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By J. Drelich

The wetting behavior of liquid polymers at solid surfaces and the adhesion forces involved at polymer-filler interfaces should always be considered in the fabrication of high quality polymer composites, including those made with mineral fillers. Spontaneous polymer spreading over the filler surface is a basic condition in the fabrication of the polymer-mineral composites. In this regard, the wetting and adhesion characteristics of polymer-mineral systems are reviewed in this contribution. It appears that several aspects of wetting phenomena at mineral filler surfaces are not well described in the literature and require further systematic study. Specifically, it is clear from this review that efforts should be made to determine the effects of mineral surface contamination (including surface hydration) on wetting and adhesion phenomena, and to determine the wetting characteristics of molten polymers at mineral filler surfaces. It is expected that any improved fundamental understanding of wetting and adhesion phenomena for the polymer-mineral composites will provide the basis for further technological development.

Jan 1, 1995

A computer simulation of the automatic control of continuous mining machines has been prepared, similar to previous simulations of longwall mining systems and coal thickness sensors. The simulation allows for programmed variation of the horizon detection method, the azimuthal guidance system, the type and configuration of the miner, varying hardness in the unmined face material (leading to varying error in the machine heading), and the miner's cutting cycle. It simulates control of the miner in three axes. Use of the simulator makes it possible to anticipate problems arising from the complex character of underground mining, which include unpredictable multi-pass coupling and unpredictable variation in geological conditions.

Jan 1, 1993

By Staff

"In 2018, the total estimated value of nonfuel mineral production in the United States increased by 3 percent from 2017 to $82.2 billion. The estimated value of metals produced domestically decreased by 4 percent, and the estimated value of indusrial minerals produced domestically increased by 7 percent (Table 1).Some idle U.S. metal mines and processing facilities restarted in 2018, including two primary aluminum smelters in Indiana and Missouri, a rare-earths mine in California and a zinc mine in New York. In contrast, four iron ore mines in Minnesota and a pelletizing plant in Indiana were shut down. Increased oil and natural gas drilling activity in 2018 led to increased production of some industrial mineral commodities that are used for oil and gas drilling, including barite and industrial sand and gravel. Production of industrial minerals primarily used in infrastructure and residential construction — including, cement, construction sand and gravel, crushed stone and gypsum — increased in 2018. Overall, mining activity trended upward for the second consecutive year because of increases in oil and gas extraction and industrial mineral mining (Table 2).Mineral industry performanceDiscussion of mine production is commonly segmented according to the type of materials produced within the broad categories of metals and industrial minerals (also known as nonmetallic minerals). Industrial minerals can be further subdivided as natural aggregates and other industrial minerals. Metals tend to have higher unit values but very low production quantities compared with those of industrial minerals, such as crushed stone or construction sand and gravel, which have higher production quantities but are lower-valued materials. Therefore, for discussion and analysis of the performance of the nonfuel minerals industry, the value of production is used rather than the tonnage produced. Tonnages of natural aggregates are orders of magnitude larger than those for most other mineral commodities, thus making direct comparisons based on weight meaningless (Fig. 1)."

May 1, 2019

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 A. Aly Selirn

An economic simulation model was developed to predict the amount of copper recovered from copper oxide deposits and the cost of producing it as a function of the deposit parameters. The economic simulation model includes models of fragmentation design and cost, copper extraction, solution distribution and recovery, effluent solution cutoff grade, and financial analysis. Cost and price indices were also developed to evaluate the economic feasibility of in situ leaching operations as a function of their starting date. Application of the models to various properties having the same area and different ore thickness shows that the effluent solution cutoff grade does not vary with the ore thickness nor with its grade. The percent of copper recovery is, however, shown to increase with the increase in the ore thickness and is independent of the ore grade. it is also shown that while the profit per unit of extracted copper increases with the increase in ore grade or ore thickness, the rate of return on total investment does not show any correlation

Jan 1, 1977

By F. Heivilin

If the past is the key to the future, we will have ?tough? times maintaining Industrial Mineral reserves we have and proving new reserves around our plants and in new locations. The tough times will come from resources being more difficult to find, more hoops to go thru to make them Proven or Probable reserves. As always, Industrial Minerals require competitive quality, location, and costs. Since in most cases the market has suppliers, you will have to take away customers from their present supplier. This may take years or not happen even with lower cost higher quality raw materials. To determine the finished cost for a new deposit you need to design, determine capital costs, and operating costs for a new plant . Stripping, mining, hauling, processing, and transportation costs are part of the equation. After satisfying that your costs are in line you will need to do production tests to make sure the process works on the ore. You may want to complete permitting before purchasing the property. If you are new in the business you will have to prove you can deliver the right quality, the right quantity, on time consistently year after year at lower cost to take away a customer. Without being in the market this will be hard. The cut off grades to enter a market may be much lower than sale indicates because a competitor often lowers the price to keep you out of the market. We have many more items to check before the new deposits can be put on reserves. Our old reserves will require drilling to check for new products and prove that they do not contain items that would make them unusable for our product line or cause permitting problems. Archeological checks, wetlands, more water discharge testing, county zoning, and endangered species are among many items that have been added to mine permits. There will be more. A 4-6 page mining permit becomes 30-300 pages and consists of 5-15 permits, any of which might be a fatal stumbling block. It is not guaranteed that we can mine what we have on reserves. We may fight and lose. Oil-Dri?s loss in Reno and LaPort?s in England are examples where permitting failed. The NOx, sulfur, and carbon problems are just starting. Dioxin is in the background requiring monitoring on food products to Europe. What other anions, cations, endangered species, and land types are going to be problems in the future are guesses now. What new products are we going to have to test for and cause out of balance reserves? If there are none we probably won?t be here. We are competing for land use with ?Endangered Species?, wetlands, farming, forestry, cities, roads, and hunting. We?ve mined the best quality, low overburden, easiest to mine and process raw materials. The price of land and taxes are increasing. Old royalties are 2-3 times the present acre value instead of 8-10 times the property value when leased. Land taxes are up. It was and is best that we get the land in Fee Simple Title. This isn?t always possible. However, plants are closing and people have overlooked, made mistakes in drilling or interpretation of deposits. These may be opportunities. China is eating up high quality ?Industrial Minerals ?which have caused prices to rise. We may need to change our cutoffs? in terms of smaller pit sizes and higher overburden ratios. This is money in the bank. Overburden ratios and other items increasing cutoff costs need to be rethought. Suddenly doubling cutoff ratios for overburden and decreasing pit sizes are good alternatives to looking elsewhere where we might not be able to mine for a number of reasons. The higher prices make them competitive, especially when a competitor goes out of business. However, our low overburden ratios and short hauls around our plants are not safe from new roads, condemnation by county or city governments (N. J.), zoning changes (Reno, FL., CA, and environmental regulation changes (Buffers GA, MS). New roads ?Interstates? can take reserves, increase hauling distances and reduce tons per load. Let?s combine the Refractories, fullers earth, and bentonite industries and use the last 40 years as a guide to the future looking for problems and opportunities. Some or most of the following will apply to other minerals. WHERE DO WE LOOK? First, on our own properties, those next to our properties and on properties near our competitor?s plants. Where the profit margin has increased, the distance from the plant and thickness of overburden we can use is increased. The thickness of clay is decreased. For new locations we pick the ideal location and look at deposits and closed or open operations in ever increasing distances away from that location. We need to be aware of: 1. Increased transportation costs a. Access to Roads -Backhauls b. Haul with doubles and triples c. Railroads - Loading on sidings - Ability to get switches - Cars/backhauls versus rates 2. Cost of building a new plant 3. Cost of infrastructure 4. Cost of repair or new equipment when purchasing an operating or shutdown plant. 5. Local, state, and federal mine and environmental permitting. When exploring around an established operation expect that property acquisition, drilling, mining, stripping, and hauling costs will be greater due to them having second, third, or even fourth the pick of the deposits. I found this in New Jersey looking for refractories and around Quincy, Florida looking for attapulgite. You may be able to get some better properties because the operating company has angered some land owners, their drillers missed the clay, or the property wasn?t available when they were actively exploring for reserves. You may have some product lines your

Jan 1, 2009

By Richard E. Otoo, Evan J. Owen, Virginia T. McLemore

Disruption in critical minerals supply chains has resulted in the evaluation of various types of mineral deposits for critical minerals potential. Much of the study on critical minerals focuses on occurrence and characterization, but little research has addressed what concentrations of critical minerals in a mineral deposit are required to make an exploration target into an operating mine. Understanding the cut-off grades of ore deposits being actively mined is one criterion to determine if concentrations in an exploration target are high enough. Cut-off grade is defined as the minimum amount of mineral contained in a ton of ore that is sent to the processing plant. Among many factors, cut-off grade depends upon the size and type of the deposit and mining operation, the processing technique, and market prices. This research does not aim to define cut-offs for determining if a mineral deposit is economic. Rather, it defines estimates of concentrations of critical minerals that could be considered good enough for further exploration. For example, ~2% total rare earth oxide (TREO) is the cut-off grade for Mt. Pass carbonatite, but 500 ppm TREO could be an exploration target for coals.

Feb 1, 2025

By E. Hasanbas

Vibrating screens and crushers are the workhorses of material sizing. Unfortunately their natural frequency is often in the range of typical supporting structures, thereby making installations prone to vibration problems. Much of the available literature regarding the support of vibrating screens is fairly confusing and outdated. This paper presents the results of utilizing accelerometers and finite element software in the analysis and design of supports for vibrating equipment. It contains data from field studies of vibrating screen and crusher installations, design of new and repair of existing supporting structures, and the correlation between field data and finite element time history analyses. Finally, the paper summarizes a method for analyzing and designing structures subjected to vibratory loads and predicting their behavior.

Feb 23, 2014

By William Gleason

"It is the largest mining exhibition in the world that attracts thousands of attendees from around the world to Las Vegas, NV once every four years. Despite the recent struggles in the mining industry, MINExpo International 2016 promises to be as big as ever. In the following pages, Mining Engineering takes a look what some of the more than 1,800 companies plan to showcase during the three-day exhibition.CaterpillarCaterpillar will support MINExpo 2016 with an exhibit showcasing machines, technology, expertise and practical knowledge that miners can apply to help address their cost, productivity and efficiency challenges in today’s mining environment.Caterpillar will once again occupy the largest space at the event and will showcase both surface and underground machines, but the talk at the booth will focus on how Cat technology and know-how combines to help mining operations address and solve the issues that are most important to them. The main stage in the exhibit will feature presentations describing how mining companies, Cat dealers and Caterpillar work together to improve operations.“The challenge for all in the mining industry now is to optimize operations — to drive costs down while creating sustainable businesses that can weather downturns,” said Caterpillar Resource Industries group president Denise Johnson. “We believe that through our expertise and the knowledge of our dealers —combined with innovative technologies and our growing data analysis capabilities — we can help them not only survive, but thrive in these challenging times.” Johnson was selected by the National Mining Association (NMA) to chair MINExpo 2016. “Chairing this show is a great honor, and it’s a testament to Caterpillar’s partnership with this critical industry,” she said. “We’re proud to be a long-time supporter of the NMA, and we are excited to participate in another MINExpo. It’s an opportunity for us all to learn from each other how to increase productivity, control costs and improve overall operations.”Surface mining displays. The surface mining section of the Caterpillar exhibit will showcase the new MD6420C rotary drill. This is autonomy ready and optionally equipped to leverage the safety and productivity benefits of Cat MineStar Terrain. This high-precision drill management system optimizes utilization and improves drilling and blasting operations by accurately guiding the operator and improving precision of hole placement and drilling depth — and the next step is fully autonomous operation, Command for drilling. The third-generation drill incorporates proven Cat components throughout for superior reliability and durability."

Sep 1, 2016

By Robert W. Gordon

The art of excavating tunnels with continuous, full-face boring machines began almost 90 years ago, in the early 1880's. At this time, Colonel Beaumont designed and manufactured a seven-foot diameter tunneler for boring under the English Channel, Despite the absence of modern materials and manufacturing techniques, Beaumont's tunneler, powered by compressed air piped in from the surface, was quite successful. During its short, but impressive existence, this machine set a record of advancing in chalk 50 feet per day for 53 days - which is impressive even by today's standards. Despite the apparent success of this early tunneler, almost 80 years passed before any further significant development was accomplished in this field. Demands from the construction and mining industry and society itself have motivated the development of the modern tunneling machine. Our rapidly growing civilization needs faster, less expensive and safer means of excavating tunnels. Space age technology and materials have played a major role in making hardrock tunneling machines possible.

Jan 1, 1970

By Nagashi Ogushi

Geochemical prospecting method using stream sediments, soils and rock chips has been tested to see the applicability for the typical Kuroko field in Japan. Three independent anomalies have been detected in maps being shown by grav densities of cells which are represented by the results of factor analysis as well as distribution of minor elements scaled in logarithm. A small vein type mineralization which has outcrops could be attributed to the origin of them whereas the one near the surface of known Kuroko deposit to a coincidence. The addition of drill core geochemistry is required to complete the interpretation.

Jan 1, 1982

By Michael L. Ogilvie

The proportion of underground coal production as a percentage of overall Australian production has fallen in the last 10 years, with underground production remaining more or less static at about 53 Mt (58 million st). However, underground coal mining remains a viable industry in Australia, due to use of modern longwall mining systems. In 1993-1994, 26 longwalls were in operation, with total production exceeding 39 Mt/a (43 million stpy). Some of these longwalls achieve productivity levels approaching efficient opencut operations, and in some cases, they exceed them. These high-production longwall mines are not without problems when depth and distances from outcrop increase and the gas content of the seams approaches or exceeds critical limits. When gas content of a coal seam exceeds 6 m3/t (233 cu ft/st), gas flows into the mine may be sufficient to interrupt production from time to time.

Jan 1, 1995

By Alan A. Campoli

The US Bureau of Mines (USBM) conducted research to develop improved guidelines for selecting the type and pattern of roof support in different geologic environments. The goal is to minimize the over and under design of mine roof support, resulting in more productive and safer mines. To obtain the necessary data on roof behavior and support performance, USBM conducted several field studies. Each study covers roof geology, stress regime, ground reaction, support interaction and mining environment. A consistent experimental design is being used. This includes measurements of roof bolt loads and roof movements. So far, 10 studies have been conducted in several geologic settings.

Jan 1, 1996

By Magnus Ericsson

The unexpectedly quick recovery in world crude steel production in the second half of 2009 was due almost entirely to increased production in China that began in late 2008. Previous peaks in monthly production in China were matched by April 2009. The rest of the world had still not reached pre-crisis production rates by May 2010. Chinese production drives growth, but there has been some growth in most other larger crude steel producing countries as well, compared to production in 2009. If the production rate of the first four months of 2010 continues, the total output of crude steel in 2010 will be somewhere around 1,410 Mt (1.5 billion st), the same as in the record year of 2007.

Jan 1, 2010

By H. Copur

Roadheaders have become widely used in underground mining and tunneling operations because they offer the flexibility to excavate soft- to medium-strength rock formations. A critical issue in successful roadheader application is the ability to develop accurate and reliable estimates of machine production capacity and the associated bit costs. Increased pressure to improve productivity and lower costs in the mining and civil construction industries has been the driving force behind the more wide- spread use of mechanical excavation systems. This has caused both industries to move away from the conventional drill and blast methods. Additional benefits of mechanical mining include improved safety, reduced ground support requirements and fewer personnel. These advantages, coupled with recent enhancements in machine performance and reliability, have resulted in mechanical miners taking a larger share of the rock excavation market. Roadheaders are the most widely used underground partial-face excavation machines for soft- to medium- strength rocks, particularly for sedimentary rocks. They are used for development and production in soft rock mining (main haulage drifts, roadways and crosscuts), particularly in coal, industrial minerals and evaporitic rocks. In civil construction, roadheaders are used to excavate railways, roadways, and sewer and diversion tunnels in soft ground conditions. They are also used to enlarge and rehabilitate underground structures. Their ability to excavate almost any profile opening also makes them attractive to those mining and civil construction projects where various opening sizes and profiles are needed. In addition to their high mobility and versatility roadheaders are generally low capital cost systems com- pared with most other mechanical excavators. Because of higher cutting-power density due to a smaller cutting drum, roadheaders can excavate rocks harder and more abrasive than continuous miners and borers.

Jan 1, 1998

By Y. J. Zhang

This paper presents the results of a recent study on the development of an in-situ testing method for determining the coal strength in mine pillars. The strength testing is performed in the horizontal holes drilled into the coal rib using the penetrometer. It is a hydraulically powered device that uses an indenter to press the surface of the borehole until the load reaches the failure point of coal. The pressure and the penetration of the loading pin are recorded by the data acquisition unit. The results collected from several coal mines indicate that this testing method is ideally suited for the realistic coal strength measurements. The new testing system not only improves the accuracy of pillar strength determination, but it is more cost efficient than the conventional method.

Jan 1, 1995

By Robert W. Curtis

Kaiser Aluminum & Chemical Corporation's (KACC) entrance into the alumina market began in 1946 with the purchase of a small plant in Baton Rouge. Louisiana. Since that time KACC has been involved with the design, construct; on, and operation of many alumina plants around the world. One of these plants is located in Gramercy, Louisiana. The Gramercy Works is a multiplant installation consisting of an alumina plant, a caustic-chlorine plant, a petroleum coke calciner and a fluorochemicals plant. Each of these plants require their own specific environmental control programs to abate pollution. Kaiser has made significant progress through the years on their own initiative in pollution control. But many new challenges have been and continue to be created with the enactment of environmental laws. The 1970 Clean Air Act Amendments, the resurrection of the old "Refuse Act" in 1970 and finally the 1972 Federal Water Pollution Control Act Amendments prompted the formulation of our current philosophy towards the abatement of pollution. Since the formulation of these complicated pieces of legislation, others equally complicated, have come to being. The Federal Insecticide, Fungicide and Rodenticide Act as amended by the Federal Environmental Pesticide Control Act of October, 1972, the Toxic Substances Control Act of 1976, the Solid Waste Disposal and Resource Recovery Act of 1976 and the Safe Drinking Water Act sighed in December of 1974 have all contributed to the challenge for an alumina plant to meet regulatory constraints. However, this paper will only discuss the alumina plant?s environmental programs designed to meet compliance with air and water pollution legislation. At the Gramercy Alumina Plant, over $25 million has been spent for pollution control since 1969. The Gramercy Plant is a prime example of KACC's commitment to meeting the environmental challenge.

Jan 1, 1978

By Sandeep Kumar Jeripotula, Govinda Raj Mandela, Aruna Manglapady

Dumper operators are frequently exposed to whole body vibration (WBV) in surface mines. Surface mining activities involve the amalgamation of comparatively high intensity of vibration and extended exposure durations. Efficient risk reduction mandates knowing of important phases of a task that poses a threat to health of dumper operators. So far in India very limited studies have been reported on WBV exposure with regard to surface mines. This paper evaluates WBV of dumper operators based on ISO 2631-1:1997 Standards and European Union (EU) Directive 2002 for different phases of job cycle. Six dumpers were considered for this study and the vibration measurements were made for all the four phases of the job cycle by placing the triaxial accelerometer on the operator’s seat-surface and at the seat-back, independently. The findings of the study revealed that the haulage task (loaded travel and empty travel) remains the chief contributor to vibration exposure according to seat-surface and seat-back measurements. Maximum frequency weighted root mean square (RMS) of 1.12 m/s2 and 1.09 m/s2 were reported for empty travel task for seat-surface and seat-back measurements, respectively. For seat-surface measurements based on RMS, Z axis remains as the dominant axis of vibration for all the dumpers during haulage task, whereas for seat-back measurements, the dominant axis varies between X and Y. Exposure action value (EAV) based on RMS has exceeded the threshold value of 0.5 m/s2 for all the dumpers during loaded travel and empty travel for seat-surface as well as for seat-back measurements.

By M. Pillay

INTRODUCTION Heat stress continues to be a safety concern in underground mining. This is due to a number of reasons including increasing depths of mining, increased levels of heat generated from machines, ventilation systems being constrained from providing suitable levels of airflow and others. In order to assess if a thermal environment is safe for miners under normal or modified work arrangements, or to specify stop work conditions a heat stress index is used to guide decisions. Historically, a number of heat stress indices have been developed and applied in underground mines. These can be classed under three broad headings; single measurement, empirically based and rational indices. Do any of these indices perform better than the others? Which one allows simple determinations and decisions to be made in the mine? This paper aims to provide answers to these questions by comparing and contrasting three indices; effective temperature (ET), simple air cooling power (ACP) and Thermal work limit (TWL) for a range of typical mining wet and dry bulb combinations? The paper concludes with the identification of areas for future research. BACKGROUND Heat stress causes discomfort, increases physiological strain, decreases productivity and performance, and contributes to increased incidents [1]. Effective management and control of heat stress is particularly important in mining where hot working conditions are very common [2]. Heat stress index is a common indicator that is used by mine safety advisors and managers to guide decisions about safe work practices in mining under normal or modified conditions. According to Howes and Nixon [3] A safe heat stress control strategy for an underground mine has three elements: • Application of an environmental measure which reflects physiological strain with sufficient accuracy for the range of conditions encountered underground. • Acceptance of a functional relationship between the environmental measure and human performance which is used to optimise the environmental conditions achievable with either ventilation or ventilation and refrigeration. • A management control strategy based on the environmental measure which is designed to ensure that work in environments where excessive physiological strain may occur is prevented and corrective action is initiated. The link between these elements is an environmental measure that reflects the physiological strain a worker is subjected to. Since the turn of the twentieth century various indices of thermal stress have been developed (McPherson [4], Howes and Nixon [3], Brake [5]). In selecting a suitable environmental measure or index one problem that must be addressed is the ease with which it can be physically obtained relative to it accurately reflecting the physiological strain. No index can be universally applied and there is no single correct measure or index. However if an index has provided adequate control in a particular circumstance, then it can be regarded as correct for that situation.

Jan 1, 2019

By R. J. Sheets

In 2009, the Gold Quarry openpit mine experienced multiple large-scale slope failures of the upper east highwall that reduced gold ore extraction for nearly 18 months. The slope failures occurred within a weak, consolidated sedimentary sequence that exhibits strength characteristics that are transitional between soil and rock. Instability initiated as mining exposed the lower, high plasticity subunits of the Carlin Formation. This deformation created preferential flow paths that allowed ground water from the upper sandy subunits to infiltrate low-permeability, clay-rich subunits, thereby enhancing deformation of the slope toe, which, in turn, destabilized the upper portion of the highwall. The outcome was a 160 m high slope failure that had a lateral run-out of 850 m. The effort to return the pit to ore production required geotechnical and hydrogeological investigations and the preliminary remediation mining activity to be concurrent. This required the development of detailed safety procedures and a requirement to modify the remediation design as new results were obtained. An initial challenge was to mitigate a near vertical, 90 m headscarp with localized, blast-induced slope failures. Back-analyses with numerical modeling software indicated that the failure surface could be shallower, which contradicted the initial failure interpretations. Eventually, drilling results confirmed this alternative failure geometry. The final remediation design incorporated shallower slope geometries and an approximately 3 Mt buttress along the base of the Carlin Formation and bedrock contact to reinforce the subunits with residual strength properties. The results are a stable highwall within the Carlin Formation following nearly 10 years of repeated slope failures, and an example of the necessity to conduct appropriate geotechnical and hydrogeological studies during the early stages of a new layback evaluation or new openpit development.