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By B. J. Sauer

Misapplication of AC induction motors for mine crusher and mill applications has long been a frustration for both the driven equipment supplier and the mine operator. Proper selection of AC induction motors is critical to providing efficient production. This paper focuses on the selection of AC induction motors for gyratory crusher, cone crusher, and grinding mill applications. The criteria for motor selection includes: proper enclosure, driven equipment torque requirements, bearing life, temperature rise, starting requirements, ambient temperature, altitude and accessory requirements.

Jan 1, 1999

By M. Dondi, M. Surracco, G. Alfano, P. Saba

Recent investigations on fine grinding with jet mill miprototypes of original design, constructed at the DIMM and Centro Studi of the National Research Council at Cagliari University, have led to the realization of a third generation micronizer characterized by large capacity and high efficiency. The new model and its distinctive features are described here and the results are presented of grinding tests on typical, high grade Sardinian minerals used for quality products. The operating principles of the jet mill are described in relation to the mechanico-elastic properties of the minerals treated. In particular the efficacy of the comminution process is demonstrated in terms of both solid treated and of impact, attrition and shearing forces generated in the micronizer. Particle size distribution of the finished products are reported, that satisfy the most stringent market specifications for the different minerals, as well as energy consumptions. The alternative operating options for solving particular grinding problems and minimizing energy consumption are discussed. Lastly, the main developments of the jet mill for a possible application at industrial scale are suggested.

Jan 1, 1995

By S. K. Kawatra, S. J. Ripke

Iron ore concentrates pellets are currently in duration heat hardened (sintered) under oxidizing conditions. Pellets produced from magnetite ore concentrate are completely oxidized during induration and finish as hematite pellets. These pellets then require a blast furnace to reduce the hematite to metallic pig iron. Partially reduced pellets would save energy and fuel during transportation and further reduction. It has been stated in the literature “the most important single factor responsible for the development of strength in fired magnetite pellets containing no additive is the oxidation of the magnetite to hematite and the subsequent recrystallization and grain growth of this constituent.” However experiments shown in this paper reveal that oxidation is not necessary to produce high-strength pellets. Magnetite concentrate pellets developed similar strength when indurated at 1350°C under either oxidizing (air) or inert (argon) atmosphere; the pellets sintered under argon remained magnetite. In addition, magnetite concentrate pellets indurated under reducing (CO) atmosphere also remained as magnetite, but required induration temperature of approximately 150°C less than the other pellets.

Jan 1, 2003

By J. W. Keck

Pilot plant grinding and concentration test results indicate that conglomerate native copper ore can be ground and concentrated using conventional techniques. Single stage autogenous grinding and rod mill-ball mill grinding required the same amount of energy far the required comminution. Metallurgical results were comparable for both types of grinding investigated.

Jan 1, 1973

By A. C. Smith, J. H. Rowland III

The Mine Improvement and New Emergency Response Act of 2006 (MINER Act) established a Technical study panel (the Panel) to provide recommendations on the utilization of belt air and new technology that may be available for increasing the fire resistance properties of conveyor belt used in underground coal mines. The Panel Report recommended use of the belt evaluation laboratory test (BELT) as the method for testing and approval of flame resistant conveyor belts used in underground coal mines. The research conducted to establish the correlation of the BELT with large-scale belt fire flammability tests was done using 91 - 107 cm (36- to 42-in.) wide conveyor belt. Due to today’s coal haulage capacity, the mining industry is using 183 cm (72 in.) and wider conveyor belts. The U.S. National Institute for Occupational Safety and Health (NIOSH) conducted a study to determine if the BELT will also qualify wider belts as fire resistant for use in underground coal mines. This paper describes the results of recent experiments comparing results from using the BELT and the large-scale tests for six different belts.

Jan 1, 2011

By J. J. Harrington

The pH control system at Kennecott Copper Corporation's Nevada Mines Division concentrator consists of two independent systems, lime dilution and lime addition. Lime dilution is accomplished in a mixing tank where slaked lime and water are introduced proportionately. The desired dilution of the milk of lime is determined by the electrical inputs provided by eight pH probes, one per grinding section. The inputs are averaged and applied to a time base generator. The summation output of the time base generator determines the proportion of lime and water that are to be mixed and applies this input to a voltage sensitive switching device. The switching device provides a signal to one of two relays which will add either slaked lime or water, dependent upon the summation output. The entire cycle is based on a two-minute repetition rate to allow for sufficient mix time. Responsivity is controlled by maintaining a limited maxi- mum solution level in the mix tank. Lime addition is controlled independently within each grinding section. The electrical input from the pH probe in a given section controls the solenoid valves which provide lime to each of the ball mills. The valves remain open within a time range capable of maintaining the pH of flotation feed at a given set point.

Jan 1, 1975

By Steve Kral

San Francisco, CA will host about 1,500 tunneling and underground construction professionals from around the world during the biannual Rapid Excavation and Tunneling Conference (RETC), June 19-22. These professionals are gathering in a city that has seen much under-ground work throughout its history. And, today, the San Francisco region has more than $4.6-billion in tunneling projects under way. The RETC will include three-and-a-half days of technical programming, complete with proceedings, two short courses, two field trips and a host of social activities. In addition, the accompanying exhibit has attracted 127 exhibitors in 152 booths, an RETC record. The following is a brief list of activities that will take place during the conference. A more complete program is provided in the official showguide that is bound into this issue of Tunneling & Underground Construction.

Jan 1, 2011

By M. Scaggs

"Respirable dust in underground coal mines has long been associated with lung diseases, and regular dust sampling is required for assessing occupational exposures. At present, respirable dust concentration and crystalline silica content are commonly determined, but considering recent and yet unexplained increases in the incidence of lung disease amongst miners in specific geographic regions, more information about specific dust characteristics is urgently needed. While particle-level dust analysis is ideal, it is impractical for large numbers of dust samples because it is both time and cost intensive. Thermogravimetric analysis (TGA), however, is an alternative option, which offers the ability to determine the total coal to mineral mass ratio in a dust sample – analogous to proximate analysis of bulk coal samples for determining ash content. Here, preliminary development of a TGA method for this purpose is presented. The method is being developed to evaluate dust collected on mixed cellulose ester (MCE) filters using approved permissible sampling equipment. INTRODUCTION Based on the particle size, airborne mine dust can be classified in three categories: inhalable dust (< 100 µm in size), thoracic dust (< 25 µm in size), and respirable dust (< 5 µm in size) (Ramani et al., 2003). The World Health Organization (WHO, 1999) defines inhalable dust particles as those which can be breathed into the nose and mouth, and thoracic dust particles as those which can penetrate airways of the head and enter the airways of the lung. On the other hand, respirable dust particles can penetrate beyond the terminal bronchioles into the gas-exchange regions (alveoli) of the lungs (WHO, 1999). Hlavay (1992) reported that the seriousness of the damage in the lungs and respiratory tract is based on amount of dust remaining in these organs, and the amount of dust depends on the extent of dust exposure, the size distribution of the dust particles, and the capability of the body for dust elimination. Inhalation of respirable coal dust by miners can cause a disabling and potentially fatal lung disease which is called coal worker’s pneumoconiosis (CWP). Silicosis is another fatal lung disease caused by inhalation of respirable silica dust. In CWP and silicosis, dust particles deposit in the lungs, damage the lung tissue, and ultimately cause scarring which cannot be reversed (Colinet, 2010). While overall incidence occupation-related lung disease amongst coal miners in the US has been declining for over 40 years, it appears that there has been a recent increase in specific locations in Central Appalachia (CDC, 2006; Pollock et al. 2010; Suarthana et al., 2011). Although this trend is yet unexplained, one theory is that particular dust characteristics in these locations may be a factor (Hassan and Lau; Page & Oraniscak 2002). For example, several studies have indicated that different coals may generate different amounts of respirable dust (e.g., see Page, 1993 and Litton and Page, 1994), and the surrounding geology may also play a role in terms of the types of dust particles generated. Although respirable dust concentration and crystalline silica content are commonly determined as part of regulatory compliance sampling, more information about specific dust characteristics (e.g., size, shape and composition) is urgently needed."

Jan 1, 2015

By K. E. Hjelmstad

Solution mining operations often encounter difficulty maintaining adequate leach solution flow into the ore formation because of loss of formation permeability near the injection well. Permeability loss caused by swelling and breakup of clays and fine particle migration can often be the cause of the problem. Combined permeability and leaching tests were done in the laboratory on samples of clay bearing ores to evaluate a clay-stabilizing polymer&apos;s effectiveness in preventing the problem. Test results indicate that treating the ores with cationic polymers could maintain permeabilities two to five times greater than the long-term permeabilities present in untreated ores. Both alkaline (pH 8.5) and acidic (pH 2.0) leaches were used in the permeability leaching tests. To determine the reasons for the success of the clay stabilizing polymer, clay swelling tests and zeta potential measurements were made on untreated ore samples and on ore samples treated with the cationic polymer. Test results indicate the cationic polymer could reduce the degree of negative charge on fine particles and their tendency to disperse, as well as reduce clay swelling. Test results indicate a potentially beneficial effect on operating parameters such as capacity and injection pressure during leaching, if clays and fines are kept stabilized. This may be done by treating the zone of high fluid velocity near injection wells with cationic polymers.

Jan 1, 1991

By A. Pomianowski

A spectrophotometric study of xanthate solutions alone and their mixtures with equimolar amounts of alkyl trimethyl ammonium bromide (CnTAB) has established the additivity of ultraviolet spectra (190 - 400 my) for potassium ethyl xanthate (KEtX) and C12TAB. No obvious effect of C12TAB addition on the decomposition rate of KEtX was observed. The kinetics of collector abstraction by copper, nickel and sphalerite powders were studied in 10-5 - 10-3M solutions of KEtX alone and in equimolar mixtures of KEtX and C12TAB. Presence of C12TAB caused a 2 - 3 fold increase in the amounts of xanthate (equivalent to many monolayers) abstracted by copper and, nickel powders but had no effect on the abstraction of xanthate by unactivated sphalerite. The adsorption of C12TAB itself from the mixed solutions was very low, at most ore monolayer only, and was not influenced by the nature of the solid powder used. The results are interpreted in terms of molecular associations and synergistic action of xanthates and quaternary amines.

Jan 1, 1963

By R. W. Lake

The decision to develop an ore body can lead to multi-million dollar profits, or equally substantial losses. Accordingly, the effort required to adapt a valuation model to the specific proposal at hand, or even the development of a new model from basic principles, is clearly warranted. In the formulation of a model of this nature, one is faced with some major questions. For example, with the long term obligations that it implies, on what basis should a decision to initiate mining operations be made? Furthermore, how can the vagaries of inflation and the uncertainties that shroud the future be accommodated? Beyond the general principles by which mineral deposits are evaluated, specific cost behaviour is a function of the geology of the deposit, and of the mine design. Moreover, mine design, during the life of the mine, must be a continuing process somewhat akin to dynamic programming. An initial, apparently optimal, design is selected and mining commences. With production, a continual process of information updating leads to revisions. Thus if the maximum value is to be obtained, the mine design must be adjusted to conform to the changed conditions.

Jan 1, 1977

By Ken J. Richards

Industries dependent on pyrometallurgical processing generally find themselves facing a common set of problems, namely, serious environmental restrictions, heavy capital requirements for new facilities and for plant modernization, the certainty of rapidly escalating fuel costs, and the uncertainty of fuel availability. To remain competitive, it has become clear to industry that a new dimension of attention must be given to assuring the maximum performance from plant facilities already in place and from those that are built in the future. In the last decade or so, in response to these needs, there has been an acceleration in the development of new pyrometallurgical process concepts. Their application, though spotty, is increasing. A common factor in this developing base of technology is the need for effective process control. Digital control is an indispensable element of meeting the challenge. We cannot make the point, however, by looking to a general survey of instrumental control of pyrometallurgical processes. Computer control is in its awkward adolescence. Its application is so new that only isolated applications can highlight the trends. For this reason, the authors have chosen to focus on the nonferrous smelting industry to illustrate the status of pyrometallurgical processing and control. We believe this approach will best meet the interests of most readers of this edition and the background of the authors.

Jan 1, 1979

In cold regions rinsing of spent cyanide leach heaps is stopped during winter and is resumed again after snow melts. The effect of this idle time on the overall cyanide removal process was studied in this work. Samples were collected for rinsing tests from one heap at the Ryan Lode Mine of Citigold Alaska, Inc., near Fairbanks. The material was tested for cyanide removal a large column, 1.22 m high by 20 cm square, and in a small column, 1.22 m high by 10 cm in diameter. The rinse water was analyzed at regular intervals to determine the rate of cyanide removal from the solids. It was found that diffusion plays a major role in the removal of cyanide from the ore particles. Calculations showed that the insulating effect of the snow cover on the heap provides an excellent moderates the interior temperature of the heap, and would be expected to help the progress of the diffusion reaction during winter. The result expected result wil1 be higher cyanide values reporting to the rinse water after snow-melt.

Jan 1, 1993

By Glenn H. Damon

Concern about environmental pollution goes back many centuries, but until recently most efforts to control it have been perfunctory and spasmodic, aimed largely at coal smoke and other visible pollutants. Air pollution is to a large degree a byproduct of our economic development, and scientific knowledge of the causes and character of such pollution is more extensive than the technology to handle the waste byproducts of our industrial civilization. The removal of all constituents foreign to the air from the effluents produced by an industrialized society is obviously impractical at this time. There is widespread difference of opinion regarding acceptable ambient air concentration levels for the Various pollutants produced by combustion processes, but there is basic agreement that the pollution of the atmosphere must be controlled and eventually reduced. The magnitude of the air pollution problem has been increasing rapidly because our expanding economy calls for an ever-increasing consumption of energy, and fossil fuels are a principal source of energy. For example, the consumption of electricity has been increasing at an average annual rate of approximately 8 percent over the last 10 or 1.5 years. Table 1 shows the estimated emission of the principal pollutants into the atmosphere in 1966. The approximately 90 million automobiles, trucks, and buses on American highways contribute the largest proportion of pollutants to the atmosphere, but that fact does not alter the growing problems of the coal industry. You will note that sulfur oxides, particulates, and nitrogen oxides are all products of the combustion of coal. Of these air contaminants, sulfur oxides are now receiving major emphasis in terms of research to develop effective means for control, Table 2 shows that the combustion of coal produces approximately 60 percent of the sulfur oxides discharged to the atmosphere. While the utilization of coal is the principal source of particulate matter, this is not considered as serious a problem as it was in the early part of the century because of technological developments that have produced sound methods for the removal of particulates from waste gas streams.

Jan 1, 1968

By T. P. McNulty

During the last decade, many exhaustive studies have been made of process energy requirements for the production of various metals and materials. Some excellent technical papers and text books have resulted, and some of these are included in the bibliography of this paper. These studies were, of course, prompted by the economic pressures which resulted from the beginning of the "Energy Crisis" in 1973. Our intensified consciousness of the cost of energy led, then, to a greatly improved understanding of the energy consumption attributable to individual mining, processing, and refining steps. It is worth noting, however, that an awareness of the cost of energy is not new and that efforts to minimize this cost were an important part of sound mine and plant management practice throughout the earlier days of our industry. One only has to read a few accounts of mining operations around the beginning of this century to develop an appreciation for the cost of supplying wood, coal, fuel oil, or electric power to remote locations.

Jan 1, 1983

"Mining of ore bodies that are located at great depths enforces long distances to move the excavated rock masses to the surface. The excavated rock mass contains not only ore that can be economically extracted from the face but also waste, which is usually discarded several steps further downstream in the process. As a result, a large amount of rock is transported to the surface, influencing the costs at which the ore is produced. Reducing the amount of waste rock being transported to the surface by introducing a near-to-face sorting plant would improve the in many cases strained transport system in the deep mine. In this study, one of Boliden’s cut-and-fill mines was analysed with respect to the challenges related to rock transportation and increasing mining depth. The study aims to evaluate the potential use of a new near-to-face sorting system in the operating underground mine. Discrete event simulation was used to study and analyse the rock transportation system with and without the near-to-face sorting plant. The paper shows how the underground rock transportation system and the production were influenced when the near-to-face sorting equipment was added into the current system. INTRODUCTION The locations of waste rejection in the mining processes and the cost of removing waste from the system compared with the cost and energy necessary for further comminution are important parts in the material handling system (Bowman and Bearman, 2014). In an underground mine, longer material transportation distances generate the need for further investment in the mobile fleet and ancillary equipment in order to reduce the waste from the material handling as early as possible. One of the ways of reducing the waste (coarse particle size) in material handling is by use of pre-concentration. The benefits of pre-concentration are well known (Schena et al. 1990; Feasby, 1995; Peters et al. 1999; Klein et al. 2002), as well as the factors governing the feasibility of underground pre-concentration (Peters et al., 1999) and the mining integration issues (Klein et al. 2003). In the Onaping Depth orebody in Sudbury, Ontario the study of implementing the pre-concentration resulted in increased capital costs of 6% and a reduction in the operating costs of between 20-40% (Bamber et al, 2004). In this paper, the effects on the production and the transportation system of implementing underground pre-concentration by means of a near-to-face ore sorting plant in the Kristineberg mine are modeled and analyzed using the AutoMod tool. This tool is based on discrete event simulation (DES) (Banks, 2004), allowing high flexibility in customization and enabling the user to view the production of the system before ore sorting plant integration. The sorting plant selected in the simulation is built from modules. The material is fed by conveyor and goes through the comminution, classification, sorting and service processes after which the waste is redirected to backfill headings via trucks. The system mechanically ejects the particles from the feed stream on the basis of the information obtained from both the XRT sensor’s signal and 3D laser scanner based on both density and rate of refraction of light within a particular mineral. The sorting plant could pre-concentrate the metal ore up to 300 mm size. The plant requires little auxiliary infrastructure, is easily modularized for underground installation and can be easily relocated to different areas."

Jan 1, 2016

By E. Asselin

Passivation of Fe-Ni-Co alloys during the Caron leach process is thought to result in low cobalt recoveries in ammoniacal ammonium carbonate solutions. A brief review of the available thermochemical data for the (Fe, Ni, Co)-NH3-H2O systems has been undertaken. The stability of the Co(II) and Co(III), Ni(II) and Fe(II) am-mines was examined through the use of speciation and Pourbaix diagrams at 298 and 333 K and at 6 M total ammonia. Increasing the temperature reduces the stability fields of the ammines and generally constrains the thermodynamic window for the leach. The Fe(II) ammines are only thermodynamically stable under reducing conditions. Polarization experiments show that these ammines are unlikely to form if oxygen is present. Fe-Ni-Co alloy passivation may be alleviated by careful management of potential.

Jan 1, 2011

By E. Asselin

Passivation of Fe-Ni-Co alloys during the Caron leach process is thought to result in low cobalt recoveries in ammoniacal ammonium carbonate solutions. A brief review of the available thermochemical data for the (Fe, Ni, Co)-NH3-H2O systems has been undertaken. The stability of the Co(II) and Co(III), Ni(II) and Fe(II) ammines was examined through the use of speciation and Pourbaix diagrams at 298 and 333 K and at 6 M total ammonia. Increasing the temperature reduces the stability fields of the ammines and generally constrains the thermodynamic window for the leach. The Fe(II) ammines are only thermodynamically stable under reducing conditions. Polarization experiments show that these ammines are unlikely to form if oxygen is present. Fe-Ni-Co alloy passivation may be alleviated by careful management of potential.

Nov 1, 2011

By Osvaldo A. Bascur

Most mining and metallurgical plants have developed predictive maintenance policies based on statistical analysis and special techniques, like vibration analysis, oil and lube analysis for critical equipment. Process control strategies have also been installed in several metallurgical sites. These control strategies require instrumentation maintenance from local personnel. The availability of real time and process history to identify the most critical part of the processing system from mechanical integrity is a must for global plant optimization. Specialized performance control monitoring algorithms are required to justify their existence and contribution to the bottom line. Emerging technologies are combining these techniques into a single total plant system. Tools are required to assist in troubleshooting and adapting these process control instruments and strategies. The key is the plant equipment and process control availability and utilization rather than just maintenance.

Jan 1, 1997

By Jack V. Hill

A unique type of grinding mill liner has been developed by Waagner-Biro A.G. of Austria. This liner system, termed an angular spiral lining (.ESL), was, successfully tested by Magma Copper Company&apos;s San Manuel concentrator in both their 10 Ft x 10 Ft (3.05m x 3.05m) and 12 Ft, 6 In x 14 Ft (3.81m x 4.27m) grate discharge wet grinding ball mills. Magma Copper&apos;s savings in power and grinding balls justified conversion of more than half of their twenty-six ball mills to the ESL system.1,2 The ASL system was provided by the Capitol Castings Division of Midland Ross Corporation, the exclusive licensee for such conversions. Capitol Castings proposed the following as expected benefits from installation of an ASL system in an 18 Ft x 21 Ft (5.49m x 6.40m) overflow discharge wet grinding ball mill at the Pinto Valley Operation of Cities Service Company: "(a) Reduction of power consumption per ton of ore milled = 12%, (b) Increased throughput = 6%, (c) Reduction of ball consumption = 6%."

Jan 1, 1982