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By F. Stanley, A. Noble, G. Luttrell

"The supply chain for coal-fired power stations involve a multi-stage network of mining units, preparation plants, blending facilities and transportation systems. Attempts to optimize the supply chain have historically been difficult due to the lack of communication/coordination between the various groups involved in coal production, transportation and utilization. In light of this issue, a new approach for globally optimizing the coal supply chain called Micro-Price Optimization has been developed to simplify the optimization problem and to provide coal producers with fundamental insight needed to improve the profitability of their operations. This fundamental concept assigns unit values to each particles (or groups of particles) passing through production units. Optimization occurs whenever the maximum tonnage of positive value particles are recovered and passed to market, while the minimum tonnage of negative value particles are recovered. Elements considered by the concept include factors such as target boiler cost/efficiency, waste disposal costs, coal quality parameters, emission penalties, transportation charges, or other quantifiable impact factors. This article reviews the basis for the micro-price concept and provides a detailed industrial case study involving the determination of optimum coal qualities that need to be supplied by mine operators to feed a coal-fired power station. INTRODUCTION The performance of coal preparation plants have long been known to play an important role in determining the overall profitability of mining operations. This significance is due to the fact that the misplacement of just 1 ton/hr of clean coal to reject resulting from poor plant performance can represent nearly $300,000 per year in lost revenues for a mine producing a steam market coal (i.e., 1 ton/hr x $50/ton x 6,000 hr/yr = $300,000/yr). This loss can be even more pronounced, occasionally approaching $1 million per year for each 1 ton/hr of misplaced clean coal, for operations producing high-quality coking coal products sold into the premium metallurgical market (i.e., 1 ton/hr x $150/ton x 6,000 hr/yr = $900,000/yr). Detailed economic studies indicate that improvements in plant yield resulting from increases in organic efficiency have one of the largest overall impacts on mine revenue when compared to other cost centers within the mining operation. One of the first studies to show this important financial impact was reported by Norton-Hambleton Consultants (Norton, 1979). Their study indicated that an unfavorable change in plant efficiency was second only to coal transportation in terms of its impact on profitability, while an unfavorable change in the cost of underground mining was a distance third. This longstanding realization has continued to provide a strong financial incentive for coal producers to optimize the separation efficiency of their coal processing and blending operations."

Jan 1, 2015

By Lester G. Rollins

Coal today enjoys a dominant position, serving the energy and metallurgical marketed The measure of success in the market place is, and will continue to be, the price per million BTUs or price per ton delivered to the user. The Coal Industry's remarkable record of price stability since World War II is well known. The next twenty years promise to be equally as challenging. This challenge will be met our president, Mr. Drain, has often stated that, ?The Joy Manufacturing Company is betting that coal will meet the challenge.? To this end, the resources of Joy have been committed to doing its part. Joy's efforts are directed toward a target which has been defined as: 1. Deliver coal to the user at a price of $.15/MBTU or less. or; 2. Deliver coal to the mine portal at a cost of $1.00 or less.

Jan 1, 1966

By D. -P. Georgescu

A native sulfur mineralization associated with pyrite and iron oxides containing 20% iron was quarried in Calimani Mountains, Oriental Carpathians. The wastes resulted from this exploitation activity, with a volume of 33 millions m3, were stored in four dumps while the wastes resulted from ore processing using flotation and the subsequent treatment were disposed of in a settlement pond. The investigations carried out in the entire mining area focused on the following two aspects: - the impact of environmental factors mainly on the hydrographic network; - the characterization all pollution sources, namely dumps, leachates and the quarry and the assessment of acidic drainage generation. The total sulfur content of the excavated ore was 3.8% while in dumps it ranged between 0.54 and 1.06%. Analysis of samples collected along the hydrographic network, draining the mining area, resulted in pH values ranging between 1.7 and 2.83 as well as high concentration of iron (4525 mg/L to 1.6 mg/L), copper (1.87 mg/L to 0.04 mg/L) and zinc (13.13 mg/L to 0.3 mg/L). Samples from the quarry, the dumps and the tailings pond were analyzed in order to deter-mine: - the maximum potential acidity (MPA); - the acid neutralization capacity (ANC); - the net acid production potential (NAPP).

Jan 1, 2005

By J. H. Adkins

The goal of the project reported in this paper was to make recommendations for changes in roof bolting procedures and bolter design that would reduce roof bolter accident rates. To that end the project identified the major hazards associated with each task a roof bolter operator per-forms, normalized task accident frequencies. by the time spent on each task, reviewed equipment design features and operating procedures related to the identified hazards and developed recommendations for equipment and procedural changes that would reduce, if not eliminate, the hazards. The research steps completed during the project were: a. A review of related literature and re-search including roof bolting time studies b. The collection and analysis of 1975 accident data pertaining to roof bolter activities c. The normalization of the accident frequency data on the basis of time/task data d. A review of roof bolting equipment e. The development of a field data collection instrument f. The selection of mines for bolter observations g. The collection of field data h. Data analysis and problem specification i. The development of recommendations for corrective measures

Jan 1, 1978

By Erich Sarapuu

Today's increasing needs for rapid excavation have stimulated efforts to break rocks without explosives. The application of electric energy for this purpose has been studied by a number of investigators. Following principles have been used in electrical rock breaking: 1. induction heating5 2. high frequency heating4, 14 3. microwave heating6 4. contact resistance heating9,12 5. resistance heating11,13 6. electron beam heating1, 3 7. plasma jet heating2, 8 8. arc heating7 9. condensor discharge energy14 In this paper the presentation of the principles of electrical fragmentation is limited to a process called "electrofracing". This technique uses electrical heating of rock by electrode contact resistance9 and resistance heating" phenomena. The electrically induced stresses inside of rock generate forces which break up the material. The fracturing of ore takes place by tensile stresses instead of compressive forces. The electric energy merely creates fractures in the rock and the separation of fractured material takes place by subsequent mechanical handling. Energy requirements in secondary breaking of iron ores have been about one to two kilowatt-hours per ton of ore. Power requirement is a function of the degree of fragmentation.

Jan 1, 1969

By J. F. Power

Returning the original soil material to the surface of smoothed mine spoils is n practical means of restoring agricultural productivity. Research has established that high-sodium spoils in North Dakota (a) must be covered with about 70 cm of soil material to achieve maximum production; (b) topsoil must be segregated and spread separately from subsoil; (c) potential production depends on the quality of the soil material returned; and (d) erosion and upward salt movement must be controlled for sustained production. Erosion is best controlled by reducing final grades as much as possible during the smoothing process followed by prompt establishment of vegetation. Almost half the nation's cool reserves are in the Northern Great Plains underlying several million hectares of agricultural land. Social pressures to return mined land to agriculture or other productive uses have resulted in recent enactment of state and federal legislation, which is intended to restore productivity to disturbed areas. All such legislation relating to the Northern Great Plains has stipulated that useable soil material be saved and returned to mined land after spoils are smoothed. This requirement immediately raises questions as to how much soil material is needed, what criteria are important in defining useable soil material, how is the soil material to be handled in the earth-moving operations involved, and how can replaced soil material be maintained and revegetation. Scientists at the USDA Northern Great Plains Research Center at Mandan, North Dakota have conducted research on the reclamation of disturbed lands since 1970. Initially this research was designed to identify and characterize those physical and chemical properties of spoils that are most restrictive to plant growth (1). Basically, they found that any properties of spoils that reduced the efficiency of storage and utilization of the limited precipitation received adversely affected plant growth. Thus, in the Northern Plains, revegetation of mined land was found to depend upon the management of factors affecting the availability of water to plants - the same as on unmined land. After the major problems in revegetation were identified, technologies were developed to circumvent the effects of the growth-limiting factors (2). Basically two approaches were identified by which plant growth-restricting properties of spoils could be corrected: (a) various amendments (gypsum, sulfur, Fertilizers, mulches, calcium chloride, etc.) could be applied to spoils to improve their ability to conserve precipitation and provide water for plant growth; or (b) undesirable spoils could be covered with suitable soil materials to reduce or alleviate adverse effects. The latter approach appeared to be more feasible in most instances And is the approach specified in current legislation. The remainder of this paper discusses research on the use of roil materials returned to spoils and summarizes the information obtained.

Jan 1, 1978

By C. S. Wageman

Staying competitive in the highly aggressive Powder River Basin is a challenge facing all operators. Any advantage that a mine utilizes to improve productivity and reduce costs could mean the difference in the tight spot coal market. Technological advances in mining equipment and data acquisition at the Eagle Butte Mine in Gillette, Wyoming result in productivity gains and increased maintenance awareness. A new overburden haulage truck fleet with an onboard payload and fault monitoring system interacts via telemetry with the loading shovel and PC's located in production and maintenance offices, enabling staff to monitor production and maintenance on a real-time basis. This paper will describe the system and highlight the benefits realized as a result of its implementation.

Jan 1, 1996

By A. Noble

For the past 30 years, process flowsheet design has been accomplished largely through modeling and simulation. This approach provides circuit designers the freedom to test various separation approaches while minimizing physical and human resource requirements. The Limn® software provides a unique approach to process simulation, through a Microsoft Excel interface. While the software comes with standard process models for numerous unit operations, the Excel calculation environment and the accompanying VBA platform provide a convenient interface for custom model integration, even for non-experienced programmers. This feature is especially useful for university students in introductory process modeling and simulation-assisted flowsheet design courses as well as experienced practitioners with proprietary process models. This paper shows how the Limn® software may be used to solve basic process engineering problems as well as more comprehensive circuit design challenges. Industrial examples as well as opportunities for training and education are presented.

Feb 23, 2014

By O. Ozdemir

Soda ash, an essential raw material for major industries, such as the glass, chemicals, soap and detergents, pulp and paper, mining and water treatment industries, is traditionally produced by chemical and thermal treatment of trona ore. The treatment processes for trona ore are not only chemically expensive but also energy intensive. Hence, the production of a high-purity trona concentrate at a lower energy and operating cost is of considerable interest to the trona industry. In this study, we describe a possible two-stage process for concentrating trona ore, involving dry magnetic separation followed by flotation, to remove insoluble impurities from the trona ore. The results showed that a trona concentrate of 91.7% purity with a recovery 91.1% can be obtained by two-stage magnetic separation, which could be further improved to 98.1% purity at a recovery of 83.8% by subsequent flotation of the non-magnetic trona product. The purity of trona concentrate is limited by the particle size and impurity content of the trona ore. The operating parameters for magnetic separation and flotation have been identified to obtain an acceptable quality concentrate.

Jan 1, 2011

By Fouad Faraj

For every blast pattern, zones of unique material types need to be classified before mining. Most material types can be summarized into different kinds of ore and waste. Blocks generated from blasthole assays are too small to be selectively mined, so areas with a single material classification meeting the mine’s selective mining unit must be defined. Current industry standard practices are to manually draw ore/waste dig limits, but this process is subjective and results in quantities of dilution and ore loss that can be improved upon to enhance the profitability of mining operations. In this study, two weeks of production data from a homogeneous copper (Cu) porphyry and heterogeneous manto-type Cu deposit were used to assess the variability in the hand-drawn dig limits of 20 geologists, mining engineers and ore control specialists, which were compared with the optimal ore/waste delineation. The profit for 20 distinct hand-drawn dig limits for the homogeneous mine varied by 3.7 percent, from $10.5 million to $10.9 million, averaging at $10.8 million. The percentage was nearly double for the more heterogeneous mine at 5.9 percent, from $17.9 million to $19.0 million, averaging at $18.6 million. Using the optimal ore waste delineation, the profit increased to $11.0 million (1.9 percent increase) and $19.3 million (7.0 percent increase) for the homogeneous and heterogeneous deposit, respectively. The natural variability, diggability requirement and selectivity are identified as the main drivers of ore loss and dilution. Recommendations are provided for reducing the subjectivity in manual hand-drawn dig limits by integrating dig limit optimization algorithms as a tool to assist practitioners.

Oct 1, 2024

By A. Haghighat

The Missouri University of Science and Technology?s (Missouri S&T) Experimental Mine is a teaching and research facility which has been excavated in limestone by mining engineering students over almost 100 years. The mine is currently being extended to a second level. Available fans for ventilation are two surface fans of 24 kW and two underground booster fans of 12 kW. The design of a ventilation network in conjunction with multi surface fans and booster fans entails a complex procedure. Ventsim Visual software modeling has been used for network analysis to determine the optimum surface and booster fans locations, blade settings, and speeds. Both natural and mechanical induced ventilation pressures have been taken into account. Three working faces on each level have been designated as target points that minimum air quantities are required. The model has been calibrated against a pressure and quantity survey. Design of ductwork, door/stopping positions and different fans characteristics have been examined. The optimum flow rate at identified working faces, efficiency and minimum energy losses and annual network power cost determine the best scenario. The optimum design has been determined for the ventilation network for the next 100 years. The optimum flow rate across working faces is the key criterion selected.

Feb 23, 2014

By A. Iannacchione

Most legacy drift mines entered the coal reserve from outcrop and developed up-dip. The Surface Mining Control and Reclamation Act of 1977 changed this way of mining, requiring all new mines with acid- or iron-producing coal seams to be designed so as to prevent gravity water discharges from the mine. This Act requires engineered barriers to contain the mine pool. In many cases, mine layout designs focus primarily on the size and hydraulic performance of the un-mined coal barrier between the up-dip mine pool and areas where down-dip surface discharge is possible. In other cases, designs focus on preventing discharges from barriers contained within the strata surrounding the mined coalbed. This paper focuses on a detailed analysis of the factors responsible for preventing mine pool discharges to surface waters. Important factors include: mine layouts, mining methods, hydraulic head and conductivity, and geology. While the exact causes for the successes and failures could not always be determined, reasonable mechanisms are presented.

Feb 23, 2014

By P. Amelunxen

Over the past several years, the combination of higher energy and steel costs and the recent commercial deployment of high-pressure grinding rolls (HPGR) technology in hard rock mining have led many multinational mining companies to evaluate the suitability of HPGR technology for their particular comminution circuits. HPGR technology is perceived to require a higher capital investment while delivering lower long-term operating costs. This paper undertakes a critical evaluation of this perception. By evaluating the capital and life-of-mine operating costs of competing circuit designs for soft, medium and hard ores, the HPGR break-even point can be identified, at which the incremental capital cost of an HPGR circuit is equivalent to the net present value of the projected operating cost reductions. For ores with hardness parameters above the break-even point, HPGR circuits could offer economic benefits, while for softer ores, SAG mill/ball mill/pebble crushing (SABC) circuits are likely to be more economical and energy efficient. This evaluation considers both an SABC reference circuit and a traditional stage crushing configuration. Other influential factors are also discussed.

Jan 1, 2011

By S. S. Klima, H. Jiang, T. W. Beck, Y. Zheng

Researchers at the National Institute for Occupational Safety and Health (NIOSH) performed a series of lab tests to evaluate the respirable dust removal capacity of an industrial air-cleaning fan. Limestone and coal dust were tested separately in NIOSH’s full-scale drill table simulator at the Pittsburgh Mining Research Division (PMRD). Gravimetric samplers with Dorr-Oliver Cyclones and 37-mm filters were used at two upstream and four downstream locations inside and outside of the drill shroud chamber. There were six tests performed for both the limestone and coal dust experiments. In the limestone tests, an average respirable dust concentration of 98.86 mg/m3 was achieved upstream of the air-cleaning fan. The filter results show that the averaged respirable limestone dust reductions were 7.84%, 8.81%, 10.94%, and 18.02% at the four sampling locations downstream of the fan. In the coal tests, upstream samplers achieved an average of 129.03 mg/m3 of respirable coal dust. The averaged dust reductions were 9.54%, 9.83%, 18.54%, and 19.21% at the four downstream sampling points. The results indicate limited cost benefits of using this technology because of the relatively low dust reductions determined from this laboratory study.

Feb 1, 2023

By T. McDonald

Test work indicated and plant operation has since confirmed that SAG milling is a viable option for INCO's Sudbury Operation milling rationalization project only if pebble crushing is included in the SAG/ball mill circuit. Throughput increases more than fifty percent with pebble crushing incorporated into the comminution process. The finer product of high speed pebble crushing provides further energy savings. The unconventional approach of pumping the pebble crusher product, while simplifying plant layout, has produced challenging wear problems.

Jan 1, 1992

By Joseph A. Whitchurch

The N20 to N25 Tunnel (basic) segment was the second tunnel contract awarded for construction by The PB/MK Team. This project embodied 3.9 km (2.4 miles) of tunnel and was located within the northwest quadrant of the 86.9 km (54 mile) long main collider ring. The contract required the excavation and initial support of a 54.3 m (178 vlf) deep ventilation shaft, a connecting horseshoe shaped Adit and TBM starter tunnel and 3,865 m (12,680 If) long main collider tunnel with a 4.3 m (14 ft) minimum finished diameter. This paper discusses the construction methods, equipment utilized and the production achieved in the construction of the ventilation shaft, connecting adits and the main collider tunnel.

Jan 1, 1995

By J. L. Post

A large body of readily available Na-montmorillonite is present about 24km (15 miles) east of Fallon, Nevada. The clay is comparable to Wyoming Na-bentonite, but with somewhat less MgO and somewhat more Fe2O3 in its crystal structure. The physical and industrial properties of the Nevada clay are comparable to those of the Wyoming clay. The Na-montmorillonite is presently mined for use as hazardous waste barrier material and as a sealant for canals. It may be economically feasible to process the clay material for removal of impurities.

Jan 1, 1996

By James S. Browning

In 1975 bituminous coal and lignite production in the United States reached an all-time high of 637 million tons, an increase of 6 percent over production in 1974. The output, valued at $11.9 billion f.o.b. mines, was produced at 5,100 mines in 24 states (6). Coal mining is the largest mining industry in Alabama. Production from Alabama's mines in 1975 was over 21 million tons, and present projections forecast a steady increase in production, with tonnages almost doubling by 1985 (5). Of the total quantity of coal produced, about 16 million tons were consumed in electric power generation and the remainder was used for metallurgical coke production, extraction of chemicals and petroleum based products, and power for industry. The fact that 75 percent of Alabama's power is generated by burning coal attests to the importance of this fossil fuel to the State. Approximately 14 million tons of coal were produced by strip-mining methods in Alabama during 1975 and about 7 million tons were produced by underground mining during the same period. Surface mining is expected to continue at about 14 million tons per year, but by 1980 underground coal mining is expected to increase to about 25 million tons (3). About 7 million tons of surface-mined coal in Alabama is subjected to some means of washing or cleaning. The methods used are screening accompanied by heavy media separation, jigging, tabling and flotation. Some of the simpler approaches employ screening and jigging, or tabling. Except where flotation is used, the screen undersize fraction (finer than 0.25 inch) is rejected, with the result that 10 to 15 percent of the coal is lost. Thus, in the State of Alabama an aggregate of about 1 million tons of coal is wasted annually in the fines which are impounded from treatment of surface-mined coal. The use of the Humphreys spiral to concentrate fine coal was practiced as early as 1947. At that time the Hudson Coal Company (1) used Humphreys spirals to concentrate anthracite fines. In 1950, the use of spirals to treat fine-size

Jan 1, 1977

By E. Woodburn, H. W. Smith, M. C. Fuerstenau, R. Putman

This paper presents a review of developments to date in computer control practice, based in large part on Canadian experience. The basic problem examined is that of stabilizing control; matters considered are control strategies, hardware and software aspects of system implementation, reliability, human factors, and economic results.

Jan 1, 1976

By R. L. Grayson, R. C. Althouse, M. J. Klishis

The health and safety of employees, efficiency of the operating system, and production are paramount goals in underground coal mining. The section foreman assumes responsibility for making his part of the total system function to meet these goals. However, section foremen often have not been prepared to assume the full range of their responsibilities upon becoming a supervisor. This paper addresses the full range of section foreman responsibilities and concomitant authority. Management principles that must be mastered by him are presented, and performance expectations as well as criteria for their evaluation are examined. The benefits realized from effective foreman training are discussed.

Jan 1, 1987