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By J. G. Groppo

Froth flotation technique is an effective and efficient process for recovering of ultra-fine (minus 74 pm) clean coal. Economical dewatering of an ultra-fine clean coal product to a 20 percent level moisture will be an important step in successful implementation of the advanced cleaning processes. This study is a step in the Department of Energy's program to show that ultra-clean coal could be effectively dewatered to 20 percent or lower moisture using either conventional or advanced dewatering techniques. The main focus of the pilot plant study was on proof-of-concept testing of a dewatering technique for a fine clean coal product. The coal industry is reluctant to use the advanced fine coal recovery technology due to the non-availability of an economical dewatering process.

Jan 1, 1997

By S. K. Kawatra

It is common in coal-cleaning operations to produce a fine waste stream which contains a considerable amount of coal, but which is not economical to recover both because it is mixed with large amounts of difficult-to-remove clay slimes, and because the fines are often heavily oxidized. Conventional froth flotation machines cannot produce an acceptable product from such material in a single stage of flotation, and even flotation columns often have difficulty cleaning this type of feed. A new type of flotation column was designed specifically to deal with these problems, and was installed and tested in a coal-cleaning plant in Ohio. The feed coal contained 39.8% ash as fine clay, and 2.83% total sulfur, and was 80% passing 176 micrometers. The coal was a thickener product which had oxidized for some time, and was very difficult to float. However, using the new column it was possible to recover up to 85% of the calorific value in a product containing less than 11% ash, and up to 60% of the calorific value in a product of less that 8% ash. The bulk of the pyritic sulfur was rejected from the coal as well. Multistage flotation tests showed that the flotation column was able, in a single stage, to produce the best froth flotation product that it was possible to recover from this coal.

Jan 1, 1994

By D. D. Schlepp

There is a continuing debate about the influence of circulating load and classifier efficiency on the capacity of the circuit. Specifically, the effects of preferential classification, bypassed fines, and the sharpness of classification will be examined. Horizontal cyclones have also proven to be very successful in a number of operations but their impact on the circuit capacity has not been clearly defined.

Jan 1, 1990

By L. Alan Weakly

The U.S. Department of Energy (DOE) has entered into a $l.5 million Cooperative Agreement with Alpine Equipment Corporation/Astro International Corporation ("Alpine") of State College, Pennsylvania, for the evaluation of water-jet-assisted (WJA) mechanical cutting of oil shale under actual mining conditions. A commercial-sized, heavy WJA mechanical miner is being assembled based upon the successful "factory testing" of a smaller prototype miner utilizing standard tungsten-carbide and Polycrystalline Diamond Composite (POC) bits in large oil shale boulders. Actual field testing of the machine will be conducted in an oil shale mine located in the Piceance Basin of Western Colorado. In-mine logistical support is being provided by several oil shale companies through the Colorado Mining Association (CMA) and the U.S. Bureau of Mines (USBM).

Jan 1, 1990

By Chris McKee

Quartz has been of interest in occupational health for years because it can cause silicosis after prolonged exposure. New OSHA regulations (Air Contaminant; Final Rule) list perlite as a nuisance dust. They conclude that perlite is nontoxic when air-borne total particulate concentrations are 15 mg/m3 or below and when quartz content is less than 1% crystalline silica. OSHA has established an 8-hour PEL of 15 mg/m TWA for total perlite dust containing less than 1% quartz. OSHA has established a 5 mg/m3 TWA PEL for respirable perlite. These limits will protect workers from significant risk of eye, skin, or other physical irritation. This regulation is based on a Group 2A classification as a probable carcinogen in humans, at the 0.1% crystalline silica level, by the International Agency for Research on Cancer (IARC 1987a, b). IARC found sufficient evidence for carcinogenicity of crystalline silica in animals and limited evidence in humans. Perlite is not listed as a carcinogen by OSHA or the National Toxicology Program.

Jan 1, 1990

By C. J. Roos

Ground-engaging tools are used to prevent damage to the main components of earth-moving equipment. These tools consist of everything from shovel teeth to replaceable drill bits to dozer wear plates. The costs of these "consumable" items are increasing with the costs of raw materials. This project developed a tool to be used by Newmont Mining Corp. to predict the consumption of excavator teeth at a particular mine site. This paper presents the results of the Montana Tech research project in which an equation was developed to predict excavator teeth consumption based on production rates and rock properties.

Jan 1, 2010

By Jaeheon Lee, Jai‑Won Byeon, Junmo Ahn, Jun‑Jae Lee, Eun‑Woo Kim, Yoo‑Jin Kim, Jiajia Wu, Jae‑Yeon Kim

Growing demand for valuable battery materials and environmental issues from battery disposal make the recycling of spent lithium-ion batteries (LIBs) essential. Specifically, the green approaches using organic reagents have garnered many attentions for battery recycling. In this study, a synergetic organic leaching system using methanesulfonic acid (MSA) of strong organic acid and citric acid (CA) with good chelating ability was investigated to extract valuable metals from LiCoO2. Hydrogen peroxide was used as a reducing agent to enhance leaching kinetics. Cobalt extraction of 98% and lithium extraction of 97 % were achieved in the optimized condition; 2.4M MSA, 1.6M CA, 1.0 vol% H2O2, S/L ratio 80 g/L, 85 °C, and 1 h. The optimal leaching condition of the MSA-CA mixed leaching system exhibited good applicability to various cathode scraps, such as LiCoO2, LiNixMnyCo1- x-yO2, and LiNixCoyO2. The dissolved Co and Li ions in the MSA-CA leachate were selectively recovered with high recovery efficiencies of 99 % and 97 % as Co3O4 and Li3PO4, respectively. The recovered Co3O4 and Li3PO4 were utilized to regenerate cathode materials. LiCoO2 and LiFePO4 were also synthesized through a solid-state reaction and hydrothermal method. The recycling process based on the MSA-CA-H2O2 synergetic leaching system was proposed, and it might be applied as a green and economical organic leaching system for the recycling of various types of spent LIBs.

Sep 20, 2023

By Richard C. Corson

The objective of blending materials in a bedding pile is to reduce the variation in successive samples taken from the materials to be blended. In designing a bedding and reclaiming operation, several mechanisms are available to effect the reduction of variability, or increase in homogeneity, of the materials. These mechanisms can act before stacking, in the stacking process, in reclaiming and after reclaiming. In evaluating alternative methods of stacking and reclaiming, the potential user must judge each method on the basis of certain criteria; the capital cost of the equipment, the allowable absolute variability of the reclaimed product and the effectiveness of blending. Several stacking and reclaiming methods have been tested using a computer simulation. Based on the results of this program, factors were developed to describe the effectiveness of blending for chevron stacking of discrete materials and preblended materials, bucket wheel reclaiming and drum reclaiming. From these factors, the total effectiveness of a combined stacking and reclaiming system can be determined.

Jan 1, 1985

By L. Yan, B. Lambie, J. Srednicki, J. Carr

Electromagnetic emissions from electrical devices may interfere with electronic safety systems or other devices in the mining environment. This electromagnetic interference (EMI) may cause unwanted changes in the performance of the affected devices and may cause safety issues for miners. To minimize the risk of EMI, the National Institute for Occupational Safety and Health (NIOSH) has conducted research quantifying the electromagnetic emissions of several types of equipment that might be used in the mining environment. Previous research has shown that welding arcs can give off ultraviolet (UV) emissions, visible light, and infrared (IR) emissions that can cause health problem on skin and eyes. In this study, the electromagnetic emissions of the shielded metal arc welding (SMAW) process were monitored and measured. Several factors including operating mode (AC, DC positive or DC+, DC negative or DC-), current setting (low, medium, high, maximum), and electrode type were investigated to compare their effect on emission level. The test shows that the emission level from the welding process can be affected by those factors. The test data also shows that, among those factors, the operating mode has more influence on emission level than do current setting and electrode type. The information in this paper can be useful for the mining industry to better understand the emission in the 9-kHz to 500-MHz frequency range from a SMAW welder.

Feb 1, 2023

By Lyman File

This paper discusses the overall challenges to construct a two-lane highway tunnel located in southwestern Colorado on U.S. Highway 160 for the Colorado Department of Transportation by the Kiewit Western Company. The purpose of this project is to provide the excavation and temporary support for a highway tunnel 280 m (916 feet) long. The tunnel cross section is 14.3 m (47 feet) wide by 8.5 m (28 feet) high, 105 m2 (1,130 SF).Construction methods include conventional drill and blast excavation with rockbolt and shotcrete ground support. This unique tunnel is being constructed under alpine tunnelling conditions and in the immediate vicinity of active highway traffic.

Jan 1, 2003

By E. J. Garrison

A.C. Noble presents a clear and concise summary of the factors pertinent to a competent reserve evaluation of a mineral occurrence. However, I believe that he confuses the difference between a resource and a reserve. By definition, a reserve estimate includes all known economic, legal, mining, metallurgical and environmental factors impacting the recovery of the product(s) found in the deposit. A resource estimate, however, is an estimate of what is there - what is available for exploitation and should not include economic and other considerations. Only after defining the resource, its extent, location, physical and chemical properties, can an intelligent selection process begin of the extraction and processing technologies most appropriate to the circumstances encountered. The early and almost certainly inappropriate application of these often cookbook choices has probably lead many companies to walk away from good properties. (How many mines have been found in others rejects?) An example of the process is the early selection of metallurgical samples, after encouraging values are found in a few holes or surface samples, in an attempt to determine the economics of the prospect. Unfortunately, the sampler does not know how representative of the occurrence the sample is because he does not know what the deposit looks like. As a consequence, the property becomes saddled with a bad metallurgical sample that is often inappropriately used in evaluating the deposit which it does not represent.

Jan 1, 1994

By Rahul Singh, Sunil Kumar, Erich Dohm, Maoming Fan

The rapid increase of P2O5 use for food, biofuels, and LiFePO4 batteries etc. accelerates the depletion rate of phosphate reserves. In the phosphate industry, a significant amount of ultrafine phosphate has been discarded as slime tailing due to processing difficulties. The major problems associated with ultrafine particle flotation are low probability of bubble-particle collision and adhesion, and high probability of unwanted gangue particles entrainment. This paper investigates the enhanced ultrafine phosphate particle flotation probability by Eriez’ CavTube generated fine/ ultrafine bubbles and the improved flotation selectivity by wash water etc. Ultrafine phosphates with various gangue minerals of quartz/muscovite, calcite/dolomite, and iron/ silica were studied. Microscopic observations show that the entrained ultrafine gangue minerals can be minimized by using wash water in column flotation. A three-factor threelevel central composite experimental design was conducted for ultrafine phosphate flotation. For comparison, both benchtop mechanical cell and laboratory column flotation tests were performed at their optimal respective flotation conditions. Using Eriez CavTube column flotation technology for Industries Chimiques du Senegal (ICS) ultrafine slime tailings, a concentrate grade of 36.0% P2O5, was achieved at 89.4% P2O5 recovery. Improved flotation performance was achieved using column flotation as compared to benchtop mechanical cell flotation. The benefits of Eriez’ column flotation technology realized from this study include the high P2O5 grade and recovery.

Feb 1, 2024

By Matthew Holden, Jason Emery, Matthew Benjamin, Peter Craig

Over the last 25 years, through adversity and a growing level of risk mitigation, Australian Longwall mines have been using higher and higher capacity cable bolts for secondary support. A recent survey revealed 85% of Australian longwall cable bolts are a 70 tonne capacity pre-tensioned hollow post groutable system. Mines avoiding pumping cementitious grouts are sometimes using pre-tensioned resin encapsulated solid cable bolts of over 90 tonne capacity. Results from various industry and University research has led to manufacturer's fine tuning the construction of their cable bolts. A review of this research explains how smooth wire construction is now dominant. Aggressive shear has also led to some mines using 8 tonnes pre-tension instead of the previous common 20 tonnes pre-tension. Lower pre-tension acceptance is now leading to a greater use of threaded cable bolt end fittings, these are tensioned to 8 tonne using the drill motor torque. A recent development is the TEX cable bolt, a slim line threaded end fitting that fits with the drill hole like a standard rock bolt. This cable is being installed at the coal face as primary support off bolter-miners. The laboratory and in-situ testing of the TEX cable is presented. In a bid to improve gateroad development rates and ground support in the last several years, a 100 tonne tensile capacity Goliath cable system was developed. The latest development in resin anchored solid cables is a 110 tonne capacity cable bolt, with laboratory and in-situ testing results presented.

Jun 25, 2024

By D. E. Nash

Environmental compliance programs for mining companies are not only important management tools, but can deflect serious civil and criminal penalties if violations of environmental laws do occur. The paper discusses the legal foundation for such programs and their basic structure.

Jan 1, 2001

By B. Seegmiller, W. A. Hustrulid, O. Stephansson

Introduction The concept of in-the-wall haulage was formally introduced to the mining community in the early 1970s. The basic concept is simple. Rather than the traditional in-the-pit haulage/access ramp, single or twin ramps driven in the pit wall are used with crosscut connections on the working levels. The in-the-wall pit haulage system could be considered as part of the opening of a new mine, a way of completing to final depth an existing pit, or part of the transition from open-pit to underground mining with the ramp remaining as part of the access. This paper is intended to acquaint the reader, particularly mine planning engineers, with some of the possibilities presented by the concept. Nordstrom (1983) said, "In many countries, mining engineers are either open-pit or underground specialists and, hence, often don't consider the possibilities for combining the best aspects of each into a hybrid mining system." This is believed to be true. There are few "hybrid mines" employing, for example, open-pit methods with underground haulage systems. One reason is the variance with the experience of the mining company and the engineers involved. However, with today's low metal prices, innovative and unconventional thinking may be just what a property requires to remain in production. All the possible situations where an in-the-wall ramp might be considered cannot be presented here. Rather, a few examples will be discussed for illustration purposes. Potential savings in stripping costs A major cost in open-pit mining is associated with the removal of overburden and waste rock. Although much of this stripping cannot be avoided, the volume (V) associated with the presence of an in-pit haul road can be quite large, V 100 (pit depth) a (road width) 2 x road grade (%) As an example, consider a vertical ore body 400 m (1312 ft) long, 60 m (197 ft) thick, extending to a depth of 160 m (525 ft). Cross sections are shown in Fig. 1. Other data are: ore tonnage = 11 Mt (12 million st), ore density = 2.9 t/m3 (0.09 st per cu ft), waste rock density = 2.7 t/m3 (0.08 st per cu ft), road width = 20 m (66 ft), road gradient = 10%, and level interval = 10 m (33 ft). The evaluation has been made assuming that the pit slope (0) is constant around the pit except on the side with the haul road. On this side, the slope is decreased to allow for the road. Slope angles of 30° to 60° have been selected to indicate the dependence of stripping volume (V) on slope angle. The stripping at the ends have been calculated assuming representation by cones. The volume associated with the haul road is 2.6 Mm3 (92.8 million cu ft). A comparison of the strip volumes involved is shown in Table 1. As can be seen, the percent savings in strip volume varies from about 4% to 17% and depends greatly on the slope angle. It is perhaps more interesting to examine the savings in stripping costs that could then be used to cover the cost of the access ramp and the crosscuts for stripping costs of $3/m3 ($0.08 per cu ft). The cost with the road volume is 2.6 million x 3 = $7.8 million.

Jan 1, 1988

By M. Frenzel, D. Ebert, K. Bachmann, A. D. Renno, R. Möckel, J. Gutzmer, J. Krause

With the increasing demand for metalliferous and mineral raw materials and the consequent depletion of the global natural resource base, the possible utilization of secondary raw material sources is receiving more and more attention. In the present study, we present results from a detailed vanadium deportment study of three basic oxygen furnace slag (BOS) samples known to containing elevated bulk concentrations of vanadium. Complementary analytical methods that were used to quantify the abundance and composition of V-containing phases include SEM-based automated mineralogy, X-ray fluorescence analysis, and X-ray powder diffraction as well as electron probe microanalysis. The vanadium deportment was quantified using Monte-Carlo simulations of the data obtained from automated mineralogy and electron microprobe analysis. The total V concentrations identified by XRF are between 1.7 and 2.2 wt.% V. The most important hosts of vanadium are larnite-, brownmillerite- and portlandite-solid solutions. In two samples Ca carbonates also significantly contribute to the V deportment, while wuestite, lime, and native iron do not contribute significantly to the vanadium deportment. A thorough consistency check identifies considerable uncertainties in the density of the V-bearing phases as the most likely reason to explain remaining discrepancies between measured and calculated V values.

Oct 14, 2023

By Saurabh Kundu, Shakuntala Tudu, Indrajit Paul, Chandra Sekhar, Manikanta Nallamilli, Shaik Mahaboob Basha, Neha Gupta, Srinivas Dwarapudi, Dhiraj Madhukar Kadhe

Iron ore pelletizing using compressive and shear action on wet mixture feed has been studied. The physical properties, namely, moisture content, drop strength, green compressive strength (GCS), dry compressive strength (DCS), porosity, and cold crushing strength (CCS), have been studied. Pelletizing tests were carried out on four different types of ore, namely, hematite ore, magnetite ore, goethite ore, and sinter return fines. The inference of shear forces on silica distribution index in dry pellet has been studied using optical and scanning electron microscopy. Significant improvement in physical strength was observed due to compressive and shear forces on the pellet mixture feed. However, decrease in moisture content and ball porosity has been observed. Silica distribution index improved by 1.72 times for hematite ore, 1.47 times for magnetite ore, and 1.68 times for goethite ore. It has been found that bubble cavity has been reduced which is good indicator in terms of physical properties.

Jan 29, 2022

By Robert D. Harris

In 1958, the coal industry, through Bituminous Coal Research, Inc., and the electric utility industry, through the Edison Electric Institute and the Association of Edison Illuminating Companies, initiated a joint program to study coal pyrite and its removal as a means of lowering the sulfur content of steam coals. It was assumed that significant amounts of pyrite often remained in washed steam coal not because available systems for coal cleaning were inadequate, but because the pyrite was small and widely disseminated, During the first two years, samples of coal were examined petrographically to determine the size, association, and mode of occurrence of the pyrite in the raw coal and in the products of laboratory separation, Samples of coal were also pulverized in different equipment to determine how effectively pyrite was released by pulverization and if the mode of pulverization affected the liberation of pyrite. From these studies, the following tentative conclusions were made (1 ): 1. Much of the coal pyrite is within a 250-70 micron size range, and therefore is too small to be removed by conventional coal cleaning, but relatively large when compared to the size of coal as pulverized for combustion in large boilers. 2. The degree of pyrite liberation is mainly determined by the size of the product and not by the type of crusher. 3. For improved pyrite removal, the coal should be cleaned during or after pulverization at the power station.

Jan 1, 1965

By L. A. Khan

This paper first discusses the physicochemical cleaning methods used to process fines followed by an analysis of the subprocesses of froth flotation and the adverse effects of slimes and particle oxidation. These subprocesses include the phenomena of interception, contact, adhesion and levitation. Preventive and corrective measures to combat the generation of fines and their effects are suggested. Preventive measures include controlled grinding, limited liberation, flotation at coarser sizes. Means of preventing oxidation and/or removing oxidation products are a1 so discussed. Corrective measure to increase recovery include intensive aeration, aggregation of particles, intensive mixing, increased retention time, and reduction of detachment. Measures leading to improves selectivity involve means to reduce slime coating, achieve selective mineralization of bubbles and minimize entrapment.

Jan 1, 1986

By Liaqat Ali Shah, Muhammad Farooq, Zait Ullah Shah, Francisco Rolando Valenzuela-Díaz

Bentonite collected from Nowshera (Pakistan) was treated with NaCl, and the < 2-μm clay fractions were separated by sedimentation process. The textural changes in NaCl treated purified bentonite were compared with raw and physically purified sample. It was detected that the NaCl-treated purified bentonite and the sample purified by simple sedimentation, respectively, consist of sodium-montmorillonite and calcium-montmorillonite as a major clay mineral. The honeycombed-type morphology was observed for both the purified samples; however, the particles of NaCl treated purified bentonite were relatively in a compact form. The particle sizes of both the purified samples were found considerably smaller. The high volume percent of the fine particles was noticed in the NaCl-treated purified bentonite. This attributed that the sodium exchange has a valuable impact on the bentonite dispersion in aqueous media during particle size measurement. The relatively high mesopore area/volume and micropore area/volume and specific surface area (SSA) were detected in purified samples. The NaCl-treated purified sample showed relatively high mesopores area/volume than the sample obtained by simple sedimentation. These changes seem to be originated from either high montmorillonite contents and/or the smaller particle size, which might be produced after the layer rearrangement during the interlayer cation replacement by Na+ ions. The large SSA and high porosity of purified samples particularly the NaCl-treated bentonite suggest their potential use as adsorbents, catalysts, pharmaceuticals, and cosmetics.

Jan 7, 2021