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By John S. Wakeman

The progress results of a pilot plant study on the effects of ball top size and other mill operating parameters are reported. Test series on taconite and quartzite crude ores using a 1.7m diameter primary mill in closed circuit with a vibrating screen indicate clear trends on the improvements of mill throughput and power consumption when using larger diameter balls. Possible effects on mill liner and ball consumption as well as future research plans are discussed.

Jan 1, 1984

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

"Mine Safety and Health Administration (MSHA) regulations require underground coal mines to use refuge alternatives (RAs) to provide a breathable air environment for 96 hrs. One of the main concerns with the use of mobile RAs is the heat and humidity buildup inside an RA. The accumulation of heat and humidity can result in miners suffering heat stress or even death. MSHA regulations require that the apparent temperature in a fully occupied RA must not exceed 95°F. To investigate this issue, the National Institute for Occupational Safety and Health (NIOSH) conducted testing on a 23-person tent-type RA in its Experimental Mine (EM) in a test area that was isolated from the mine ventilation system. The test results showed that the average measured air temperature within the RA increased by 9.4°C (17°F) and the relative humidity (RH) approached 94 %RH. The test results were used to benchmark a thermal simulation model of the tested RA. The validated thermal simulation model predicted the average air temperature inside the RA at the end of 96 hours to within 0.6°C (1.0°F) of the average measured air temperature. INTRODUCTION If an accident occurs in an underground coal mine, miners who fail to escape from the mine can enter an RA for protection from adverse conditions, such as high carbon monoxide levels. One of the main concerns with the use of mobile RAs is the potentially adverse thermal environment inside an RA from the metabolic heat of the occupants and the heat released by the carbon dioxide (CO2) scrubbing system. Moreover, the humidity within the RA will increase through occupants’ respiration and perspiration and from the chemical reaction within the CO2 scrubbing system. The accumulation of heat and humidity can result in miners suffering heat stress, heat stroke, or even death. In its 2007 report to Congress, the National Institute for Occupational Safety and Health (NIOSH) Office of Mine Safety and Health Research (OMSHR) recommended that RAs should be designed to ensure that the internal apparent temperature (a temperature-humidity metric) in an occupied RA does not exceed 35°C (95°F). However, a standard method to determine compliance with this metric does not exist. The heat transfer process within and surrounding an RA is very complex, and is not easily defined analytically or experimentally. To investigate the related issues, OMSHR conducted heat and humidity testing on a 23-person tent-type RA in its Experimental Mine (EM) in a test area that was isolated from the mine ventilation system. During the testing, numerous parameters were measured: heat input to the chamber, the air temperature and relative humidity inside the RA, the air temperature in the mine, the mine strata temperatures versus depth, and the airflow inside and outside the chamber. The focus of this paper is on the temperature rise within an RA. TAITherm heat transfer analysis software was used to develop a thermal simulation model of the RA as it was tested in the mine, using the test results as the benchmark. Both sensible and latent heat were used in the test and the model."

Jan 1, 2016

By W. H. Strickland

The research reported here characterizes ultrasonic ranging sensors for autonomous navigation on underground mine mobile equipment. Because ultrasonic rangers are inexpensive, have no moving parts, have no lenses to clean, are small and unobtrusive, and can measure distances in dusty environments, they are especially sui ted to underground mi ne environments. The investigation began with laboratory tests of field of view, angle of incidence, intersensor variation, and ranging accuracy of individual rangers and a ring array of 24 sensors. The results showed the sensors have good accuracy and low variability. Additional experiments at AHAX' s Henderson mine Showed the sensors could accurately and reliably measure rib features, convex and concave corners, and drift intersections. The results showed that when used and analyzed properly, the sensor data may be used reliably for underground mobile equipment navigation.

Jan 1, 1990

By Dolf Vos

The balling section of the pelletizing plant at Hoogovens IJmuiden consists of 7 balling drums. Each with an average capacity of 100 tons of green pellets per hour. The balling drums are equipped with rotating scrapers and water-spraying systems. The scrapers are installed in order to restrict the growth of the race to a certain thickness. The spraying system is used to adjust the desired value of the moisture-content of the rewetted ground ore, the pellets and the race. The desired value is the value by which the balling- process is stable, good pellets are formed and surge occurs within certain limits. In October 1980 the construction of one of the balling drums has been modified. The rotating scraper was removed and the inner wall of the drum was supplied with a rubber-lining. In 1982 a second balling drum has been rubber- lined. At the same time the Tyler vibrating screen of this balling circuit has been replaced by a roller(bed)screen. By the end of 1983 all 7 balling circuits will be equipped with rubber-lined drums in combination with roller(bed)screens. The combination of these two modifications will improve the quality and the screen analysis of the green pellets, moreover resulting in savings on energy- and maintenance costs. This paper describes the influence of a rubber- lining on the balling process and the green pellet quality by carrying out in-plant testruns in November/December 1980. The testrun results have been compared with the results of a not modified balling drum.

Jan 1, 1983

By D. C. Torre

The need for a successful, efficient and reliable continuous face- haulage .system for use with continuous mining machines has been apparent since the first continuous miners were introduced some twenty-five years ago. Some thought and effort were given to the development of continuous haulage over the last twenty years or so. Some initial success was experienced in this area by The Long Company with a system involving bridge conveyors, as far back as the late 1950's. However, extensive success with continuous face haulage for use behind modern, high product¬ion, continuous miners escaped the industry until the early 1970's. It is true that continuous face haulage was successfully introduced into low seam mining, generally in seams ranging under 1.07 m (42") in height, in the 1960's, for use with relatively low production, low seam, auger type continuous miners. However, those available systems which have achieved success in the lower seams, where relatively low capacities are adequate, are not directly applicable for use with today's medium and high seam miners with their standard production capacity of 9.1 - 10.9 mtpm (10 - 12 tpm). Since the late 1960's and early 1970's, several machinery manufacturers, and at least two major coal companies, have devoted considerable expense, time and effort to developing truly successful continuous face haulage for use in coal seams ranging upward from 1.2 m (4') in height. Continuous face haulage equipment has been developed in the last five years employing a variety of transportation media and design concepts, including some which have received wide publicity such as those employing hydraulics, and pleated belt. The truth of the matter is, however, that the only universally applicable and widely successful continuous face haulage equipment introduced to date has been that employing a combination of bridge conveyors and mobile, self-propelled, bridge carriers, connected at the inby end to the tail of the high production continuous miner, and at the outby end attached directly to the panel conveyor (Fig. 1 & Fig. 2) or, on occasion, to a short, self-contained conveyor which, in turn, empties directly onto the panel conveyor. While these bridge type continuous haulage systems are available with both belt and chain conveyor components, the most widely applied and successful system in seams above 1.07 m (42") in height is that offered by The Long-Airdox Company. The standard unit for use with 9.1 - 10.9 mtpm (10 - 12 tpm) continuous miners is normally equipped with belt. However, they have built, and successfully applied, versions of this system employing chain conveyors, (Fig. 3), mainly for operators having extremely difficult mining conditions, including excessive amounts of water

Jan 1, 1977

By T. M. Klemetti, T. J. Batchler, T. J. Matthews

"From 2011–2016 there were 1,511 documented injures, including 7 fatalities, from ground falls in U.S. underground coal mines. The majority of these ground fall injuries were not caused by a major roof collapse, but from falls of smaller rocks from the immediate roof. Roof screen can significantly reduce the number of these injuries and has been widely utilized in underground coal mines for surface control. Because of the potential of reducing ground-fall injuries, the National Institute for Occupational Safety and Health (NIOSH) is further evaluating the performance characteristics of welded wire screen as used in underground coal mines by conducting a laboratory testing program at the Mine Roof Simulator (MRS) in Pittsburgh, PA. The load-displacement characteristics of a 2.4-m x 3.7-m panel of 8-gauge welded screen were evaluated using a newly designed, large laboratory screen test frame with multiple load pull locations. This screen was tested in a configuration that simulates current installation practices in U.S. coal mines. In this study, the effects of displacement loading rate, load pull surface geometry, and the inclusion of roof channel on the screen performance were evaluated. Ultimately, the type of information obtained in this and similar studies can be used to aid in developing wire roof screen design criteria and to assist mine operators in the selection and use of roof screen in underground mines. INTRODUCTION Over 1,500 injures, including 7 fatalities, occurred from 2011–2016 from ground falls in U.S. underground mines with the majority of these ground-fall injuries caused by falls of smaller rocks from the immediate roof. Various controls are currently being used in mines to control this surface rock, including the use of wire roof screen. In mines where wire roof screen has been installed, injuries from rock falls have been reduced dramatically (Robertson and Hinshaw, 2001). Roof screen has the potential to prevent hundreds of injuries caused by the fall of small rocks between permanent roof supports (Comptonet al., 2007). Because of this potential for reducing ground-fall injuries, the National Institute for Occupational Safety and Health (NIOSH) is evaluating the performance characteristics of welded wire screen as used in underground coal mines by conducting a laboratory testing program at the Pittsburgh Research Laboratory (PRL)."

Jan 1, 2018

By J. Morris

Petro-diesel is a common collector for fine coal froth flotation but partitioning of diesel range organics (DROs) in process streams has not been widely studied. Preliminary research suggested that under normal dosing schemes total residual DRO in process waters should be limited to the sub-ppm water-soluble fraction (WSF). Further, polycyclic aromatic hydrocarbons (PAHs) should partition proportionately with DRO. The purpose of this study was to confirm these findings in laboratory flotation tests. Total DRO and specific PAHs were measured in tailings and concentrate streams, and coal recovery and ash rejection were tracked. Results show that concentrate waters consistently had higher DRO than tailing waters, and DRO in both streams generally increased with increasing diesel dosage. DRO again appeared to be limited to the WSF and PAHs tended to partition proportionately with DRO. Results indicate optimal flotation performance should generally coincide with minimal DRO partitioning to process waters. Under typical operating conditions residual DRO should not present an environmental concern; however, conditions should be avoided that allow significant overdosing of diesel.

Feb 23, 2014

By F. L. Pirkle

The mineral zircon is mined for use as specialty foundry sands, abrasives, ores of ZrO2 and zirconium metal, refractories, and zirconium chemicals. It is produced as one of several products from heavy-mineral sand deposits associated with fossil shorelines. Because of its low coefficient of thermal expansion, its high melting point, its high refractive index, and its chemical inertness, it is an attractive refractory material. Zircon varies from deposit to deposit in terms of grain size, grain shape, and chemical impurity. Thus, there is a wide range of commercial products differing in impurity levels, particle shapes, and grain sizes.

Jan 1, 1992

By J. Weinstein

New erosion, corrosion resistant metal, ceramic, and polymer composite technologies are being developed and marketed by Alanx Products L.P. for use in hydrocyclones, pumps, valves, and other applications in mining and minerals processing. This paper will present an overview of the ceramic/metal composite material system and properties developed, which include excellent erosion/ corrosion resistance. Wear data will be shown from a variety of laboratory tests in dry and wet conditions, in aqueous neutral and corrosive environments. Comparisons will be made with a variety of competitive materials currently used in the industries sited. Data will also be presented on field tests with pumps and hydrocyclones in hard rock mining and other abrasive/corrosive environments. Field data from North and South America, as well as Australian mining applications will be highlighted.

Jan 1, 1992

By M. T. Ityokumbul

The liquid phase mixing in Western Research Centre (WRC) pilot plant flotation column with diameter of 0.76 m has been characterized using a salt tracer. The process variables studied were gas and liquid flow rates. The response of the column to a tracer pulse input was monitored at three axial and two radial locations. For all the experimental conditions investigated in the present study, radial and axial concentration gradients were not observed. It is thus concluded that the 2 tph flotation column is behaving as a well mixed tank. This finding is consistent with the observed poor recoveries of coarse fractions in the column flotation circuit. Based on the findings of this report, it is recommended that several schemes of reducing the backmixing be implemented and evaluated for their effectiveness in improving the column recoveries.

Jan 1, 1994

By Richard A. Thomas, Connor B. Brown, Thomas H. Dubaniewicz, Teresa Barone

Electric vehicles powered by lithium-ion (Li-ion) batteries are being developed by mining vehicle manufacturers as a replacement for diesel-powered vehicles. Explosion-proof (XP) enclosures are frequently employed to enclose electrical ignition sources in gaseous underground mines to prevent the spread of an internal methane-air explosion to a nearby explosive atmosphere. Due to thermal runaway (TR), Li-ion batteries have the potential to cause pressurized explosions in an enclosed structure. Past research has shown the potential for well-confined Li-ion cell TR to drive pressures beyond the conventional pressure specification for XP enclosures. Researchers at the National Institute for Occupational Safety and Health (NIOSH) used an Accelerating Rate Calorimeter (ARC) to induce thermal runaway of Lithium Titanate or Lithium Titanium Oxide (LTO) type 18650 cells enclosed within containers with various volumes and found an inverse power relationship between the TR pressure and available free space. The results were similar in magnitude to that of lithium iron phosphate (LFP) cells, which were used in prior testing. Temperatures, gas amounts, and TR pressure-rise rates were also recorded. The data indicate that with enough free space, the pressures can be lowered below the conventional pressure specification for XP enclosures.

Feb 1, 2024

By R. Kramer, A. Habibi

A ventilation survey was conducted in an underground longwall trona mine. The mine is relatively shallow and categorized as a gassy mine. The ventilation system includes three intake and six exhaust shafts, and three surface axial fans ventilate the mine in a blowing configuration. Airflow quantity, pressure losses and air psychrometric characteristics were quantified, and the influence of moving cages and skips in the shaft examined. The benefits of utilizing high-accuracy digital pressure transducers and advanced psychrometers were seen when undertaking a “leapfrogging” survey to gather data needed to build a computer ventilation model. Two underground booster fans with VFDs are idle but available at the mine. The ventilation model was used to determine the optimal booster fan locations to decrease operating cost by reducing the load carried by the main fans. A leakage study was conducted to evaluate the effects on the system of additional pressure from a booster fan. The study finally prepares a future ventilation model for the next 15 years of mine operation and investigates the effect of proposed scenarios.

Jan 1, 2014

By R. K. Mehta

Stirred ball mill feed used for ultra-fine grinding application requires fine size separation step in order to avoid over-grinding. This paper presents the selectivity curves obtained for oil shale and complex sulfide are using 460 mesh (30 micron) Derrick vibrating screen. Interestingly, the selectivity curves generated from the experimental data were monotonic increasing selectivity for oil shale but not monotonic increasing for sulfide ore. These non-monotonic increasing selectivity curves were similar to the mechanical air separator fishhook selectivity curves described by Luckie and Austin. A 2 stage classification in series model describing the fishhook selectivity curve has been used in proposing the classification mechanism for fine vibrating screens when heterogeneous multicomponent sulfide are undergoes size separation.

Jan 1, 1992

By Edward R. Mueller

As an alternative to a million dollar, sensor based, computer dispatching system, Cyprus Pima Mining Company has installed a home¬made analog computer. The device is used in conjunction with a standard radio-dispatching system; it is inexpensive and very simple to build and operate. It enables the dispatcher to make near opti¬mum dispatching decisions and to identify all off schedule haulage trucks. Since installation, Cyprus Pima has experienced significant increases in pit productivity.

Jan 1, 1977

By Walter H. Schwedes

Ore grinding mills are really just slowly rotating barrels, but barrels that are growing in size so fast that the application of electric drives for them is rapidly approaching a technology like that for wind tunnels or pumped storage drives. This application is particularly worthy of care because some 40% of the 75 megawatts of power used by a large copper ore concentrator, or some 60% of the 200 megawatts supplied to a large iron ore concentrator, are for grinding. These ore plants are located where the ore is, not where a utility happens to be. So, the challenge is not only to choose a drive and .power transmission for reasonable cost, high performance, reliability and minimum maintenance, but to afford the interface between mill drive and power distribution and source systems to minimize the whole ore plant's monthly power bill, or costs of self generation. Conclusions can be reached in optimizing a drive selection only for each particular ore plant's set of parameters, but by identifying the criteria for selection and then weighting each type of drive per criteria, yardsticks for final choice become apparent. This is the purpose of this paper. Grinding action takes place inside the barrel, where the ore charge is ground with the aid of balls, or mill length rods, or large chunks of ore as in autogenous grinding.

Jan 1, 1972

By John A. Meech

In many multiple-sulphide ore flotation processes, it is desirable to concentrate each of the various valuable minerals into separate products. Although there are a variety of techniques and chemicals which can be employed to produce efficient separation, two basic types of flotation circuits are used: The Differential Flotation Circuit and the Bulk/Selective Flotation Circuit. Figure I depicts these two circuits in their most simplified form for the production of two concentrates and one tailing product. If three or more valuable minerals are present in an ore, a variety of combinations or extensions of these two basic flowsheets may be used. There are many examples of the successful application of both circuit types with ores containing similar minerals. Each ore must be tested individually to decide on which circuit is best. However, the following general statements can be made: 1) The differential circuit will have higher capital and operating costs than will the bulk/selective circuit due to higher rougher capacity requirement. 2) The differential circuit will achieve better separation than will the bulk/selective circuit since it is usually easier to reactivate a depressed mineral than it is to depress an already active mineral. If the deactivation problem with the bulk/selective circuit . . in can be overcome, there is a clear economic argument for its use

Jan 1, 1977

By Yongsik Jeong, Kwangmin Kim

Most tailings storage facility (TSF) failures occur in active, upstream-type TSFs, often due to extreme and unexpected weather conditions—specifically, heavy rainfall and strong winds. This case study of a TSF in southern Arizona examines the use of the optimum safe beach distance (Doptimal, the optimum distance between the crest and decant pond) as a tool for monitoring geotechnical stability and reducing catastrophic failures. A digital model of the TSF was used to determine the critical beach distance (Dcritical) under normal weather conditions, and Doptimal was then determined by adding incremental distances to account for the effects of heavy rainfall (Drainfall) and strong winds (Dwind). To overcome accessibility issues, a drone was used to map the TSF geometry and create a digital model. This model served as the basis for conducting a coupled stress-seepage, finite-element (FEM) analysis with a safety factor of 2.0 to assess geotechnical stability (Dcritical). The safe beach distance increments were determined using the PMP (probable maximum precipitation) and possible maximum wind speed. Based on this analysis, the optimal safe beach distance at the study site was identified as 202.2 m. Since the current beach distance (371 m) exceeds this value, the TSF was considered to be stable and satisfied the design safety factor of 2.0. However, this distance should be reassessed periodically to account for changes in the TSF geometry and other conditions. Furthermore, it applies only TSFs that are well-managed and feature a smooth, non-undulating beach surface with a consistent slope.

By R. M. Damodaran

The flotation performance of Florida phosphate rock was evaluated in terms of the mixing behavior of reagents with particulates during anionic conditioning of phosphate slurries. The various conditioning variables that influence mixing, namely, solids loading, agitation speed and the conditioning time were investigated to determine their effect on reagent coating on the particles. The phosphate recovery was used to monitor the conditioning efficiency. The mixing characteristics of the phosphate feed were evaluated in terms of the ratio of the mixing power P, to the minimum power Pm' required to keep the slurry in suspension. It was found that mixing conditions govern the conditioning time required to obtain high recovery. Reagentization was slower at lower P /P m ratios. At higher P /P m ratios, the flotation recovery was optimized and the agitation speed was found to have no significant effect on it. Optimum mixing conditions were obtained for a 74 wt% slurry at an agitation speed of 450 (47 rad/s) rpm. Under the optimum conditions of mixing, recovery was improved at low collector dosages and short conditioning times.

Jan 1, 1995

Factors which cause thiourea consumption in gold-leaching systems include adsorption by gangue mineral particles, complexation with base metal ions, thermal degradation, and oxidation by air/ferric iron. Of these factors oxidation by ferric iron is the most significant factor. Of course, ferric sulfate is desired as an oxidant for the gold leaching reaction, but an excess of ferric sulfate leads to high thiourea consumption. In this regard, the rate of gold leaching by thiourea must be balanced against the rate of thiourea decomposition. It is important to note that the thiourea decomposition reaction in ferric sulfate solution is relatively slow in pure solutions and has been found to be first order with respect to both thiourea concentration and total ferric iron concentration. However, when mineral particles from gold-bearing ores or concentrates are present, the decomposition rate can become quite significant. As might be expected, the catalytic activity of mineral surfaces varies with particle composition and size. Experimental results are discussed with respect to the consumption of thiourea.

Jan 1, 1997

By H. Dho

The role of sodium silicate in the anionic flotation of a Florida phosphate ore was investigated using laboratory continuous flotation tests, frothability tests and SEM observations. In the absence of sodium silicate, Ca++ promoted the unwanted activation of quartz by forming calcium bearing precipitates. The addition of sodium silicate enhanced the flotation efficiency through: (1) the removal of impurity minerals and calcium-bearing. precipitates from quartz surfaces by dispersion, (2) drier and more persistent froths stabilized by oily droplets containing calcium silicate precipitates, and (3) higher specific flotation rates of phosphate relative to quartz, leading to faster flotation rates and increased selectivity of separation.

Jan 1, 1990