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A PDP 11/34 computer has been inter- faced to existing instrumentation in a 400 tph rod-mill/ball-mill grinding circuit and programed with a Kalman filter to estimate several unmeasured variables. A dynamic two-size- fraction model of the circuit is used to predict the complete state of the circuit including particle size distributions around the circuit, mass holdups and flowrates, the ball-mill grinding rate, water additions and cyclone parameters. Online measurements of sump level, slurry densities and product particle size are used to update the model values sequentially on a 20-second interval. This procedure results in optimal estimates of circuit variables given the relative reliability of measurements and the accuracy of the model.

Jan 1, 1983

The introduction of on-stream analysis in flotation circuits has raised the possibility of automatic control of flotation performance by digital computers. The development of control strategies for an industrial zinc cir- cuit is discussed with reference to identifi- cation of the major disturbances, investigation into the performance of the circuit, the design of the control algorithms, the testing of their performance and their implementation in a production environment.

Jan 1, 1983

By F. F. Aplan

Separation of the slightly soluble minerals (Ksp? 10-10), one from the other is one of the more difficult tasks confronting flotation engineers. This study has focused on means of separating such prominent members of this class as scheelite, fluorite and calcite from one another. Some experimental work has also been done on the minerals magnesite, dolomite and apatite. Carboxylic acid-type collectors are commonly used industrially to float all of these minerals. Thus, the problem at hand is to ascertain means of achieving selectivity between minerals known to respond rather similarly in flotation. Four techniques have been proposed for the separation of minerals of this class from each other: 1. Control of potential determining ions 2. Use of stereo-specific collectors 3. Use of flotation rate differences 4. Use of selective activating and depressing compounds. This study was directed toward a cursory evaluation of each of these techniques, and each was found to be a possible method of achieving selectivity. Stereo-specific collectors -- those whose parking area may closely match the available adsorption site on one mineral but not on another -- are a possible means of achieving selectivity between scheelite, fluorite and calcite. Stereo-hindered carboxylic acid salts and sulfonates all show selectivity between the three minerals tested. Separations also appear to be possible by the controlled use of the lattice ions (e.g., Ca and [W0=4] for scheelite, CaW04), H+, [OH-, C0-3 and HCO=3]; all of them ostensibly potential determining in the systems studied. Flotation rate differences of the minerals as a function of pH under conditions of starvation collector usage also showed promise. Scheelite and fluorite float most rapidly with sodium oleate in slightly acidic (pH 4-7) solutions whereas calcite floats most rapidly near pH 10. Use of Mn++, Pb++, or other heavy metal hydroxy complexes as activators was seen to effect each of the slightly soluble minerals differently. This is in sharp contrast to the oxygen containing, relatively insoluble minerals, where all minerals respond in a similar manner to such activation procedures. Results indicate that all four methods outlined above may potentially be used to achieve flotation separation of the slightly soluble minerals. More extensive research should be undertaken to detail the spcific applicability of each of the procedures and to make a more complete evaluation of the effect of collector type and concentration, mineral type, pH and size effects.

Jan 1, 1983

By D. E. Shanks

The Bureau of Mines surveyed a variety of inorganic ion-exchange materials to determine their suitability for removing valuable accessory elements and troublesome contaminants from metallurgical process and waste streams. Most of the materials, which included molecular sieves, heteropolyacid salts, and hydrous metal oxides, did not give adequate separations, did not have the necessary stability in strong acids or bases, or were not in a physical form suitable for ion-exchange use. Many of the suitable inorganic materials, especially the hydrous oxides, were capable of cation exchange with high capacity only in basic conditions, which caused hydrolysis of most of the cations tested. Multivalent anions, such as arsenate and phosphate, were easily removed from acidic solutions by hydrous oxides. Hydrous zirconia was the best material for this purpose. Multivalent anions were not easily des orbed because of compound formation; therefore, conventional ion-exchange techniques could not be employed. As an alternative approach, hydrous ferric hydroxide was used as a filter material to remove arsenate and phosphate from acid solutions. One gram of arsenic was removed from solution for each 20 g of ferric hydroxide. Ferric hydroxide is preferable to hydrous zirconia for use as a filter material because of low cost.

Jan 1, 1983

By Raymond V. Adolphson

The introduction of a new explosive component in 1955-56, called ANFO, featured much safer, effective blasting characteristics when compared to dynamite, accompanied by a notable reduction in cost. These savings mounted as borehole diameter or depth was increased with ANFO volume subsequently enlarged.

Jan 1, 1983

By A. L. Bleloch, A. M. Starfield

This paper is concerned with heat flow in the plane of a typical cross-section of a deep underground airway. A new algorithm, called the quasi-steady method, is presented for the calculation of rock temperatures in that plane. The algorithm is used in the computation of heat and moisture transfer rates from the rock to the ventilating air for an airway that is wet on part of its circumference and dry elsewhere. The speed and accuracy of the new method are demonstrated on a microcomputer, and it is argued that this method offers a considerably more versatile and physically meaningful alternative to previous methods for the prediction of increases in air temperature along mine airways. The algorithm is also used to explore the concept of a uniformly wet airway that is equivalent to a partly wet airway in terms of its effect on the ventilating air. The concept is shown to be reasonable, but more complex than one might have anticipated. Finally, several useful extensions and applications of the new method are suggested.

Jan 1, 1983

By R. E. Doerr

The successful technical demonstration of coarse coal slurry transportation at Consolidation Coal Company's Loveridge Mine in West Virginia suggests that it is now appropriate to seriously consider this technology in other applications, especially the transport of ' coal in surface mining. Early examination indicates that coarse coal slurry transport may be highly competitive with existing haulage systems, depending on a number of factors. These factors are not yet completely defined, but certainly will include production rates, coal physical and chemical properties, terrain, soil conditions, climate, water availability and quality, availability of skilled labor and other economic considerations impacting the existing haulage systems.

Jan 1, 1983

By Alan Bauer

In recent years there has been increasing interest in employing the technique of explosive casting in strip mines. Explosive casting, applied to dragline mining, describes the procedure whereby the overburden is horizontally displaced by blasting causing a portion of the material to be thrown into the previously mined cut. Therefore, it is not necessary to subsequently excavate this waste with the stripping equipment. In addition, allowing the overburden unrestricted movement during the blast most often results in improved fragmentation and enhanced machine productivity. The method is receiving attention because the capital and maintenance costs of stripping equipment has risen rapidly in relation to explosives costs. Improved productivity is necessary to maintain unit costs at an acceptable level.

Jan 1, 1983

By H. S. Hanna, C. Rampacek

The problems and limitations encountered in the Physical beneficiation of the Appalachian Red Iron Ores are discussed. Two major problems are identified - the high phosphorus content and the fine dissemination or encapsulation of mineral impurities in the iron-bearing minerals. A process that combined extreme fine grinding techniques with magnetizing roasting or flotation-separation methods is suggested. By these methods, concentrates assaying 60-61 % Fe, exceeding the widely accepted upper limit of 56% Fe set for these ores, were produced with 75-90% iron recovery. Moreover, it was shown that the phosphorus content of these concentrates could be reduced from 0.25% to 0.03% phosphorus by acid leaching. A brief discussion on production costs based on current and future developments in iron ore processing is given.

Jan 1, 1983

By Richmond A

Like many industries the coal mining industry has, since the beginning of this century, undergone many changes. Technological advances and the increasing demand for fossil fuels have introduced new mining methods and techniques which allow the extraction of thicker and deeper coal seams at higher rates of production. Most new methods of mining (or for that matter any other processes) introduce problems which the engineers of the industry are expected to face and resolve. Unfortunately, spontaneous combustion has plagued the coal mining industry since the first attempts to mine coal, and is no doubt partly responsible for the reputation that coal mining is a hazardous industry. The financial loss and toll of human lives due to the occurrence of spontaneous combustion of coal in coal mines is enormous, if not incalculable. Its occurrence today is less likely to claim lives, due to both improved methods of working and in the detection of spontaneous combustion sites.

Jan 1, 1983

By I. Shah, L. G. Austin

A method for quantitative investigation of the phenomena involved in fine grinding of materials that follows the changes in the breakage rates of fine particles has been presented. For relatively hard, brittle, non-coating material like quartz, the slowing down effect of breakage rates starts to be significant at relatively coarse sizes, which goes often undetected in closed circuit grinding systems, producing relatively coarse product, say P80=75µm However, for fine grinding systems, as the -10µm fractions begin to build-up, and classification becomes more difficult, the build-up of fine sizes causes a slowing down effect Compounding this problem is the difficulty of obtaining accurate cumulative weight size distributions in the fine size region.

Jan 1, 1983

By Charles A. Beasley

Coal conversion to electricity or to substitute natural gas requires a significant quantity of natural and human resources including, in addition to the coal resource base, land, water and the construction and operating labor force. Each method of coal conversion has its advantages and disadvantages relative to conversion efficiency, preferred method of resultant energy transportation, resources consumed, and impact on the environment. Regulations which have been passed in recent years to maintain or restore the pre-project environment can add significantly to the capital and operating costs of both a conversion facility and its associated mine.

Jan 1, 1983

By Braes J. R, Neale J. R

The New Broken Hill Consolidated Limited (NBHC) mine currently produces 1.42 million tonnes of silver, lead and zinc ore annually. All of this ore is treated by the NBHC milling ccx[plex. This paper describes the crushing, grinding, flotation and filtration circuits used in the treatment of this ore and lists the major items of equignent used in these circuits. Metallurgical results, manning levels and consumption rates of reagents and grinding media are shown.

Jan 1, 1983

By V. J. Hucka

Coal, which was discovered in Utah in 1849, covers about 18% of the total area. Production in 1981 vas more than 14 million tons. However, some Utah coal mines are quite gassy. If longwall face technology is applied, then a release of a high volume of methane may be expected during the mining process. Investigations on methane content have been made by use of an isothermic bubble desorbometer. The desorbable methane content of 5 m3 to 16 m3 of methane per ton of coal mined has been determined.

Jan 1, 1983

By Xin Jingmin

The present trend toward concentration of mining activities into fewer sections of a coal mine and application of automation and remote control technologies favor utilization of the longwall mining method. Longwall mining also offers the potential for improving safety and productivity, better ground control and higher levels of recovery. The production potential of a longwall operation is determined by the interaction of several factors including the rate of face advance, the thickness of extraction, the speed of cutting and hauling equipment, the physical dimensions of a longwall panel, and the reliability and availability of the equipment. Some of these factors are dictated by the environment in which the extraction process is to be undertaken. Some other factors, however, can be manipulated in order to optimize the production of the system. The objective of this paper is to develop a stochastic model to simulate the production operations in longwall mining. The activities and parameters that affect the production potential of the longwall operations and the relationships between the activities are identified. An attempt is made to verify these relationships through the use of existing data. The model is then used as a computer simulator to investigate the effects of various activities and parameters on the production capacity of a panel.

Jan 1, 1983

By Kenneth E. Mathews, Ross D. Hammett, S. Byron Stewart

Theoretical models have been important throughout the history of engineering as a means of understanding past experiences and predicting future performance. Most modelling involves assumptions and a degree of idealization, and it is shown that it is important that the effects of these be recognized when making use of models. One of the principal concerns in underground mining is the effect of the excavations on the states of stress in the rock adjacent to these excavations. As mining proceeds to depth, stress concentrations may be sufficiently high to cause inelastic behaviour of the rock and yielding along joint surfaces. At this stage, attention must be given to the sequencing of the mining process to ensure that the ground control techniques applied are optimized. Increasing use is being made of computer modelling techniques to assist with design. Three case studies are presented to illustrate the application of computer models in mine planning and ground control. In all cases, the data available for design was limited, but the mines were fully developed and openings could be inspected. The mining methods studied are cut and fill stoping, room and pillar stoping, and longhole stoping.

Jan 1, 1983

By Guy A. Johnson

To improve productivity and cut costs, modern underground mining operations have become more mechanized. This mechanization has increased the usage of fuels, hydraulics, and electrical equipment associated with diesel-powered vehicles, thereby also increasing the hazards of underground mine fires. The Bureau of Mines evaluated the fire hazard problem and assembled prototype components for a system that would automatically sense and extinguish fires on mobile underground equipment. The prototype system and alternative designs were in-mine-tested and proved effective. This report summarizes this technology, which can cost effectively help solve the problem of fire hazards on underground vehicles.

Jan 1, 1983

By Heikki K. Jalkanen

Thermodynamic properties of copper-iron mattes and slag-matte distribution of copper and some minor matte constituents (Ni, Co, Mo, As, Sb and Bi) are discussed on? the basis of equilibrium measurements: a change from. oxidic to sulfidic solubility as the predominant form of dissolution of copper takes place as matte grade decreases. Distribution coefficients of minor matte constituents are complex functions of sulfur and/or oxygen potentials?. The distribution behaviour of different? metals can be qualitatively derived from their affinities to copper and stabilities. of their sulfides and oxides. The equilibrium results are compared with commercially observed values. from Outokumpu.Oy flash smelting furnace.

Jan 1, 1983

By Victor R. Spironello

The Bureau of Mines has studied slags associated with ferrous melting, to evaluate substitutes for the auxiliary flux mineral, fluorspar. A waste material recovered from alumina reduction cells, "used potlining," was tested in an 18-in-ID basic-lined cupola and in a 1/4-ton, pilot-scale, basic oxygen furnace (BOF). One potlining fraction, No. 1 cut, is a carbonaceous (graphitic) material and represents the bulk of the entire cell lining. The other fraction, No. 2 cut, is a refractory backup. These materials contain significant quantities of fluorine and other elements fn various compounds. The potlining fractions were blended in ratios believed representative of available materials. Both lump and pelletized forms provided extremely fluid slag. No adverse effects were found on furnace performance, chemistry or strength of the metals produced, or the environment. Fluorine recovery in the slag and fluorine losses to the scrubber water and solids were about the same as when fluorspar was used. There was apparently no lining loss from the cupola, but there was lining attack in the BOF. Since the fluidizing ability of potlining is due in part to sodium and other elements such as aluminum and silicon, less fluorine is needed in the slags when potlining is used.

Jan 1, 1983

By Zhengbo Pan, Fujun Gou, Jifei Chen

This paper discusses the various alternatives that are technically feasible for "over-the-raise" continuous advancing in gently inclined coal seams and the computer-aided selection of the optimal mining option. Examples in Wangshiao Coal Mine and Chaohua Coal Mine are cited to illustrate the interval between raises, face length, single or double raise layout and single or double face layout.

Jan 1, 1983