and economic crisis and stock markets collapsing are the issues that are already hitting everyone?s bottom line and draining the treasuries of every mining company around the world. Higher energy costs are affecting the bottom line more than ever before, which is creating more risk for companies. Mining companies have major land positions around the world and they have major energy needs. Uncontrollable increases in energy costs, increased regulations for diesel fuel emissions and energy intermittencies are costing mining companies more time, money, and man-power, which are cutting into profits and hitting the balance sheet. The good news is, there are practical energy solutions which are off the grid, tried and true methods which can be implemented in a cost-effective manner and will increase profitability and save shareholder values as well as energy security for these companies and their projects. To date, most of the mining resource industry has not yet considered or used other forms of power like clean, sustainable, or alternative energy for their own energy needs. The reasons have primarily been pushback from the mining industry due to beliefs of older technologies in alternative energy, a lack of understanding of the cost advantages long term, and perceptions of environmental relativity.

Jan 1, 2008

By James W. Bass

Introduction Atmospheric fluidized bed combustion (AFBC) is an improvement over coal-fired boiler design. It offers several advantages over conventional boilers. AFBC can meet sulfur and nitrogen oxide emission regulations without the need for add-on flue gas treatment equipment. The relatively low combustion temperature inhibits ash melting, thus reducing slagging and fouling that can in turn increase a boiler's fuel flexibility. AFBC process The fluidized bed boiler that operates at atmospheric pressure on the fire side (AFBC) is relatively simple and no different in purpose from those pulverized coal boilers used by utilities today. Fluidized bed boilers can generate steam at the pressure and temperature needed by modern steam turbines. Only the firing system is different. In fluidized bed combustion, the fuel can be almost any coal or waste fuel. It is burned in the presence of a bubbling bed of limestone. Air is forced through the bed at a velocity sufficient to support the weight of the bed particles. When the bed is fully fluidized, it bubbles like a boiling liquid. Although the burning coal makes up less than 1% of the fluidized bed, all the bed particles are heated quickly by the turbulence. The calcium in limestone reacts with sulfur dioxide produced in coal combustion to form calcium sulfate in a dry solid state. In this way, sulfur emissions regulations can be met without installing flue gas desulfurization equipment. Boiler tubes submerged in the bed absorb heat directly from the turbulent solids. The heat converts water in the tubes to steam or superheats the steam. Because of the intimate contact of the boiler tubes with the fluidized bed, heat transfer is highly efficient. Consequently, less boiler tubing surface is needed to generate the same amount of steam as in a comparable pulverized coal boiler. The optimum temperature for sulfur capture is relatively low, about 815°C (1500°F) as opposed to 1370°C (2500°F) for pulverized coal boilers. This results in the formation of lower levels of NON. Because operating temperatures are below those that fuse coal ash, a single design can burn a variety of coals without slagging or fouling problems. TVA's AFBC development program Tennessee Valley Authority's (TVA) involvement in AFBC development began in 1974 and has addressed the technical uncertainties through a comprehensive program of design, experimental, and analytical studies. In 1979, TVA and the Electric Power Research Institute (EPRI) developed plans for a 20-MW AFBC pilot plant, a 10-fold scale-up over the next largest test facility. Pilot plant design features TVA constructed the pilot plant at the Shawnee Steam Plant near

Jan 4, 1986

By Murat Erdemoğlu, Turan Uysal, Thierno Saidou Barry, Mustafa Birinci

The rapid development of the global alumina and aluminum industry is straight coupled with the demands and the needs of these materials. Nowadays, the only well-known accessible resources to produce alumina and aluminum are bauxite ores. But bauxite ores are limited, and the remaining exploitable reserves do not have high contents in alumina. In countries where there is little or no bauxite reserves or where the recovery of existing bauxite ores to produce alumina with the Bayer process are not economic, alternative resources for alumina have been explored. The most attractive resources for replacing bauxites are aluminosilicate clay minerals and coal fly ash. The important processes developed for the recovery of alumina from these sources are acid leaching and alkaline leaching processes. The acid leaching is known as the most efficient in which thermal and mechanical activation are included for improving the performance of the process. The objective of this review is to give a comprehensive insight on the production of the alumina from thermally or mechanically activated clays and coal fly ash by hydrochloric, sulfuric, and nitric acid leaching processes.

By V. L. Franzen, Z. J. Hladysz, C. A. Kliche

The Wharf Resources mine, located in the Bald Mountain Mining District approximately 6.4 km (4miles) west of Lead, South Dakota, has operated a surface gold and silver mine and heap leaching processing facility since 1983. Wharf Resources intends to mine and process gold and silver ore from the Wharf Expansion area which is located on the eastern flank of the currently permitted Foley Ridge Mine. The Trojan Pit for the Wharf Expansion area was initially designed with an overall highwall slope angle of 45o. During mine permit presubmission meetings with personnel from the SD Department of Environment and Natural Resources (SD DENR), the question arose as to whether a detailed slope stability analysis of the proposed Trojan Pit highwalls was completed to justify the 45o slope. Wharf’s response was that the highwall design was based, in part, upon studies completed in1987 on the Annie Creek and Foley Ridge Mines; and, in part, upon subsequent slope stability analyses conducted by Wharf mine personnel through 1996. It was suggested by the SD DENR that the stability study be updated to reflect structural geological conditions in the Wharf Expansion area.

Jan 1, 2000

By O. A. Bascur

The lack of integration of mining and metallurgical information with sufficient detail for analysis causes inefficient operation and hence sub-optimal energy and water use. It is difficult to analyze the performance of mining and metallurgical processes without an integrated view of mine transactions, stockpile inventories, process flows and assays. To take action requires real time information from manufacturing assets, corrected for gross errors from trucks, shovels, conveyors, faulty sensors, bad instrument calibration. This paper presents an infrastructure with advanced tools that sift through available data, identify and eliminate gross errors, and transform the data into business information for continuous improvement and optimization. Collaboration is a key component of improving efficiency of energy and water use, and the evolution of Web technology enables collaboration and troubleshooting of plant information to more quickly act on issues to reduce wasteful operation. Keywords: Mine Concentrator Optimization, Real Time Performance Management, Data Unification, Integration of Operational and Business systems, Mass and Energy Balances, Real Time Web Services, Equipment Availability, Efficiency.

Jan 1, 2009

By William H. Langer

Large amounts of limestone fines co-produced during the processing of crushed lime-stone may be useful in the sequestration of carbon dioxide (CO2). Accelerated weathering of limestone (AWL) is proposed as a low-tech method to capture and sequester CO2 from fossil fuel-fired power plants and other point sources such as cement manufacturing. AWL reactants are readily available, inexpensive and environmentally benign. Waste CO2 is hydrated with water to produce carbonic acid. This reacts with and is neutralized by limestone fines, thus converting CO2 gas to dissolved calcium bicarbonate. AWL waste products can be disposed of in the ocean. Feasibility requires access to an inexpensive source of limestone and to seawater, thus limiting AWL facilities to within about 10 km (6 miles) of the coastline. The majority of U.S. coastal power-generating facilities are within economical transport distance of limestone resources. AWL presents opportunities for collaborative efforts among the crushed stone industry, electrical utilities, cement manufacturers and research scientists. There is a concern that CO2 generated from human activities is contributing to climatic and environmental changes. Approximately one-third of anthropogenic CO2 emissions come from burning fossil fuels to generate electricity. Each power plant is capable of emitting several million tons of CO2 annually. A variety of other industrial processes, such as cement manufacture, oil refining, and iron and steel production, also emit large amounts of CO2. The level of atmospheric CO2 can be reduced by capturing CO2 from point-source emissions and storing or sequestering it in isolation from the atmosphere (U.S. Department of Energy, 2003). In 1999, G.H. Rau and K. Caldeira proposed a geochemistry-based method that is referred to as accelerated weathering of limestone (AWL) in a paper titled ?Accelerating carbonate dissolution to sequester carbon dioxide in the ocean ? geochemical implications.?

Jan 1, 2009

By Russell Barr

Strategic alignment throughout a mining organization is critical to effective strategic execution and good business performance. The alignment of strategic goals and objectives in the different operations and functions in a large global operation is a challenge facing executive management in light of legacy organizational structure and processes. An additional confounding factor in strategic alignment of acquisition and new project expansion is that mining projects and operations are frequently multi-cultural in terms of country origin as well as organizational culture. This brings together many cultures to accomplish the project or complete an acquisition (Financial Times, 2006). The mining industry presents numerous challenges to executives and mine management by the nature of the operation and organizational processes used in running it. For example, there seems to be an inherent conflict between the individual goals of the components that constitute a mineral processing operation (the mine, the mill, the smelter and the refinery), and lowest cost production of the final product. Managers of these component operations have specific objectives passed down from the corporate executives. Those site managers tend to be compensated based on throughput and perform to this main metric. This tendency to maximize throughput for an individual operation can contradict the general process flow of a best-fit solution to producing the final product at the lowest cost. In an effort to become more aligned, firms are increasingly using balanced scorecard derivatives at great cost and effort (whether internally or externally sourced) in an attempt to help with strategic alignment. Balanced score-cards have been effective in providing a good strategic scorecard to companies with some measure of strategic alignment. Many firms make this effort of using balanced scorecards. However, most firms are not strategically aligned or, at best, are sub-optimized, in terms of strategic alignment (Kaplan and Norton, 2006). The tendency in mining operations is to focus on operating individual components as optimally as possible and stretching existing assets to the best possible production rates. ?Making tons? is the common operational focus. Numerous factors underpin this focus and can affect the ability of the operation?s ability to align properly with the corporate strategy and strategic goals. Critical factors are legacy organizational structure, culture, processes and performance measurement systems. Changing anyone of these factors to affect better strategic alignment requires significant attention to managing change.

Jan 1, 2008

By Alain S. Kivava, Olawale K. Aromolaran, Charles Nzolang, Anthony T. Bolarinwa, Georges M. Kasay

Rare earth elements (REEs) are crucial in high-tech and green technologies. The Democratic Republic of Congo (DRC), rich in mineral resources, shows potential for REE deposits in carbonatites, pegmatites, and placers. This paper reviews global REE resources, highlights potential REE targets in Africa, and emphasizes the need for further research and exploration in the DRC to unlock its REE potential.

Feb 4, 2022

By R. Unger, L. Mallett

The use of virtual reality (VR) technologies to train miners is an evolving area in research and development. In July 2006, representatives of 14 international organizations met to discuss current VR-related efforts and explore ways to employ VR in the future. This paper gives an overview of the various approaches presented at the meeting and discusses directions for future implementation. An example of a training package that teaches mine map-reading skills is presented. The meeting was the first step to building collaborations for furthering VR applications for mining. Planning has begun for a 2008 meeting open to broader participation.

Jan 1, 2007

By K. R. Griffin

Atmospheric conditions underground are constantly changing and from a safety perspective, it is critical to identify when conditions are trending abnormally. Atmospheric monitoring in underground coal mines allows mine operators to analyze atmospheric conditions underground in real-time. Real-time monitoring can then be used to identify whether atmospheric conditions underground have become problematic. The implementation of a risk assessment and management process allows operators to then use a risk-informed decision making to identify comprehensive site specific ventilation parameters. Establishing risk-informed ventilation parameters and tracking conditions relative to these parameters, management can modify ventilation plans as mine conditions develop to manage evolving risks. Ventilation risk assessment and management allows developing atmospheric monitoring technologies to be fully utilized in order to increase safety standards in the United States. This paper reviews general risk assessment approaches, state of the art ventilation based risk assessment, and the risk assessment and management application within the United States regulatory framework.

Feb 27, 2013

By E. C. Robertson

D.G. Wilder I found the suggestion that the amount of displacement of a fault can be numerically related to the thickness of gouge or breccia to be both intuitively satisfying and intriguing. I have long agreed that there is some type of relationship between the amount of gouge and the amount of displacement of faults. I congratulate the author for developing a numerical relationship between them. However, I am concerned that the limits for applying this relationship be fully understood. An underlying assumption in this approach is that there is either a uniform thickness of gouge or breccia along a given fault or the thickness does not vary widely. Since it is not always possible to confirm this, the displacements derived by this method should be viewed with caution unless significant fault extent can be observed. At the Nevada Test Site, in drifts constructed in granite for test emplacement of spent nuclear reactor fuel, we found a fault with 0.3 to 0.4 m (12 to 16 in.) of clay gouge. Within a few meters of this location, the fault had no clay gouge, but rather consisted of a highly fractured zone with significantly altered rock and some slickensides. Based on Fig. 1, the 0.3 to 0.4 m (12 to 16 in.) thickness of gouge would indicate a displacement in excess of 30 m (98 ft). However, no gouge thickness would indicate essentially no displacement. Based on a quartz vein that terminated on the fault, and is not identified nearby, an estimated displacement of more than a few meters was made. This estimate is consistent with that obtained using the regression line proposed in the paper if the 0.3 to 0.4 m (12 to 16 in.) thickness for the gouge is used. However, using the regression curves with zero thickness would not yield results consistent with what was observed in the field. Therefore, it is important to recognize that the suggested procedure would properly yield a range of probable displacements. ? *Work performed under the auspices of the US Department of Energy by the Lawrence Livermore National Laboratory under Contract W-7405-Eng-48. Reply by E.C. Robertson It is certainly true that the t (thickness) of gg-bx (gouge and breccia) on a fault does vary along the fault. My observations have been that near the termination of a fault, the displacement d is small and the t is also small, whereas the maximum d and t will usually be found in the central part of the fault. The information on gg-bx and t of the fault found in granite in the NTS tunnel by Mr. Wilder could be interpreted somewhat differently than he does. He speaks of the fault changing within a few meters from 0.3 to 0.4 m (12 to 16 in.) of clay gg to "a highly fractured zone with significantly altered rock and some slickensides," but no gg. The highly fractured rock may be taken to be bx, rock not so finely ground as gg but still crushed by the fault movement, equivalent to the gg in my usage, and probably occupying about the same t. Mr. Wilder's estimates for the fault in the NTS tunnel for t of 0.3 to 0.4 m (12 to 16 in.) and for d of a quartz vein, in excess of "a few meters," would place the point on the low side of the central trend line in my Fig. 1, at the lower limit. There is, of course, a problem with determining d using displacement of only one planar surface. It would be greater or lesser depending on the rake of the movement. Finally, estimating the d of a fault from its t should be made with awareness of our present uncertainties, as pointed out by Mr. Wilder. Although the central trend line in my Fig. 1 has a ratio of d/t of 100, I have put the limiting ratios at 10 and 1000. Understanding of the values of the ratio will be improved only with collection of more data, for which the discussion of Mr. Wilder is much appreciated. G.C. Waterman E.C. Robertson's paper provides significant information to a geologist attempting to deduce fault offset by noting the products of structural dislocation. However, considerable mapping in underground and open-pit mines, and examination of structures produced in different geological settings, have convinced me that gouge and breccia thickness are controlled by geological conditions and fault movement. The following paragraphs suggest geological variables that control them. 1. Depth of Loading A near-surface fault resulting from tensional stress has more breccia/gouge than is produced by a similar stress at considerable depth. A deep-loaded compressional stress may produce a linear zone of schist, or structural dislocation may occur along an earlier formed belt of schist. Such "shear zones" are common in Canadian mines in precambrian rocks. In neither case can offset be directly deduced by an analysis of the minimal gouge/breccia in the shistose rocks. At greater depth, stress may be partially to wholly relieved by flowage. I vividly recall first noting the regional "Midas Thrust" in the Lark mine, Bingham Mining District, UT (where we called the structure the North Fault). My recorded notes, as I remember them, showed a narrow gouge streak separated the `Jordan" and "Commercial" limestone units from impure, muddy limestone beds of uncertain stratigraphic position. The visible structure did not indicate the great importance of this premineral fault

Jan 12, 1984

By H. Sato, B. Thornton, K. Nishi, A. Usui

"Northwestern Pacific submarine seamounts are believed to be future marine mining areas of ferromanganese crusts, which contain hi-tech industrial metals, such as Co, Ni, Te, Ti, Pt, and REEs. The Takuyo No. 5 seamount is a member of the Cretaceous super-plume seamounts in the north Pacific, located within a Japanese EEZ (100 nm from the Minami- Torishima Is. or Marcus Is.), and only 300 nm away from the Japan’s Licensed area for exploration of Co-rich ferromanganese crusts under the ISA. This is an on-going program supported by independent academic communities but not a state-run program or managed by private funding.We have observed, sampled, measured, and analyzed the occurrences, distribution, physical properties, and microbiological environments at a selected flat topped seamount named Takuyo No.5 as a model area for scientific study of ferromanganese crusts within the Japanese EEZ. We then characterized crust structures, composition, age, and growth history, resulting in an understanding of the overall nature and distribution of these deposits from wide range of areas, water depths and geological environments. The study started with a ROV (Hyper-Dolphin 3K of JAMSTEC) exploration jointly with universities and national institutions (Japan Agency for Marine-Earth Science and Technology, Japan Oil, Gas, and Metal Exploration Corporation, and Geological Survey of Japan) in 2009 using marine geology vessels, remotely-operated vehicle, an oceanbottom drill machine, deep-tow TV camera, as well as conventional dredges and corers. We have been studying the topography, geology, nature of the bottom material of the seamounts using delicate sampling devices and measurement tools, and characterized the distribution patterns of the metal-rich ferromanganese deposits from chemical, mineralogical, and microbiological points of view."

Sep 1, 2014

By Georgene Renner, William R. Yernberg, Steve Kral

ABB offers complete electrical revamps of mining shovels with ac or dc drives, drive control, frequency converters with insular gate bi-polar transistor technology, intelligent control packages and visualization. Many of the world’s shovel excavators and draglines (walking excavators) were built in the1980s. After 15 to 20 years of round-the clock operation in openpit mines, these machines start to feel their age. Electrical parts are particularly vulnerable. Their performance deteriorates and availability and productivity fall. Even with regular ser-vice and maintenance, a machine of this age will accumulate 400 hours of unscheduled downtime a year. The need for a replacement becomes pressing, but the expense is often prohibitive.

Jan 1, 2005

By Don W. Deere

Faults under high rock cover represent some of the most severe ground conditions a Tunneler can encounter. High ground water pressures and flows are usually associated with mountain faults. Ground behavior can range from blocky ground to flowing sands and squeezing clays. Sticking a IBM within a fault zone for many weeks, with the disastrous financial consequences, is still a common occurrence. Interpreting the geology and detecting the location of a fault prior to penetrating it is a fundamental step to successful tunneling. Ground water control through predraining or pre-grouting is the second fundamental step. This paper discusses techniques applied for detecting and crossing mountainous fault zones through the use of case histories across the globe.

Jan 1, 2007

By D. Parks, A. Miller, M. McNinch, R. Jacksha

Each year, hundreds of mine workers are involved in machinery-related accidents. Many of these accidents involve inadequate or improper use of lockout/tagout (LOTO) procedures. To mitigate the occurrence of these accidents, new safety methods are needed to monitor access to hazardous areas around operating machinery, improve documentation/monitoring of maintenance that requires shutdown of the machinery, and prevent unexpected startup or movement during machine maintenance activities. The National Institute for Occupational Safety and Health (NIOSH) is currently researching the application of Internet of Things (IoT) technologies to provide intelligent machine monitoring as part of a comprehensive LOTO program. This paper introduces NIOSH’s two phase implementation of an IoT-based intelligent machine monitoring system. Phase one is the installation of a proof-of-concept system at a concrete batch plant, while phase two involves scaling up the system to include additional sensors, more detailed safety/performance metrics, proximity detection, and predictive failure analysis.

By J. Kretschmann

Around the world, mining has been done for thousands of years for the benefit of humankind. The winning process in mining operations ends with the depletion of the deposit or its closure if the operation becomes economically unprofitable. After that, a period of post-mining follows which may last for a very long time and which is generally regarded as a period of hazards, risk and high cost. In the USA alone, approximately 500,000 abandoned mines do exist; worldwide, there are millions. In Germany, too, we have had to deal with abandoned mines for a considerable period of time now.

Jan 1, 2012